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Grosskraftwerk Mannheim AG

GKM – Operating a coal fired CHP-power plant in

an urban area

Dr.-Ing. Matthias Meierer

Flexibility-Workshop / VGB Power Tech - IGEF-Study-Tour

September 19, 2016 in Berlin

Contents

1. Introduction / GKM Power Plant

2. Actual situation in Germany („Energiewende“)

3. New GKM heat storage system / optimization of

CHP Process

4. Conclusions

| 1 VGB IGEF Flexibility-Workshop September 19, 2016 Berlin GKM CHP-Power Plant Dr. Meierer

GKM history: the beginnings

1921 GKM is founded on

8th of November Start of construction work at a

good location: close to town of

Mannheim and directly sited at

river Rhine; start of electricity

generation in 1923

Mastermind: Dr. Karl

Friedrich Marguerre,

Executive Direktor

VGB IGEF Flexibility-Workshop September 19, 2016 Berlin GKM CHP-Power Plant Dr. Meierer | 2

Das GKM – damals und heute GKM – founded 1921 … new unit 9 in erection …


| 4

unit 6

unit 8 unit 7

unit 9

GKM plant today

river Rhine

VGB IGEF Flexibility-Workshop September 19, 2016 Berlin GKM CHP-Power Plant Dr. Meierer

CHP process (combined heat and power) in GKM


air

fuel

flue-gas cleaning

steam

turbine generator

condenser

boiler

to destrict heat water

systems in cities of

Mannheim, Speyer,

Heidelberg, …

| 5

river Rhine

SCR-DeNOx

ESP

FGD

GKM power generation (electricity)


1920 1930 1940 1950 1960 1970 1980 1990 2000 2010

three-phase

10.0

8.0

6.0

4.0

2.0

0 single-phase current

TWh

GKM district heat generation


0,0

0,5

1,0

1,5

2,0

2,5

3,0

1935 1945 1955 1965 1975 1985 1995 2005 2015

heating water

process steam

TWhth

50 Hz three-phase

alternating current (share holders of GKM AG) RWE Generation SE (40 %)

EnBW AG (32 %)

MVV RHE GmbH (28 %)

16.7 Hz single-phase

alternating current

DB Energie GmbH

(German Railway)

District heat

MVV RHE GmbH

Mannheim

energy for share holders and German Railway: reliable, cost-effective

and friendly to environment

efficient generation of electricity and district heat

GKM generates electricity for over 1.5 million people, trade, industry and railway as well as

heat for about 120,000 households in Mannheim and the region.


GKM plant in 2016

GKM plant: Installed capacity: 2.146 MWel (units 6,7,8,9)

Start up year Gross Capacity in MW Shut-down


Das GKM – damals und heute GKM plant overview


flow sheet of GKM unit 6 (CHP)

| 11

distric heat

system (Mannheim,

Heidelberg,

Speyer)


new unit 9

Energy for Mannheim

and the Region


unit 9 – flow sheet

combined heat and power unit 9 (CHP)

cleaned flue gas ammonia water

stack

limestone

FGD

bituminous coal gypsum

fly ash

SCR DeNOx

ESP

pulverizer

combustion air

boiler

steam turbine

transformer

generator

condensator

modular cooling

cells

coolingwater

pumps

river Rhine district

heat system

water


unit 9


unit 9

facts and figures

Commissioning/start of commercial operation 1st May 2015

Investment volume 1.2 bil. €

Gross output 911 MWel

Electrical net efficiency 46.4 %

District heat generation with CHP max. 500 MWth

Fuel utilization for CHP max. 70 %

Railway electricity (16.7 Hz) (per transverter) 100 MW


Contents




CHP Process

4. Conclusions


electricity generation / actual situation in Germany (example)

Fr 28. Mar 2014

| 17

Conventional.

Power Plants

Water Biomass Solar Wind Electricity Consumption in Germany

Ele

ctr

icity G

enera

tion a

nd C

onsum

ption

remarkable export of electricity from Germany to neighbour countries during

high generation of solar and wind power

24th March 25th March 26th March 27th March 2014


GKM / daily operation situation 2007 vs. today

Wednesday, March 21, 2007

MW

GKM Operation in 2007 and today (planned and real output)

MW

today‘s requirements in electricity market mean high demands on equipment

and personell in GKM: high flexibility in load changes and timing


real output planned output („day ahead“)

Monday, March 16, 2015

0%

20%

40%

60%

80%

100%

120%

0 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23

live

ste

am [

%]

time [h]

load of unit 8 February 17, 2014

begin start up

GKM / unit 8 load diagram (example)


0

20

40

60

80

100

120

0 50 100 150 200 250

live

ste

am [

%]

time [minutes]

start up diagrams of unit 8 (cold-, warm-, hot-start)

Heiß

Warm

Kalt

105 minutes 150 minutes 190 minutes

< 8 h

> 8 h < 48 h

> 48 h

40 Min 55 Min 70 Min

hot

warm

cold

-start

GKM / start up diagrams of unit 8


Contents




CHP Process

4. Conclusions



Heidelberg

Speyer

GKM

Mannheim district heat system / GKM CHP Plant

district heat extension

district heat concentration

district heat main lines

| 22

GKM Plant / district heat system until 2013

G

20 bar / 530 °C steam system

district heat turbines M20/21

district heat system (Mannheim, Heidelberg, Speyer)

unit 7 unit 8 unit 3 unit 4 unit 6

G

condensing turbines

50 Hz / 16,7 Hz

G

condensing turbines

50 Hz / 16,7 Hz

auxilary

boilers


process steam

GKM „2-units-operation“ necessary at minimum load because of need for

secure supply of district heat system (until end of 2013)

heater


CHP plants in Germany / need for energy storage

In energy supply systems for heat and power energy storage sytems help to

bring energy consumption and energy generation into balance

Actual need for higher and more energy storage capacities in Germany:

• increasing capacities of „renewables“ (esp. solar (PV) and wind) for power

(electricity) and heat supply

• combined heat and power plants (CHP) „struggle with economics“: low

EEX-prices for electricity and „must run production of electricity“ because of

need to produce heat continuously


energy storage systems / thermal storage

Thermal energy storage: heat storage: worldwide use of different types in large

scale

• different substances (e.g. water, salts, sand, concrete, aquifer, …)

• different temperature / pressure

• different technical types / functions

• integrated in different systems e.g. power plants; CHP; district heat systems;

local heat systems, industrial systems, …

• activities in research and developement: to develop systems with higher

capacities (MWh, MW) and improvement of the technical systems

• focus: better integration of renewables in existing energy supply systems (heat

and power)


heat storage systems / overview

heat storage

thermal energy chemical energy

sensible heat latent heat heat of reaction

liquid solid object solid-liquid liquid-gaseous

water stone melting steam

aquifer


thermal storage systems / water not pressurized

Water energy storage systems / not pressurized: worldwide use since long time in

power plants, industry, and heating systems

• simple constructions / different types / easy to integrate in power plants

• storage system type „Dr. Hedbäck“ >80 tanks worldwide, most in Europe and

South Korea

• water system (well known)

• positive long time experiences

• limited temperature level (<100 °C), atmospheric pressure, high volumes (up to

50,000m3 per tank) and capacities (up to 300 MW, up to 1500 MWh)

• reasonable investment costs (depending on system integration demand)


heat storage systems / conclusions

• thermal energy storage (heat): worldwide use of different types in large scale

• water is most common storage substance (easy to handle, cheap, not

corrosive, high heat capacity, friendly to environment, …)

• research and developement for other storage substances (e.g. salts, sand,

concrete, aquifer, metals, …) and process optimization ongoing

• better integration of renewables and other sources (e.g. waste heat) in existing

energy supply systems (heat and power) needed

• focus: energy storage systems with high capacities (MW, MWh), high load

flexibility and gradients

• actual: difficult commercial conditions for large storage systems and

installations


Load demands on CHP Plant GKM

• 50 Hz Electricity Generation for RWE, EnBW, MVV

• 16,7 Hz Electricity Generation for DB Energie

• Distric Heat Generation and secure supply of Mannheim, Heidelberg and

Speyer

Situation at German Eletricity Market

• GKM Plant Load corresponding to EEX Prices (Spot-Market „day-ahead and

intraday“): volatile and often not fitting to district heat energy consumption

Functions of new heat storage system in GKM

• in times of low EEX Prices the GKM Electricity Generation must be as low as

possible (minimum technical load)

• the new heat storage tank enables GKM to operate only 1 unit during minimum

load (instead of 2 units before)

• during minimum load the heat content in the tank is sufficient to supply the

district heat nets at least for 2 hours

• additionally the heat storage tank is used to optimize the plant operation

depending on EEX Prices (e.g. charging at night, discharging by day)

task / functions of new GKM heat storage system


G


district heat turbines M20/21

district heat system (Mannheim, Heidelberg, Speyer)

heat

storage

tank

98 °C

unit 7 unit 8 unit 6

G

condensing turbines

G

condensing turbines


process

steam

auxilary

boilers

unit 9

GKM Plant / district heat system since 2015

GKM „1-unit-operation“ possible at minimum load / if district heat

load < 250 MW (since heat storage system finished: end of 2013)

new heat storage system enables GKM CHP plant to reduce the minimum load significantly



heat storage tank

98 °C

destrict heat supply line

destrict heat return line

steam

condensate

heater

GKM water heat storage system / not pressurized

| 31


heat storage tank / integration district heat system

Rhenania

Altriperstr.

Plinaustraße

Marguerrestr.

Belfo

rtstr.

Angelstr.

line HD

line Mannheimnorth

line Mannheim

west

G GM20 GM21

Steam manifold 20 bar / 530 °C

M21M20unit 9

straße

DN 1000

DN 800

DN 600/700

(Vorl/Rückl)

232 MWth

232 MWth

232 MWth

300 MWth

500 MWth

HDMDND1-3

Aufeldstr.

GKMHauptpforte

heat

storage

98 °C

20 bar/300 °C

M21

| 32

supply/return


GKM new heat storage tank and system

0 m (96 m NN)

13600

800 14000 800 innen Fernwärmespeicher 40000 mm

36000

400

3970

existing

building

building for pumps,

piping, heater,

switchgear,

transformers, …

exis

ting b

uild

ing

heat storage tank

diameter 40m

cylindric height 36m

new supply line DN900 (district heat system)

new return line DN900

| 33


GKM Plant / location for new heat storage tank

location of new heat storage tank

| 34


technical data GKM heat storage system

Heat storage tank ("system Dr. Hedbäck")

diameter tank m 40

cylindric height tank m 36

storage capacity m³ 43.000

max. flow to / from tank t/h 6.200

max. storage water temperature °C 98

effective heat storage capacity MWh 1500

max. load (water flow) MW 250

| 35

heat storage tank / beginning of mantle erection (floor already finished, January 2013)



heat storage tank / built by „spiral method“ (roof already finished, March 2013)


heat storage tank / „spiral method“ (April 2013)


heat storage tank / „completely welded“ (during water pressure test in June 2013)


heat storage tank / heat insulation of mantle (September 2013)


heat storage sytem / building for pumps, piping

and heater in erection (July 2013)


heat storage system / new district heat lines DN900 supply and return lines in erection (July 2013)

| 43 VGB IGEF Flexibility-Workshop September 19, 2016 Berlin GKM CHP-Power Plant Dr. Meierer | 43

GKM heat storage tank completed (September 2013)


time / date

energy content [%]

energy content [%]

| 44

charging

dischharging

operation of heat storage tank (7 days, example)


Contents




CHP Process

4. Conclusions

| 45

0

50

100

150

200

250

300

2005 2006 -12 2013 2014 2015

Min

imu

m lo

ad [

MW

]

Minimum load GKM

unit 3/4 from 2006 unit 6 (before unit 7)

GKM / reduction of minimum load 2005 vs. today


Actual situation of CHP Plants in Germany / „Energiewende“

• increasing and high capacities of „renewables“ (esp. solar (PV) and wind) for

electricity generation with fixed and governmental garanteed compensation

• since more than 4 years constantly decreasing and volatile EEX Prices

Situation at GKM

• GKM Plant load corresponding to EEX Prices (Spot-Market „day-ahead and

intraday“), production volume and operation hours of units are decreasing

• need for permanent Distric Heat Generation and secure supply of Mannheim,

Heidelberg and Speyer

• combined heat and power plants (CHP) „struggle with economics“

Functions of new heat storage system in GKM

• new heat storage system enables GKM to operate only 1 unit during minimum

load (instead of 2 units before)

• heat storage system is used to optimize the plant operation depending on EEX

Prices (e.g. storage tank charging at night, discharging by day)

Conclusions


GKM Plant in Mannheim

| 48

Thank you for

your attention.

WWW.GKM.de


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