english - STEAG

steag.com

english - STEAG

Leuna

Refinery Power Plant

www.steag.com


Power and heat for the future

Efficient energy supply for the

Leuna refinery complex

As fifth biggest electricity producer in Germany, with ultramodern

power plants in and outside Germany and a variety of

services, STEAG GmbH safeguards the energy supply of the

future – reliably, efficiently, and with low environmental impact.

STEAG blazes the trail for the energy sources biomass,

biogas, mine gas, geothermics, wind and solar thermics. The

engineers of STEAG Energy Services GmbH develop, build

and operate power plants all over the world and are experts

for the modernization of existing plants and for made-tomeasure

energy supply which goes easy on the climate and

at the same time is economical.

Power plants at home and abroad

STEAG operates eleven power plants at ten locations in

Germany with an installed capacity of about 7,500 MW; nine

of these plants use hard coal as primary energy source. At

two sites, each of which integrates an industrial power plant,

refinery by-products also are used to produce steam, compressed

air and electricity. Most of the electricity from hard

coal is supplied to industrial and public utilities. The customers

include RWE, EnBW and Deutsche Bahn, the German

Railways. Where there is a demand for it, cogeneration –

the simultaneous production of power and useful heat – is

practiced. This heat either is used for heating purposes or

is purchased by industrial enterprises in the form of process

heat for their production processes. Outside Germany, too,

the company contributes to public power supply with three

hard-coal-fired power plants, capacity about 1,700 MW, in

Turkey, Colombia and the Philippines. The efficient power

plants of STEAG make an active contribution to a secure and

sustainable supply of energy.

The Leuna refinery power plant is located on the grounds of

the Leuna chemical park, one of the biggest industrial chemicals

sites in Germany. The power plant supplies the refinery

at the site with electricity, process steam, compressed air,

process water, feedwater and cooling water. The supply of

energy to the refinery in Leuna was the first project of its kind

worldwide. Up until then, the oil companies had financed,

built and operated their power plants themselves. In Leuna,

for the first time an external partner, STEAG, was given a

chance. Thanks to STEAG’s longstanding know-how, it was

and is possible to use refinery residues as fuel despite stiffer

environmental protection regulations.

Symbiosis of power plant and refinery

The smooth cooperation between power plant and refinery is

important for supplying the site. This symbiosis has functioned

almost without a hitch since 1996. One chief reason

for this is the close coordination between power plant and

refinery concerning current energy consumption and operative

measures.

Via online links each party is well informed about the current

operating data of the other party. This coordination is backed

up by long-term and medium-term planning. Power plant

and refinery begin at midyear to draw up the schedule for the

coming year.

STEAG also continually invests in the power plant site in order

to meet the changing needs of the refinery. For example,

paralleling the expansion of the refinery processing capacity

from just under 10 million tons of crude to 12 million tons

annually, investments were made in 30 projects at the power

plant to increase its reliability and energy efficiency. In refinery

power plants, capacity is not as important as availability, because

the refinery is dependent on an uninterrupted supply

of energy.


The power plant

Site plan

Characteristic of the Leuna refinery power plant is that it

self-sufficiently supplies the refinery and installations belonging

to the complex with electricity, process steam at

various pressure levels, compressed air and various process

waters, feedwaters and cooling water. The fuels used are

very viscous distillation and conversion residues from the

refinery process. Owing to the sophisticated environmental

technology of STEAG, especially the highly efficient flue gas

desulfurizing (FGD) system, these residues are turned into

raw materials again.

The residues are delivered via pipework at a temperature of

about 150 °C. The fuels are stored for the interim in tanks

in the power plant and then preheated to around 230 °C. In

addition, excess fuel gas from the refinery and synthesis gas

from a methanol plant find use.

The fuel is injected into the boiler at a temperature of 230 °C.

There it burns and heats the water in the boiler tubes to

make steam. The steam drives the turbines and is transformed

into electricity in the generators or supplied directly to

the refinery as process steam.

Annually, 250,000 tons of these high-viscosity oils, as the

black mass is termed, are processed in this way in the Leuna

refinery power plant. For one thing, this saves disposal costs

and, for another, it reduces the use of fossil energy sources.

The refinery needs large quantities of steam at differing pressure

levels to drive pumps and turbine-driven units as well as

for mass transfer. Process water and boiler feedwater for the

refinery come from the water treatment plant. The required

cooling water is made available from a closed recooling water

circuit constructed specifically for the refinery.

The power plant also operates a water demineralizing plant.

It works on the reverse osmosis principle and, with its capacity

of 510 m 3 / h, is one of the biggest in Europe.

In addition, the condensates returning from the refinery

(410 m 3 / h) are treated in a dedicated condensate polishing

plant and returned to the process water and feedwater.

1

2

2

4

5

18 18

3 3

3 3

6

18 19

17

7

12

11 11 11

10 10 10

8 8 8 9

18

7

7

16

17 17

13

14

20

15 15 15

22 21

23 24 24

25 27 26

1 Gatehouse

2 Fuel tank

3 Fuel tank

4 Fuel supply / preheating

5 Fuel supply / preheating

6 Fuel supply / preheating

7 Boilerhouse with DeNo x

8 Wet electrostatic precipitator

9 FGD wastewater treatment plant

10 Scrubber

11 Quench cooler / stack

12 Quench cooler / stack

13 FGD wastewater treatment plant

14 Gypsum silo

15 NH 3

supply system

16 Turbine house

17 Transformer

18 Transformer

19 Switchgear building and control room

20 Switchgear building

21 Demin water plant

22 Demin water plant

23 Demin water plant

24 Demin water plant

25 Cooling towers

26 Cooling towers

27 Cooling towers


Data and facts *

Installed capacity 162 MW (of which 56 MWel equivalent = 204 MW th

)

Useful electricity output

Steam and compressed air output

Fuel input

about 558 GWh / a

about 282 GWh / a

about 330,000 tce

Components 1 demineralization plant (510 t / h)

1 HP steam turbine (33.6 MWel)

1 IP steam turbine (38.3 MWel)

1 LP steam turbine (34.2 MWel)

3 oil-fired boilers (178 t / h each)

1 gas-fired boiler (156.6 t / h)

Initial start-up 1996

Operator

Owner

RKB Raffinerie-Kraftwerks-Betriebs GmbH

STEAG-Raffinerie-Kraftwerk-Sachsen-Anhalt GmbH

STEAG refers to the gross maximum capacity under nominal

conditions as installed capacity. This is the continuous

output that can be attained under normal conditions. It is

limited by the weakest part of the plant (bottleneck), is determined

by measurement and converted to normal conditions;

stated in MW, calculated as MW electric and equivalent

(thermal output).

The standard coal equivalent or ton of coal equivalent

(tce) is a commonly used unit of measure in Central Europe,

though not a statutory unit of measure, to compare the energy

content of primary energy sources. 1 ton coal equivalent =

29.3076 gigajoules (GJ) = 8.141 thermal megawatt-hours

(MWh th

).

A site with a tradition

The Leuna refinery power plant is located on the grounds

of the Leuna chemical complex, which is very well known

for its past history and outstanding developments. Leuna

gained an international reputation through its coal hydrogenation

processes. Nobel Prizes for scientists at the site in the

1920s and 1930s attest to this. The changeover to the raw

material petroleum took place in several stages in the early

1950s. After the turnabout in East Germany in 1989, the Elf

Group (today TOTAL) won a contract to build a completely

new refinery in Leuna. This was the birth of TOTAL-Raffinerie

Mitteldeutschland (TRM), the most up-to-date, most efficient

refinery in Europe.

STEAG, which already had built a combined-cycle power

plant and a demineralizing plant in Leuna, was commissioned

by Elf to build the refinery power plant. All in all this

was a project of superlatives, for it was the biggest German-

French economic investment of the postwar period. After just

about two years of construction, the industrial power plant

took up commercial operation in December 1996.

* as at December 31, 2011


STEAG GmbH

Rüttenscheider Strasse 1–3

45128 Essen

Germany

Phone +49 201 801-00

Fax +49 201 801-6388

Email info@steag.com

www.steag.com

RKB Raffinerie-Kraftwerks-Betriebs GmbH

Werkteil II Bau 3691

06237 Leuna

Germany

Phone +49 3461 548-2222

Fax +49 3461 548-2209

Email info-rkb@steag.com

V-UK, as at June 2012

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