“steinmüller-tagung” 2013 23. – 24. april 2013 · tubesheet dia. 2.9 m. no. of tubes 1878....
TRANSCRIPT
Steam Generation – Concepts and Supplies 11
“Steinmüller-Tagung” 2013 23. – 24. April 2013
Gummersbach, Germany
Title:
Presenter:
Steam Generation – Concepts and Supplies
Dr. Ralph Ernst
Steam Generation – Concepts and Supplies 2
Employment Record Ralph Ernst
Since 2013
STEINMÜLLER ENGINEERING GMBH
Department Manager Steam Generation2010 - 2012 Department Manager Chemical Plant Components
2009 - 2010 Process Engineer Chemical Plant Components
2008 - 2009 Process Engineer Flue gas Cleaning
2005 - 2007FISIA BABCOCK ENVIRONMENT GMBHProcess Engineer Flue gas Cleaning
2002- 2005
TECHNISCHE UNIVERSITÄT DARMSTADTErnst Berl Institut für Technische ChemiePost – Doc (Homo- and heterogeneous catalysis)
1998 - 2002 PhD „Simultaneous ad – and desorption of HCl and SO2 on MgO supported active carbon coke“
1991 - 1997Universitary studiesChemical Engineering in Darmstadt / Bordeaux
Steam Generation – Concepts and Supplies 3
A. Services for power plants
•
Motivation
•
Engineering services
•
Examples
B. Components for chemical plants
•
Objectives
•
Examples
C. Summary
Content
Steam Generation – Concepts and Supplies 4
A) Services for power plants - Motivation
Reasons for pressure part modifications
• Boiler capacity and efficiency increase
• Change in fuel qualities
• Problems with wear, fouling, corrosion
• Enhancing part load performance
• Specific needs for SCR units
• Enhanced flexibility
• Reduction of start –
up time
ZÜ-Austritt
Überhitzer-Schott
Ü3
ZÜ2Ü4
ZÜ 1.2
Ü2
ZÜ 1.1
EK3
EK5
EK4
Überhitzer-Eintritt
EK2
ECO 2
ECO 1
ECO 3
HD - 1.2
HD - 1.1
Speisewasser-
Eintritt
EK1
ZÜ-Eintritt
HD-AustrittZÜ-Austritt
Überhitzer-Schott
Ü3
ZÜ2Ü4
ZÜ 1.2
Ü2
ZÜ 1.1
EK3
EK5
EK4
Überhitzer-Eintritt
EK2
ECO 2
ECO 1
ECO 3
HD - 1.2
HD - 1.1
Speisewasser-
Eintritt
EK1
ZÜ-Eintritt
HD-Austritt
Vattenfall EuropeLignite fired boilerJänschwalde535 °C / 175 bar / 815 t/h
Steam Generation – Concepts and Supplies 5
Appropriate process calculation is key technology for all
pressure part engineering works
•
SE provides a detailed simulation of complex boilers by its
in-house design tool DimBo
•
DimBo’s governing equations for heat transfer and material
properties are based on actual FDBR standards
•
Various scenarios and load cases are calculated within one model
A) Services for power plants – Engineering
DimBo
Circulation ratio
Heat transfer
Thermodynamics
Pressure drop
Steam Generation – Concepts and Supplies 6
A) Services for power plants - Engineering
Engineering according to various relevant design codes
and standards
• Material design
• pressure part stress calculation
• structural design
calculations
• Basic and detail engineering
• Drawings
• Specifications
Steam Generation – Concepts and Supplies 7
A) Services for power plants – Example PCK SchwedtOriginal plant key data
•
PCK refinery, Schwedt (Germany)•
Two parallel boilers•
Continuous steam output: 620 t/h•
Main steam parameters:
520 °C / 90 bar•
Fuels:-
High Soaker Conversion residue (HSC-R)-
Visbreaker / vacuum residue-
Heavy fuel oil-
Refinery gas
Schwedt
©
PCK Raffinerie GmbH
Steam Generation – Concepts and Supplies 8
A) Services for power plants – Example PCK Schwedt
Objectives
• Enable throughput of 45 t/h HSC-R• Increase steam output to 750 t/h• Good burnout, minimum unburned carbon• Reduce fouling• High full-load availability
Steinmüller Engineering
• Conceptual design• Basic Engineering• Detail Engineering
Balcke Dürr
• Manufacture of heating surfaces• Installation works
Scope split
Steam Generation – Concepts and Supplies 9
Measures 2006 / 2007
1.
Modification of existing burners
2.
Additional counter air flow system
3.
Two additional burners
4.
Examination of FD fan and additional fresh-air suction system
5.
Change of evaporator screen and Superheater 3
6.
Modification of the drum
7.
Additional soot blowers in front of the evaporator screen
By Client8.
Refurbishment of the feedwater pump
9.
New ID fan
7
2 1
34
6
5
A) Services for power plants – Example PCK Schwedt
Steam Generation – Concepts and Supplies 10
A) Services for power plants – Example PCK Schwedt
SH 3TB
=90 mm
EVATB
=360 mmSootblowers
EVATB =180 mm
SH 3TB =180 mm
Before retrofit After retrofit
Pressure part modification• Rearrangement of EVA• Rearrangement of SH3• Additional Sootblowers
Steam Generation – Concepts and Supplies 11
A) Services for power plants – Example PCK Schwedt
New heating surfaces
Steam Generation – Concepts and Supplies 12
A) Services for power plants – Example PCK Schwedt
Performance test on Boiler 1 in March 2007
Project design data Contract Performance test
Steam generator output 750 t/h 750 t/h
Fuel consumption HSC-R 45 t/h 45 t/h
Main steam temperature 520 °C 520 °C
Main steam pressure 90 bar 90 bar
Pressure loss water/steam -
side <10 bar < 10 bar
NOx before SCR (@ 3 % O2
, dry) ≤1200 mg/Nm³ < 800 mg/Nm³
CO before SCR (@ 3% O2, dry) ≤
10 mg/Nm³ < 10 mg/Nm³
Steam Generation – Concepts and Supplies 13
A) Services for power plants – Example PCK Schwedt
Measures 2010 - 2012
Installation of new Economizer & Bypass line
SE Scope
• Conceptual engineering• Basic engineering• Specifications• Consulting during procurement• Supervision during installation works
Client
• Procurement of heating surfaces• Installation works
Motivation
• Enhance the thermal efficiency of the boiler• Lower the air heater inlet temperature by 30 K• Enlarge running time• Gain flexibility for part load
Steam Generation – Concepts and Supplies 14
A) Services for power plants – Example PCK Schwedt
• Examination of various concepts• Result: two –
staged heating surface downstream SCR• Bypass line to
• compensate fouling during running time• enhance flexibility for part load operation
Installation of new EconomizerHeating surfaces
Steam Generation – Concepts and Supplies 15
A) Services for power plants – Example PCK Schwedt
Distributor
New heating surface –
finned tubes
Steam Generation – Concepts and Supplies 16
A) Services for power plants – Example PCK Schwedt
New sootblowers
New duct
Steam Generation – Concepts and Supplies 17
A) Services for power plants – Example Mehrum Power Station
Plant key data•
Electrical power: 750 MW
•
Bituminous coal fired boiler
•
Steam parameters:
535 °C / 200 bar
Objective
•
Maintaining the flue gas temperature down-
stream ECO over the entire boiler load to ensure proper performance of the DeNOx plant (Selective Catalytic Reduction)
Mehrum
Steam Generation – Concepts and Supplies 18
EVA Separator
A) Services for power plants – Example Mehrum Power Station
Measures
• New bypass line
• Additional valves and fittings
• Additional measurement devices
• Modification of boiler control
Scope Split
SE: • Conceptual design• Basic engineering• Detail engineering
Client:• Procurement• Installation
Steam Generation – Concepts and Supplies 19
B) Components for chemical plants - Introduction
Engineering and supply for• Process gas coolers (downstream sec. reformer)
• Syngas coolers for coal gasification plants
• Waste heat boilers for catalytic processes (nitric acid plants and similar)
Motivation• Increase of plant capacity
• Optimization of thermal and mechanical designTechnologies• Natural circulation
•
horizontal fire tube boilers
•
vertical fire tube boilers
•
Texaco boilers
• Forced circulation –
water tube boilers incl. superheater
• Radiant syngas coolers
Steam Generation – Concepts and Supplies 20
B) Components for chemical plants – Example ChalampéReplacement of a reactor / waste heat boiler for catalytic HCN - synthesis
Client: Rhodia / ButachimieLocation: Chalampé, FranceProcess: Catalytic Reaction (Andrussow Process)
CH4 + NH3
+ 1.5 O2
HCN + 3 H2
O
• Exothermic reaction•
Product tends to decompose at high temperatures
• Fast cooling required to enhance yield• Plant capacity increased by 15 %
Chalampé
Steam Generation – Concepts and Supplies 21
Scope split and technical data
Steinmüller Engineering Client (Rhodia / Butachimie) basic and detail engineering erection
supply of hardware installation
transport to location thermal insulation
installation of refractory catalyst
commissioning (with SE support)
Project design data Gas side Water / SteamTemperature @ inlet 1100 °C 227 °C
Temperature @ outlet < 285 °C 227 °C
Pressure 2.1 bar 26.5 bar
Mass flow 156 000 kg/h 121 000 kg / h
B) Components for chemical plants – Example Chalampé
Steam Generation – Concepts and Supplies 22
Technology• Natural circulation• Vertical arrangement• Fire tube boiler• Conical upper tubesheet• embedded tubesheet
SE’s Scope of supply• New waste heat boiler• Ceramic ferrules• Drum internals• Refractory• Piping modification (red)
B) Components for chemical plants – Example Chalampé
Steam Generation – Concepts and Supplies 23
Design supported by CFD simulationand FEM stress calculation
B) Components for chemical plants – Example Chalampé
Steam Generation – Concepts and Supplies 24
Challenges•
Large tubesheet diameter (2.8 m) •
Short time schedule (12 month)•
Heavy forgings •
Stress calculation•
Steam outlet on actual plant
Design improvements1.
Conical tubesheet to ensure cooling2.
Double walled ring3.
Grids with low resistance to enhance circulation
4.
Number of risers doubled
1 2
3
3
4
B) Components for chemical plants – Example Chalampé
Steam Generation – Concepts and Supplies 25
Upper conical tubesheet embedded in double walled ring
Upper double walled ring “Knuckle”
Heavy forgingsB) Components for chemical plants – Example Chalampé
Steam Generation – Concepts and Supplies 26
Manual welded upper tubesheet
Assembly of vessel and upper part
B) Components for chemical plants – Example Chalampé
Steam Generation – Concepts and Supplies 27
DimensionsHeight over all
11 m
Max diameter
4.4 m
Tubesheet dia.
2.9 m
No. of tubes
1878
Weight
80 tons
•
Fabrication in German workshop
•
Engineering and manufacturing
time 12 month
•
Commissioning: June 2013
B) Components for chemical plants – Example Chalampé
Steam Generation – Concepts and Supplies 28
B) Components for chemical plants – Example GrowHow Ince
Revamp of a reactor / waste heat boiler for catalytic NO – synthesis
Ince
Client: Kemira GrowHow Ltd.Location: Ince, UKProcess: Catalytic Oxidation (Ostwald Process)
2 NH3
+ 2.5 O2
2 NO + 3 H2
O
Replacement of existing WHB with design modifications
Steam Generation – Concepts and Supplies 29
Scope split and technical data
Steinmüller Engineering Client (Kemira GrowHow UK) basic and detail engineering erection
supply of waste heat boiler installation
supply of new burner cover catalyst (Pt –
gauze)
commissioning (with SE support)
Project design data Gas side Water / SteamTemperature @ inlet 900 °C 249 °C
Temperature @ outlet 690 °C 249 °C
Pressure 9 bar 38 bar
Mass flow 160 000 kg/h 45 000 kg / h
B) Components for chemical plants – Example GrowHow Ince
Steam Generation – Concepts and Supplies 30
New design of burner cover and flange connection
• design supported by FEM calculation • reduction of thermal stress• automatic ignition device (swivel motor)
B) Components for chemical plants – Example GrowHow Ince
Steam Generation – Concepts and Supplies 31
Technology• Water tube boiler with forced circulation
• Vertical arrangement
• Spiral evaporator bundle
• Bended wall coils
• Headers and distributors outside vessel
• Purchase order received 02 / 2013•
All components manufactured in German workshops
•
Vessel fabrication and final assembly at Balcke Dürr (Germany)
• Delivery date 02 / 2014
B) Components for chemical plants – Example GrowHow Ince
Steam Generation – Concepts and Supplies 32
C) Summary
Steinmüller Engineering is a competent partner for
•
Process engineering
•
Mechanical design
•
Stress calculation
•
Technical specifications
•
Project execution
•
Hardware supply
in a wide range of applications for steam generation
Steam Generation – Concepts and Supplies 33
Thank you
for your
attention!