Integrated Solutions

Plant|Performance
Heat Recovery

Fossil-fired steam power plants use only portion of the energy contained in the flue gas leaving the boiler, namely for air preheating. A large amount of remaining heat energy is discharged unused through the stack. In addition, if temperatures are higher than design then added load is applied to the electrostatic precipitators (ESP) with a subsequent drop in dust collection performance. In case of fabric filters (FF), bag life is significantly shortened. With the Heat Recovery Module, ALSTOM Power provides a solution to turn part of the flue gas energy into improved thermal plant performance. This can result in significantly raised plant efficiency or output whilst accompanied by enhanced performance improvements for the electrostatic precipitators and thus an improved environmental footprint.
Customer Benefits Generation of green megawatts Increase of plant efficiency ESP performance improvement Extended fabric filter bag life Reduction of back end temperature
Heat content of flue gas downstream air heater 100 MWth Heat recovery by module 30 MWth Heat rejection to atmosphere 70 MWth
Particulate emission cut up to 50 %

Without Heat Recovery

Background
Electricity demand together with improved environmental performance requirement continues to rise. As the installation of new power plants takes considerable time and cost, upgrading of existing plants is a promising alternative to maintain competitive plants for mid term requirements. The Heat Recovery Module enables the plant owner to improve output and or thermal performance together with improved flue gas particulate collection on existing older power plants.
Figure 1: Recovery of usually wasted flue gas heat (example: 600 MWel unit)

Figure 2: Improved dust collection by low temperature ESP operation when firing low sulphur coals

Solution
The Heat Recovery Module developed by ALSTOM Power is based on proven technology applied for new and some older units. Recovery of the usually wasted flue gas heat (see fig. 1) is transferred to the thermal cycle where it is used for low- pressure feed-water heating. This results in less turbine steam extraction for existing heaters so that the saved steam can directly contribute to power generation and efficiency.

Improvement levels are dependent on existing plant conditions but are outlined in fig. 4.

Product Description
A configuration of the Heat Recovery Module installed into a unit is schematically given in fig.3. The flue gas heat exchange occurs upstream of the ESP recovering heat for feed-water heating and reducing flue gas temperatures for improved dust precipitation.

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THERMAL POWER

With Heat Recovery

Integrated Solutions

The implementation concept of the Heat Recovery Module depends on the following: Flue gas temperature and reduction limits Demand of capacity increase and efficiency improvement Available space for the heat exchanger in the flue gas ducts After an assessment and feasibility check, the site-specific application of the module can be evaluated depending on the specific boundary conditions together with the customers technical and economic requirements.

LP feed-water heater

Boiler

Air Heater ESP or FF Flue gas/water heat exchanger ID fan Stack

Figure 3: Schematic of unit with retrofitted Heat Recovery Module upstream of dust precipitator

Customer Benefits
The Heat Recovery Module enables the customer to profit from: Generation of green megawatts Increased plant efficiency and relative fuel savings

CO2 emission reduction Reduced back end flue gas temperature for improved ESP performance Consequential reduction of dust emissions Increased fabric filter bag life
50000

3,0% Unit capacity: 210 MW 2,5%

2,0% 30000 1,5% 20000 1,0% Flue gas temperature downstream APH: * assumed efficiency of flue gas heat/power conversion = 15 % 140 130 120 110 100

0,5%

0,0%

T = 200 C T = 180 C T = 160 C T = 140 C

90

10000

Flue gas temperature downstream of flue gas/water heat exchanger [C]

Figure 4: Estimated heat rate improvement and CO2 emission reduction depending on flue gas temperatures for a coal-fired unit of 210 MW capacity

ALSTOM 2010. All rights reserved. Information contained in this document is indicative only. No representation or warranty is given or should be relied on that it is complete or correct or will apply to any particular project. This will depend on the technical and commercial circumstances. It is provided without liability and is subject to change without notice. Reproduction, use or disclosure to third parties, without express written authority, is strictly prohibited.

THERMAL POWER

9DESER00019F01

CO2 emission reduction* [t/a] (8000 h) x

40000

Heat rate improvement* [%]