“Build, Dismantle and Build” Replacement at Coal-Fired ...steag.in/sites/.../Build_Dismantle_and_Build_Replacement_for_enhanc… · “Build, Dismantle and Build” Replacement

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

I. “Build, Dismantle and Build” Replacement:

Isogo ModelIsogo Model

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

1. Background of Replacement (3/3)

Source : J-POWER, IHI2

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

Comparison of thermal power

plant space efficency

4. Key Initiatives (1/5)


Side view of new unit #1


Source : J-POWER

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


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


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


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

II. On-going initiativeII. On-going initiative

5. Overview of Takehara TPS, J-POWER 1/3

Source : J-POWER



Source : J-POWER

6. Replacement plan underway at Takehara TPS

1/5


2/5


3/5


4/5


5/5

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

ReferenceReference

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/


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. 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

Documents

“Build, Dismantle and Build” Replacement at Coal-Fired ...steag.in/sites/.../Build_Dismantle_and_Build_Replacement_for_enhanc… · “Build, Dismantle and Build” Replacement