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Innovations in power generation. The UNITS 200+ project in Poland

Ziaja Jolanta, Lichota Janusz

Rynek Energii

2024

Nr 1

82--91

The purpose of the “Units 200+” project is to develop methods that can adapt 200 MWe class generating power units, which represent almost 25% of Poland's installed capacity, to safely transform the structure of electricity generation in the country. The project has several sub-goals, including reducing start-up time from the cold state to 5 hours, shortening start-up time from the warm state to 2.5 hours, and reducing start-up time from the hot state to 1.5 hours. Other goals include changing the power growth gradient to 4% of rated power MW/min, maintaining minimum power at stable/longterm operation on base fuel with adherence to current emission parameters at 40% of the rated capacity, developing an IT and control and measurement solution to forecast the impact of operating activities on failure rates and availability of the unit, increasing the efficiency of electricity generation to 60% of the achievable power without significant interventions/ modifications to the turbine flow system, and meeting BAT requirements for dust emissions. To achieve these goals, several design changes have been undertaken, including the installation of a steam air heater on the by-pass of the main primary air duct to the coal mills in the boiler building, the execution of a partial ECO by-pass in the form of hot flue gas ducts from the second boiler draft duct before ECO in the boiler room to the external flue gas duct after LUVO to SCR (on both sides of the boiler), and the construction of a heat exchanger (heat station) to maintain circulation in the downcomers. Other changes include heating the drum of a boiler with 1.7 MPa process steam, installing air fans WP inverters, supplying 850 kW motors and 6 kV bypass, installing flue gas fans WS inverters, motors and 6 kV bypass, and reducing the pressure in the drum from 15.5 MPa to the value required to ensure adequate circulation in the boiler evaporator system. Other changes include implementing an electrostatic precipitator flue gas recirculation system, supplying an acoustic system for measuring temperature distribution in the combustion chamber, supplying a calculation server for monitoring, optimization and advanced regulation of the technological process, delivering a system for analysis and control of temperature rise in metal, and supplying a system based on artificial intelligence for optimization of the combustion process. Other changes include delivering a system for advanced regulation of steam temperatures, supplying a system for advanced regulation of power and steam pressure, delivering a system to analyze the impact of increased flexibility of unit operation on failure rates and availability with economic optimization, delivering a system for advanced diagnostics of mills equipped with an automatic response module to prevent mill failures, and delivering a system that estimates the readiness of a start-up burner for firing. The goals indicated above have been achieved.

Influence of membrane CO2 separation on the operating characteristics of a coal-fired power plant

Kotowicz J., Janusz-Szymańska K.

Chemical and Process Engineering

2010

Vol. 31, z. 4

681-698

The influence of a carbon capture and storage (CCS) installation with membrane separation on the efficiency and economic characteristics of a supercritical coal unit has been presented. The algorithm of the minimization of energy consumption of the process of membrane CO2 separation was worked out. It allows, with the assumed parameters of separated CO2 (e.g., purity and recovery ratio), determination of the optimum process parameters such as permeate and feed pressure and the membrane surface area. The possibilities include significant lowering of the energy consumption of the CCS installation through the use of compressors and vacuum pumps with interstage cooling. It was shown that the supercritical power unit throughout the use of the analysed installation will cause only a 6.07 percentage points efficiency decrease, which is realistically 6.96 percentage points. The analysis of the economic consequences of the introduction of the CCS installation to the examined unit was performed. The break-even price of electricity and the cost of avoided emissions were determined. The influences of the lifetime of the membrane and its price on the mentioned quantities were also investigated.

Pokazano wpływ instalacji do sekwestracji CO2 (ang. carbon capture and storage - CCS) z separacją membranową na charakterystyki sprawnościowe i ekonomiczne nadkrytycznego bloku węglowego. Opracowano algorytm minimalizacji energochłonności procesu membranowej separacji CO2. Pozwala on przy założonych parametrach oddzielonego CO2 (tj. czystości i stopnia odzysku) wyznaczyć optymalne parametry procesu. Są to ciśnienie permeatu i zasilania oraz powierzchnia membrany. Pokazano możliwość znacznego zmniejszenia energochłonności instalacji CCS przez zastosowanie sprężarek i pomp próżniowych z chłodzeniem międzystopniowym. Wykazano, że nadkrytyczny blok węglowy wskutek zainstalowania badanej instalacji CCS utraci granicznie jedynie 6.07 punktu procentowego mocy, realnie 6.96 punktu procentowego. Przeprowadzono analizę konsekwencji ekonomicznych wprowadzenia instalacji CCS do badanego bloku energetycznego. Wyznaczono graniczną cenę sprzedaży energii elektrycznej i koszt emisji uniknionej. Zbadano wpływ długości czasu użytkowania membran i ich ceny na wymienione wielkości.