Development and customized application of modern ......Case Study – Kostolac Coal: Lignite LHV: ~ 7.8 MJ/kg W: 42-45% A: 20-26% Sulzer type steam generator SH steam flow 1.000 t/h

Steinmüller Engineering Conference 2016 Steinmüller Engineering Conference 2016

Development and customized application of modern combustion systems

Steinmüller Engineering Conference 2016

Speakers: Paolo Schmidt-Holzmann (Department Manager Combustion Systems Proposals) Dr.-Ing. Stefan Hamel (Department Manager Combustion Systems Process)


Our Approach – Customization / Product Development

Engineering – Methods and Solutions

Future Development

Introduction – Changing Markets for Combustion Systems

Case Study – Lignite Firing System

Modern Combustion Systems


1. Introduction – Why is this topic important?

Source: Wikipedia


1. Introduction – Where are the main consumers – Top Ten

Lignite

Bituminous coal

SE Home Market IHI Home Market


1. Introduction – Fuel Range Selection




Future Development

Introduction – Changing Markets



2. Our Approach – How to handle the change?

Source: teneigthygroup

Customization


2. Our Approach – From Needs to an Optimized Solution

Very low emission

Tight time schedule

High flexibility

Low operating costs

Customized Solution


2. Our Approach – Customized Solution / Technical

Customized Solution


Experience of Field Service

Individual Design of the Components of the Combustion System

One of a Kind

Design Tools

Experienced Engineers

2. Our Approach – Customized Solution / Technical Components


2. Our Approach – Customized solution / Scope

Customized Solution


2. Our Approach – Product Development / SM-V-Burner Tests

• IHI combustion test facility in Aioi, Japan

• SM-V burner combustion tests with detailed evaluation and improvement of combustion behaviour




Future Development




3. Engineering

Client Requirements

- Change of Boundary Conditions

(legal, economic)

- Change in Fuel Quality

- Improvement of Slagging Behaviour

- Reduction of Emissions

- Increase of Efficiency

- Intention to Save Operational Costs

- ……….


3. Engineering

Client Requirements

Analysis of Plant Performance


3. Engineering – Analysis of Plant Performance

Milling and Drying

Analysis of Combustion Performance



3. Engineering

Client Requirements

Fuel Analysis



3. Engineering – Fuel Analysis

Hard Coal Lignite Peat Wood

Volatile Matter in wt.-% (dry)

LHV in MJ/kg (dry)

10 30 20 40 50 60 70 80 90 100 0

20

40

35

30

25

C, H in daf


3. Engineering – Fuel Analysis A

sh

So

fte

nin

g a

nd M

eltin

g T

em

pe

ratu

res in

°C

Range of Softening

Range of Melting


3. Engineering

Client Requirements

SE Design Tools, CFD

Fuel Analysis



3. Engineering – SE Design Tools / SM-V-Burner

Secondary air I + II

Coal / Air

Core air


3. Engineering – SE Design Tools / SM-V-Burner Design Tool

SM-V Burner:

Process Design/ Dimensioning in Excel • Automatic interface

connection to 3D CAD tool

• On-the-fly Design check


3. Engineering – CFD

Gas-/Solid Flow

Single Burner

Furnace

Solution

Furnace

Itera

tion


3. Engineering

Client Requirements

Experience

SE Design Tools, CFD

Fuel Analysis



3. Engineering – SE Experience / Boiler Types

3-Pass

2- Pass

Tower

131

m


3. Engineering – SE Experience / Furnace Types

Grate Opposite Wall Slag Tap Front Wall

Tangential CFB T-Firing Gas-/Oil


25 t/h

Bit. Coal

1000 t/h

Lignite

2000 t/h

Bit. Coal

2500 t/h

Lignite

3. Engineering – SE Experience / Plant Size

Cologne Cathedral

(156m)


3. Engineering

Client Requirements

Experience

CFD, SE Design Tools

Fuel Analysis



Our approach – Customization / Product Development


Future Development




4. Case Study – Kostolac

Coal: Lignite

LHV: ~ 7.8 MJ/kg

W: 42-45%

A: 20-26%

Sulzer type steam generator

SH steam flow 1.000 t/h

SH pressure / temp. 186 bar/540°C

RH pressure / temp. 43.7 bar/540°C

Reduction of NOx Emissions from 450 mg/Nm³

to <191 mg/Nm³ (6% O2)

Reduction of Excess Air 1.28 to 1.15 at Furnace Exit

Maintaining Steam Temperatures

Target


4. Case Study – Kostolac / Scope of Supply

New Over Fire Air System

Steinmüller RSM® Low-NOx burner

New Coal Dust Distribution System


4. Case Study – Kostolac / Results

NOx reduction

from 450 mg/Nm3 (6% O2)

to 191 mg/Nm3 (6% O2)

boiler efficiency = const.

Average 175 mg/Nm³ (6% O2)


Our approach – Customization / Product Development


Future Development




5. Future Development


Summary

Steinmüller Engineering provides

- long term experience in: - Firing systems (solid fuel, gas, oil firing)

- Various fuels (all coals, biomass, gas, oil, refinery residues…)

- Calculation tools / Engineering methods (inhouse tools, DimBo, CFD,….)

- own technology for firing systems to reach lowest emissions: - SM-V burners for bituminous coals

- RSM® Low-NOx burners for lignite coals

- customized solutions to each client: - Adaption of SE burner and firing systems to individual clients

- Optimization of existing burner/firing systems

- overall solutions: - Firing system – Steam generator – Flue gas cleaning


Thank you for your attention

Documents

Development and customized application of modern ......Case Study – Kostolac Coal: Lignite LHV: ~ 7.8 MJ/kg W: 42-45% A: 20-26% Sulzer type steam generator SH steam flow 1.000 t/h