Hitachi Coal Fired Power Plant Technology Yoshiyuki Miyamoto October 14, 2013

Hitachi Coal Fired Power
Plant Technology
October 14, 2013
Yoshiyuki Miyamoto
Engineering Headquarters
Power Systems Company,
Hitachi, Ltd.
© Hitachi, Ltd. 2013 All rights reserved.
Index
1. Hitachi Power Systems Company
2. USC (Ultra Super Critical) Technology
3. Retrofit
4. Air Quality Control System Technology
© Hitachi, Ltd. 2013. All rights reserved.
1. Hitachi Power Systems Company
© Hitachi, Ltd. 2013. All rights reserved.
Hitachi Global Portfolio
Others
Information
& Telecommunication Systems
Financial Services
Digital Media
& Consumer Products
3
8
11
18
Revenues
Power Systems
9
96.0 billion US$
8
Social Infrastructure
& Industrial Systems
FY2012
Automotive
Systems
13
13
High Functional Materials
& Components
7
10
Electronics Systems
& Equipment
Construction Machinery
© Hitachi, Ltd. 2013. All rights reserved.
4
Power Business in Hitachi
Thermal Power Business
Coal-fired Thermal Power Plants
Nuclear Power Business
Boiling Water Reactor Nuclear Power Plants (ABWR ESBWR)
Gas Turbines
Preventive Maintenance, Nuclear Fuel Cycle, etc.
Major Equipment of Coal-fired Thermal
Power Plants
60%
Steam Turbines
20%
FY2012
Consolidated
Revenues
9.6 billion
US$
Transmission & Distribution,
Renewable Energy and Other Businesses
Particle beam
therapy systems
Wind Power
Generation Systems
20%
Boilers
Air Quality Control System
Transmission &
Distribution (T&D) Systems
Photovoltaic Power
Generation Systems
Hydroelectric Power Generation Systems, Drive Systems, Smart Grids,
Power Semiconductors, etc.
ABWR: Advanced Boiling Water Reactor
ESBWR: Economic and Simplified Boiling Water Reactor
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5
Total System Technology
Integrated supply of BTG + AQCS
Boilers
(B)
Turbines
(T)
Generators
(G)
AQCS
DeNOx
Systems
Catalysts
Steam Turbines and Generators (TG)
Turbines and
Generators
Optimize entire plants
Precipitators
DeSOx
CCS
Boilers (B)
Low-pressure
Turbines
Air Quality Control System
DeSOx (Spray Type)
DeNOx Catalyst
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6
Competence in fossil-fired power plant
More than 65% of a high efficiency power station
can be supplied by group members.
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7
2. USC (Ultra Super Critical) Technology
© Hitachi, Ltd. 2013. All rights reserved.
Experiences of Wide Range Coal Properties
%
80
Wide Range of Coal Qualities Fired
Lignites
70
60
Bituminous Coals
50
Low LHV
Lignites
40
30
20
Low Volatile
Coals
10
0
0
0
10
2,000
20
4,000
40 MJ/kg
30
6,000
8,000
kcal/kg
Net Calorific Value
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9
Development of Steam Condition
The efficiency of the coal fired power plant has improved
by making the steam condition a high temperature.
Japan
since 1995
700
620
Isogo # 2 (600MW)
Tachibana Wan #2 (1050MW)
Hitachi-Naka #1 (1000MW)
Haramachi #2 (1000MW)
Matsuura #2 (1000MW)
600
Europe, Lignite coal
Europe, Bituminous coal
Walsum Datteln
Neurath F/G (750 MW)
(1100 MW)
(1100 MW)
RKW NRW (550 - 600 MW)
Boxberg R
Moorburg
(670 MW)
(800 MW)
Niederaußem K (1000 MW)
580
Nanao-Ohta #1 (500MW)
560
Shinchi #1 (1000MW)
Noshiro #1 (600MW)
Hekinan #2 (700MW)
540
Bexbach 1 (750 MW)
180
subcritical
220
Altbach 2 (300 MW)
Staudinger 5 (550 MW) Lippendorf (2 x 930 MW)
Boxberg (900 MW)
Rostock (550 MW)
Schkopau (2 x 400 MW)
Studstrup
(350 MW)
240
supercritical
260
280
300
SH Outlet Pressure [bar]
380
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10
Japanese USC Technology
Plant Performance
Japan
40%
Germany
U.S.A
Korea
China
Australia
Indonesia
30%
India
1991
2010
Year
Source Energy balance s of OECD/
Non-OECD countries-2012
Steam Conditions Improvement
State of the Art: 600oC/620oC
USC: 593oC
600
500
1960
1980
2000
Year © Hitachi, Ltd. 2013. All rights reserved.
11
Steam Condition and CO 2 Reduction
Higher Thermal Efficiency, Lower CO2 Emission
*HHV, Net output base
10
900
8
-5%
6
-7%
800
4
2
0
Sub
SC
USC
Pressure
(MPa)
700
Sub
SC
USC
Temperature
(o C)
Sub: Sub-Critical
16.7
538/538
SC: Super Critical
24.1
566/566
USC: Ultra Super Critical
25.0
600/600
Assumption Ourselves
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12
Latest USC Coal Fired Power Plant (EPC) in Poland
Site: Kozienice Unit 11
Site Location
Owner: ENEA Wytwarzanie S.A.
Commercial Operation: 2017
Kozienice
70km south-southeast
of Warsaw
Contract signing on September 21th, 2012
Construction status as of September 2013
© Hitachi, Ltd. 2013. All rights reserved.
13
Latest USC Coal Fired Power Plant (EPC) in Poland
<Leading Specification>
Type: Ultra Supercritical
Output: 1,075MW (Gross)
Steam Condition
24.3MPa / 600 / 620
Plant Net Efficiency 45.5%(LHV)
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14
3. Retrofit
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Retrofit for Steam Turbine : Needs & Objectives
Needs of Retrofit
Modernization, Refurbishing and Life Extension for Aging Power-plant.
Improve Reliability & Efficiency to Reduce the Operating Cost and
Environmental Emissions.
Objectives of Retrofit
Utilization of Latest Steam Path Technology
to extend Plant Life
to improve Reliability
to improve Plant Efficiency
HITACHI
Over 30 Years of Experience in Retrofit of Steam Turbines
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16
Recent Retrofit Experiences
Hitachi has successfully up-graded more than 120 Units
(Including Approx. 40 Units
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17
Recent Retrofit Experiences
Australia / Liddel 500MW / LP-
Renewal Parts
LP Rotors
Moving Blades
Diaphragms
Inner Casings
Seal Parts
)
Efficiency
Improvement
4.8% (Relative)
AFTER
RETROFIT
Carbon dioxide (CO2)
emission reduction
120,000 ton / Year
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18
4. Air Quality Control System Technology
© Hitachi, Ltd. 2013. All rights reserved.
Air Quality Control System
AQCS
Air Quality Control Systems
Boiler
DeNOx(SCR)
Stacks
DeSOx (FGD)
ESP
SCR : Selective Catalytic Reduction
ESP : Electrostatic Precipitator
FGD : Flue Gas Desulfurization
AQCS Performance
Items
SO2 Emission Level
(mg/Nm3, dry, vol 6%O2)
NOx Emission Level
(mg/Nm3, dry, vol 6%O2)
Dust Emission Level
(mg/Nm3, dry, vol 6%O2)
Boiler outlet
AQCS outlet
~2,800
< 150(*)
< 200(**)
< 150
(< 200: Lignite)(*)
~55,000
< 10(***)
Performance
FGD performance:
SO2 removal
efficiency = 95%
**: When RS burner is applied.
ESP performance:
Dust removal efficiency = 99,94%
*: EU emission standard (Directive 2010/75/EC)
***: 10mg/Nm³ at stack, 30mg/Nm³ at ESP outlet
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20
Feature of SCR Catalyst (Plate Type)
PLATE TYP E
Catalyst Element
Meshed Center Metal
HONEYCOMB TYPE
GAS
GAS
DUST
Catalyst Material
Catalyst Unit
CENTER METAL
DUST
CATALYST
CATALYST
Features: Erosion Resistance, Plugging Resistance, Low Pressure Drop
PLATE
TYPE
HONEYCOMB
TYPE
REMARKS
ACTIVITY
EROSION RESISTANCE
AGAINST DUST
CENTER METAL PLATE
PLUGGING RESISTANCE
FEW CORNERS
PRESSURE DROP
PRESSURE DROP
HANDLING
COMPACT
CATALYST VOLUME
FOR INITIAL LOADING
SPECIFIC SURFACE
FOR LONG TERM OPERATION
LONG LIFE
CATALYST STACKING
: EXCELLENT
: ADVANTAGEOUS
: AVERAGE
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21
FGD Development and Supply
Limestone
Stack
Water
(or SeaWater)
from ESP
Absorber
Gypsum
Dewatering
WWTS : Waste Water
Treatment System
WWTS
Ash : 0.6ton/y
Gypsum
High grade
treat
Sea
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22
Experiences
© Hitachi, Ltd. 2013. All rights reserved.
Boiler Supply Record
Total Installed Capacity: 98.7 GW
Europe
North Asia
11.5
West Asia
38.0
15.3
1.2
North America
4.1
Japan
Africa
4.5
South East Asia
Central &
South America
12.3
Oceania
5.8
4.5
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25
Boiler Supply Record
Over 200MW
Natural Circulation
Once-Through
72 units / 22,192MW
71 units / 46,919 MW 21 units
21,050
22,000
20,000
31 units
19,554
Total Output (MW)
18,000
42 units
14,380
16,000
14,000
12,000
10,000
8,000
28 units
6,612
13 units
4,915
6,000
4,000
2 units
1,200
2,000
0
200-299
300-499
500-899
6 units
1,400
200-299
300-499
500-899
900-1050
Unit Output (MW)
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26
Latest Lignite Boiler Supply
P.S. Neurath F&G (BoA II)
P.S. Boxberg R
Output :
2 x 1,100MW
Main Steam flow :
2 x 2,959 t/h
Output :
1 x 670MW
Main Steam flow :
1 x 1,760 t/h
Superheater Steam :
600oC / 272 bar
Superheater Steam :
600oC / 315 bar
Reheater Steam :
605oC / 57 bar
Reheater Steam :
610oC / 72 bar
Plant in Operation :
Fuel :
2012
German Lignite
Commissioning :
Fuel :
2012
German Lignite
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27
Steam Turbine Supply Record
Total Installed Capacity: 120 GW
North Asia
Europe
3.6
West Asia
20.6
64.0
2.4
North America
Africa
4.8
11.2
Japan
5.3
South East Asia
Central &
South America
3.3
Oceania
4.5
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28
Steam Turbine Supply Record
Steam Turbine Generator under Contract since 2002
Total 71 Sets
(end of 2012)
Turbine Type
Rating output (MW)
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29
Latest USC Project
STEAG-EVN (Germany)
Walsum No.10
Generator Output :
Frequency:
Steam Conditions :
Commercial Operation :
790 MW
50Hz
26.4MPa / 600oC / 620 oC
2013
Electrabel (Germany)
Wilhelmshaven
Electrabel (Holland)
Centrale-Rotteldam
Generator Output :
Frequency:
Steam Conditions :
790 MW
50Hz
25.0MPa / 600 oC / 620oC
Commercial Operation : 2013
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30
Latest USC Project
MidAmerican Energy Company (USA)
Council Bluffs No.4
Generator Output :
870 MW
Frequency:
60Hz
Steam Conditions :
25.3MPa / 566 oC / 593 oC
Commercial Operation : 2007
Tokyo Electric Power Co., Ltd (Japan)
Hitachi Naka Unit 1
Generator Output :
Frequency:
Steam Conditions :
1,000 MW
50Hz
24.5MPa / 600 oC / 600 oC
Commercial Operation :
2003
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31
SCR (DeNOx) Supply Record
BHK Catalyst
Manufacturing Facility
in China (BHHE)
BHK Catalyst
Manufacturing Facility
in Japan (Akitsu Works)
BHK 21%
Europe: 91GW
BHK
47%
Korea: 32GW
USA,AES/
Somerset No.1
675MW,Coal
USA,LA DWP/
Haynes No.1 230MW,
LNG
23%
BHK
Germany,
Mehrum No.3
700MW,Coal
North America: 126GW
Poland,PGNiG
Siekierkie
No.10,11,14,15
140MW 4,Coal
BHK
16%
BHK
31%
Japan: 116GW
BHK 24%
China: 348GW
BHK
76%
Taiwan area: 24GW
Total:743GW Supply Experience in the world
World Share 24% (No.1 in the World) (Dec 2012)
Japan,TEPCO/
Hitachi Naka No.1
1000MW,Coal
Japan,TEPCO/
Sodegaura No.1
1200MW,LNG
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32
FGD (DeSOx) Supply in Europe
Poland
Kozienice II & IV
(800MW x 2)
Poland
Kozienice #11
(1075MW)
Approx. 17 GW
Equivalent in total
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33