“build, dismantle and build” replacement at coal-fired...
TRANSCRIPT
Japan Coal Energy Center (JCOAL)
“Build, Dismantle and Build” Replacement
at Coal-Fired Power Station
Japan Coal Energy Center (JCOAL)
1
International Seminar on
“Environmental Compliances in Thermal Power
Plants –
Issues and Challenges” at India Habitat Centre
on 30th January 2017
Contents
I. “Build, Dismantle and Build” Replacement: Isogo ModelI. “Build, Dismantle and Build” Replacement: Isogo ModelI. “Build, Dismantle and Build” Replacement: Isogo ModelI. “Build, Dismantle and Build” Replacement: Isogo Model
1.1.1.1. BackgroundBackgroundBackgroundBackground
2.2.2.2. Comparison of the specificationsComparison of the specificationsComparison of the specificationsComparison of the specifications of Old unit and New unit of Old unit and New unit of Old unit and New unit of Old unit and New unit
3.3.3.3. Schedule and Procedure of “Build, Dismantle and Build” Schedule and Procedure of “Build, Dismantle and Build” Schedule and Procedure of “Build, Dismantle and Build” Schedule and Procedure of “Build, Dismantle and Build”
2
3.3.3.3. Schedule and Procedure of “Build, Dismantle and Build” Schedule and Procedure of “Build, Dismantle and Build” Schedule and Procedure of “Build, Dismantle and Build” Schedule and Procedure of “Build, Dismantle and Build”
Replacement Replacement Replacement Replacement
4.4.4.4. Keys and ConstraintsKeys and ConstraintsKeys and ConstraintsKeys and Constraints
II.II.II.II. OnOnOnOn----going Initiativegoing Initiativegoing Initiativegoing Initiative
5. Overview of 5. Overview of 5. Overview of 5. Overview of TakeharaTakeharaTakeharaTakehara TPS, JTPS, JTPS, JTPS, J----POWERPOWERPOWERPOWER
6. Replacement plan underway at 6. Replacement plan underway at 6. Replacement plan underway at 6. Replacement plan underway at TakeharaTakeharaTakeharaTakehara TPSTPSTPSTPS
ConclusionConclusionConclusionConclusion
1. Background (1/3)
*To cope with the stringent environmental regulations
*Slightest chance for construction on greenfield land
*Surging power demand in metropolitan suburbs
2
1. Background (2/3)
Changes in the annual average concentration of each environment value in Japan
1970197019701970----2014201420142014
Subcritical to USC Replacement with HELE applicationSubcritical to USC Replacement with HELE applicationSubcritical to USC Replacement with HELE applicationSubcritical to USC Replacement with HELE application
New IsogoNew IsogoNew IsogoNew Isogo25MPa25MPa25MPa25MPa××××600/610600/610600/610600/610℃℃℃℃、、、、25MPa25MPa25MPa25MPa××××600/620600/620600/620600/620℃℃℃℃
COD: Unit 1 in 2002, Unit 2 in 2009COD: Unit 1 in 2002, Unit 2 in 2009COD: Unit 1 in 2002, Unit 2 in 2009COD: Unit 1 in 2002, Unit 2 in 2009
Efficiency Improvement
Sub-Critical, Efficiency = 40%Ultra Super Critical, Efficiency = 45%
Old IsogoOld IsogoOld IsogoOld IsogoCOD in1967COD in1967COD in1967COD in1967
2. Comparison of specifications of
Old unit and New unit (1/3)
7
Cleaner Environment
IncreasingPower supplyCapacity 530MWCapacity 530MWCapacity 530MWCapacity 530MW((((265MW265MW265MW265MW××××2 2 2 2 )))) Capacity 1,200MW(600MWCapacity 1,200MW(600MWCapacity 1,200MW(600MWCapacity 1,200MW(600MW××××2) 2) 2) 2)
0
20
40
60
80
100
SO
x(
pp
m )
OldSub-C
New USC0
25
50
75
100
125
150
175
NO
x (
pp
m )
OldSub-C
New USC0
20
40
60
80
PM
(m
g/m
3)
OldSub-C
New USC50
60
70
80
90
100
Old Sub-C New USC
CO
2R
edu
ctio
n(
-)
250
500
750
1000
1250
1500
Old Sub-C New USC
Cap
aci
ty (
MW
)
35
40
45
50
Old Sub-C New USC
Eff
icie
ncy
(%
)
Cleaner EnvironmentCleaner EnvironmentCleaner EnvironmentCleaner Environment
Unit1Unit2Unit2
Unit1Unit2
Unit1
Source : J-POWER
2. Comparison of the Specifications
of Old units and New units (2/3)
Old Units New Units
#1: 265MW, #2: 265MW #1: 600MW, #2: 600MW
16.6MPa #1: 25MPa, #2: 25MPa
566ºC/566ºC #1: 600ºC/610ºC, #2: 600ºC/620ºC
Domestic Coal
0.65MT x 2
Domestic Coal and Overseas Coal
1.36MT x2
Item
Output
Main Steam pressure
Steam temparature
(Main/Reheat)
Fuel
Source : J-POWER
Outdoor/ coal yard
120,000t
Indoor/ Clover-type silo
100,000t
30 days on site10 days on site
20 days at coal center
Natural circulation drum type boiler Tower-type, once-through boiler
Utilization rate: 90% or more
(Amount generated: 0.17MT/year)
Utilization rate: 90% or more
(Amount generated: 0.38MT/year)
12.1ha12.4ha
(Addition of Offshore Deck)
15% 20%
Coal ash use
Proportion of greened
to total area
Coal storage
Coal stockpiles capacity
Boiler
Site Area
3
2. Comparison of the Specifications
of Old units and New units (3/3)
Old Units New Units
N/ADry-type De-NOx (SCR)
Efficiency: #1 87.5%, #2 91.9%
ESP
Efficiency: 99.75%
ESP
Efficiency: #1 99.94%, #2 99.97%
Wet-type De-SOx System
(Lime Gypsum Process)
Efficiency: 89%
Dry-type De-SOx System
(Active Carbon Absorption Process))))
Efficiency: #1 95.0%, #2 97.8%
De-NOx System
Dust Precipitator
De-SOx System
Item
Source : J-POWER
Efficiency: 89% Efficiency: #1 95.0%, #2 97.8%
1,972,000m3N/h#1: 2,000,000m
3 N/h
#2: 1,992,000m3 N/h
NOx 159ppm #1: 20ppm, #2: 13ppm
PM 50mg/m3N #1: 10mg/m
3 N, #2: 5mg/m
3 N
SOx 60ppm #1: 20ppm, #2: 10ppm
#1: 120m
#2: 140m
200m
(Centralized type of two stacks)
Gas discharge volume
(wet gas)
Sm
oke a
nd
so
ot
em
issio
n
Smoke stack
4
3-phased Approach taken at Isogo TPS <1>
3. Schedule and Procedure of “Build,
Dismantle and Build” Replacement (1/3)
Source : J-POWER, IHI 8
(3) Completion of the replacement
with the construction of new unit #2
3. Schedule and Procedure of “Build,
Dismantle and Build” Replacement (2/3)
3-phased Approach taken at Isogo TPS <2>
Source : J-POWER, IHI
The entire schedule of replacement of Isogo power StationThe entire schedule of replacement of Isogo power StationThe entire schedule of replacement of Isogo power StationThe entire schedule of replacement of Isogo power Station
3. Schedule and Procedure of “Build, Dismantle
and Build” Replacement (3/3)
Year <New #1 Unit> <New #1 Unit> <New #1 Unit> <New #1 Unit> Environmental Assessment Electric Power Development Adjustment Start of Construction of New #1 Unit Coal Silos and Stack Construction work New #1 Unit design New #1 Unit production New #1 Unit installation New #1 Unit Commissioning
2004 2005 2006 2007 2008 20091995 1996 1997 1998 1999 2000 2001 2002 2003
12Source : J-POWER, IHI
New #1 Unit Commissioning COD of New #1 Unit <Old #1 & #2 Units> <Old #1 & #2 Units> <Old #1 & #2 Units> <Old #1 & #2 Units> Decommissioning of Old #1 & #2 Units BTG Island dismantling BOP Island dismantling <New #2 Unit> <New #2 Unit> <New #2 Unit> <New #2 Unit> Construction of New #2 Unit New #2 Unit commissioning COD of New #2 Unit
Power Generation of Isogo TPS Power Generation of Isogo TPS Power Generation of Isogo TPS Power Generation of Isogo TPS 530MW 600MW
1200MW
Basic plan of layoutBasic plan of layoutBasic plan of layoutBasic plan of layout and Construction orderand Construction orderand Construction orderand Construction order
Existing (Old) Plants layout(Before Replacement)
Layout of Power StationLayout of Power StationLayout of Power StationLayout of Power Station Construction Items and orderConstruction Items and orderConstruction Items and orderConstruction Items and orderSecure space for New Unit #1- Reducing outdoor coal yard- Construction of deck- Construction of silos & stack
4. Key Initiatives (3/5)
15
New Plant layout(After Replacement)
Layout of New Unit #1(New Unit #1 starts operation)(Old Units are under operation)
- Dismantle of Old Units- Construction of New Unit #2
- Construction of silos & stack- Construction of tanks- Dismantle of old tanks- Construction of new water
intake / outlet- Construction of New Unit #1
Dismantled/disassembled items at BTG & BOP IslandDismantled/disassembled items at BTG & BOP IslandDismantled/disassembled items at BTG & BOP IslandDismantled/disassembled items at BTG & BOP IslandWeight (ton) Recycle rate (%)
Valuable items Iron scrap, machinery and equipment 22,000 100
Concrete 84,366 100
Asphalt 348 100
Other materials 1,397 53
Insulation filling 232 0
wood waste 39 100
Oil and miscellaneous 323 52
Dismantled/disassembled items at BTG island
Stable substance
Substance requiring specific or
special management
4. Key Initiatives (4/5)
Source : J-POWER
Oil and miscellaneous 323 52
asbestos insulation 699 100
109,404 99
Weight (ton) Recycle rate (%)
Valuable items Iron scrap, machinery and equipment 13,145 100
Concrete 48,073 100
Asphalt 981 100
Other materials 517 71
Insulation filling 94 100
miscellaneous 791 4
asbestos insulation 118 100
63,719 98.6
Dismantled/disassembled items at BOP island
special management
Stable substance
Substance requiring specific or
special management
Total
Total
16
4. Key Initiatives (5/5)
Landscape planning from multiple perspectives�Every consideration was given to the appearance of the power station
as part of the entire landscape as well as the plant by itself:
�Design, arrangement and coloring of the power station were well
coordinated and have the plant outstanding from rest of conventional
coal fired power stations.
�The flat oval shape of the stack and its position were determined in
consideration of the view of the Sankeien Garden.
Source : J-POWER
We look forward to working with you!We look forward to working with you!We look forward to working with you!We look forward to working with you!
Website: http://www.jcoal.or.jp/index-en.html
Contacts: Mr. K. Murakami ([email protected])Ms. Yamada, F.([email protected])
27
Erection Erection Erection Erection ---- JackJackJackJack----up methodup methodup methodup method----Top GirderTop GirderTop GirderTop Girder4. Construction of New No.1 Boiler (1/2)4. Construction of New No.1 Boiler (1/2)4. Construction of New No.1 Boiler (1/2)4. Construction of New No.1 Boiler (1/2)
4. Keys and constraints observed in
Isogo Model 2/
Source : J-POWER, IHI9
Erection Erection Erection Erection ---- JackJackJackJack----up methodup methodup methodup method----Top GirderTop GirderTop GirderTop Girder4. Construction of New No.1 Boiler (1/2)4. Construction of New No.1 Boiler (1/2)4. Construction of New No.1 Boiler (1/2)4. Construction of New No.1 Boiler (1/2)
Source : J-POWER, IHI9
4. Construction of New No.1 Boiler (2/2)4. Construction of New No.1 Boiler (2/2)4. Construction of New No.1 Boiler (2/2)4. Construction of New No.1 Boiler (2/2)Manufacturing and ErectionManufacturing and ErectionManufacturing and ErectionManufacturing and Erection
Boiler large block, MultiBoiler large block, MultiBoiler large block, MultiBoiler large block, Multi----floor block, Jackfloor block, Jackfloor block, Jackfloor block, Jack----up methodup methodup methodup method
550 ton 1150 ton
MultiMultiMultiMulti----floor blockfloor blockfloor blockfloor block
Source : J-POWER, IHI
550 ton
1650 ton
1150 ton
310