CBPG News 1-12_en_RZ.indd - Clyde Bergemann Power Group

Transcription

Clyde Bergemann News
Clean Energy Solutions
Edition 01/12
Power market in South America
South America can be considered one of the most attractive emerging energy markets in the world. With more than $ 116 billion in
power generation project construction starts scheduled for 2012, Latin America is one of the hottest world regions in terms of power
generation project development. The top five Latin American countries for planned power generation project starts in 2012 are Brazil,
Argentina, Chile, Peru and Mexico. These five countries represent 75 % of the value of planned power generation project starts in 2012.
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Content:
- Power market in South America
- Indonesia – sustained growth for power
sector
- SMART CleanTM solutions to latest EPA
regulations
- Challenges and opportunities by use of
biomass in coal-fired power plants
- New on-load boiler cleaning system for
boilers fired with waste, biomass and
refuse-derived fuels
- First biomass unit to implement
complete SMART CleanTM system
- Clyde Bergemann Atlanta secures first
Shower Cleaning System order
- On-load boiler cleaning systems at a
glance
- Clyde Bergemann Africa team plays it
safe at Medupi Power Station
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- Every accident is one too many –
occupational safety and health are crucial
when working in a power plant
- Doosan Heavy Industries & Construction
selects Clyde Bergemann for Rabigh Power
Plant 2 project
- Slovenia's state-of-the-art coal-fired plant
decides for intelligent on-load boiler cleaning
- Case study: Process monitoring with
SMART IsoTemp at coal-fired AS Pontes
power plant, Spain
- Fabrication and testing of first United
States DRYCONTM project completed
- Clyde Bergemann Power Group Americas
awarded a contract from Metso for the
GREC Fabric Filter & Injection Systems
- DeNOx performance exceeds expectations
of Chinese 1,000 MW power plant
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- Clyde Bergemann Power Group Americas
awarded over US$ 20 million in contracts
for gas-fired power plant equipment
- Power surge in the Middle East
- Clyde Bergemann Termotec expands
resources
- Imtech Deutschland chooses Clyde
Bergemann technology
- Partner of steel and copper industry
- High Energy Efficiency Burner for
emissions far below the legal requirements
- Technology Seminar supporting UK Waste
to Energy & Biomass markets
- Annual Clyde Bergemann Power Group
Sales Conference
- Doncaster enterprise for learning
- Events Diary
- Personnel Developments
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www.clydebergemannpowergroup.com
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Power market in South America
energy supply that will support economic
growth, also positioning the region’s
countries well, as the cost of fuels and
emissions increases in the future. Chile
currently has 12 coal-fired power projects
under development. The projects have a
total investment value of $ 7 billion, four
of which are in the engineering phase, five
in the planning phase, and the remainder
under construction. Some of the largest
plants include the 740-MW Punta Alcalde
coal-fired power station, the 152-MW
Source: Industrial Info Resources
Latin American economies are charging,
despite of global economic woes, growth
rates of 7 percent or even higher in some
countries. Energy needs are expected to
grow in tandem or even faster. For instance,
power demand grew 11.5 percent in Brazil
in 2010, and an average 4.5 percent per
year since 2001 in the region as a whole.
Brazil and Mexico, among other Latin
American economies, are in dire need
of new electricity generation to fuel their
growing economies.
The need to curtail increasing carbon
emissions resulting from strong economic
growth is imperative to Latin American
countries, if they are to remain competitive
and to maintain a sustainable energy
growth. Demand for goods is becoming
ever more sensitive to the carbon footprint
they carry, especially in developed countries.
The IEA’s Current Policies Scenario
from their yearly World Energy Outlook
publication states that Latin America could
increase its CO² emissions by roughly
50 percent between 2008 and 2035. Latin
America is still developing more coherent
policies and regulatory frameworks for all
renewable energy sources, as commitment
to renewables in general grows. It is expected
that current challenges will be ironed out
in time, allowing clean energy investments
to increase even more in the region. This
will secure a clean and competitive future
Sources: Industrial Info Resources, Power Engineering International,
World Energy Insight 2011
Guacolda coal-fired unit addition, and the
750-MW Mejillones coal-fired unit addition.
President Piñera stated that by 2020 an
additional 8,000 MW will need to be added
to the national grid in order to respond to
the country's future demand for electricity.
Argentina is second in Latin America for the
value of power project starts for 2012, with
61 projects totaling $ 13.8 billion. Argentina
relies mainly on thermal generation (61 %
of installed capacity) and hydropower
generation (38 %). New renewable energy
technologies are taking off in the country.
The Patagonia region has some of the best
conditions in the world for wind power
generation.
Brazil, with 294 projects totaling $ 43.4
billion, leads the region, accounting
for about 37 % of the value of projects
scheduled to begin construction during
the year. These projects will add 31 GW
to the current 117.5 GW online in Brazil.
During the same period of time, about
48 new power plants accounting for 7.51
GW will begin operations, representing a
6 % increase in the country's total installed
capacity. This growth is boosting output
to 145 GW in readiness for Brazil to play
host to the 2014 World Cup and the 2016
Olympic Games. Brazil's explosive economic
growth is expected to cool slightly before the
2014 FIFA World Cup. However, that year,
the South American nation's economy will
eclipse that of India to become the world's
sixth largest, according to the Economist
Intelligence Unit. And by 2020, Brazil could
also outflank Germany, becoming the
world's fifth biggest economy.
These figures point to Brazil's heavy
reliance on renewables. This trait has been
emphasized over the past years, after the
government decided to organize periodic
energy auctions as a means to foster power
generation, transmission and distribution
by helping power producers make their
way into the consumer market. The system
has helped lower the price that users pay
for electricity. The auctions have promoted
renewable energy sources above others.
To help increase energy from alternative
sources and make the required technology
more easily available, the government has
also sponsored auctions specifically oriented
for a specific renewable source, such as
wind power or biomass-fired power.
Chile, Peru, Mexico, Panama, Ecuador,
Bolivia, Venezuela, El Salvador, Uruguay,
Costa Rica and Colombia all have in excess
of $ 1 billion worth of scheduled Power
Industry project starts in 2012.
Contact Details:
Franz Bartels
Clyde Bergemann Power Group
[email protected]
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Indonesia – sustained growth for power sector
Forecast electricity demand (in TWh)
in Indonesia
TWh
350
300
250
200
150
Indonesia
100
Java-Bali
Western Indonesia
50
Eastern Indonesia
0
2010
2011
2013
2015
2017
2019
Source: RUPTL PLN 2010-2019
Indonesia is a large archipelago with over
17,000 islands and a population of around
234 million, the fourth most populous
country in the world. Population, economic
activity and industry are most concentrated
in Java and Sumatra Islands. As of 2011,
Indonesia’s GDP growth stands at around
6.1 % and nominal GDP is US$ 700 billion.
Indonesia has no interconnection system to
the smaller remote islands, the main islands
for transmission electricity are Java-Bali,
Sumatra, Kalimantan and Sulawesi.
Until the first quarter of 2011 the
electrification ratio in Indonesia stood
at 68 %, some 12 % behind the state
electricity company PLN and Energy and
Mineral Resources ministry target of
80 % electrification by 2011. Indonesian
electricity demand growth annually
is forecast at 9.5 %, and annually
additional power generation is 7.8 GW
with composition coal power plant
58.8 %, combine cycle 12.6 % and the
rest 28.6 % is renewable energy.
To meet this demand, the Indonesian
government has implemented a 10,000
MW acceleration program, phase 1 and
phase 2. The construction of the phase 1
acceleration
program
has
been
completed and 80 % of the plants are
now operational.
In order to tackle this situation,the
Indonesian government will build small
sized power plants with a capacity below
100 MW in the remote areas. In total,
around 120 units or 75 % of the total
power generation will be built up this
way.
The power generation fleet on phase
2 acceleration program is on the table
below.
In light of these market developments and
future potential in Indonesia, the Clyde
Bergemann Power Group has opened a
business unit in the city of Jakarta. The
locality of the new facility along with
local knowledge of the team put in place
to run the establishment will ensure that
the Clyde Bergemann Power Group is in
a key position to support this market.
PT. Clyde Bergemann Indonesia, as it is
now known, covers the business territory
for Indonesia, Malaysia, Singapore, the
Philippines and Vietnam.
Power plant type
Capacity (MW)
Coal power generation
7,616
Combine cycle
1,440
Hydro
174
Geothermal
2,125
Source: RUKL PLN 2010-2019
Phase 2 acceleration program’s focus is
to fulfill electricity demand on the smaller
islands and remote areas which cannot be
reached by the interconnection system.
Contact Details:
Agustinus Tjhay
Clyde Bergemann Indonesia
[email protected]
John Cannon
Clyde Bergemann Indonesia
[email protected]
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SMART Clean™ solutions to latest EPA regulations
In light of the latest Environmental
Protection Agency’s (EPA’s) regulations, it is
important for plants to understand what is
needed remain compliant and what kind of
economic impacts they can expect. Clyde
Bergemann Atlanta’s SMART Clean™
technologies, in combination with products
from our sister companies, offer a total
cost efficient solution for plants who are
looking to lower emissions and retain their
efficiency.
The “Utility MACT” rule, set by the EPA,
requires coal and oil-fired power plants to
reduce emissions of CO², SO², mercury and
other toxics within the next three years. The
emission limits must represent Maximum
Achievable Control Technology (MACT),
defined as the top 12 % performance of
existing units.
In order to meet these emission limits plants
will need to install air pollution controls,
including activated carbon injection (ACI),
scrubbers or dry sorbent injection (DSI), and
upgrade particulate control systems such as
fabric filters and electrostatic precipitators
(ESP). These technologies, however result
in parasitic power loss. Parasitic power loss
is referred to as the reduction in efficiency
or MW output new equipment consumes
from the plant, with no added benefit.
SMART Clean™ can help plants regain this
lost efficiency, resulting in a quicker return
on their investment.
Studies done by the EPA, National Energy
Technology Laboratory (NETL), and Sargent
and Lundy all show Intelligent Sootblowing
as one of the recommended technologies
plants can use to increase boiler efficiency,
thereby reducing emissions. The studies
also show the economic benefits of
Intelligent Sootblowing as being the most
cost effective method.
Contact Details:
Tim Martin
Clyde Bergemann Atlanta, USA
[email protected]
Challenges and opportunities by use of biomass in coal-fired power plants
Lode Smeets, Project Manager Renewable Energy at Tractebel Engineering, summarizes the key aspects of
the use of biomass in coal-fired power plants.
Tractebel Engineering offers international,
independent and multidisciplinary expertise
for direct biomass combustion, cocombustion, bio-gasification and biomethanation installations, from early
identification of a potential project to
commissioning. Through 15 years of
experience in biomass projects, generating
a total of more than 600 MW, Tractebel
Engineering has developed a technology
for biomass handling and co-firing in large
scale power plants.
Availability & quality
Because of their relatively high energy
density, availability and combustion
characteristics, clean industrial wood pellets
are considered to be the preferred fuel for
the conversion of large scale coal plants.
Clean wood pellets are mainly drawn from
forest residues from the sawmill industry.
The demand for pellet is expected to rise
rapidly, from 15 million t/y to up to 50
million t/y by 2020. Nevertheless, the pellet
market remains immature compared to
coal with a consumption of 7,000 million
t/y. International quality standards are still
non-existing while the quality is decreasing
due to the growing demand. These issues
have to be taken into account from the
beginning when considering biomass firing
on a large scale.
Biomass co-firing
In general, a plant for biomass co-firing
consists of train or ship unloading facilities,
a pre-cleaning step, pellet storage units,
pellets milling into dust and a pneumatic
wood dust transport system to the burners.
Biomass is more difficult to grind compared
to coal and needs a adequate milling system.
After milling, wood particles still remain
larger than coal – up to 1.5 mm vs. 0.075
mm. This slows the heat up and volatiles
release, causing delay in ignition and the
need for longer residence time for complete
burnout. Higher co-firing rates will impact
the boiler behavior. Modifications to the
combustion air system, burners and flue
gas cleaning system have to be evaluated
for each case separately. Depending on the
quality of the pellets and performance of the
milling system, increased unburned carbon,
slagging, fouling and corrosion rates also
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require specific attention and mitigating
measures. The extent depends on the boiler
design but a 100 % conversion to biomass
causes a derating in almost all cases.
Risks
The handling of pellets always generates
dust due to pellet decomposition. Because
wood dust is very explosive, every biomass
installation has to be designed according
to a safety first approach. Through years
of experience, Tractebel Engineering has
defined the necessary measures for fire
and explosion protection, first to prevent
the formation of an explosive atmosphere:
dedusting systems, closed conveying, etc.;
prevention of ignition sources; detection
systems for early warnings; and finally to
limit the impact of an explosion: explosion
panels, compartmentation, suppression
systems, etc.
Contact Details:
Lode Smeets
Tractebel Engineering
[email protected]
Developments
Tractebel
Engineering
evaluated
combustion technologies and solutions for
highest global electrical net efficiency with
biomass. The study demonstrated electrical
net efficiencies of more than 42 % to 44 %
are now feasible. When considering a
biomass project, rather than the investment
costs it is important to look at the total cost
of ownership for a biomass plant. Fuel costs
in general represent about 70 % of the
total costs while CAPEX & OPEX take only
approximately 15 % each for their account.
The increasing demand for biomass fuels
makes the profitability of a project largely
dependent on the ability to burn more
challenging fuels.
Lessons learned:
• SAFETY – “Safety first approach”
The question is not how to avoid
explosion because it will explode, but
how to manage the explosion.
• COMBUSTION – “There is no such thing
as clean biomass”
Slagging, fouling, corrosion provoke less
efficiency and less availability.
• ECONOMICS
Fuel cost represents 70 % of the total
costs, the focus has to be on fuel flexibility.
• SOURCING
Market not yet mature, no real fuel
quality standards defined. The supply
chain needs to be secured.
Some
references
of
Tractebel
Engineering:
Gelderland
power
plant
(The
Netherlands): 600 MW – CFPP converted
to 25 % pellet co-firing | Rodenhuize
power plant (Belgium): 285 MW – CFPP
converted to 100 % pellet co-firing with a
capacity of 195 MW | Polaniec power plant
(Poland): 195 MW – greenfield circulating
fluidised bed unit (20 % agri / 80 % wood
chips)
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RX-SMART Helix-W
New on-load boiler cleaning system for boilers fired with waste, biomass and
refuse-derived fuels
Fuels with the most variable heating values
and chemical compositions are used in
incinerators and biomass boilers. Due to
their tendency to develop complex deposits,
waste, refuse-derived fuels and biomass are
seen as challenging energy sources.
Incinerators and biomass boilers often have
low steam parameters for the sootblowers
so intensive cleaning is not possible. The
strong deposit build-up in the convective
area can also mean that conventional
steam sootblowers will not work effectively.
Consequently, the fouling will continue to
increase, causing unplanned downtimes
and reduced boiler availability.
The new RX-SMART Helix-W is a fully
automatic cleaning system using water
as the cleaning medium. It consists of a
long retractable sootblower and a media
supply unit with modules for the pump, for
water inlet, water outlet and an automation
unit.
RX-SMART Helix-W employs two gear
motors, one for the axial and one for
the rotational movements. This enables
the cleaning system to precisely position
the water jet in the gaps between the
heat exchanger tubes and to perform the
cleaning rotating without axial speed.
This so-called “Go-Stop-Clean-Go” mode
avoids metal surfaces being hit by water
and therefore thermal load. Sophisticated
control of the water circuit ensures that the
water jet will only be applied for cleaning
and interrupted on the spot by a pressureactive nozzle. If no cleaning is performed,
the nozzle stays closed so that the water
cools the long retractable sootblower in a
closed cooling circuit.
Water as the cleaning medium is capable of
producing the required intensive cleaning
effect. To perform the cleaning as gently
as possible on the heat exchanger pipes,
specially designed hardware and software
components and two gear motors with
incremental rotary encoders ensure that the
RX-SMART Helix-W moves precisely to the
cleaning position within the space between
the heat exchanger tubes. Water is released
for cleaning only.
Novel water jet controls guarantee an
instant build-up and interruption of the
water outlet from the pressure-active
nozzle. If no cleaning is performed, the
entire water flow is used for cooling the
long retractable sootblower in a closed
cooling circuit.
The operation of this new on-load boiler
cleaning system can be viewed by means of
a 3D animation at www.clydebergemann.
de under the section Media/Downloads. A
brochure is available there, too.
Contact Details:
Arnd Benninghoff
Clyde Bergemann GmbH, Germany
[email protected]
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First biomass unit to implement complete SMART Clean™ system
Clyde Bergemann Atlanta is working with
Factory Sales & Engineering, Inc on a project
for the Abengoa Cellulosic Ethanol Plant in
Hugoton, Kansas. The facility, scheduled to
be commissioned in 2013, will convert about
315,000 dry tons per year of crop residue
and cellulosic energy crops to 25 million
gallons of ethanol, while also generating 25
megawatt (MW) of electrical power.
This project is the first biomass unit to
implement Clyde Bergemann’s complete
SMART Clean™ system and will include:
US Retractable Sootblowers, Cleaning
Contact Details:
Huiying Zhuang
Clyde Bergemann PG Americas, USA
[email protected]
WLB100A SMART Cannon System, 9 SMART
PLC Module, 15 US Partial Retractable
Sootblowers, SMART Convection, and
SMART Controls.
Abener Engineering (a division of Abengoa)
was tasked to design and engineer the
new biomass unit which will burn a variety
of challenging fuel including corn stover,
wood chips, switchgrass, syrup from
ethanol manufacturing process, waste
treatment sludge, etc. This will be the first
biomass unit in the world to burn these
types of fuels which have a very low ash
fusion temperature and a high slagging
tendency. Severe slagging is expected
from the furnace to the backpass portion
of the boiler. In addition, this unit will
supply steam and power to the ethanol
manufacturing process making reliability
critical.
Our SMART Clean™ technologies proved
the best fit for this challenging application.
The SMART Cannon can remove the molten
slagging in the furnace very effectively while
our SMART US Sootblowers can target the
specific slagging area in the superheater
and generating bank to prevent them from
plugging. The use of SMART Convection
will tell which tube bundle is dirty and
remove the slag before it gets too severe
to clean. For the low temperature areas
such as economizer and air heater, partial
tract retractable sootblowers are very
cost effective and clean more effectively
than rotary sootblowers, which were the
standard design for small biomass units.
Clyde Bergemann Atlanta secures first Shower Cleaning System order
Clyde Bergemann Atlanta secured its first
Shower Cleaning System (SCS) order with
Covanta Energy’s Niagara Plant located
in Niagara Falls, New York. This energyfrom-waste plant processes 2,250 tons of
waste per day selling the steam to adjacent
chemical facilities and the electricity to the
New York State power grid.
The use of waste and biomass as a fuel is a
challenge. Noticeable consequences of this are
increased deposit formation in the open passes,
accelerated corrosion processes, and unplanned
shutdowns. In particular, deposits in the open
passes of incinerators strongly influence plant
availability. Fouling on the membrane walls of
the open passes can lead to significantly reduced
heat transfer which consequently increases
superheaters. Raised flue gas temperature the
flue gas temperature before the and corrosive
chemical components combine to produce a
substantial risk for high-temperature corrosion.
When using waste and biomass as the fuel,
the cleaning effectiveness of a water based
on-load boiler cleaning system depends
on the actual fuel composition and the
consequential deposit characteristics. Clyde
Bergemann’s SCS uses water as the cleaning
medium. Located on the boiler roof, it
removes deposit from the lower side, the
membrane walls, the pendant heater, and
superheater surfaces. By using different
nozzle designs and cleaning parameters,
the cleaning efficiency can be adjusted to
specific surface deposit characteristic.
• Stable flue gas temperature
• Lower risk for high-temperature corrosion
and reduced corrosion rate
• Shorter revision period as timeconsuming manual primary cleaning is
almost eliminated
• The construction of SCS allows cleaning
of narrow designed open passes
• Corrosion protection of the flange by
applying sealing air
Advantages of using SCS on waste and
biomass fired boilers include:
Contact Details:
John Malone
[email protected]
• Increased plant availability due to reliable
cleaning of the open passes which are
important for efficient plant operation
Shower Cleaning System
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On-load boiler cleaning systems at a glance
In a new brochure, Clyde Bergemann
presents the complete scope of supply
for the efficient cleaning of heating and
reaction surfaces. This 20-page brochure
covers all devices which remove slagging
and fouling by means of steam/air, water
or by impact energy. Solutions for boiler
diagnostics/analysis
and
optimization
as well as the in-house competence in
automation are covered, too.
This
brochure
is
available
at
www.clydebergemann.de under the section
Media/Downloads.
Clyde Bergemann Africa team plays it safe at Medupi Power Station
View of Medupi power station, Lephalale, in
South Africa
On 12 October 2011, the Clyde Bergemann
Africa (CBZ) team on Package 32, Medupi
Power Station, reached their safety target
of 150,000 hours LTI (Lost Time Injury)
free. This is the second Health & Safety
achievement for the year 2011, after the
team was awarded a gold certificate for one
year without LTI in August.
CBZ was rated by the Medupi Engineering
Team as the best contractor for its size
in terms of quality, with a nearly perfect
record over five audits. CBZ’s scope for
Medupi is the design, construction, supply
and commissioning of the fly ash handling
and conditioning systems. The company
is also acting as the on-site construction
supervisor taking care of erection control
and commissioning services for the onload boiler cleaning equipment supplied by
Clyde Bergemann in Germany.
The team’s goal is to still be LTI free in
April this year when the next 6-monthly
assessment is done. Responsible for this
impeccable record are Gerardine Henning
(Safety & Environmental Officer) and Eliza
Haystek (Quality Officer).
Contact Details:
Jaco van der Westhuizen
Clyde Bergemann Africa, South Africa
[email protected]
9
Every accident is one too many – occupational safety and health are crucial
when working in a power plant
Employees of Clyde Bergemann GmbH in Wesel, Germany show competence of high safety standards by
passing SCC checks successfully.
Occupational safety is of major importance
to power plant operators. Suppliers can
be excluded from contract qualification
if they show no evidence of compliance
with safety standards. Certification under
“Safety Certificate Contractors“ (SCC)
assesses the health and safety management
system of companies performing work on
the premises of third parties.
Since 2005, Clyde Bergemann GmbH has
been certified in accordance with SCC
guidelines that apply all over Europe. The
SCC certificate provides evidence to Clyde
Bergemann’s customers – among which
are operators of coal-fired power plants,
incinerators and industrial boilers – that
employees have received training in all
aspects of occupational safety and health
protection.
In order to qualify for the certification process
or to retain the seal of approval, no more
than two reportable industrial accidents
should have occurred during any given year.
Quite recently, another 35 employees of
Clyde Bergemann came together to attend
a preparatory workshop with subsequent
examinations in the in-house training and
conference center in Wesel, Germany.
Topics ranged from legal aspects to the
identification and assessment of risks and
analysis of accidents. The Elsevier Academy,
as an accredited SCC auditor, supervised
and evaluated the examination results.
All participants have successfully provided
evidence of their proficiency.
Employees of Clyde Bergemann GmbH in Wesel,
Germany attend a preparatory workshop for
SCC examination at the in-house training and
conference center.
Contact Details:
Erich Stratmann
[email protected]
10
Doosan Heavy Industries & Construction selects Clyde Bergemann for Rabigh
Power Plant 2 project
The on-load boiler cleaning devices for
the new build Rabigh Power Plant 2 will
be supplied by German-based Clyde
Bergemann GmbH. South Korea’s Doosan
Heavy Industries & Construction recently
ordered 160 long retractable sootblowers
type PS-LL along with Thermo Probes. The
control system will also be commissioned by
Clyde Bergemann.
Jeddah, Saudi Arabia. The end user is Saudi
Electricity Company.
Compared to the figures in 2000, the
country’s electric power consumption is
expected to triple to 309,100 GWh by
2016.
Contact Details:
Ulrich Balsmann
[email protected]
The 4 x 700 MW heavy fuel oil and crude oil
fired units are located 150 km northwest of
Slovenia’s state-of-the-art coal-fired plant decides for intelligent on-load
boiler cleaning
Power Plant Šoštanj
EPC-contractor ALSTOM Power Systems
GmbH, of Stuttgart, Germany, awarded a
contract to Clyde Bergemann as the sole
supplier of the on-load boiler cleaning
solution for unit 6 of the Šoštanj coalfired power plant in Slovenia. With a net
efficiency of 43 %, the new 1 x 600 MW
ultra supercritical tower-type unit, whose
construction is in progress, will make
this station one of the most efficient and
advanced in Slovenia.
According to the specific cleaning
requirements of the different boiler areas,
e.g. furnace, superheater, economiser,
air heater and DeNOx, the overall 128
sootblowers consist of the series water
cannon, long retractable, helical, rake
and rotating element. The furnace will be
equipped additionally with the SMART
Furnace-FACOS optimisation system. This
system uses sensors to detect the position
and intensity of slagging in the furnace
area. This data will be linked with the
current performance data of the steam
generator to decide upon stored algorithms
which cleaning action needs to be done
and at what intensity. SMART FurnaceFACOS not only regards the level of slagging
but also the influence of the imminent
cleaning operation on boiler performance.
Clyde Bergemann carries out engineering,
installation and commissioning.
Termoelektrarna Šoštanj d.o.o. operates
the Šoštanj station. Coal is supplied by the
nearby Premogovnik Velenje lignite mine.
When operational in 2014, unit 6 replaces
the older units which have been brought on
line from 1956 to 1977.
Contact Details:
Arnd Benninghoff
[email protected]
11
Case study: Process monitoring with SMART IsoTemp at coal-fired As Pontes
power plant, Spain
promote the cooling of the ash particles in
the vicinity of the wall.
This results furthermore in a reduction of
deposit formation. Thereby, the formation
of local limited slagging in the furnace can
be reduced.
Solution
Important control parameters for qualitative
evaluation of the combustion are the flame
and flue gas temperatures.
Installed SMART IsoTemp for thermal diagnostics
Situation
Variable boiler operation with changes
in mill and burner combination leads to
unpredictable imbalance in the flame
position. This results in thermal overload
at the membrane walls in the evaporator.
Slagging hotspots will build on these areas
of the furnace.
By altering the boiler design and changing
from local lignite coal to imported subbituminous coal the problems cannot be
completely avoided. In thermal overloaded
areas, the evaporator tends to slag, in spite
of using imported coal with a very low ash
portion.
Objective target
The main objective target of using SMART
IsoTemp was to gain a stable operating
performance by retention of the variable
boiler operation. Essential for this was to
have a symmetrical and constant positioning
of the flame in the middle, which would
Contact Details:
Daniel Bartels
[email protected]
SMART IsoTemp is an optical measurement
device which records and evaluates these
parameters continuously and contactless in
real-time. Based on the results, corrective
actions in the firing operation can be carried
out just in time to keep the temperature in
optimised operation and to stabilize the
operation performance.
Realization
The furnace conditions call for six SMART
IsoTemp pyrometers. To establish the desired
optimisation all SMART IsoTemps have to be
installed at the same level at the boiler wall
at the end of the furnace. Due to the high
ambient temperatures, a fibre optic detects
the radiative temperature of the furnace
and sends this to the pyrometer.
The control centre receives easily
interpretable information and is able to
optimize the following parameters in realtime:
• Air feed and velocity
• Fuel mass flow
• Burner and mills combinations
Results:
• Transparent process flow – The control
centre easily recognizes the quality of the
combustion process and can optimise it in
real-time. This is especially helpful during
the start-up process of the boiler after
shut-downs, strong reductions in the
boiler load and changes in mills.
• Results of the corrective actions for flame
adjustment will be recognized.
• Changes in the fuel mix are procedural and
at any time controllable. The important
control parameters, flame temperature
and location, are continuously monitored
so that the temperature distribution can
be presented as information that is easily
understood.
• High fractions of unburned coal can be
noticed.
A PC-based detection system transfers
the radiation into temperature signals,
from which the temperature profile of the
complete furnace section will be generated.
The visualization is presented in a two
dimensional image. Using an interface,
the visualization along with the measured
temperature signals, the temperature
distribution and the absorption coefficients
will be transferred to the process control
system.
Visualisation of the temperature distribution by
thermal diagnosis with SMART IsoTemp
12
Fabrication and testing of first United States DRYCON™ project completed
removal system to a dry system. CBAM was
awarded the contract to supply engineering
and equipment utilizing our DRYCON™
technology.
DRYCON™ for Seminole Electric
Clyde Bergemann Power Group Americas
(CBAM) has successfully managed to
fabricate, assemble, and test their first
DRYCON™ module for Seminole Electric
ahead of schedule and under budget.
Seminole Electric’s two 650 MW coalfired units in Palatka, Florida needed to
convert their existing wet bottom ash
With the project being awarded last March
of 2011, Clyde Bergemann Malvern used
CBAM's engineering team in Atlanta
and CBAT's facility for fabrication with a
completion date goal of spring 2012. As
of the beginning of February 2012, the
secondary conveyor for the DRYCON™
project has been completed, tested,
and shipped. Fabrication for the primary
conveyor has been completed with
assembly underway. Testing of the unit
will occur mid February with shipment
happening at the end of the month. The
whole CBAM team has worked very closely
with Seminole Electric to ensure timely
delivery of the project and to meet their
budgetary expectations.
Ron Tempesta, President of Clyde
Bergemann Malvern, comments: “This is
the first DRYCON™ project fabricated in
North America for Clyde Bergemann and
we are very pleased with the results we
have achieved. This demonstrates CBAM's
ability to deliver on-time, on-budget
results. We hope this will open the door for
future opportunities at other major North
American utilities with Clyde Bergemann
Malvern's DRYCON™ technology and other
potentially new product lines."
Contact Details:
Ron Tempesta
Clyde Bergemann Malvern, USA
[email protected]
Clyde Bergemann Power Group Americas awarded a contract from Metso for
the GREC Fabric Filter & Injection Systems
Clyde Bergemann Power Group Americas
(CBAM) headquartered in Atlanta, GA has
been awarded a contract from Metso Power
to provide the multi-pollutant emissions
control system for the Gainesville Regional
Energy Center (GREC) BFB Biomass plant
in Gainesville, FL. The system is being
supplied by Clyde Bergemann Hanover, the
air pollution control business unit within
CBAM. The GREC plant, which will burn
waste wood from logging and mill activity
as well as urban wood waste from clearing,
is scheduled to come online in 2013.
Due to the strong positive relationship
between the two companies, Metso is very
confident in Clyde Bergemann’s ability to
apply its proprietary technology to achieve
the low air emissions required for the GREC
project. Clyde Bergemann’s APC solution
includes its proprietary pulse jet fabric filter,
dry sorbent injection and activated carbon
injection systems to achieve the cleanest
air emissions ever required for a biomass
boiler in the USA. The modular fabric filter
will utilize proprietary technology and
be applied to the hot side of the plant‘s
low dust SCR, handling elevated gas
temperatures while achieving filterable
particulate matter emissions consistent with
the plant’s air permit.
In coordination with the fabric filter, an
activated carbon injection system will
provide dioxin/furan and heavy metal
control while a sodium-based injection
system provides acid gas mitigation. The
material handling equipment for the
injection systems will be furnished by Clyde
Bergemann Malvern, CBAM’s Material
Clyde Bergemann’s fabric filter and
APC solutions
Handling business unit. The complete fabric
filter and sorbent injection systems will be
delivered to site in early 2012.
Contact Details:
Mike Newbury
[email protected]
13
DeNOx performance exceeds expectations of Chinese 1,000 MW power plant
In October 2007, Clyde Bergemann
Huatong signed a contract to supply
advanced DeNOx technique for 1,000 MW
unit 5 of the Anhui Energy Tongling Power
Plant Phase VI. The scope of supply covered
conceptual design, detail design, equipment
procurement and delivery, erection
supervision and commissioning on-site.
Major equipment of the system are DeNOx
reactor, duct work, catalyst, dilution fan,
sonic blower, ammonia tank, evaporator,
flow regulator, pressure regulator station as
well the required instruments and electrical
equipment. This is the first DeNOx system
supplied by Clyde Bergemann Huatong.
In September 2011, the DeNOx system’s
performance 5 day tests, attended jointly
by Anhui Energy Tongling Power Plant Co.,
Ltd, general contractor of Tongling Power
Plant, Clyde Bergemann Huatong and Xi’an
Thermal Power Research Institute Co., Ltd,
was going smoothly. The performance tests
include all parameter measurements at two
full load at 1,000 MW, one medium load
at 700 MW and one low load at 500 MW
conditions. The measured parameters are
DeNOx efficiency, SO² / SO³ conversion rate,
ammonia slip rate, ammonia consumption
and pressure loss of the DeNOx system as
specified in the contract.
In May 2011, the 168-hour trail-run of unit
5 came to end and CBH’s first DeNOx system
was successfully put into operation. During
the trail-run operation, as the first ammonia
injection succeeded, the DeNOx system was
put in automatic run and it is shown that
DeNOx efficiency was satisfactory to the
specification.
The results indicate that all the actual
performance values are better than the
specified ones. The success of Clyde
Bergemann Huatong’s first DeNOx system
has laid the foundation for future projects.
With collaboration, Clyde Bergemann
Huatong and Xi’an Thermal Power Research
Institute Co., Ltd carried out these tests,
and the results were recorded as follows:
Parameter
Unit of
Performance
Actual test value
measurement guarantee value
De-NOx efficiency
%
Ammonia slip
Contact Details:
Xiao Weinong
Clyde Bergemann Huatong, China
[email protected]
µL/L
Conclusion
75
76.5 (full load)
75
76.1 (medium load) conforming
75
77.3 (low load)
conforming
3.0
0.56 (full load)
conforming
3.0
0.44 (medium load) conforming
conforming
3.0
0.27 (low load)
conforming
SO²/SO³ conversion rate %
1.0
0.19 (full load)
conforming
Pressure loss
Pa
800
636 (full load)
conforming
Ammonia consumption
kg/h
440.7
210.6 (full load)
conforming
14
Clyde Bergemann Power Group Americas awarded over US$ 20 million in
contracts for gas-fired power plant equipment
Combined cycle gas turbine system
Clyde Bergemann Auburn, the air-gas
handling division of Clyde Bergemann
Power Group Americas, has secured
contracts totalling over US$ 20 million to
supply equipment and services for new
power plants being constructed in Africa
and the Middle East.
The company was selected to supply
dampers, stacks, silencers and other exhaust
system components and services for gasfired plants in Egypt and the United Arab
Emirates. These projects will add nearly
4,000 MW power generating capacity in
a region that is experiencing tremendous
growth in energy demand. The plants are
expected to begin operation by the middle
of 2013.
“As evidenced by these awards, Clyde
Bergemann Auburn‘s reputation for
delivering quality technology is recognized
globally, and we continue to demonstrate
our strengths in a very competitive
environment“, said President Fred Koch.
Guillotine damper as part of a combined cycle
gas turbine system
The equipment will be installed in gas-fired
combined cycle power plants designed for
high efficiency and low carbon emissions.
A combined cycle plant, which conducts
secondary processing of combustion exhaust
by way of a heat recovery steam generator,
typically produces approximately 50 % more
energy thus causing less carbon dioxide and
other pollutants than a conventional simple
cycle plant generating the same MW.
Clyde Bergemann Auburn, is a global
engineering company focusing on highperformance clean energy solutions for
Power, Utility, Petrochemical, and Industrial
applications. The company develops and
supplies custom designed and fabricated
systems including dampers, diverters,
expansion joints, stacks and exhaust system
components for gas turbine and fossil
fired power plants. The company is ISO
9001:2008 certified.
Clyde Bergemann Auburn’s customers,
engineering, procurement and construction
(EPC) companies for the projects are based
in China and Korea. The company has
previously collaborated with the firms on
numerous projects around the world.
Commenting on the market outlook, Koch
said, “We are now seeing some good
activity in our core markets. These orders
reflect a strong company-wide effort and
intense focus on our markets, customers
and opportunities.”
Contact Details:
Chris Caiazzo
Clyde Bergemann Auburn, USA
[email protected]
15
Power surge in the Middle East
Robust growth prompting new construction projects
Quickly becoming one of the most exciting
markets for power generation development
is the Gulf Cooperative Council (GCC)
region of the Middle East. Energy demand
in the GCC, which encompasses Bahrain,
Kuwait, Oman, Qatar, Saudi Arabia, and
United Arab Emirates, is experiencing
aggressive growth.
Driven
by
accelerated
economic
development, a growing population,
and water desalination initiatives, the
corresponding increase in energy demand
– currently about 8 % annually – is fueling
a robust rate of construction of power
generation facilities throughout the
region.
A combined cycle plant typically produces
approximately 50 % more energy than a
simple cycle plant with the same amount of
fuel. Combined cycle plants also cause less
carbon dioxide and other pollutants than a
conventional simple cycle plant generating
the same MW.
Clyde Bergemann Auburn (CBAU), a
business unit of CBPG, is participating in
one of the largest energy projects in Saudi
Arabia. The company is participating in
the repowering of the existing PP10 site
in Riyadh. The project will increase the
plant’s capacity from 2,200 MW to 3,400
GW. CBAU supplied the original simple
Industry experts foresee energy demand
continuing to grow steadily over the
long term, in fact, tripling over the next
25 years. The World Energy Council
estimates 100 GW of additional capacity,
representing investments of US$ 50 billion
in power generation and US$ 20 billion in
desalination, will be required in just the next
decade.
Such sustained growth will call for longterm additions to the Middle East’s power
grid, supported by reliable equipment that
is up to the task of operating reliably and
economically under extremely challenging
ambient conditions. Clyde Bergemann
Most of the electricity generation capacity
coming online in the Middle East is from
gas- and oil-fired plants, in some cases
very large-scale “mega” installations
constructed in multiple phases involving
10-, 20-, or more, unit configurations.
Many electricity producers seeking to
boost output rapidly at existing facilities
are repowering their existing simple
cycle plants to more efficient and cleaner
combined cycle operation. Repowering of
a simple cycle gas turbine unit consists of
adding a Heat Recovery Steam Generator
(HRSG) so that the exhaust gas which was
being ejected to the atmosphere is now
sent through the HRSG to provide steam
for either electric generation by a separate
steam turbine or for some other process
(e.g. desalination, heating, etc.).
Contact Details:
Chris Caiazzo
[email protected]
cycle stacks which were required to be
capable of future conversion to combined
cycle operation The CBAU repowering
scope of supply includes converting the
previously supplied elbows to diverter
dampers, blanking guillotines, and auxiliary
equipment.
Auburn’s proven track record in the region
will continue to make it the supplier of
choice for major power projects requiring
high performance air-gas handling
equipment.
16
Clyde Bergemann Termotec expands resources
The Clyde Bergemann Termotec Dry Cooling
team (left to right):
Ralph Ludwig (Managing Director),
Kurt Rüdel (Sales Director), Manfred Thomas
(Engineer), Christoph Schulze (Managing
Director), Uwe Wink (Project Manager),
Hans-Georg Schrey (Design & Development),
Richard Leitz (Director)
Since 1982, Clyde Bergemann Termotec has
been a competent partner for heat exchanger
plants. Within the Clyde Bergemann Power
Group, Clyde Bergemann Termotec is one
of the centers of competence in the field
of energy recovery. From development
and design to production and true-to-size
installation, Clyde Bergemann Termotec
provides forward-looking and customized
solutions.
Air Cooled Condenser and Hans Georg
Schrey is responsible for the design and
development of Air Coolers.
Recently, the team covering the range
of dry cooling heat exchangers and aircooled condensers has been enforced by
a group of well experienced specialists in
dry cooling technology. Richard Leitz, Kurt
Rüdel and Hans-Georg Schrey joined the
company and implemented their long-term
experience, especially with regard to aircooled condenser design and optimization.
Air-cooled condensers are environmentally
friendly because no cooling water is
required and no waste generated. Clyde
Bergemann Termotec supplies air-cooled
condensers in classical A-Frame or vertical
arrangement with multi-row or singlerow technology. Starting from the turbine
exhaust the complete cold end of the steam
cycle is designed and engineered by Clyde
Bergemann Termotec engineers.
The demand for air-cooled condensation
has been constantly growing over the past
decade on a world-wide scale. Thermal
power, solar, biomass stations as well as
pulp and paper plants are key users of dry
condensation technology.
An updated brochure of
the energy recovery capabilities
by Clyde Bergemann Termotec
has just been released.
It is available for download at
www.clydebergemann.de
Richard Leitz is the Director Air Cooled
Condenser, Kurt Rüdel acts as Sales Director
Contact Details:
Richard Leitz
Clyde Bergemann Termotec
richard. [email protected]
Kurt Rüdel
[email protected]
Hans-Georg Schrey
[email protected]
17
Imtech Deutschland chooses Clyde Bergemann technology
New waste incineration plant in Plymouth, Southern England gets air-cooled condenser system
Imtech Deutschland GmbH & Co. KG recently
concluded a contract with Clyde Bergemann
GmbH for the planning, manufacturing,
supply, installation and commissioning
of an air-cooled condenser system. This
installation will be used in the new thermal
recycling plant in Plymouth, a city in the
English county of Devon. The order is
carried out by Clyde Bergemann Termotec
GmbH, the specialist for heat exchanger
technology within the Clyde Bergemann
Power Group.
Operating company of the waste
incineration plant is MVV Energie AG.
Using combined heat and power, the power
plant generates 23 MW heat and 22.5 MW
electricity. The annual recycling rate of
household waste amounts to 245,000 tons.
In May 2011 Imtech was awarded the
contract by MVV for the supply of steam
generator and water-steam-cycle including
turbine and water treatment plant. The
commissioning of the waste recycling plant
is planned for 2014.
The air-cooled condenser consists of five
fan cells with auxiliary components. The
condensation capacity is approx. 48 MWt at
70 mbar with 83.25 t/h steam and fulfils the
very stringent sound emission requirements.
Contact Details:
Air cooled condenser
Kurt Rüdel
[email protected]
Partner of the steel and copper industry
Copyright: Allmeson GmbH
© Stahl-Zentrum, Düsseldorf und HKM, Duisburg
The complete scope of advanced burner and
heating technology by Clyde Bergemann
Brinkmann are presented in new brochures.
The brochures are available at www.
clydebergemann.de under the section Media/
Downloads.
FROM IRON ORE TO STEEL
Process burners, lance systems, manipulators
and heating systems for precise steel qualities
COPPER
Systems & Solutions
for melting, holding, refining and
thermal treatment
18
High Energy Efficiency Burner for emissions far below the legal requirements
This burner is an improved high impulse
burner. The innovative technology result in
an increased heat yield in the material with
near-stoichiometric operation. Thanks to the
formation of the flame with a significantly
stronger impulse and higher exit velocity
the mixing quality of oxidator and fuel
is optimised. With regard to combustion
technology, all kinds of stoichiometric
requirements can be reproducable reached.
Modern copper production places high
demands to the process and is subject to
continuously more stringent regulations
regarding NOx and CO emissions. With
the experience of over 130 years working
in the thermal process Clyde Bergemann
Brinkmann has this task accepted.
The result of the development activity is the
High Energy Efficiency Burner – in short HEE.
In view of the achieved results regarding
NOx and CO emissions the most stringent
legal requirements are fulfilled today and
also in the future. Practical experience with
the new burner proves that actual values are
less than half of the values of the German
TA Luft (Technical Instructions on Air Quality
Control).
Due to the compact construction, the HEE
burner is ideal for retrofitting.
Information about this new High Energy
Efficiency Burner as well as the complete
scope of supply by Clyde Bergemann
Brinkmann can be obtained at www.
clydebergemann.de.
Contact Details:
Ahmad Al-Halbouni
Clyde Bergemann Brinkmann, Germany
[email protected]
Technology Seminar supporting UK Waste to Energy & Biomass markets
Clyde Bergemann Scotland had pleasure
coordinating and welcoming delegates from
companies from around the UK in October
to the Radisson Hotel in Birmingham for
a technology seminar focused on the
waste-to-energy and biomass services of
the Clyde Bergemann Power Group. The
day achieved its aim of presenting group
solutions designed to help assist plants in
their strategies to increase efficiency, reduce
costs and reduce environmental impact.
Colleagues from five group companies
present their particular business capabilities
and the wider group synergies that were
possible. And from the delegate feedback
reports, all presentations were very well
received during the event.
The day was a huge success and has
yielded many opportunities including new
relationships with four of the big companies
in the industry that are currently working
on new projects. Existing partnerships were
also consolidated as the Clyde Bergemann
Power Group demonstrated its continued
commitment to technology and solutions in
this market.
More seminars of this nature will be planned
through 2012. Many thanks to all who took
part and to Neil Manson and Charlene
Alcantar who did a splendid job of ensuring
the event was managed well.
Key contributors to the event (left to right):
Wolfram Jaspers, Energy Recovery; Mike
Davidson, Air Pollution Control; Stephen
Young, Boiler Efficiency; Will Sullivan, Air
Gas Handling and Craig Buckley, Materials
Handling
Contact Details:
Charlene Alcantar
Clyde Bergemann Ltd, Scotland
[email protected]
19
Annual Clyde Bergemann Power Group Sales Conference
Clyde Bergemann Power Group held their
annual Sales Conference from the 17th
to the 18th of November 2011 at the
company’s conference center in Wesel,
Germany. More than 120 key personnel
attended the conference from the
corporate’s global sales, marketing and
R&D teams.
The sales conference provided an opportunity
to share knowledge and experience of
technology developments, major projects
and market information from around the
world. Clyde Bergemann Power Group
welcomed guest speakers including Professor
Christian Rehtanz from the Technical University Dortmund, Germany; Lode Smeets
from Tractebel Engineering; Nigel Cooke
from Lafarge.
Professor Rehtanz presented today’s
challenges of the power transmission
system to keep up with the growing feedin of wind and photovoltaic energy. Lode
Smeets presented the experience Tractebel
Engineering made with numerous coal to
biomass conversion and biomass co-firing
projects. Nigel Cooke shared his knowledge
on key issues related to the use of ash from
a cement perspective.
The guest speakers of the Clyde Bergemann
Power Group Sales conference (left to right):
Prof. Christian Rehtanz, Technical University
Dortmund; Lode Smeets, Tractebel Engineering;
Nigel Cooke, Lafarge
As every year, the two days created an
opportunity for learning and networking
to circulate knowledge and expertise
throughout Clyde Bergemann Power
Group’s business fields.
Doncaster enterprise for learning
Clyde Bergemann Materials Handling has
been presented with an award from Business and Education South Yorkshire for
their contribution towards a local enterprise
growth initiative.
By linking business with local educational
establishments over two years, the aim was
to ensure that Doncaster’s young people are
aware of the skills they will need in future
Contact Details:
Dan Young
Clyde Bergemann Materials Handling, UK
[email protected]
employment and the opportunities that are
available to them. In return, local business
has the opportunity to understand and influence the topics and methods of study in
education. The result is better enterprise
awareness in schools and better availability
of suitable employment candidates for local
businesses.
Clyde Bergemann’s contribution included
school visits to give presentations and help
with activities and providing work experience placements for engineering diploma
students. Clyde Bergemann received the
award for being one of the top 20 contributors from over 200 local businesses.
Dan Young (right), Technology Manager Clyde
Bergemann Materials Handling, receives the
award from Keith Glanville, a representative of
Business and Education South Yorkshire
20
Personnel Developments
Events Diary
Date
Participation of
Clyde Bergemann
Name of event
Location
April 2-4, 2012
BLRBAC
Atlanta, GA
April 23-25, 2012
NAWTEC
Portland, ME
Clyde Bergemann Power
Group Americas exhibits
May 8-10, 2012
VGB Keli
Berlin, Germany
Clyde Bergemann Wesel,
Germany exhibits
May 15-17, 2012
Electric Power
Baltimore, MD
May 21-23, 2012
CIBO Fluidized Bed
Combustion Conference
Raleigh, NC
June 12-14, 2012
POWER-GEN Europe
Cologne, Germany
June 19-22, 2012
Air & Waste Management
San Antonio, TX
Association
April
May
June
Ralph Ludwig (left) took over the position
as Managing Director of Clyde Bergemann
Germany and for the entire CBEUI division.
He follows Bernhard Rogalla (right),
who is now acting as Director Project
Development & Contracting and Business
Development for the entire CBEU division.
Clyde Bergemann
Power Group exhibits
July
Dr. Patrick von Hagen
took over the position
as COO of Clyde
Bergemann Power Group RoW. He will
cover this new function beyond his current
position as Group Corporate Finance
Director.
July 16-17, 2012
Reinhold APC
Conference & Expo
Baltimore, MD
July 30 August 2, 2012
CIBO Industrial Emissions
Control Conference
Portland, ME
August 15-17, 2012
Coal-Gen
Louisville, KY
August 20-23, 2012
MEGA Symposium –
Air Pollutant Control
Baltimore, MD
VGB Congress Power
Plants
Mannheim, Germany
Clyde Bergemann
Power Group exhibits
August
October
October 10-12, 2012
December
December 11-13,
2012
POWER-GEN International Orlando, FL
Sascha Herzmanatus
joined Clyde Bergemann
Power Group as Business
Control Manager. In this position, he
strengthens the Group Finance function.
Editorial
News Editors:
Printing:
Publisher:
Stacy Gentry
Clyde Bergemann Power Group Americas, USA
eMail: [email protected]
DWS Offsetdruck GmbH
Herford, Germany
Clyde Bergemann Power Group Inc.
Lydia Howes
Sonja Mayer

CBPG News 1-12_en_RZ.indd - Clyde Bergemann Power Group

Transcription

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