Capstone Project AUK Emission Controls at Kosova’s Thermal Power Plants, Current and Future Capabilities Presented by: Skender Isufi, March, 2010 Problem Background 1.1. Brief description of KEK Four core Divisions: Coal Production, Generation, Network and Supply TPP Kosova A (commissioning from 1962 - 1975) consists of 5 units with installed capacity 800MW Only 3 units in operation A3, A4 and A5 (available power capacity 450MW) TPP Kosova B (construction 1983-1984) consists of 2 units with installed capacity 678MW (available power capacity 600MW) HPP Ujman (2 x 17.5MW) HPP Lumbardhi, (2 x 4MW) Thermal vs. Hydro electricity generation 97 : 3 % TPP of Kosova are characterized by: Old technology of firing and emission control Aging of units A3 – 40 years in operation; A4 – 39; A5 - 35 B1 – 27 years in operation; B2 - 26 High specific emissions (especially dust and CO2) High specific consumption of lignite For TPP A 1.8 ton of lignite / MWh For TPP B 1.4 ton of lignite / MWh Low efficiency of units in TPP A are 20 – 27% in TPP B are 30 – 35% Electricity Generation in Kosova 2001-2008 Demand in 2008 has increased by 60% compared to 2001 Domestic electricity generation in 2008 was 77% higher than GWh in 2001 5,000 4,500 4,000 3,500 3,000 2,500 2,000 1,500 1,000 500 0 2001 2002 TPP A 2003 TPP B 2004 2005 HPP 2006 2007 Net import 2008 1.2 Type of Fuel & Lignite Consumption Cheap energy source (10 billion tons of exploitable reserves, only Sibovc field 1 billion tons) Two opencast coal mines: Mirash and Bardh Type of coal – lignite LHV = 6500 - 9500kJ/kg Carbone = 22% Ash content = 10 - 21% Moisture = 40 ÷ 45% Sulphur ~ 0.7 – 1.5% (0.1 – 0.5% organic sulfur) Extracting ratio 1.7m3 of overburden to 1 ton on lignite Year 2001 2002 2003 2004 2005 2006 2007 2008 million tons 4.26 5.23 5.64 5.59 6.27 6.35 7.11 7.46 TPP A million tons 2.02 2.24 3.13 1.71 1.27 1.77 2.47 2.44 TPP B million tons 2.23 2.98 2.50 3.88 4.99 4.57 4.64 5.02 Coal consumption 1.3. Kosova TPP and Environment - Emissions Air emissions – Dust (particulate mater), SO2, NOx Greenhouse gas – CO2 The units in TPP A and TPP B are equipped with ESP (electrostatic precipitator electro filter) Designed dust emission TPP A - 560mg/Nm3 (3.13kg/MWh) TPP B - 260mg/Nm3 (1.45kg/MWh) There are no FGD (flue gas desulphurization) plant (lignite has calcium in it’s content, which contributes to self-desulphurization) • Indicative emissions from units of TPP in Kosova (in mg/Nm3) for 6% O2the average values for 2008 and 2009 Dust emissions (mg/Nm3) NOx (mg/Nm3) SO2 (mg/Nm3) For TPP Kosova A 1200 – 1300 700-690 540-750 For TPP Kosova B 300 – 400 800 400-700 EU emission requirements According to the EU Directive 2001/80/EC the emissions from large combustion plants for solid fuels For plants which are put in operation before 2003 (existing and new plants) with >500MWth For plants which are put in operation after 2003 (new-new plants) with >300MWth Dust (mg/Nm3) NOx (mg/Nm3) SO2 (mg/Nm3) <50/100 <500 <400 <30 <200 <200 o It is required to have a continuous measurement for emissions o Existing plants (licensed before 1987) may be exempted from the requirements if they do not operate more than 20,000hrs from 2008 until 2015. Timing for LCP Directive Existing installations Part A ELV July 1987 “Old” new November 2002 “New” new installations installations Part A ELV Part B ELV According to the Athens Treaty (2005) – countries adopted this treaty among others will have to implement the LCP Directive by end of 2017. (103 bo u La rg tv ia M Li al th ta ua C nia y Sw pru e s Es den Sl ton ov ia e Au nia s Ko tria so H v un a Sl ga o ry D vak en ia m Ire ark Be lan lg d i N Fin um et la he n rl d Po and rt s Bu uga lg l G aria re R ec om e C a ze ch Fr nia R anc ep e ub lic Ita P ly G olan er d U m ni an te d Sp y Ki a ng in do m x tons) SO2 x tons) ur La g tv Ko i a so Sw va ed A u en D stria en m ar k M a Li th lta ua n C ia N yp et he r us rla n F i ds nl S l and ov e Be nia lg iu Ire m l S l and ov a Es kia to H nia un g C ze Po ary ch rtu Re ga pu l bl ic Ita Fr ly a G nce er m a G ny re e U ni Ro ce te m d a Ki nia ng do Po m la B u nd lg ar i Sp a ai n (103 xe m bo Lu xe m NOx Lu NOx and SO2 emission from LCP in 25 MS of European Union - for 2004 400 350 300 250 200 150 100 50 - 1200 1000 800 600 400 200 0 bo ur g La t v Li t h ia ua ni a Cy pr u Sw s Ne ed en th er la nd s M al ta Au st De ria nm a Sl rk ov en i Fi a nl an Hu d ng a Po r y rtu ga l B Cz ec elgi um h Re pu bl ic Ita Sl ly ov ak i Ko a so va Ire la nd Fr an ce Un Ge ite r m a d Ki ny ng do m Es to ni Bu a lg a Ro r ia m an ia Sp ai n Po la nd G re ec e Dust (103 x tons) CO2 (million tons) Li Lu thu xe an m ia bo ur g La t v Sl i a ov ak ia M al C ta yp r Ko us so Sw va ed Sl en ov en Au ia st Es ria to H ni a un ga r Ire y l Po and rt u D ga en l m a Be rk lg iu Fi m nl an Fr d N et anc he e rla n C ze G ds ch re Re ece pu bl ic Sp ai n Ita U ly ni t e Pol d an Ki ng d G dom er m an y Lu xe m Dust and CO2 emission from LCP in 25 MS of European Union - for 2004 60 50 40 30 20 10 0 350 300 250 200 150 100 50 - Current Emission from units of TPP of Kosova Years TPP A A3 A4 TPP B B1 B2 Emissions (in tons) SO 2 NOx Particulate CO 2 SO 2 NOx Particulate CO 2 SO 2 NOx Particulate CO 2 SO 2 NOx Particulate CO 2 2007 986 2,926 3,572 1,099,478 920 2,590 3,321 960,520 1,444 6,514 1,000 2,089,314 1,108 4,843 2,093 1,534,868 2008 2009 2,455 2,767 3,122 2,806 3,751 4,966 1,156,058 1,084,167 1,302 na 1,901 na 2,688 na 700,089 na 3,858 5,691 6,313 7,333 2,202 2,171 2,009,463 2,382,954 4,576 7,782 6,988 7,188 3,485 3,797 2,245,182 2,306,661 Why CO2 emissions are higher compared to other emission ? C content in lignite 22% Ash content in ignite 10 – 21% ESP Project Description The literature review (books, reports, other information) Consultations with engineers in KEK Steps of capstone project Creating the model for future analysis of emissions Collecting the necessary information and data the maximum gross power for existing units of TPP A and TPP B; the time availability for existing units; specific lignite consumption; emissions factors for the different pollutants; and the formulas for calculations Evaluate different technologies for new thermal power plant Conducting the calculations First step - Defining the scenarios for building the model Scenario 1 – the existing TPP (Kosova A and B) without abatement measures Scenario 2 – the existing TPP with abatement measures (upgrading the electrostatic precipitators - ESP, only for TPP B), construction of the new HPP Zhur 293MW and new TPP Kosova C with capacity 1x500MW Scenario 3 – the existing TPP with abatement measures (upgrading the electrostatic precipitators - ESP, only for TPP B), construction of the new HPP Zhur 293MW and new TPP Kosova C with capacity 2x500MW Scenario 4 – the existing TPP with abatement measures (upgrading the electrostatic precipitators - ESP, only for TPP B), construction of the new HPP Zhur 293MW and new TPP Kosova C with capacity 4x500MW Decommissioning of TPP Kosova A by 2017 The time period for analysis 2010 - 2030 Second Step – Defining the characteristics of existing units The maximum average gross capacity for each unit of TPP A - 125MW for each unit of TPP B - 270MW The self-consumption of electricity for the units is 9% each The load factor for the units of TPP A ( A3- 0.7; A4 - 0.6 and A5 - 0.3). for units of TPP B - 0.8 Specific lignite consumption 1.75 t lignite/MWh – TPP A 1.4 t lignite /MWh – TPP B The emission factor: Dust: 4.76 kg/MWh for TPP A and 1.54 kg/MWh for TPP B. SO2: 2.73 kg/MWh for TPP A and 2.45 kg/MWh for TPP B NOx: 2.30 kg/MWh for TPP A and 2.7 kg/MWh for TPP B CO2: 1.48 t/MWh for TPP A and 1.18 t/MWh for TPP B Third step - Combustion Technologies for new TPP in Kosova Selection criteria: cost, efficiency, and low emissions Available combustion technologies for future TPP 1. Pulverized firing with subcritical parameters – PC Pressure below 221bar Size up to 1000MW Requires installation of equipments for emissions control (FGD, low NOx burners, ESP) Efficiency is rather low compared to other technologies High availability, and there is successful experience in design of boilers Pulverized firing with supercritical or ultra-supercritical parameters – SC and USC 2. Similar to subcritical boilers Operating pressure 230 – 250bar for SC and up to 300bar for USC Fresh steam temperature up to 600 0C Requires high quality of material for pipes and blades of turbine (HP&IP part) Efficiency up to 45% for SC respectively 48% for USC Third step - Combustion Technologies for new TPP in Kosova cont’ 3. Circulating fluidized bed combustion – FBC 4. Similar to PC boilers in many aspects Operates at lower temperature in furnace (820 – 870oC) Injection of limestone in furnace to capture SO2 The low temperature limits the formation of NOx Size of units not larger than 300MW Integrated gasification combined cycle – IGCC Gasification of coal and production of synthetic gas Power is produced from gas and steam turbine Commercial up to 500MW Most successful technology for air emission reduction Summary of Technologies SC & USC Status FBC SC – commercial up to Commercial up to 1000MW, ultra SC - needs 250 -300MW demonstration IGCC Commercial up to 500MW SO2 reduct. (%) 4 - 12 >95 Up to 99 NOX reduct. (%) 4 - 12 30 - 70 80 - 90 CO2 reduct. (%) 4 - 12 Negligible 10 - 20 Efficiency (%) SC 40 – 42% Ultra-SC ~ 48% 36 - 38 40 - 44 Capital costs SC 1000 – 1300 €/kW ultra-SC: 1400 – 2000 €/kW 600 – 1100 $/kW up to 3300 $/kW 30 ÷ 70 30 ÷ 45 Fixed O&M costs SC: 25 ÷ 32; ultra-SC: 30 ÷ 35 ($/kW/year) Step four – Calculations of electricity generations and emissions estimates for all scenarios For units in TPP A and TPP B the calculation is done based on the information given before For new units of TPP “New Kosova” the calculation are based on the table Demand growth 4% Item Designation Unit Result [1] Average gross power MW 500 [2] Number of hours per year hours 8760 [3] Load factor - 0.85 [4] Gross electricity production GWh ([1] x [2] x [3])/1000=3723 [5] Net electricity production GWh 0.9 x [4]=3350.7 [6] Specific lignite consumption t/MWh 1.1 [7] Lignite consumption kiloton [6] x [4]=4095 [8] Specific dust emission* kg/MWh 0.14 [9] Dust emission through the stack tone [4] x [8]=521 [10] Specific emission of CO2* t/MWh 0.85 [11] CO2 emission kiloton [4] x [10]=3481 [12] Specific emission of SO2* kg/MWh 0.5 [13] SO2 emission tone [4] x [12]=1852 [14] Specific emission of NOx* kg/MWh 1 [15] NOx emission tone [4] x [14]=3723 Project Findings Electricity production and demand – scenario 1 12000 11000 10000 9000 8000 6000 5000 Import 4000 3000 2000 1000 0 20 10 20 11 20 12 20 13 20 14 20 15 20 16 20 17 20 18 20 19 20 20 20 21 20 22 20 23 20 24 20 25 20 26 20 27 20 28 20 29 20 30 GWh 7000 Net import Net electricity domestic production Available electricity Electricity production and demand – scenario 2 12000 11000 10000 9000 8000 GWh 7000 6000 5000 4000 3000 2000 1000 Import Import 0 20 09 20 10 20 11 20 12 20 13 20 14 20 15 20 16 20 17 20 18 20 19 20 20 20 21 20 22 20 23 20 25 20 27 20 29 20 30 -1000 Net import Net electricity domestic production Available electricity Electricity production and demand – scenario 3 12000 11000 10000 9000 8000 GWh 7000 6000 5000 4000 3000 2000 1000 Import 0 -1000 Export -2000 -3000 Net import Net electricity domestic production 20 30 20 28 20 26 20 24 20 23 20 22 20 21 20 20 20 19 20 18 20 17 20 16 20 14 20 12 20 10 -4000 Available electricity Electricity production and demand – scenario 4 17000 15000 13000 11000 9000 GWh 7000 5000 3000 Import 1000 -1000 Export -3000 -5000 -7000 Net import Net electricity domestic production 20 30 20 29 20 27 20 25 20 23 20 22 20 21 20 20 20 19 20 18 20 17 20 16 20 14 20 12 20 10 -9000 Available electricity Costs or revenues from net import or net export of electricity for all scenarios 400.0 Import & Export price estimated 45Euro/MWh 350.0 300.0 250.0 200.0 Million Euro 150.0 Revenues 100.0 50.0 0.0 -50.0 -100.0 -150.0 Costs -200.0 -250.0 -300.0 -350.0 -400.0 2010 2012 2014 2016 2017 2018 2019 2020 2022 2024 2026 2028 2030 Scenario 1 Scenario 2 Scenario 3 Scenario 4 Total CO2 emission forecast for Scenario 1 and 2 10,000 8,000 9,000 7,000 8,000 7,000 5,000 CO2 (kt/a) 4,000 3,000 6,000 5,000 4,000 3,000 2,000 2,000 1,000 1,000 0 0 09 10 11 12 13 14 15 16 17 18 19 20 21 22 23 26 30 20 20 20 20 20 20 20 20 20 20 20 20 20 20 20 20 20 TPP A TPP B 20 09 20 10 20 11 20 12 20 13 20 14 20 15 20 16 20 17 20 18 20 19 20 20 20 21 20 22 20 23 20 26 20 30 CO2 (kt/a) 6,000 TPP A TPP B TPP C Total CO2 emission forecast for Scenario 3 and 4 12,000 20,000 11,000 18,000 9,000 16,000 8,000 14,000 CO2 (kt/a) 7,000 12,000 6,000 10,000 5,000 4,000 8,000 6,000 3,000 4,000 2,000 1,000 2,000 0 0 20 0 20 9 10 20 11 20 1 20 2 13 20 1 20 4 15 20 16 20 1 20 7 18 20 1 20 9 20 20 2 20 1 22 20 23 20 2 20 6 30 CO2 (kt/a) 10,000 TPP A TPP B TPP C 09 010 011 012 013 014 015 016 017 018 019 020 021 022 023 026 030 0 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 2 TPP A TPP B TPP C Emission Trading Scheme and CO2 credits 20 16 14 Cap of CO2=11 million tons 12 10 8 Cap for CO2 emissions form TPP 6 11 million tons 4 2 0 2010 2012 2014 2016 2017 2018 2019 2020 2022 2024 2026 2028 2030 total CO2 emission scenario 1 total CO2 emission scenario 2 total CO2 emission scenario 3 total CO2 emission scenario 4 200 150 Cost of credits for CO2 = 25 €/t million Euro million tons of CO2 18 Potential costs for buying CO2 credits 100 50 0 -50 -100 2018 2019 2020 2022 cost of CO2 scenario 3 2024 2026 2028 cost of CO2 scenario 4 2030 SO2 emission forecast for Scenario 3 and 4 Scenario 4 16,000 12,000 14,000 10,000 12,000 SO2 (t/a) 14,000 8,000 6,000 10,000 8,000 6,000 4,000 TPP A TPP B TPP C 30 29 TPP C 20 27 20 25 20 23 20 22 TPP B 20 21 20 20 20 19 20 18 TPP A 20 17 20 16 20 14 20 20 10 20 20 30 20 26 28 20 20 23 24 20 20 21 22 20 20 19 20 20 20 20 20 20 20 20 17 18 0 14 16 0 10 12 2,000 12 4,000 2,000 20 SO2 (t/a) Scenario 3 NOx emission forecast for Scenario 3 and 4 Scenario 4 Scenario 3 24,000 22,000 22,000 20,000 20,000 18,000 18,000 16,000 16,000 NOx (t/a) 24,000 NOx (t/a) 14,000 14,000 12,000 12,000 10,000 10,000 6,000 6,000 4,000 4,000 2,000 2,000 0 0 TPP B TPP C 20 20 TPP A 0 20 9 1 20 0 1 20 1 1 20 2 1 20 3 1 20 4 1 20 5 1 20 6 1 20 7 1 20 8 1 20 9 2 20 0 2 20 1 2 20 2 2 20 3 2 20 6 30 8,000 0 20 9 1 20 0 1 20 1 1 20 2 1 20 3 1 20 4 1 20 5 1 20 6 1 20 7 1 20 8 1 20 9 2 20 0 2 20 1 2 20 2 2 20 3 2 20 6 30 8,000 TPP A TPP B TPP C 8,000 6,000 TPP A TPP B TPP C 0 20 9 1 20 0 1 20 1 1 20 2 1 20 3 1 20 4 1 20 5 1 20 6 1 20 7 1 20 8 1 20 9 2 20 0 2 20 1 2 20 2 2 20 3 2 20 6 30 10,000 Dust emissions [t/a] 12,000 20 0 20 9 1 20 0 1 20 1 1 20 2 1 20 3 1 20 4 1 20 5 1 20 6 1 20 7 1 20 8 1 20 9 2 20 0 2 20 1 2 20 2 2 20 3 2 20 6 30 20 Dust emissions {t/a] Dust emission forecast for Scenario 3 and 4 Scenario 3 Scenario 4 16,000 16,000 14,000 14,000 12,000 10,000 8,000 6,000 4,000 4,000 2,000 2,000 0 0 TPP A TPP B TPP C Conclusions Specific emission of CO2 from TPP Kosova A is high due to lower efficiency compared to units of TPP Kosova B. Specific emission of CO2 from units of TPP “New Kosova” are 75% lower than TPP Kosova A or 39% lower than TPP Kosova B. The scenario 2 is moderate scenario; the total emission will be increased by 20% more than are today. The scenario 3 will have 80% higher total emissions than current, while for the scenario 4 the emission of CO2 will be three times more than today. The simulation with the CO2 trading allowance shows that scenario 4 represents high potential costs for buying credits of CO2. To comply with CO2 emission reduction only scenario 3 is acceptable To comply with EU directive 2001/80, scenario 2, 3 and 4 are acceptable Conclusion - cont’ Because of the aging and high specific emission, TPP Kosova A units has to be decommissioned by 2017 (not before the new TPP starts operation) The units of Kosova B power plant, has to refurbish the ESP and to install low NOX burners to comply with EU Directive 2001/80. To cover the demand with sufficient and reliable electricity only scenario 3 and 4 are acceptable. These scenarios shows considerable potential for generation of revenues The annual demand growth by 4%, requires construction of new power generation capacities (otherwise we will depend on import) The assessment of technologies have shown that the best technology is pulverized firing, subcritical or supercritical pulverized firing. The equipments for emission control has to be installed. The existing hydro potential will be utilized and the new HPP Zhur has to be build by 2018 Recommendation Implementation of scenario 3 as the best scenario regarding the reduction of emissions and fulfilling the demand of electricity and crating the condition to induce the electricity export for considerable period of time. By 2017 respectively 2018 to make investments in TPP B for improvements of air emissions by installing low NOx burners and refurbishment of ESP. The technology for the new power plant is recommended to be subcritical or supercritical boilers with regard to the characteristics of lignite. The new units should have installed modern equipments for dust collection – efficient ESP, low NOx burners, and desulfurization equipments. Installation of continuous measurement of air emissions NOx, SO2 and dust on unit B1 and B2 of TPP Kosova B are required by the EU Directive for LCP. Utilizing the hydro potential by construction of HPP Zhur to increase the share of electricity produced by renewable resources (3 to 4 %). List of References KEK-Statistical Data, Strategic Development Office KEK – Working Manual for Boiler and Turbine, Kosovo B Power Plant, 1995 Energy Sector Technical Assistance Project, Module G – Lignite Development Strategy, World Bank, 2002 Government of Kosova, Ministry of Energy and Mining: (2008): Strategic Environmental and Social Assessment Directive 2001/80EC of the European Parliament and the Council, Official Journal of the European Community, 2001 Entec, (2008), Evaluation of the Member States’ emission inventories 2004-2006 for LCPs under the LCP Directive (2001/80/EC), Final Report, European Commission http://eper.ec.europa.eu/eper/emissions_pollutants.asp?i Power Station Emission Handbook- www.ccsd.biz/PSE_Handbook/index.cfm Gjurgjeala. B,(2007) Efficiency of TPP, Prishtina Travoulareas. S & Jozewicz. W, (2005): Multipollutant Emission Control Technology Options for Coal fired Power Plants, EPA, Washington DC. www.babcock.com/products/boilers/images/swup.gif http://www.babcock.com/products/boilers/circulating_fluidized_bed_specs.html www.ccsd.biz/factsheets/images/igcc1.gif http://www.power-technology.com/projects/rwe-neurath/ List of References T. Hatakka, “Vattenfall Capital Markets Day 2009”, Amsterdam 2009, Presentation (Reviewed online on February 2010 at http://www.vattenfall.com/en/file/tuomo-hatakka-business-group-_8459841.pdf) Duke Energy, “Cliffside Steam Station Modernization - Project Overview”: (Reviewed online January 2010) at http://www.duke-energy.com/aboutus/cliffside-overview.asp) http://www.miga.org/documents/Maritzabrief.pdf http://www.energy.ca.gov/2007_energypolicy/documents/2007-0529_workshop/presentations/Dalton_EPRI_Clean_Coal.pdf http://www.power-technology.com/projects/comanche/ http://www.energyjustice.net/coal/igcc/factsheet.pdf Course lectures “Energy Policy” – AUK, 2008 The Emission Trading System, http://www.youtube.com/watch?v=y7veRksc_Yk ElectroWatt – Ekono, Jaakko Pöyry Group, (2006), Pre-feasibility studies for the new lignite fired power plant and for pollution mitigation measures at Kosovo B power plant, Lot 2. Prishtina, European Agency for Reconstruction Carl Bro, (2003), Environmental Impact Assessment and Action plan for Kosova A and B Power Plants and Coal Mines, European Agency for Reconstruction Energy Community Treaty: http://www.stabilitypact.org/energy/Treaty.en05.pdf Acknowledgment…. Thank you for your attention! Questions! Contact address: skender.isufi@kek-energy.com Phone: 038 560 287