Plant Design

At the average coal-fired power plant, the battle to reduce net heat rate is complicated by skin-tight maintenance budgets, staff reductions, and—for some—the switch from baseload to mid-peaking service. The most fruitful approach to improving a plant’s heat rate is to optimize combustion in its boiler, particularly by minimizing the amount of “stealth” air in-leakage.

Cost overruns of nearly $1 billion to build the 582-MW Kemper integrated gasification combined cycle (IGCC) plant in Kemper County, Miss., were underscored on May 20 as Mississippi Power’s Board of Directors took the dramatic step of replacing the Southern Co. subsidiary’s leadership.

Every piece of equipment that transports or processes coal creates some level of particulate matter. Having a strategy for coal dust management in your plant is essential.

The integrated gasification combined cycle (IGCC) plant located in Kemper County, Mississippi, is a 2 x 1 plant that will produce 582 MW at peak and 524 MW fired on syngas, with ammonia, sulfuric acid, and carbon dioxide as by-products. The carbon dioxide will be used for enhanced oil recovery (EOR). Engineering was completed in Q3 2012, and the facility’s commercial operation date is planned for May 2014.

Recent experience on the Deely 2 SCR retrofit project reminds us that the time spent in thoroughly planning a project prior to the start of construction is usually repaid with avoided construction delays.

The world’s first supercritical pulverized coal–fired low mass flux vertical tube Benson boiler is Jinzhushan 3, located in the Hunan Province of the People’s Republic of China. The 600-MW Babcock & Wilcox Power Generation Group Inc. once-through boiler burns Chinese anthracite using downshot pulverized coal (PC) technology. Part 1 of this three-part article presented a summary of the project design features. Part 2 discussed the boiler technology. This third and final part reviews the plant’s performance test results.

While the war on coal is working to reduce coal generation and consumption and associated carbon dioxide emissions in the United States, many world economies are looking toward coal for future generation needs. China, India, Russia, and Germany, to name a few, are building coal-fired power plants.

This synopsis of today’s most interesting research related to power generation gives you a glimpse of what’s possibly coming to your plant in the not-so-distance future. Research under way today will surely determine how power plants are designed, operated, and maintained for many years to come.

Insulation and lagging are key to saving energy in a typical steam plant, and plant operators would be well advised to pay close attention to energy losses in their insulation and lagging systems.

The world’s first supercritical pulverized coal–fired low mass flux vertical tube Benson boiler is Jinzhushan 3, located in Hunan Province of the People’s Republic of China. The 600-MW Babcock & Wilcox Power Generation Group Inc. once-through boiler burns Chinese anthracite using downshot pulverized coal (PC) technology. Part 2 of this three-part article discusses the boiler technology. The third and final part will review the plant’s performance test results.