Gas and coal fired cogeneration plantcogen3.com/presentations/asean/cogenweek2004phil/manila/Success... · Power Plant in Map Ta Phut Power Plant in Map Ta Phut 1. Map Ta Phut Industrial

EC-ASEAN COGEN Programme Phase IIIProven, Clean & Efficient Biomass, Coal, Gas Cogeneration

The EC-ASEAN Business Facilitator1

Leif Mortensen, Chief Consultant, Coal Expert

Gas and coal fired cogeneration plantGas and coal fired cogeneration plant

COCO IIIA successful coal & gas-fired cogeneration project in Thailand

2004 Cogeneration Week in Philippines21 - 22 June 2004 Mandarin Oriental Hotel, Manila

24 June 2004 Queen Jennifer Hotel, Isabela



Structure of the Thai electricity sectorStructure of the Thai electricity sector



Location of the SPPLocation of the SPP



Power Plant inMap Ta Phut

Power Plant inMap Ta Phut

1. Map Ta Phut Industrial Estate and Eastern Industrial Estate, Rayong

2. Strategic areas for development of petrochemical and steel industries



Power 514 MW, Steam 200 t/h, Demin. Water 150 cum/hOperation date: September 1999/March 2000Fuel type: Natural gas/imported bituminous coal/ diesel oilProject cost: 574 million USD

SPP Phase 3 Hybrid CogenerationSPP Phase 3 Hybrid Cogeneration



Customers of the plantCustomers of the plant

• Electricity Generating Authority of Thailand (EGAT)

PPA’s under the Small Power Producer (SPP) scheme

• 29 Industrial Customers



Bangkok Synthetics Co.,Ltd. (BST)

Thai Olefins Public Co.,Ltd. (TOC)

Vinythai Public Co.,Ltd. (VNT)

Siam Styrene Monomer Co.,Ltd. (SSMC)

Thai Plastic and Chemicals Public Co.,Ltd. (TPC)

Thai Polypropylene (1994) Co.,Ltd. (THPP-2)

The Aromatics (Thailand) Public Co.,Ltd. (ATC)

Crompton Specialties Ltd. (CROMPTON)

TPC Paste Resin Co.,Ltd.

Rayong Olefins Co.,Ltd. (ROC)

Thai Polyacetal Co.,Ltd. (TPAC)

Thai Polycarbonate Co.,Ltd. (TPCC)

Thasco Chemical Co.,Ltd. (THASCO)

Siam United Steel Co.,Ltd. (SUS)

BST Elastomers Co.,Ltd. (BSTE)

Thai Polyethylene Co.,Ltd. (HDPE-2/HDPE-3)

Carbide Chemical (Thailand) Limited

Siam Tinplate Co., Ltd. (STP)

Siam Polyethylene Co., Ltd. (SPE)

Thai MMA Co., Ltd. (TMMA)

Tuntex (Thailand) Public Co., Ltd. (TTC)

Bayer Thai Co., Ltd. (BTC)

Asia Silicones Monomer Ltd. (ASM)

GE Toshiba Silicones (Thailand) Ltd. (GETOS)

Shin-Etsu Silicones (Thailand) Ltd. (SEST)

Thai Aerosil Co., Ltd. (TAC)

BHP Steel Thailand Co., Ltd. (BHP)

Thai PET Resin Co., Ltd. (TPRC)

Electricity Generating Authority of Thailand (EGAT) under the SmallPower Producer Project (SPP)

Siam Mitsui PTA Co., Ltd. (SMPC)

Customers ListCustomers List



Electricity and Steam Contracted CapacityElectricity and Steam Contracted Capacity

Petrochemical Petrochemical and Plastic Industriesand Plastic Industries

Electricity: 30.9%Electricity: 30.9%Steam: 97%Steam: 97%

EGATEGAT

Electricity: 64.4%Electricity: 64.4%

Total contracted capacity 500 MW of Electricity and 200 t/h of Total contracted capacity 500 MW of Electricity and 200 t/h of SteamSteam

Fiber Industries Fiber Industries


Steel IndustriesSteel Industries


Steam: 3%Steam: 3%



COCO III area1990

COCO III area1990



COCO Phase IIICogeneration Plant today

COCO Phase IIICogeneration Plant today



The Hybrid Block ConceptThe Hybrid Block Concept

• Multiple fuel technology (coal/gas/diesel oil)

• Gas/oil fired combustion gas turbines for power production

• Heat recovery units for feed water heating and steam re-heating

• Coal fired CFB boiler for steam production

• Steam turbine for power production



Hybrid Cogeneration ProcessHybrid Cogeneration Process

~

Exhaust

Hot watercoalLime stone

Heat Recovery Unit (HRU)

PTTFuel Gas

2 x 35 MW

Hot GasAir

Gas turbineGenerator water

Bottom ash

Fly ash

exhaust

MP steam

152 MW

Sea water cooling

Steam turbinegenerator

Circulating Fluidized

Bed Boiler (CFB)

Gas End Coal End

~

steam

HP Steam



Coal Harbour and Coal YardCoal Harbour and Coal Yard



Coal Ash ManagementCoal Ash Management

• Non-hazardous waste certified by Department of Industry

• Types of the ashFly ash 4,000 tons per monthBottom ash 1,000 tons per month

• Existing system of ash disposalUtilization for ready-mix concrete industry and cement industryPromotion of the fly ash brick to local communities



Air Quality ManagementAir Quality Management

• Emission Control at source

CFB BoilerFabric Filter Use of high quality coalUse of lime-stone for SO2 removal

• Continuous Emission Monitoring System (CEMS)

• Regular inspections and maintenance

• Third party audits as per EIA Approval



Hybrid Cogeneration EmissionsHybrid Cogeneration Emissions

ppm

March-April 2003

161

320

152

350

2.52

870

8.2560

0

100

200

300

400

500

600

700

800

900

SO2 Nox CO TSPGlow SPP Phase 3 StandardSPP Phase Standard

(mg/m3)



• Plant visit to get the public learn and understand Hybrid Cogeneration Process and bituminous coal utilization

The number of visitor as of 2002 : 72 groups: total 2,591 outside visitors

As of June 2003 = 589 persons

Community Relations ActivityCommunity Relations Activity



• Promotion of coal ash utilization.To sponsor the coal ash bricks production project

• Donation and sponsorship on educational, sports and religious programs

• Scholarship program

• Being active member and participate in the activities of Map Ta Phut Public Relations Club

• Sponsorship on leadership training programs for local teachers/students

Community Relations ActivityCommunity Relations Activity



Project implementation only if feasibility study shows positive net present value

• Comply with Environmental Impact Assessment (EIA) approval and other environmental regulations

• Work with local community from the start

• Strategically well located in an industrial area with growth

• Long term power purchase agreement with EGAT under the SPP scheme

• Medium to long term contracts with local industrial customers for power and steam sales

Key factors leading to success of SPP Cogeneration

Key factors leading to success of SPP Cogeneration



• Long term agreement with PTT on gas supply

• Long term agreement with local company on coal supply of high quality coal

• Long term land lease agreements, including additional land for potential expansion

• Use of proven and reliable equipment

• Clearly defined operational and maintenance strategies in order to achieve maximum reliability, availability and efficiency

• Continued search for and implementation of plant improvements

• Service oriented organization which focus on customer satisfaction

Key factors (cont.)Key factors (cont.)



Generation of electricity & heat based on Generation of electricity & heat based on biomass in large scalebiomass in large scale

A presentation made by Jon Kringelum & Stig Møller Andersen, ENERGI E2, Denmark

Presented by Leif Mortensen, Chief Consultant, Coal Expert



ENERGI E2 ENERGI E2 –– KeyKey figuresfigures

• Largest power generating company in Eastern Denmark• 7 large- and 10 small-scale power plants in Eastern Denmark -

mainly Combined Heat and Power (CHP)• Generating capacity (Europe), electricity:

– 4,500 MW • Generating capacity (Denmark), heat:

– 2,600 MJ/s (district heat)– 1,800 t/h (steam)



Target for the use of biomass in Danish power plants by 2000:1,2 mil. tonnes of straw0,2 mil. tonnes of wood chips

Additional agreement by July 1st. 1997:0,2 mil. tonnes of straw is converted to the same amount of wood chips

Follow up on original agreement by March 22nd. 2000:The time limit for the fulfilment of the agreement is postponed to the end of 2005

Newest revision by march 29th. 2001 (New yearly capacity):ENERGI E2 (Eastern Denmark):

300.000 tonnes of wood pellets at the Avedøre, unit 2130.000 tonnes of straw pallets at the Amager, unit 2

ELSAM (Western Denmark):250.000 tonnes of straw200.000 tonnes of wood chips

BackgroundBackground for for biomassbiomass activitiesactivitiesThe biomass agreement from 1993The biomass agreement from 1993



0

100

200

300

400

500

600

700

800

900

1000

1989 1991 1993 1995 1997 1999 2001 2003 2005 2007 2009

1,00

0 to

nnes

/yea

r

Haslev straw Slagelse straw Masnedø straw Maribo Sakskøbing strawJunckers wood chip Avedøre straw AVV2 wood pellets Amager straw pellets

Amager Unit 2 Straw-pellets

Avedøre Unit 2 Wood-pellets

Avedøre Straw in Bales

Junckers Wood Chips

ENERGI E2ENERGI E2’’s s ExpectedExpected BiomassBiomass ConsumptionConsumption



KKøøge ge BiopelletBiopellet FactoryFactory

Production capacity, wood: 180,000 tonnes / year

Production capacity, straw: 130,000 tonnes / year



KKøøge ge BiopelletBiopellet FactoryFactory -- StrawStraw

Hammer mills

Pellet machinery

Straw Shredder



14 bar process steam

4 bar

To sewer

Flare

4 bar process steam

Buhler

Wood pellets

Wet wood chips pile

KKøøge ge BiopelletBiopellet FactoryFactory -- WoodWood



AvedAvedøørere Power StationPower StationCommissioned in 1989 (unit 1) and 2001 (unit 2)Commissioned in 1989 (unit 1) and 2001 (unit 2)



AvedAvedøøre Power Station unit re Power Station unit 22

Straw bales(Grate firing)

Natural Gas

Fuel Oil

Wood Pellets(max 70% load,Dust firing)

Natural Gas

Main Boiler

580 / 600°C & 300 BarSteam Turbine

Gas Turbine unit

Electrical power

Electrical power

District heat

570 MWel/ 0 MJ/s490 MWel / 570 MJ/sBiomass Boiler

545°C & 300 Bar



Amager Power Station, unit 1, 2 and 3Amager Power Station, unit 1, 2 and 3

3 2 1



District heat

Amager Power Station, unit 2Amager Power Station, unit 2

AMV unit 2 Coal StrawIn operation 1972 2003Electricity MW 109 59District Heating MJ/s 190 166Steampressure bar 141 120Steamtemperature °C 537 480Electrical efficiency % 37 26.7

Main Boiler

Steam TurbineFuel Oil

Straw Pellets(max 70% load,Dust firing)

Electrical power



Summary and Summary and conclusionsconclusions

• Increased use of biomass in ENERGI E2• Target amount: 850.000 tonnes each year• Greater market flexibility• Know-how on refining technologies• New challenges in large-scale biomass dust firing• Ongoing improvements of grate firing technology



Thank You !

For more information, please visit COGEN 3 Website at:

http://www.cogen3.net

Documents

Gas and coal fired cogeneration plantcogen3.com/presentations/asean/cogenweek2004phil/manila/Success... · Power Plant in Map Ta Phut Power Plant in Map Ta Phut 1. Map Ta Phut Industrial