belchatow-poland-supercritical-steam-coal-power-plant-editorial

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LIGNITE POWER 858 MWe supercritical extension for Belchatow The supercritical unit under construction at Belchatow will be Poland's largest and most efficient lignite fired plant. Supercritical boiler Andrzej Twardowski, Alstom, Poland From the early 1990s onwards it was clear that major investment was needed to rehabilitate and/or replace Polish power plants, to improve operating performance and to address the effects of ageing and obsolescent technology. Furthermore, after a brief period when electricity consumption decreased, due to closure of obsolete production facilities and a decline in the power-intensive sectors of industry, over the past few years power demand has been increasing steadily in tandem with the country's GDP growth. The situation in the power sector was exacerbated by Poland's joining of the European Union in May 2005, which brought the burden of additional emissions reduction obligations, with limitations on emissions by Poland as a whole and by the Polish power sector specifically. All these factors created the necessity for the Polish power sector to embark on a very large investment programme to meet the requirements of growing power demand, increased market competition and tightening environmental regulations. Estimates suggest that to meet these requirements some 9 GW of new or radically rehabilitated generating capacity will need to be put in operation between now and 2015. Indigenous coal remains the mainstay of Polish power, accounting for about 152 TWh of the 162 TWh gross production in 2006 (some 94%, with oil, gas and hydro providing the rest). Lignite accounts for about a third of the coal generation. The first big project was rehabilitation of units 1-6 of the Turow lignite fired plant, a huge undertaking that started in 1994 (with the awarding to an Alstom-led consortium of a contract to rehabilitate all six LMZ-designed 200 MW units) and continued until 2005. The first three units were uprated to 235 MWe, and the subsequent three units to 262 MWe. Another significant project was the construction of a 460 MW supercritical lignite fired plant at Patnow (replacing two old 200 MW LMZ designed oil fired units), for which Alstom was awarded the turbine island and boiler contracts in 2001 and which is currently under commissioning. The next key phase in the replacement of old generating capacity in Poland was the start of construction of the world's first supercritical CFB plant, at the Lagisza site of PKE (Southern Poland Power Company). Lagisza is scheduled to enter commercial operation in early 2009. The boiler for this 460 MW unit is being supplied by Foster Wheeler, while in December 2003 Alstom received an EPC contract covering the turbine island package (including civil works) and the cooling system, including cooling tower. The new 858 MWe lignite fired supercritical unit to be built at Belchatow represents a further key stage in the modernisation of Poland's power generation infrastructure.
LIGNITE POWER Belchatow, pillar of Polish power – a utility perspective Piotr Szmaj, chief engineer, new unit, BOT Elektrownia Belchatow Even before the addition of the new 858 MWe supercritical unit (described in the main article), Belchatow hosted the largest coal (lignite) fired plant in Europe – with a current installed capacity of 4400 MWe (12 x 370 MWe) – and has been called the capital of the Polish power generation industry. Following completion of the modernisation programme started in 1997, which added 120 MWe to the installed capacity (by modernisation of the turbine LP stages), the plant fulfils all EU requirements and standards. Indeed, BOT Elektrownia Belchatow was the first company in Poland to receive a permit under the EU's Integrated Pollution Prevention Control (IPPC) scheme to run its installations in line with the IPPC directive. The power station being the lowest cost and the most efficient electricity producer in the country is a pillar of the Polish power generation industry, helping to stabilise the national energy market. Since the late 1990s, with an annual electricity output of about 28 TWh, Belchatow has provided some 20% of Poland's power, well ahead of any other power station. The design of the original Belchatow units was developed in the 1970s and did not anticipate any measures to limit emissions of sulphur oxides emissions because at that time flue gas desulphurisation technologies were largely unknown and only in the development phase. However, in the years 1988 to 1990, BOT Elektrownia Belchatow turned its attention to developments in Polish desulphurisation technologies as well as those being applied worldwide, and subsequently fitted FGD to ten of the 12 Belchatow units (numbers 3 to 12). To maintain a leading position in the Polish electricity market BOT Elektrownia Belchatow has adopted a strategy for capacity development, which entails comprehensive modernisation of Belchatow units 3 to 12, starting in 2007 – with the aim of enabling them to reach 320 thousand hours of operation, ie to operate until around 2035 – plus construction of the new unit, as described in the main article. The strategy, which assumes maintenance of high power production capabilities in association with optimal utilisation of available coal deposits (about 1 billion tonnes of lignite) in the Belchatow and Szczercow open cast mines, can be summarised as follows: • Construction of the new 858 MW power unit, with commercial operation scheduled for October 2010. This represents the largest investment of its kind yet in Poland. In 2001, official acceptance from the Ministry of the Treasury was obtained to commence a project to build a new 833 MW power unit. The capacity was subsequently increased to 858 MW, thanks to improved plant integration by EPC contractor Alstom. The tender procedure began in 2002 resulted in the selection of the Alstom consortium. The design was approved in 2005 and a construction permit issued. Construction work began in October 2006. The power plant will use best available technology (BAT), as required under IPPC, and will also fulfil the requirements of the EU Large Combustion Plant directive. First synchronisation with the Polish national grid is anticipated in February 2010. The project includes a new transmission link to the system switching station in Trebaczew. • Reconstruction and modernisation programme. Refurbishment of units 1 and 2 (which do not have FGD) was done in 2004 and 2005, while modernisation of units 3-12 will be done according to the following schedule: unit 3 in 2007, unit 4 Germany Belchatow in 2009, units 5 and 6 in 2010, units 7 and 8 in 2011, units 9 and 10 in 2012, and units 11 and 12 in 2013. The basic goals of the modernisation process include: extension of the operating lifetime of units 1 and 2 (to 2016) and of units 3-12 (to 2030-2035); improvement of operating performance; reduction in environmental impact, including compliance with EU Directive 2001/80/EC; and increase in turbine-generator unit power from 370 MW to 380 MW. The total investment cost (new build plus refurbishment) is 1.6 billion euro, with banks providing 880 million euro. The project won the Euromoney/Project Finance award for best European power deal of 2006. The new unit and the refurbishment programme are in line with BOT Elektrownia Belchatow's policy of striving to continuously upgrade and improve its power technology assets. The management system is also being continuously improved. The power plant holds a PCBC and IQNet certificate for an Integrated Management System for Quality, Environment, Occupational Safety and Information Security (IMS-ISO), compliant with the requirements of the PN-EN ISO 9001:2001, PN-N-18001:1999, PN-EN ISO 14001:1998 and PN-I-07799-2. Lodz Baltic Sea Piotrkow Trybunalski Poland Lodz Warsaw Slovakia Lithuania Belarus Ukraine Belchatow site, showing the 12 existing units Visualisation of the new 858 MWe unit at Belchatow, with existing units, right Poland's biggest The Belchatow extension will be the largest generating unit ever built in Poland and also the most efficient lignite plant, expected to achieve almost 42%. Alstom is supplying the plant to utility BOT Elektrownia Belchatow SA (which is owned by the state power generation holding company BOT Gornictwo i Energetyka) under a full turnkey EPC (engineering, procurement, construction and commissioning) contract. The contract was signed in December 2004 and the pre-engineering phase started immediately. Financial close and the official launch of the project (notice to proceed) was obtained in October 2006. Commercial operation is scheduled for the last quarter of 2010. There are already twelve 370 MWe lignite fired units at the Belchatow site, which started operation in the early 1980s and run in baseload mode. There was an urgent need to rehabilitate these units due to their age, emissions and economics. Ten of the units will be upgraded, over the period 2007 to 2013, while the oldest two will be shut down permanently before 2016, with the new plant more than making up the loss of power production. The end result will be increased electricity production in full compliance with European environmental regulations, including the Large Combustion Plant and Integrated Pollution Prevention and Control Directives. The total cost of the new plant plus the refurbishment of the existing units is estimated to be around 1.7 billion euros. The EBRD is providing a loan of 125 million euros for the new plant. Other investors include EIB, 220 million euro, Nordic Investment Bank, 150 million euro, and ING and Citibank, which are providing various facilities totalling 604 million euro. BOT Elektrownia Belchatow decided to build the new 858 MWe unit as an extension of the existing unit in order to secure continuous deliveries of electricity to customers as well as maintaining a constant level of lignite consumption from the local open mine (a major cost factor for the power plant). Thanks to the project BOT Elektrownia Belchatow will: • secure its income by maintaining electricity production;
Page 1: October 2007 858 MWe supercritical
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