development and customized application of modern ......case study – kostolac coal: lignite lhv: ~...
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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)
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Steinmüller Engineering Conference 2016 Steinmüller Engineering Conference 2016
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
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Steinmüller Engineering Conference 2016 Steinmüller Engineering Conference 2016
1. Introduction – Why is this topic important?
Source: Wikipedia
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1. Introduction – Where are the main consumers – Top Ten
Lignite
Bituminous coal
SE Home Market IHI Home Market
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Steinmüller Engineering Conference 2016
1. Introduction – Fuel Range Selection
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Steinmüller Engineering Conference 2016 Steinmüller Engineering Conference 2016
Our Approach – Customization / Product Development
Engineering – Methods and Solutions
Future Development
Introduction – Changing Markets
Case Study – Lignite Firing System
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2. Our Approach – How to handle the change?
Source: teneigthygroup
Customization
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Steinmüller Engineering Conference 2016 Steinmüller Engineering Conference 2016
2. Our Approach – From Needs to an Optimized Solution
Very low emission
Tight time schedule
High flexibility
Low operating costs
Customized Solution
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Steinmüller Engineering Conference 2016 Steinmüller Engineering Conference 2016
2. Our Approach – Customized Solution / Technical
Customized Solution
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Steinmüller Engineering Conference 2016
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
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2. Our Approach – Customized solution / Scope
Customized Solution
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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
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Steinmüller Engineering Conference 2016 Steinmüller Engineering Conference 2016
Our Approach – Customization / Product Development
Engineering – Methods and Solutions
Future Development
Introduction – Changing Markets
Case Study – Lignite Firing System
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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
- ……….
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Steinmüller Engineering Conference 2016 Steinmüller Engineering Conference 2016
3. Engineering
Client Requirements
Analysis of Plant Performance
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3. Engineering – Analysis of Plant Performance
Milling and Drying
Analysis of Combustion Performance
Analysis of Plant Performance
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Steinmüller Engineering Conference 2016 Steinmüller Engineering Conference 2016
3. Engineering
Client Requirements
Fuel Analysis
Analysis of Plant Performance
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Steinmüller Engineering Conference 2016 Steinmüller Engineering Conference 2016
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
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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
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3. Engineering
Client Requirements
SE Design Tools, CFD
Fuel Analysis
Analysis of Plant Performance
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3. Engineering – SE Design Tools / SM-V-Burner
Secondary air I + II
Coal / Air
Core air
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Steinmüller Engineering Conference 2016 Steinmüller Engineering Conference 2016
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
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3. Engineering – CFD
Gas-/Solid Flow
Single Burner
Furnace
Solution
Furnace
Itera
tion
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Steinmüller Engineering Conference 2016 Steinmüller Engineering Conference 2016
3. Engineering
Client Requirements
Experience
SE Design Tools, CFD
Fuel Analysis
Analysis of Plant Performance
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Steinmüller Engineering Conference 2016 Steinmüller Engineering Conference 2016
3. Engineering – SE Experience / Boiler Types
3-Pass
2- Pass
Tower
131
m
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3. Engineering – SE Experience / Furnace Types
Grate Opposite Wall Slag Tap Front Wall
Tangential CFB T-Firing Gas-/Oil
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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)
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Steinmüller Engineering Conference 2016 Steinmüller Engineering Conference 2016
3. Engineering
Client Requirements
Experience
CFD, SE Design Tools
Fuel Analysis
Analysis of Plant Performance
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Steinmüller Engineering Conference 2016 Steinmüller Engineering Conference 2016
Our approach – Customization / Product Development
Engineering – Methods and Solutions
Future Development
Introduction – Changing Markets
Case Study – Lignite Firing System
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Steinmüller Engineering Conference 2016
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
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Steinmüller Engineering Conference 2016
4. Case Study – Kostolac / Scope of Supply
New Over Fire Air System
Steinmüller RSM® Low-NOx burner
New Coal Dust Distribution System
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Steinmüller Engineering Conference 2016
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)
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Steinmüller Engineering Conference 2016 Steinmüller Engineering Conference 2016
Our approach – Customization / Product Development
Engineering – Methods and Solutions
Future Development
Introduction – Changing Markets
Case Study – Lignite Firing System
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5. Future Development
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Steinmüller Engineering Conference 2016 Steinmüller Engineering Conference 2016
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
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Thank you for your attention