High Flexibility Power Plants-25 Years of Danish Experience

Transcription

High Flexibility Power Plants
25 Years of Danish Experience
Blum
•Rudolph
ENS-China
Workshop on Future Flexible Power System
Energy
Concepts and Systems
for Renewable
Energy Grid Integration
former Director R&D
•DONG
Beijing
December,
2013
Energy2nd
Thermal
Power
Torkild Christensen
Senior Engineer / Specialist
Added Values
ENS-China workshop meeting on Future Flexible Power System for Renewable Energy Grid Integration
Beijing - December 4nd, 2013
2013-12-04
1
Agenda
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2013-12-04
General introduction
Overview of the Danish energy system
Achieved flexibilisation of Danish power plants, examples
Summary and conclusion
ENS-China workshop meeting on Future Flexible Power System for Renewable Energy Grid Integration, December 2013
2
Torkild Christensen
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1991 M. Sc. Thermo Mechanical Engineering
1992 - 1994: Chemical/pharmaceutical process plants
1995 - 1997: Offshore oil & gas process platform DNV
1997 - 2000: Elsam wind power division performing
wind resource assessments and aeroelastic
wind turbine load/fatigue simulations
• 2000 - 2013: Elsam & DONG Energy. Design,
optimisation and flexibilisation of thermal power plant
• 2013 - present: Added Values. Design, optimisation and flexibilisation of
thermal power plants
• 2006 – 2013: Member of German VGB research project steering
committee on ‘Joint Operation of Renewables and Thermal Power Plants’
2013-12-04
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Rudolph Blum
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1972: M.Sc. Chemistry & Metallurgy
1973 – 1986: Power station chemist and head of
materials department power company ELSAM
1986 – 1998: R&D coordinator for development of highly
efficient coal and biomass fired power plants
1998 – 2013: R&D Director for power plant development
at ELSAM/DONG Energy
2013: Head of consultant company within energy
concepts and systems
Chairmanships and memberships during my career
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2013-12-04
Danish Power Plant Material Society
Danish Academy of Science - ATV
VGB Materials Committee
COST – European Energy Material R&D
ECCC – European HT Materials Counsel
ZEP – European CCS forum
CCICED – Sustainable use of Coal
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Agenda
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2013-12-04
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General data 2012
Total Energy Consumption 756 PJ
Oil
Gas
Coal
Waste
Renewables
290 PJ
155 PJ
104 PJ
17 PJ
190 PJ
39%
20%
14%
2%
25%
Total electric energy generated: 32 TWh
• 25 % of total energy consumption
based on renewable energy
• 43 % of all power production
based on renewable energy
• Wind power covers 33 % of
all power production
Goal for 2020 is 50 % or more
Total electric generation capacity: 13,5 GW
– Thermal capacity:
9.0 GW, all CHP  ( < 7 GW in 2020)
– Wind Power capacity: 4.5 GW  ( > 6.5 GW + 1 GW solar in 2020)
At present daily consumption varies within 2.5 – 6.5 GW
2013-12-04
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From central to distributed generation
1990
1990
2013-12-04
Denmark
5.6 mio. citizens
43,000 km2
Coastal climate
2013
2013
7
Demand and production in Denmark 2013
•
Annual electricity demand 120 PJ: Average 4 GW, Peak 6-7 GW
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Annual district heating demand 120 PJ: Average 4 GW, peak 10 GW
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Thermal power operating capacity 9 GW: 8 GW central power plants, 1 GW
decentralised small units. Those 9 GW produce 65 % of total electricity demand
– Hereof 80 % CHP plants covering 66 % of total district heating demand
– Energy mix: Fossil fuel/Biomass: 70 % / 30 %
– Central PP are highly efficient and flexible: η ~ 39-49 %, average 42 %; dp/dt ~ 4 – 9 %/min
•
Wind power capacity 4,5 GW; production 35 % of total electricity demand
– Onshore 3 GW
– Offshore 1.5 GW
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Wind power electricity production capacity is above average demand!
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Renewable electricity production is 45 % of total annual demand!
2013-12-04
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Sources of renewable energy in Denmark
Production Mix during 1990 - 2012
2013-12-04
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Evolution of Power Production in Denmark
Decrease of
separate power
production
Constant
heat & power
production
Central power plants separate power production
Central power plants combined heat and power
Power
Plants Separate
Power Production
Decentralised
heat and power
Industrial
plants
Power
Plants
Combined Heat&Power
Wind power
Increased
wind power
production
Central
Central
Decentralised Heat&Power
Industrial Plants
Wind Power
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CHP share of national power production
Year 2008
2013-12-04
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Development of Danish Power Plants
1980 - 2015
• The development of the Danish power plants during the last
35 years have focused on five key qualities:
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Clean
Green
Efficient
Flexible
Reliable
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Development of coal-fired CHP plants
DONG Energy 1970 - 2010
1970 – 1980
State of the art
sub-critical
Oil to coal conversion
Full CHP potential
η 38-40/85-90
1980 – 1995
supercritical
coal power plants
First world record
optimised supercritical
coal
η 45/90
1995 – 2000
Second world record
USC double reheat
coal/gas
η 47 – 49/91
2000 – 2005
USC multifuel
Biomass/gas (coal)
η 45 – 48/92
All plants were designed primarily for base load operation!
2013-12-04
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Development of SO2 emissions
from power plants 1988 - 2005
250
SO2 [kton/year]
 Wet FGD (3210 MW e)
200
150

Amagerværket (AMV3, 250 MW e, ABB, 1989)
Emissions
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Avedøreværket (AVV1, 250 MW e, MHI/FLS Miljø, 1990)
Permissions
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Esbjergværket (ESV3, 370 MW e, MHI FLS Miljø, 1992)
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Asnæsværket (ASV5, 650 MW e, ABB, 1992)
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Enstedværket (ENV3, 640 MW e, MHI/FLS Miljø, 1996)
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Nordjyllandsværket (NJV3, 385 MW e, MHI/FLS Miljø, 1998)
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Randersværket (RKV, 40 MW e, ABB, 1998)
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Stigsnæsværket (STV2, 250 MW e, Chiyoda/FLS Miljø, 1999)
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Avedøreværket (AVV2, 275 MW e, Noell/Niro, 2001)
 Semi-dry FGD (1085 MW e)
100

Studstrupværket (SSV3, 350 MW e, Niro/Fläkt, 1989)
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Studstrupværket (SSV4, 350 MW e, Niro/Fläkt, 1990)
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Fynsværket (FYV7, 385 MW e, Niro/Fläkt, 1991)
 SNOX plant (295 MW e)
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Nordjyllandsværket (NJV2, 295 MW e, HTAS, 1991)
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2112
ENS-China workshop on Future Flexible Power System for Renewable Energy Grid Integration, December 2013
2011
2010
2009
2008
2007
2006
2005
2004
2003
2002
2001
2000
1999
1998
1997
1996
1995
1994
1993
1992
1991
1990
1989
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1988
0
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SO2 emissions DONG Energy Power
SO2 Emission (dry, 6% O2), Monthly average in 2010
Power Plant
2013-12-04
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Wet FGD Costs
• Investments and operational costs
– CAPEX:
– OPEX:
45 MEUR on a 750 MW coal-fired unit
0.12 EUR/kg SO2 – 50 % lime stone and 50 % energy
• On an annual basis:
– Cost per MWh: 0.7 EUR at 47 % efficiency and 1 % sulphur in coal
• Desulphurisation costs compared to electricity trading price
– SO2 penalty:
1.2 EUR/kg SO2
– Electricity spot price: 30 – 55 EUR/MWh
– Note: 1 EUR is approximately 1.4 USD
2013-12-04
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Development of NOx emissions
from power plants 1988 - 2005
Emissions
NOx [ kton/year]
Permissions
Permissions
2013-12-04
ENS-China Workshop on Future Flexible Power System for Renewable Energy Grid Integration, December 2013
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NOx emissions DONG Energy Power plants
Monthly average in 2010
Power Plant
2013-12-04
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Cost of deNOx
• Investments and operational costs
– CAPEX:
– OPEX:
20 MEUR on a 750 MW coal-fired unit
0.27 EUR/kg NOx (0,19 EUR ammonia + 0.08 EUR catalyst)
• On an annual basis:
– Cost per MWh: 0.42 EUR at 47 % efficiency and 500 mg NOx /m3
• Costs of deNOx compared to electricity trading price:
– NOx-penalty:
0.7 EUR/kg NOx
– Electricity spot price: 30 – 55 EUR/MWh
– Note: 1 EUR is approximately 1.4 USD
2013-12-04
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Capacity and green energy goals by 2020
• Planned fuel conversions, wind power expansion, photovoltaic (PV)
capacity
– 0.5 GW more coal to biomass – wood pellets - before 2016
– 2 GW more onshore and offshore wind power – before 2020
– 1 GW PV before 2020
• Danish governmental targets for green energy in Denmark by 2020
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35 % of total energy consumption based on renewables
50 % of electricity production based on wind power
More than 10 % saving of total energy consumption compared to 2006
40 % CO2 reduction compared to 1990 demand
• Due to the announced energy policy, our energy system and our
production facilities are facing an overwhelming challenge in the future
to be able to transform to green production and comprehend the
volatile nature of the output from wind turbines and PV!
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Danish Power System right now – 3. December 2013
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The challenge for thermal power plants
Shortage
Surplus
Power
Rapid fluctuation
Consumption
Production
Time
• If Power shortage
– demand for steep positive load gradients on running plant
– demand for fast start up of hot/warm/cold thermal plant
• If Power surplus
– demand for steep negative load gradients on running plant
– demand for as low minimum stable generation as possible
• If Rapid fluctuations of power generation
– a demand for large positive/negative load gradients
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Role of history, tradition and mind set
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History, tradition and mind set plays a major role in the successful design of our plants.
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Basically Danish power plants were designed highly flexible already 30 years ago.
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Over the past 10-15 years much effort were put into increased load flexibility, reduction
of minimum load and steeper load gradients/ramping rates. All improvements were
done by own expertise as we have the required technical knowledge of all engineering
disciplines coming into play.
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Access to reliable power plant process data with high resolution for all engineers
involved over many years of operation allows us to combine theory with practice.
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The operators working in the power plant control rooms are highly educated, both in
theoretical and practical aspects.
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An important aspect is personal involvement of the control room staff in making their
power plant to operate perfectly and continuously seeking for further improvement of
flexibility and suggestions for new design/control modification. Optimisation is carried
out in close dialog between operator and engineering staff.
2013-12-04
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Consequences for the Danish energy system
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Increasing wind power capacity calls for more flexible thermal backup power
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Increased flexibility needs further development and investment in flexible
concepts
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Increasing wind power capacity minimises the annual equivalent full load
service hours for the thermal power plants and plant economy becomes difficult
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A new scheme for financing thermal power backup capacity is needed!
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CHP is part of the increasing balancing problem but can also be part of the
solution
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Further expansion of wind power capacity requires solutions for managing
the surplus of electricity by conversion to heat. Large heat pumps as a
supplement to the existing CHP plant is an effective possibility
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Agenda
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2013-12-04
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Achieved flexibilisation of Danish plants
• Daily cyclic operation of Ultra Super Critical (USC) power plants
• Reduction of minimum load (optimization approach)
• Start-up optimisation of USC units
• Comparison of flexibility within Europe
• General approach for attacking the challenge with wind power
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Daily cyclic operation of USC power plant
Overload: HP preheater
bypass mode (sliding in/out)
Base load
Load gradient on
Ngas: ± 9 %/min
(4 %/min on coal)
Automatic power
balancing of wind,
load gradient 9 %/min
Night operation below
Benson minimum
Benson minimum (once-through)
Original design minimum
Achieved minimum through optimization (level depends on power plant)
Several Benson-pass cycles in one day! Components designed
for 50 passes year. Redesign of component required due to
fatigue. Assessment concluded no problem with life time in
this case. In other cases the assessment may conclude that
component
after Workshop
X years. on Future Flexible Power System for Renewable Energy Grid Integration, December 2013
2013-12-04 must be replaced
ENS-China
27
Reduction of minimum load
Optimization approach used in Denmark
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Use stepwise approach: Slow stepwise load reduction until bottle-necks pop up. Then
analyse the actual problem thoroughly and find adequate solution
It is a prerequisite that the unit is thoroughly protected by alarms and warnings and that
all required measurements are continuously calibrated, maintained and can be trusted!
50%
Optimization approach
Test it/just try it…
50-45-40% load may be achievable just by trial and error
40%
Benson min/once-through min.
30%
Increasing number of alarms and trips
that must be addressed through control
optimization, careful component analyses
and possibly component redesign,
eventually component exchanges earlier
than anticipated
Typical challenges for the optimization (among other)
- Firing stability
20%
- Feed water pump flow stability
- Minimum steam flow through turbines
- Distributed Control System (DCS) programmable limitations
- Control room operators must participate actively
- ….challenges differ from power plant to power plant
2013-12-04
10%
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Start-up optimisation of USC Units
Synchronization
90  60 minutes
Rigid, non-reprogrammable control software
Start-up criteria are fixed today.
New software will allow flexible code:
If ∆T< x°C then continue start-up…
Future optimisation, though already slightly touched:
1) Warm-keeping of vital components at higher temperature
2) Redesign: convert creep life time to cyclic operation/fatigue
3) Conservatism in design to be discussed.
Power plant data
 Commissioned 1998
 Steam parameters, double reheat
580/580/580°C, 285/74/19 bar
 CHP with district heating
2013-12-04
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Designed mainly for baseload
Benson/once-through > 33% load
Minimum stable load: < 20% load
Ramp rate 4%/min (34-95% load)
Ramp rate 1-2%/min (20-33% load)
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Comparison of flexibility within Europe
• Typical positive load gradients
– Germany: 2-3 %/min (hard coal fired PP)
– Denmark: 3-4 %/min (hard coal fired PP)
– Denmark: 8-10 %/min (gas fired PP)
– CCGT commissioned 2011: 3 %/min
• Typical minimum stable generation (minimum load)
– Germany: 45-55 % (hard coal fired PP)
– Denmark: 10-20 % (hard coal fired PPs commissioned between 1985 and 1997)
– CCGT commissioned 2011: 50 - 52 %
• This superior flexibility is due to decades of ongoing improvements!
2013-12-04
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Integration of wind power is attacked
at all levels from system to equipment
Research &
Development
Offline input
Scenario studies
Portfolio
optimisation
Thousands of
measurements per
power plant processed
Detailed
engineering
process
optimisation
Online thermodynamic
process supervision software
(comparison of actual and ideal process)
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Agenda
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2013-12-04
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Assumptions and Risks
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2013-12-04
Full organisational acceptance
Adaptation to local conditions
Showstoppers
Going to the edge and knowing it
Avoiding plant trips but ready to take risks during
implementation phase
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• 25 years experience with integration of a fast growing and significant
wind power capacity has demonstrated satisfactory results
• Thermal coal-fired power plants designed as base load units have been
transformed to some of the most flexible power plants in Europe
• Today’s standard is:
– load gradient about 4 % per min. for coal fired units, 9 % per min. for gas fired units
– minimum load down to 10 %
– fast start in less than 1 hour
• Clear goals, strong – competent and committed - development and
implementation teams have successfully developed and implemented the
necessary concepts to fulfil the goals
2013-12-04
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Optimising wind integration in Baicheng City
Attack the challenges on three levels
1. Scenario studies looking 10 - 20 years ahead to understand changing
demands in the area
A.
B.
Study the economical value of all flexibility handles and
rank which flexibility handles should be prioritized/implemented first
Use historical wind data and so on from the area and scale wind power
2.
Top-down/Portfolio optimisation through development of software
3.
Power plant optimisation (each unit to be analysed)
A.
B.
2013-12-04
Load gradients, minimum load, start-up time and costs, timing of start
Through data analyses and operator interviews understand flexibilisation
bottle-necks and define which flexibility level is achievable
35
Thank you for your attention
Horns Rev 1 Offshore Wind Farm
160 MW, North Sea, Denmark
2013-12-04
36

High Flexibility Power Plants-25 Years of Danish Experience

Transcription

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