workshops and training on r&m and operational practices ...€¦ · chair of power plant...

www.kwt-cottbus.de/en/

Chair of Power Plant Technology

Prof. Dr.-Ing. H.J. Krautz (Head of Chair)

Dr.-Ing. M. Klatt (Thermal Power Research Group)

05 November 2012

Workshops and training on R&M and operational

practices for the SA thermal power sector, studies and

sevices


Outline

Workshops and training on R&M and operational practices for the SA thermal power sector, studies and services

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• Short Introduction of the Chair of Power Plant Technology

• Project Proposals

• Trainings

• Workshops

• Feasibility Studies

• Test & Lab Services

• References / R&D background in the thermal power sector

www.kwt-cottbus.de/en/ 3

IntroductionConventional Power Plant Technologies

0,5 MW Oxyfuel Test Rig ALVA 20 –Combustion Test Rig

Test Boiler VVS 400

CFD Modelling

Coal- and Biomass Laboratory

Lignite Drying


IntroductionRenewable Energies

WindmillFirst stone laying forH2 Research Centre

H2 Research Centre

Combined Experimental Test Rig Renewable Energies

Pressurised ElektrolyserUtilisation of Biomass


Objective• Basic knowlegde upgrade/refreshment for control engineers• Knowledge about power engineering processes• Different types of power plants• Practice in design and optimising of cyclesContents• Types of power plants, basic components of conventional power plants• Steam cycles; gas turbine cycle; methods to improve efficiency, thermodynamic

calculations of cycles• Design of power power plants and combined heat and power plants• Fuels; boiler; firing systems; combustion calculation, heat transfer• Start-up, part and full load operation, maintenance, I-T systemsOrganisation• 2 lecturers from btu• 3 - 5 days, South Africa• 15 - 25 engineers

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Proposals: TrainingsPower Plant Technology Course


Objective• Understanding of the operations of turbines and optimum system performance• Cost-effective decisions and better operations and reduced maintenance costs• Typical design solutions as well as criteria for the selection of appropriate solutionsContents• Energy conversion, thermodynamic cycles, real/ideal machine, losses, similarity • Comparison of current designs, typical design solutions, efficiency, availability,

upgrading, maintenance, life-cycle-costs• Design & improvement of rotor /blades & vanes /casing etc.• Operation, long term experience, incidents /remedies: Start-up, control, load

rejection, run-away speed. Typical failures, repair techniques combined with retrofitOrganisation• 1 - 2 lecturer from btu• 3 - 4 days, South Africa• 15 - 25 engineers

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Proposals: TrainingsMechanical Course Turbines


Objective• Deals with different technologies, with which low CO2-emissions can be achieved• Main components and their technical implementation are presentedContents• CO2 and the World Climate• Technologies for Capture

(Postcombustion, Precombustion, Oxyfuel)• Technologies for Transport• Technologies for Sequestration• Efforts and Cost for CCSOrganisation• 2 - 4 lecturer from btu• 1 week, South Africa (or 2 weeks Germany if laboratory work is included)• 10 - 15 engineers

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Proposals: WorkshopsClean Coal Technologies


Objective• Improvement of power supply quality• Efficiency enhancement and emission reduction• Optimisation of the cost-benefit-ratioContents• Process data analysis, systems and components condition identification• Environvental audit and assessment• Solutions for substantial extension (10 years or more) of the expected operating life

of the plant• Optimization of existing plant components and adaptation of the plant for operation

conditions and operation efficiencyOrganisation• 2 consultants from btu• 3 month

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Proposals: Feasibility StudiesPower Plant Rehabilitation


Proposals: Feasibility StudiesMaintenance Organisation

Objective• Improvement of maintenance organisation• Optimisation of the cost-benefit-ratio• Mobilisation of power supply by availibility enhancementContents• Availibility and failure analysis• Maintenance organisation analysis• Maintenance cost analysis• Lifetime consumption evaluation• System/component classification and ranking• Maintenance structuring recommendationsOrganisation• 2 consultants from btu• 3 month


Equipment• Coal lab

(mechanical, thermal, chemical characterisation)• Ash lab

(composition and thermal behaviour)• Corrosion test probes• Reaction kinetics batch reactor (20 kW)• Burner test facility (400 kW)

Organisation• 1 consultant, 1 - 2 lab engineers from btu• duration depends on analysis objectives and test programm

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Proposals: Test&Lab ServicesCombustion, Slagging, Corrosion, Reaction Kinetics


Research activities to improve the flexibility of lignite power plants(Research project plus endowed professorship at BTU)

• Lignite drying and integration into power plants• Development of start-up & ignition burners• Corrosion of working materials of power plants• Dynamic modelling of units as base for the improvement of block-unit flexibility

(overall concept)• Maintenance optimization for flexible load operations• CO2 transport

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R&D BackgroundFlexibility and operation of power plants


• Integration of dryer into the power plant process• Modification of steam generator for lignite dust (full and partial)

Logistic interfaces between DDWT and block-unit:

R&D needs: site-specific integration into power plant processes

Exhaust vapour usage

Dry lignite

Power supply/Instrumentation

Supply of lignite for DDWT/boiler

Cooling water supply and recycling

Heateing steam supply

Supply of inert gases

Recirculation of condensates

R&D BackgroundFlexibility of power plants


VVS 400 – Combustion test facility 400kWth

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Fuel dosing

Main burner with burner muffle

Hot water generator

Washing system

Chimney

Receiver tankNominal capacity400 kWth

Control range50 – 110%

Mode of operationAir and oxyfuel

FuelsNatural gas, lignite dust

Facility scheme VVS400



VVS 400 – Combustion test facility 400kWth

• Investigation of electrical ignition systems

• Dry coal ignition and auxiliary burners

• Corrosion investigation for different materials and load profiles

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Auxiliary air (optional)Max. 40 Vol.%-O2Swirler: 5-60°Swirl air

Max. 40 Vol.%-O2Swirler: 0-60°

Combustion airMax. 40 O2 Vol.%

Carrier gas + Lignite dust. Max. 21 Vol.%-O2

Natural gas

Core pipe Swirler

Current burner

Measurement connection



Systems modellingas the basis forblock flexibility

(general concept)



Maintenance optimization for flexible load operations



• COOTRANS – CO2 transport from the source to the sink

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CO2 transport test rig

• 4“• 800 m• 0-150 bar• 5-70°C• 30-90 m³/h

R&D BackgroundCO2 Transport


R&D background in the thermal power sector

Dynamic Systems and

Component Modelling

Availability and Maintenance

ResearchCO2 Capture &

Pipeline Transport

Flexible Power Plant

Combustion and Start-Up Systems

workshops and training on r&m and operational practices ...€¦ · chair of power plant...

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