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The right solution for Turkey’s energy future VGB PowerTech 1/2 l 2018

Authors

Kurzfassung

Die richtige Lösung für die zukünftige Energieversorgung der Türkei

Das Bruttoinlandsprodukt der Türkei wird in den nächsten fünf Jahren voraussichtlich um fast 24 % wachsen. Damit zählt die Türkei zu den am schnellsten wachsenden Volkswirt-schaften der Welt. Dieses hohe Wirtschafts-wachstum in Verbindung mit der stark wach-senden industriellen Ausrichtung der Türkei wird voraussichtlich zu einem Anstieg der Stromnachfrage von 290 TWh in 2017 auf 368 TWh im Jahr 2022 führen. Dies entspricht einem Anstieg von fast 24 %.Um mit diesem Energiebedarf Schritt halten zu können, wird erwartet, dass die Energieimporte der Türkei beträchtlich zunehmen werden, was sowohl die Energieversorgungssicherheit als auch die wirtschaftliche Entwicklung betrifft. Im Jahr 2016 wurden 33 % des türkischen Stroms aus importiertem Erdgas erzeugt, die Hälfte davon aus Russland und mehr als die Hälfte des Stroms aus Kohle wird aus impor-tierter Steinkohle erzeugt. Nur 16 % des gesam-ten türkischen Stroms wurde mit heimischer Braunkohle erzeugt. Die Türkei verfügt über 17,2 Milliarden Tonnen nachgewiesener Braunkohlevorkommen, aus-reichend, um die wachsende Wirtschaft in Zu-kunft mit Energie zu versorgen. Die Erschlie-ßung dieser umfassenden Braunkohlevorkom-men ist daher ein wichtiger Bestandteil des türkischen Energieplans „Vision 2023“, der den 100. Jahrestages der Gründung der Republik begleitet. l

The right solution for Turkey’s energy futureBob Giglio and Boguslaw Krzton

Bob GiglioBoguslaw KrztonSumitomo SHI FW

The right solution for Turkey’s energy future

Powering Turkey’s growing economy

Turkey’s GDP is predicted to grow nearly 24 % over the next 5 years, ranking as one of the fastest growing economies in the world. This high level of economic growth coupled to Turkey’s strongly growing in-dustrial base is expected to drive electricity demand growth from 290 TWh (based on 2017) to 368 TWh in year 2022, nearly a 24 % increase over this same period of time. To keep up with this insatiable need for power, Turkey’s energy imports are ex-pected to grow considerably, causing both an energy security and economic burden concern with government leaders. In 2016, 33 % of Turkey’s electric power was produced from imported natural gas, half of that from Russia and more than half of its coal and lignite power was from im-ported hard coal. Only 16 % of Turkey’s total electric power was generated using local lignite.The situation is even worst when looking at the total primary energy demand of the country, only 47 % is sourced from domes-tic sources (hydro, lignite, renewables). Said another way, 53 % of Turkey’s econo-my is fueled by imported energy, costing Turkey $ 27.2 billion in 2016.

Lignite is the key to Turkey’s energy future

Turkey has 17.2 billion tonnes of proven lig-nite reserves, enough to power its growing economy well into the future. But ironical-ly, over the past five years, imported coal capacity grew 3.5 times more than lignite power capacity (4.9 vs. 1.4 GWe). Policy makers in Turkey want to change this to im-prove Turkey’s energy security while lower-ing its energy cost. Tapping into Turkey’s massive lignite re-serves is a key part of Turkey’s Vision 2023 energy plan, timed to mark the 100th anni-versary of the founding of the Republic. The plan calls for increased use of lignite for meeting rising electricity demand while im-proving Turkey’s energy security. The plan calls for more than doubling domestic lig-nite power capacity over the next 10 years,

amounting to 10 GWe of new power capac-ity from Turkey’s lignite.The good news is that Turkey’s huge lig-nite reserves can solve its energy security problem. The bad news is that 68 % of the total lignite reserves in Turkey have low calorific  value (1,000 to 2,000 kcal/kg) which is a very challenging fuel for today’s conventional coal power plant technology. It  is no coincident that Turkey has not turned to its lignite reserves earlier in its history  and you don’t need to look very hard to find  power plants in Turkey that struggle every day to burn Turkey’s low quality lignite.

The right timing for the right technology

Today, the timing couldn’t be better for aligning the right technology to Turkey’s energy strategy. Over the last 40 years, cir-culating fluidized bed (CFB) combustion technology has grown in both scale and experience. Today, CFB has become the best choice for reliably and cleanly convert-ing low quality fuels like Turkish lignite into power. In a broader sense, CFB’s fuel flexibility and ability to control pollution during the burning process has caused many utilities, IPPs and developers to choose CFB tech-nologies for their new coal, lignite, bio-mass, petcoke, and WTE plants. But for Turkish lignite, the key words are ash and moisture, since Turkey’s low quality lignite has the highest levels of them, in the 30-50 % range. Moreover, the ash has very low melting temperatures making quite a slag-ging mess in conventional boilers.In a conventional pulverized coal (PC) or PF boiler, this ash melts causing slagging and fouling throughout the boiler. These boilers are oversized, use a lot of soot blowing, and are frequently down for maintenance, resulting in elevated plant capital and operating cost and lower plant reliability. The CFB technology avoids all these pit-falls, since the ash doesn’t melt due to its flameless low temperature combustion process. Instead, the ash is circulated throughout the boiler, cleaning the boiler’s heat transfer surfaces and evenly spread-

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VGB PowerTech 1/2 l 2018 The right solution for Turkey’s energy future

ing the fuel’s heat while completely com-busting the fuel. This one difference is the main reason that CFB boilers can achieve reliability levels unreachable by conventional PC boilers. F i g u r e 1 shows average annual plant re-liabilities between plants with SFW CFBs as compared to coal plant fleets in several world regions reported by multiple sources. There are many other advantages of the CFB combustion process as shown in F i g -u r e 2 . For instance, the CFB does not need fuel dryers, pulverisers, conduits, or burners. Instead, the fuel needs to be only coarsely crushed and dropped into chutes in the lower furnace. Most of the time, ex-pensive SCR DeNOx or downstream FGD DeSOx systems are not needed to meet per-mitted emission limits.Combustion stability and efficiency is an-other area where CFB excels. Since the CFB circulates the fuel over and over in a bed of hot solids, it completely burns all fuels, even the most difficult low volatile fuels, like anthracites and petcokes. Fuel parti-cles can stay in the CFB hot loop for as long as 30 minutes as compared to a PC with burning times of only 3 to 4 seconds. Further, the bed of hot solids in the CFB provides a large thermal inertia. This makes the combustion process very stable, allowing wide variations in fuel properties without upsetting boiler emissions or steam capacity. In contrast, the PC burning process has no thermal inertia since the fuel is instantly converted to a hot gas and molten ash particles.

The Soma Kolin Project

The new Soma power plant is located in Soma Basin, 135 km north of Izmir. The owner, HIDRO-GEN Enerji Ithalat Ihracat Dagitim ve Ticaret A.S. is a subsidiary of Turkish construction company Kolin Hold-

ing. Hidgo-GEN is following through with their plan to open the new lignite mine and build the 510 MWe lignite CFB power plant designed around SFW’s CFB boiler technol-ogy. When operational in 2018, the plant will become Turkey’s largest lignite power plant utilizing CFB boiler technology (F i g -u r e 3 ). The plant is configured with 2 x 255 MWe CFB boilers and steam turbine generators. The contract for the supply of two CFB boil-er islands with auxiliary equipment and the two CFB scrubber systems was awarded to SFW in January 2014 by EPC contractor Harbin Electric International Co. Ltd (HEI). A number of local Turkish subcontractors are working on the plant site in different areas of the power plant and mine. After a short project delay related to final site selection approvals, construction began on the plant in January 2016. Boiler hydro is scheduled for late 2017 and plant commer-cial operation is scheduled for mid-2018.

Average Annual Plant Availability* ( % of 8,760 hours)

In %

9291908988878685848382

Bituminous coal Brown coal and lignite Other fuels

SFW ‐ CFB

NERC ‐ AllBoilers

90.8 %

87.0 %

85.6 %85.3 %

91.6 %

88.6 %89.1 %

88.4 %

93.3 % 92.9 %91.5 %

90.0 %

88.7 %

Petc

oke

Clea

n w

ood

Dem

oliti

on w

ood

Mix

ed w

ood

& p

eat

Mix

ed w

ood

& a

gro

Fig. 1. Annual average plant availability of SFW CFBs and coal plant fleets. Availability means total time plant is available to run accounting for both planned and unplanned downtime. SFW CFB plant reliability values based on client supplied data reported over 2000-2015 period for CFB plants mainly located in Europe. NERC (North America Reliability Corp), VGB and WEC (World Energy Council) availability data based on thermal steam power plant (PC and CFB) data reported over 2000-2015 period.

CFB CFB Process & Design Benefits PC

Fuel milling, drying, and burnersreplaced by simple gravity fuelfeed

Non-slagging uniform, low-tempcombustion minimizes fouling,corrosion and OTU riskIn-furnace SOx captureminimizes corrosion and foulingover entire gas pathCirculating solids keep hot loopHX surfaces clean, no need forsoot blowing

SCR and full FGD not needed tomeet low SOx and NOxPerformance and reliabilitymaintained over wide range offuels

Air

Fuel& Air

Limestone

Petcoke

Biomass

<1 mm (0.04 in)

<50 mm (2.0 in)

<10 mm (0.4 in)

Fig. 2. Thermograph of conventional and CFB furnaces and comparison points. Source: Sumitomo SHI FW.

Fig. 3. When commissioned in late 2018, the 2 x 255 MWe Soma Kolin Power Plant will become the largest CFB plant in Turkey. Source: Sumitomo SHI FW.

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The right solution for Turkey’s energy future VGB PowerTech 1/2 l 2018

Building a lignite-burning power plant in the Soma region makes good economic and fuel security sense, but the challenge was finding the right technology to fire this very low quality lignite with a higher heat-ing value of 6,770 kJ/kg (1,618 kcal/kg), containing 23.3 % moisture, 42.9 % ash and 1.2 % sulphur. Each CFB is a natural circulation steam generator with reheat rated at 255 MWe (545 MWth). Main steam conditions of the CFBs are 173 bar abs/565 °C with reheat conditions of 53 bar abs/565 °C. The CFB boiler design includes steam-cooled solid separators and special INTREX heat ex-

changers, which are utilized as the final superheating stage. Due to the high ash content in the fuel, the CFBs are equipped with high capacity drum coolers which drop the bottom ash into redundant drag chain conveyors.

Emission flexibility

Since Turkey’s government has been con-sidering accession to the European Union (EU), flexibility in plant emissions was im-portant to the Kolin Group, the owner or the plant. They wanted to have the flexibil-ity to achieve a wide range of stack emis-

sions, while at the same time allowing a wide range of fuel sulphur contents expect-ed from the lignite mine over the long term. Currently, Turkish environmental regula-tion is based on Europe’s large combustion plant directive (LCP) with SOx/NOx/PM emission limits of 200/200/30 mg/Nm3. But current EU environmental rules are based on EU’s Industrial Emission Directive (IED) levels which recently have been up-dated by the BREF BAT document. The BREF lowers yearly SOx limits down to the 10-75 mg/Nm3 range, NOx down to the 50-85 mg/Nm3 range and PM down to the 2-5 mg/Nm3 range for large new coal and lignite plants. In addition, the BREF adds strict limits in the 1-3 mg/Nm3 range to several new pollutants, such as, HCl, HF, Hg, and NH3. For this flexibility, a CFB “polishing” scrub-ber (CFBS), was added behind the CFB boiler for the Soma Kolin plant (F i g -u r e   4 ). This will allow the CFB ash to be used as a reagent in the CFBS to reduce emissions while also reducing the use of expensive reagents such as hydrated lime. Two ash hydrators on site, will condition the recycled fly ash before injection into the absorber. The CFBS will also capture HCl, HF, Hg, and NH3 so the plant will be able to comply with the EU’s strict BREF limits providing multi-pollutant emission control very economically.

An example for others

The Soma Kolin project is very important to Turkey as well as other countries with large resources of low quality coals and lig-nites. CFB technology is the best choice for tapping into Turkey’s vast lignite reserves, as underscored by the Soma Kolin project. The success of Soma Kolin will encourage countries, such as India, Germany, Thai-land and Pakistan to reconsider their plans for using their low quality indigenous fuels for secure, affordable and clean power. l

Guiding and distribution plate Bag house filter Filter bag detail

RCFB Absorber

Filter bag

Water

Hydrated lime

Flue gasand fly ash

Fly ash

Rotary valve

Shutdownvalve

AirProvesscontrolvalve

Product

Lime solidsrecirculation

Rotary valve

Air Baghouse hopper

Clean gas to theID fan/stack

Fig. 4. Flue gas enters vertically upward into the scrubber and through a set of ventures that accel-erate the gas flow increasing flue gas and ash mixing efficiency. Flue gas next enters a pulse jet fabric filter for final cpture of gaseous pollutants and PM. Ash collected in the hopper can be recirculated to the CFB scrubber or sent to a holding silo for recovery. Note: RCFB absorber = Reflux CFB absorber. Source: Sumitomo SHI FW.

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