site before placement in the boiler house. Several of the key erection milestones were reached in 2015. With regards to the boiler, the first section of the feed water tank (one of four) was transported from port to site by trailer in February 2015 and HP heater No. 8 was transported from port to site by rail in March 2015. Mill classifiers were transported to site by trailer in June 2015. The other main large pieces of plant equipment, i.e. the generator stator and LP turbine rotor were shipped from Japan and transported from the port to the site by rail wagon in July 2015 and October 2015, respectively. Installations then took place throughout 2016 to allow first firing of the boiler on March 18, 2017. First steam was fed to the steam turbine four months later and the steam turbine was synchronised to the grid on September 1, 2017. Following a three-month period of tuning and testing, the unit was handed over for commercial operation on December 19, 2017. Since then the plant has operated for over 3200 hours (as of mid-May). Dr Wilkendorf noted: “The plant has been running well with an efficiency that’s been even better than expected. During the trial run we were safely above the predicted efficiency. The official test for the guarantee values, however, is still to be done. This will be performed during the first year of operation by a third party contracted by the client.” In his speech during the PAC signing ceremony at the power plant Satoshi Uchida, CEO of MHPS Europe said: “Construction of Kozienice 11 was MHPS’ first step in accessing the Polish power plant market. Poland is clearly a key market for our company and the very good collaboration with Polish partners under the lead of the customer, ENEA, is an important reference for us.” MHPSE noted that the collaboration was particularly successful when considering the “extremely complicated” Polish procurement law. “Tendering is a really complicated process in Poland,” said Helge Schulz, Head of Corporate Communications, MHPSE, “but the cooperation was very good at the Special Project Supplement the effect on the local marine environment but also uses best available technology to limit impacts on air quality. Kozienice 11 has a sophisticated environmental protection system so that emissions are guaranteed to be either equal to or lower than EU environmental limits. There are three systems: a selective catalytic converter (SCR) reduce NOx emissions from the combustion process; an electrostatic precipitator (ESP) to capture dust; and a FGD system to capture SOx. The SCR, located behind the boiler, receives gas directly after the convective heating surfaces at a temperature of about 350-360°C. Ammonia is injected into the SCR reactor, where it reacts with the NOx to form water and nitrogen. Flue gases leaving the SCR flow through an air heater before entering the ESP to capture dust. Desulphurisation is achieved through the use of the limestone gypsum process, where gypsum can be recovered as the end product for further industrial use. This process involves sulphur dioxide (SO2), hydrogen chloride (HCl) and hydrogen fluoride (HF) being precipitated in an alkaline scrubbing liquid. The flue gas enters the lower part of the MHPS absorber and ascends through the absorption section. Intelligent technology ensures that the number of nozzle levels of the contact zone and positioning of their nozzles are designed to the desired absorber collecting efficiency. Upto the-minute computations of flue gas entry angle and speed make it possible for turbulence to be kept well down inside the absorber. A large and a fine droplet separator retain the fine droplets in the flue gas before the cleaned gas leaves the absorber. The actual transition from pollutant gas to liquid occurs in an intensively intermixed gas/liquid contact zone. The limestone-induced absorption gives rise to a high-grade gypsum product. Flue gases leaving the plant do not go through the stack but instead are vented into the cooling tower. The dust emitted at the end is a combination of what is caught by the FGD and the ESP but at the cooling tower is 10 mg/Nm3. This is much lower than the 20 mg/Nm3 specified EU standard. Dr. Frank Wilkendorf, MHPSE’s Project Manager said: “All the emission values are well below the guarantee values of 100 mg/m3 for NOx and 100 mg/m3 for SO2.” Certainly Kozienice 11 is a technically impressive project that has been long in the making. Discussions on the project opened in 2010 but it was some time before the contract was awarded. Following the contract award on September 21, 2012, site access was granted on October 2nd. Demolition of some existing facilities began immediately, with preparation of underground networks etc., and the official ground breaking took place on November 26, 2012. To meet the scheduled construction dates, a significant amount of assembly work had to be done on the ground at the site and the assembled components lifted into place. This helped to speed-up construction allowing the boiler steel structure to be finalised in June 2014. Much of the required pre-manufactured material had to come from various parts of Poland, Europe and even Japan which was a logistical challenge but went according to plan. All the boiler parts were more or less fabricated and pre-assembled at THE ENERGY INDUSTRY TIMES - JUNE 2018 CAD drawing of the new unit showing a cutaway of the boiler house and turbine hall The new unit (seen here during construction) is part of an existing site, where there were already 10 units with a generating capacity of 2905 MW
Energy Industry Times June 2018
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