Combustion and Boiler Performance Assessment of Kardia Power Plant Dr. M. Michel, I. Tsolakidis DEBCO Final Conference Brussels, December 10, 2012
Thermal Calculation of the Boiler Boiler design 100%-Load (1976) DEBCO Final Conference Brussels - 10./11. Dec 2012 - P 2
Co-Firing of Cardoon The cardoon was cultivated and harvested in the region before the lignite was blended at the coal yard Source: Agriconsulting 2010 DEBCO Final Conference Brussels - 10./11. Dec 2012 - P 3
Fuel Feeding System DEBCO Final Conference Brussels - 10./11. Dec 2012 - P 4
Agenda 1st topic 2nd topic 3rd topic Samples and Data (M. Michel) Recalculation and Assessment (I. Tsolakidis) summary DEBCO Final Conference Brussels - 10./11. Dec 2012 - P 5
Samples analyzed in Stuttgart Lab Joint measurement Campaign 19.10. 19.10. 20.10. 21.10. 22.10. 23./24.10. 25.10. pure lignite lignite + biomass lignite + biomass lignite + biomass lignite + biomass No samples pure lignite K1 K7 K2/K8 K3/K9 KS1 K4/K10 K5/K6 KS2 FA1 FA2 FA3/FA4 NA1 NA2 NA3 NA4 NA5 K: fuel sample FA: fly ash sample KS: pulverized coal sample NA: bottom ash sample DEBCO Final Conference Brussels - 10./11. Dec 2012 - P 6
Analyses carried out Fuel and pulverized fuel samples Fly and bottom ash samples Proximate Analysis Ultimate Analysis Calorific Analysis Ash Analysis (major and minor ash elements) Ash melting behaviour (acc. DIN 51730) Sieve Analysis (selected coals) Water and ash content Ash Analysis (major and minor ash elements) Sieve Analysis (selected ashes) Organic and inorganic carbon in ash (TC, TIC, TOC) DEBCO Final Conference Brussels - 10./11. Dec 2012 - P 7
Fuel Analysis I Fuel type Pure Lignite [raw] K1 (19.10.) K5 (25.10.) K6 (25.10.) Moisture % 53,8 52,2 50,8 Ash % 14,2 18,6 17,8 Fuel type Pure Lignite [waf]] Volatiles % 63,9 66,8 63,1 C % 61,9 61,7 64,1 H % 4,3 4,5 4,7 S % 0,8 2,6 1,3 N % 1,7 3,7 1,9 Cl % <0,3 <0,3 <0,3 O % 31,3 27,5 27,9 LHV MJ/kg 5,346 4,677 5,731 DEBCO Final Conference Brussels - 10./11. Dec 2012 - P 8
Fuel Analysis II Lignite with 10% biomass share Fraction >10mm biomass lignite lignite with lime clay Fuel type Lignite with 10% cardoon [raw] K2-4 / K7-10 Min value Max value Moisture % 51,6 55,7 Ash % 12,4 16,3 Fuel type Lignite with 10% cardoon [waf]] Volatiles % 61,2 65,7 C % 60,5 63,1 H % 4,2 4,5 S % 0,9 1,0 N % 1,5 1,7 Cl % <0,3 <0,3 O % 29,8 32,8 LHV MJ/kg 4,987 5,558 Fraction 1-10mm DEBCO Final Conference Brussels - 10./11. Dec 2012 - P 9
Fuel Analysis III Ash Analysis Fuel type K1 K2-4 / K7-10 K5 K6 (19.10.) min max (25.10.) (25.10.) pure lignite lignite with 10% cardoon pure lignite SiO2 % 23,45 22,48 28,12 32,30 36,29 Al2O3 % 10,00 8,84 11,60 12,50 14,40 TiO2 % 0,43 0,38 0,51 0,60 0,69 Fe2O3 % 5,12 4,88 6,23 5,86 6,13 CaO % 50,80 43,00 (53,30) 51,50 36,80 30,30 MgO % 3,80 3,40 4,03 4,06 3,48 SO3 % 4,82 4,41 6,93 5,10 6,35 Na2O % 0,32 0,35 0,62 0,49 0,64 K2O % 0,78 0,82 1,24 1,07 1,28 P2O5 % 0,27 0,25 0,35 0,30 0,31 DEBCO Final Conference Brussels - 10./11. Dec 2012 - P 10
Influence of biomass I DEBCO Final Conference Dec. 10, 2012, Brussels - P <Nr.>
Fuel Analysis IV Ash Melting Behaviour Sample Fuel type Sintering point [ C] Softening point [ C] Melting point [ C] Fluid Point [ C] K1 K2 K3 K4 K5 K6 (19.10.) (20.10.) (21.10.) (22.10.) (25.10.) (25.10.) 100% lignite 10% biomass 10% biomass 10% biomass 100% lignite 100% lignite 850 884 1145 1123 827 1124 1353 1360 1320 1360 1260 1176 1420 1387 1456 1388 1285 1207 1510 1418 1488 1446 1323 1254 DEBCO Final Conference Brussels - 10./11. Dec 2012 - P 12
Ash Analysis I ash type Fly ashes from FA1 FA2 FA3 FA4 (20.10.) (22.10.) (25.10.) (25.10.) lignite firing with 10% cardoon pure lignite firing SiO2 % 26,6 27,0 32,0 35,4 Al2O3 % 11,3 11,0 12,5 13,7 TiO2 % 0,49 0,51 0,61 0,66 Fe2O3 % 5,73 6,24 6,21 6,45 CaO % 43,2 43,0 36,5 32,0 MgO % 3,71 4,04 3,85 3,64 SO3 % 5,46 6,21 6,39 5,74 Na2O % 0,48 0,52 0,54 0,62 K2O % 1,16 1,09 1,07 1,24 P2O5 % 0,31 0,32 0,31 0,30 DEBCO Final Conference Brussels - 10./11. Dec 2012 - P 13
Ash Analysis II Unburned C 20.10. 22.10 25.10. 25.10. 19.10. 20.10. 21.10. 22.10. 25.10. Organic C in bottom ash is doubled during co-firing DEBCO Final Conference Brussels - 10./11. Dec 2012 - P 14
Agenda 1st topic 2nd topic 3rd topic Samples and Data (M. Michel) Recalculation and Assessment (I. Tsolakidis) summary DEBCO Final Conference Brussels - 10./11. Dec 2012 - P 15
Combustion and boiler performance Objectives of the project in Kardia Unit I Influence of the Co-firing of Biomass (Cardoon) in the Lignite fired Boiler of Kardia unit I Content of presentation Power Station Kardia, Unit I Preparation of the mix-fuel by PPC (Lignite and Biomass) Measurement series and boiler conditions Measurements carry out from PPC Boiler recalculation, Boiler model Evaluation of the measurements Conclusion DEBCO Final Conference Brussels - 10./11. Dec 2012 - P 16
Combustion and boiler performance Boiler design 100%-Load (1976) DEBCO Final Conference Brussels - 10./11. Dec 2012 - P 17
Combustion and boiler performance Boiler sketch / cleaning of the boiler DEBCO Final Conference Brussels - 10./11. Dec 2012 - P 18
Combustion and boiler performance Tube pitch plan D o mm D i mm t q mm t l mm n q n i n par W FG in m/s W FG out m/s ECO 38 29,5 138 60 119 66 238 7,6 6,5 RH 1a 38 30,8 138 60 120 24 1440 7,9 7,6 SH 1a 38 30,8 138 60 120 32 480 8,8 7,9 RH 1b 38 30,8 138 60 120 24 1440 9,5 8,8 SH 1b 38 28,6 138 60 120 24 480 11 9,5 D o D i t q t l n q n l n par w FG in w FG out - outside diameter - inside diameter - transverse pitch - longitudinal pitch - No. of assemblies - No. of tubes in flue gas direction - No. of parallel tubes - flue gas velocity at inlet of tube heating bundle - flue gas velocity at outlet of tube heating bundle RH 2 57 47 276 100 60 24 480 10,8 10 SH 3 38 25,1 276 80 60 16 480 10,4 9,9 SH 2 38 24,8 828 46 20 78 520 10,1 9,4 DEBCO Final Conference Brussels - 10./11. Dec 2012 - P 19
Combustion and boiler performance HP- / IP Part of the Boiler HP - Part IP - Part DEBCO Final Conference Brussels - 10./11. Dec 2012 - P 20
Combustion and boiler performance Preparation of the mix-fuel by PPC Biomass and Lignite was mixed outside the power plant and was stored one month on site before combustion Average data of the fuels (ar) Biomass Lignite LHV = 14.67 MJ/kg LHV = 5.35 MJ/kg H2O = 15.43 % H2O = 53.76 % Ash = 8.63 % Ash = 14.18 % Biomass co-firing with 10% firing heat capacity. The mix-fuel was fed to the furnace with the feeders through to the mills DEBCO Final Conference Brussels - 10./11. Dec 2012 - P 21
Combustion and boiler performance Boiler conditions and Measurements Boiler conditions before each measurement No additional bituminous coal Steady operation of the boiler (no changes of mills, excess air, boiler load, ) No soot blowing DEBCO Final Conference Brussels - 10./11. Dec 2012 - P 22
Combustion and boiler performance Boiler conditions and Measurements The measurement data consist of General data Start of the measurements, last soot blowing, Boiler load, Fuel data, share of biomass co-firing HP-Part data Live steam mass flow, spray mass flow, available temperatures and pressures upstrm / downstrm of the heat exchangers IP-Part data Spray mass flow, available temperatures and pressures upstrm / downstrm of the heat exchangers Flue gas data Available temperatures, O2-content in flue gas upstream/downstream air preheater Comb. air data Temperature upstream/downstream air preheater Mills data Temperature outlet, wheel speed, feed speed, mill drive intensity,.. DEBCO Final Conference Brussels - 10./11. Dec 2012 - P 23
Combustion and boiler performance Boiler Recalculation, Boiler Model DEBCO Final Conference Brussels - 10./11. Dec 2012 - P 24
Combustion and boiler performance Evaluation of the measurements DEBCO Final Conference Brussels - 10./11. Dec 2012 - P 25
Combustion and boiler performance Evaluation of the measurements DEBCO Final Conference Brussels - 10./11. Dec 2012 - P 26
Combustion and boiler performance Evaluation of the measurements DEBCO Final Conference Brussels - 10./11. Dec 2012 - P 27
Combustion and boiler performance Evaluation of the measurements DEBCO Final Conference Brussels - 10./11. Dec 2012 - P 28
Agenda 1st topic samples and data 2nd topic recalculation and assessment 3rd topic summary DEBCO Final Conference Dec. 10, 2012, Brussels - P <Nr.>
Combustion and Boiler Performance Conclusions Fuel range of pure lignites is very wide (blended fuel properties are within the range of pure lignites) (LHV, Ash properties, fuel properties are within the range) Only the unburned carbon content of the co-firing ashes is higher No 100% Boiler load operation (approx. 80%) High excess air operation Low air heater ratio, boiler air leaking High RH-Injection, poor plant efficiency No critical flue gas temp. at furnace exit High flue gas temperature downstream APH No pollution of the furnace and heating surface banks Flue gas emission was not part of the evaluation DEBCO Final Conference Brussels - 10./11. Dec 2012 - P 30
DEBCO Final Conference Dec. 10, 2012, Brussels - P <Nr.>
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Boiler Kardia 3/4 HP / MP Part, before reconstruction HP - Part MP - Part DEBCO Final Conference Dec. 10, 2012, Brussels - P <Nr.>