Competence at WorkRely on Good Experiences with From the Past to the Present and Future “ The integration of our two companies will generate synergies and have advantages for our clients, employees and the future development of our business. ” This statement was made by Naoya Domoto, Managing Our efforts are focussed on the diversification of fuel, im- Executive Officer, President of Energy & Plant Operations, provement in plant efficiency and implementation of envi- IHI Corporation, at the welcoming meeting for all Stein- ronmentally-friendly technologies. We provide advanced mueller Engineering employees as new members of the solutions to the global challenges concerning energy and IHI group of companies, following the acquisition of Stein- the environment. We develop sophisticated technologies by mueller Engineering GmbH in July 2014. utilizing the combined knowledge, technological strengths and market experience gained in Germany and Japan. IHI and Steinmüller Engineering have a longstanding technical relationship based on cooperation between in- Our technology in particular contributes to the effective dividual employees working together on fossil-fuel power utilization of coal by focusing on the reduction of energy plant equipment. Over the past 40 years, mutual activities costs and conservation of energy resources. In addition reach back, to a time when current Steinmüller Engineer- we develop and apply environmentally-friendly technolo- ing employees worked for the former L&C Steinmüller. We gies such as our Air Quality Control and CO2 Capture and are hard at work jointly developing our technologies. Storage systems. 2 Efficiency Through Know-How Maximum performance with minimum emissions! This of projects throughout the world. Thanks to our activities is a requirement which is simply stated, but which de- in the planning, design, selection of suppliers, manufac- mands exceedingly complex and thoroughly thought- ture, construction management and commissioning of out solutions – from low emission fuel conversion in a power plants of various kinds, we gather new experiences power plant and highest possible efficiencies up to the air every day and generate new knowledge which is utilised in pollution control system. your projects. Steinmüller Engineering is sought after throughout the world as a consulting and plant construction company. As employees of the former L&C Steinmüller GmbH in Gummersbach, many of our colleagues were involved in the development, construction and operation of the ener- Company Development gy and air pollution control plants which are now to be modernised. They are familiar with the construction and Since End of June 2014 Steinmüller Engineering GmbH operation processes and know exactly where and how to is a 100% subsidiary of IHI Corporation. This is a win- improve plant performance and efficiency. win situation, as it facilitates access to the latest technologies and processes of the parent company, In addition to this first-hand experience, as a customer you enables the development of further innovative designs also benefit from our work on current new constructions and allows us to handle large-scale projects. and refurbishments as well as our activities in a wide range Success Through Expertise Founded in 2003, Steinmüller Engineering GmbH rapidly The success of our company is based on our experience developed into a key player on the local and international and passion for technology. We are engineers, who think in markets and is in a position to handle complex and sophis- terms of facts and figures and love to solve new and chal- ticated projects. lenging problems. But we are not dreamers. Our concepts are based on facts, on technical possibilities and on what is economically feasible. However, over and above all, safety Company Development has the highest priority in our activities for the modernisa- tion and new construction of power plants. Not question- t€ 25.000 ing every detail and closely examining every aspect of the plant may lead to nasty surprises. You may call us pedantic. 20.000 We take that as a compliment. 15.000 94 93 10.000 83 86 88 72 Order Entry Staff 5.000 0 Year 2009 2010 2011 2012 2013 2014 3 Dependable Support Steinmüller Engineering GmbH is your dependable partner missioning and optimization of steam generators, combus- through all stages of plant construction, from process tion systems and flue gas cleaning systems. This holistic engineering and design to the management of the project. approach and our unchallenged competence in all sub Our engineers advise you with regard to the technical areas gives you the maximum possible security, to make planning, take care of the delivery of the necessary com- your modernisation or new construction project a worth- ponents, supervise the installation and monitor the com- while investment. FIELDS OF ACTIVITY CORE COMPETENCIES FIELDS OF APPLICATION Process Engineering Consultancy Flue Gas Cleaning Design Design & Planning Steam Generation Project Management Supply Combustion Systems 4 Modify and Improve: Process Engineering Regardless of whether you wish to build a new plant or Use our company‘s know-how and rely on optimum solutions modify an existing plant due to various reasons e.g. new for your needs in the fields of: legal requirements or a change in fuel properties – the key objective is to find a solution with optimized efficiency. • Combustion Processes This can be achieved either through an increase in perfor • Thermodynamics mance, improved availability and/or future cost reductions. • Flue Gas Cleaning • Fluid Mechanics Analyse and Implement: Mechanical Design Not everything that looks good on paper can be im- plemented in reality. Rely on our experience and our • Pressure Parts in Boiler and “up-to-date” knowledge of the latest plant technology. Apparatus Engineering Our experience from our day-to-day work on construc- • Components for Furnaces, such as tion sites is included in the mechanical designs which we Pulverized Fuel Lines, Burners and Ducts develop for you. • High Temperature Reactors Together with you, we develop designs for components • DeNOX Plants (SCR) which are subjected to high stresses such as temperature, • Electrostatic Precipitators pressure, corrosion or erosion. • Flue Gas Scrubbers for Desulfurization Plants • Supporting Steel Structures Advise and Support: Project Management Once technical planning is complete, we ensure that the Rely on our extraordinary expertise for: production and installation on site is implemented just as expertly and with great care for detail. During every phase of your project, you will be supported by people who not • Project Management only have the theoretical knowledge, but also the practical • Manufacturing Supervision experience. • Installation Supervision • Commissioning • Personnel Training 5 Gesamtdarstellung Bituminous Coal and Sub-Bituminous BUNKER FUEL SCR Coal Combustion Systems HANDLING BOILER TURBINE ESP FGD Bereich Kessel BUNKER SCR FUEL HANDLING BOILER TURBINE ESP FGD Bereich Reinigung BUNKER SCR SM V®* Coal Burner TURBINE FUEL HANDLING BOILER ESP FGD LowNOX Emission Efficiency Increase Flexible Operation Application Technical Data Scope of Supply Power Plants and Industrial Boilers Burner Type: • Consultancy NOX reduction, extension of fuel range, SM V®* Coal Burner • Design of burners efficiency increase Burner Capacity: • Process engineering 15 MWth – 100 MWth • Design of furnace Emissions: Benefits CO < 100 mg/m3 (STP) • CFD-Simulations of NOX < 280 mg/m3 (STP) boiler furnace and • Optimized engineering based on combustion system CFD-simulation calculations without expensive trials Fuel Type • Supply and installation of firing system components • High availability and efficiency Bituminous Coal including burners, OFA, etc. • Increase of operational flexibility Water: 5-38 % ar Ash: 10-40 % ar • Adaptation of I & C • Reliable solution based on decades VM daf: 15-45 % • Commissioning of experience LCV: 12-32 MJ/kg Biomass * ® Registered Trademark Staged Mixing Burner www.steinmueller.com Tel. +49 2261 78950-0 Reference List Excerpt Bituminous Coal Combustion Systems Scope Client Modification and capacity increase of LowNOx firing system, EnBW Kraftwerke AG, Bituminous Coal, 330 MWel, Altbach PS, Germany Karlsruhe, Germany Concept design study for LowNOX burner technology, 200 – 730 MWel, Eskom Enterprises, Bituminous Coal, ESKOM’S fleet, South Africa Johannesburg, South Africa Investigation and recovery scope development support after boiler Eskom Enterprises, damage, 600 MWel, Bituminous Coal, Duvha PS, South Africa Johannesburg, South Africa Engineering support for manufacturing, installation and commissioning Eskom Enterprises, of PF burners, 200 MWel, Bituminous Coal, Camden PS, South Africa Johannesburg, South Africa Boiler design review and study for future change in coal quality, Eskom Enterprises, 6 x 600 MWel, Bituminous Coal, Tutuka PS, South Africa Johannesburg, South Africa Modernization of firing system and extension of coal range, installation STEAG GmbH, of LowNOX burners, 500 MWel, Bituminous Coal, Herne PS Unit 4, Essen, Germany Germany Design study on coal range extension in supercritical utility boilers, Coastal Gujarat Power Generation, 5 x 830 MWel, Bituminous Coal, Mundra PS, India Mumbai, India Boiler concept study for coal range extension, 465 MWel, Bituminous EnBW Kraftwerke AG, Coal, CHP Altbach I, Germany Karlsruhe, Germany Concept study for coal range extension at 6 x 600 MWel, Bituminous Coal, Eskom Enterprises, Duvha PS, South Africa Johannesburg, South Africa Boiler concept study for capacity increase and coal range extension, EnBW Kraftwerke AG, 330 MWel, Bituminous Coal, CHP II Altbach PS, Germany Karlsruhe, Germany Modification of the firing system and installation of LowNOX burner, EnBW Kraftwerke AG, 550 MWel, Bituminous Coal, Rheinhafen-Dampfkraftwerk (RDK) PS Unit 7, Karlsruhe, Germany Germany Conceptual design for adaptation of firing equipment to an extension of Vattenfall Europe Hamburg AG, acceptable coal specification, 2 x 100 MWel, Bituminous Coal, Germany Tiefstack PS,Germany Modification of the firing system and installation of LowNOX burner, Balcke-Dürr GmbH, 700 MWel, Bituminous Coal, Mehrum PS, Germany Ratingen, Germany, for E.ON Power Legend: PS – Power Station SCR – Selective Catalytic Reduction FGD – Flue Gas Desulphurization PF – Pulverized Fuel STP – Standard Temperature and Pressure CFB – Circulating Fluidized Bed CHP – Heat and power plant HRSG – Heat Recovery Steam Generator ESP – Electrostatic Precipitator www.steinmueller.com Tel. +49 2261 78950-0 Gesamtdarstellung Lignite Combustion Systems BUNKER FUEL SCR HANDLING BOILER TURBINE ESP FGD Bereich Kessel BUNKER SCR FUEL HANDLING BOILER TURBINE ESP FGD Bereich Reinigung BUNKER SCR RSM®*-Lignite Burner TURBINE FUEL HANDLING BOILER ESP FGD LowNOX Emission Efficiency Increase Flexible Operation Application Technical Data Scope of Supply Power Plants and Industrial Boilers Burner Type: • Consultancy RSM®* Lignite Burner • Process engineering NOX reduction, extension of fuel range, efficiency increase Burner Capacity: • CFD-Simulations of 30 – 150 MWth boiler furnace and Benefits Emissions: combustion system • Optimized engineering based on CO < 200 mg/m3 (STP) NOX < 200 mg/m3 (STP) • Design of burners CFD-simulations calculations without • Supply and installation of expensive trials Fuel Type firing system components • High availability and efficiency including burners, OFA, etc. • Increase of operation flexibility and Lignite • Commissioning capacity Water: 25 – 70 % ar • Furnace design Ash: 0 – 50 % ar • Reliable solution based on decades VM daf: 30 – 70 % • Adaptation of I & C of experience LCV: 3,5 – 22 MJ/kg * ® Registered Trademark Radial Staged Mixing Burner www.steinmueller.com Tel. +49 2261 78950-0 Reference List Excerpt Lignite Combustion Systems Scope Client Engineering and supply of a LowNOX firing system, 350 MWel, Lignite, PE Electric Power Industry, Kostolac PS B1, PE Industry, Serbia Belgrade, Serbia Lignite firing system modification, 4 x 227 MWel, Lignite, ContourGlobal, Maritza East 3 PS Unit 1 – 4, Maritza, Bulgaria Sofia, Bulgaria Engineering for firing system retrofit, 2 x 600 MWel, Lignite, RWE AG, Niederaußem PS Unit G and H, Germany Essen, Germany Wall-air system detail design, 11 x 250 MWel, Lignite, Vattenfall Europe Generation AG & Co. KG, Jänschwalde PS, Germany Cottbus, Germany Basic engineering for LowNOX firing system modification, 11 x 250 MWel, Vattenfall Europe Generation AG & Co. KG, Lignite, Jänschwalde PS, Germany Cottbus, Germany Process and basic design for proposal of 500 MWel power plant, Doosan Babcock Energy Ltd., Lignite, Turow PS, Poland West Sussex, UK Concept study and engineering for LowNOX burner modifications, RWE Power AG, 2 x 640 MWel, Lignite, Neurath PS Unit D and E, Germany Essen, Germany Feasibility study of potential modifications for NOX reduction by Siemens d.o.o., primary measures, 345 MWel, Lignite, Sostanj PS Unit 5, Slovenia Ljubljana, Slovenia Concept study for proposal, for 330 MWel power plant, Doosan Babcock Energy Ltd., Lignite, Turceni PS Unit 6, Romania West Sussex, UK Legend: PS – Power Station SCR – Selective Catalytic Reduction FGD – Flue Gas Desulphurization PF – Pulverized Fuel STP – Standard Temperature and Pressure CFB – Circulating Fluidized Bed CHP – Heat and power plant HRSG – Heat Recovery Steam Generator ESP – Electrostatic Precipitator www.steinmueller.com Tel. +49 2261 78950-0 Gesamtdarstellung Dry Lignite Combustion Systems BUNKER FUEL SCR HANDLING BOILER TURBINE ESP FGD Bereich Kessel BUNKER SCR FUEL HANDLING BOILER TURBINE ESP FGD Bereich Reinigung BUNKER SCR Dry Lignite Vortex Burner TURBINE FUEL HANDLING BOILER ESP FGD High Flexibility, Availability and Efficiency Reliable Use in Co-firing Application Technical Data Scope of Supply Coal Fired Power Plants and Burner type: • Consultancy Industrial Boilers Integrated Vortex Burner • Basic engineering Pollution reduction, extension of fuel range, Burner Capacity: • Design of burners efficiency increase 10 – 100 MW • Design of furnace Ignition burner and auxiliary burner for Emissions: CO < 100 mg/m³ (STP) • Process engineering medium and peak loads NOX < 190 mg/m³ (STP) • CFD-Simulations of boiler furnace and combustion Benefits Fuel Type system • High flexibility, availability and efficiency • Supply and installation • For reliable use in co-firing systems for Pulverized Dried Lignite of burners including all base loads optimized engineering based Water: 10 – 20 % ar related components on simulation calculations without Ash: 4 – 16 % ar VM daf: 30 – 70 % • Commissioning extensive trials LCV: 18 – 22 MJ/kg • Reliable solution based on decades of experience • Savings on expensive start up fuel www.steinmueller.com Tel. +49 2261 78950-0 Reference List Excerpt Dry Lignite Combustion Systems Scope Client Engineering for C&I implementation for dry lignite test burner, RWE, 20 MWth, Lignite, RWE Ibbenbüren PS, Germany Essen, Germany Study for integration of TBK (pre-dried Lignite) burner in anthracite RWE Service GmbH, slag-tap firing system, 848 MWel, Bituminous Coal, Ibbenbüren PS, Nordhorn, Germany Germany Engineering service for support during bidding phase for design of Ishikawajima-Harima Heavy Industries Co., boilers including a co-firing concept, 2 x 550 MWel, Pre-Dried Lignite, Ltd., Tokyo, Japan Niederaußem PS Unit K, Germany Concept design study for optimization of firing system considering RWE Power AG, dry lignite burners, 2 x 550 MWel, Lignite, Niederaußem PS Unit K, Essen, Germany Germany Concept study for a 1100 MWel dry lignite-fired steam generator, Ishikawajima-Harima Heavy Industries Co., Japan Ltd., Tokyo, Japan Design study for a super critical steam generator fired with Pre-Dried RWE Power AG, Lignite without flue gas circulation, Germany Essen, Germany Feasibility study for the implementation of dry lignite burners RWE Power AG, including test phase, Germany Essen, Germany Legend: PS – Power Station SCR – Selective Catalytic Reduction FGD – Flue Gas Desulphurization PF – Pulverized Fuel STP – Standard Temperature and Pressure CFB – Circulating Fluidized Bed CHP – Heat and power plant HRSG – Heat Recovery Steam Generator ESP – Electrostatic Precipitator www.steinmueller.com Tel. +49 2261 78950-0 Gesamtdarstellung Liquids and Gas Firing Systems BUNKER FUEL SCR HANDLING BOILER TURBINE ESP FGD Bereich Kessel BUNKER SCR FUEL HANDLING BOILER TURBINE ESP FGD Bereich Reinigung BUNKER SCR Oil and Gas Vortex Burner TURBINE FUEL HANDLING BOILER ESP FGD High Combustion Efficiency Low Emissions Application Refineries Steel Plants Power Plants Fuel Type Refinery gas Blast furnace gas Natural gas Visbreaker residues Coke oven gas Light fuel oil Vacuum residues Converter gas Heavy fuel oil HSC-R Bio fuel H2 Benefits • Almost total burnout • Minimization of organic residues • High burnout of fuel • Reliable solutions based on decades of experience Technical Data Capacity Gas: Capacity Oil: 0,6 – 100 MWth 5 – 100 MWth (0,45 – 9 t/h) Scope of Supply • Consultancy • Process engineering • CFD-simulations of boiler furnace and combustion system • Design of furnace • Design of burner • Supply of gas- and oil burners including all related components • Commissioning www.steinmueller.com Tel. +49 2261 78950-0 Reference List Excerpt Liquids and Gas Firing Systems Scope Client Study for capacity increase of firing system, Coke-Oven Gas, 240 MWel, RWE Service GmbH, CHP Hamborn 5, Germany Germany Engineering and supply of oil atomiser lances and atomiser sprayer, MAINOVA, Mainova, Germany Frankfurt, Germany Engineering and supply for retrofit of burner level oil-to-gasfiring, PCK Raffinerie GmbH, 2 x 750 t/h, Refinery Residues and Heavy Fuel Oil, PCK Schwedt, Germany Schwedt, Germany Supply of oil control valve stations, Heavy Fuel Oil and Low-Pressure- Shell Deutschland Oil GmbH, Gas, Shell Wesseling, Germany Wesseling, Germany Supply, erection and commissioning of 12 optimised oil burner inserts, MAINOVA, CHP West Unit 2, Germany Frankfurt, Germany Oil atomizer lances for an ignition system for the heat power plant Vattenfall Europe Hamburg AG, 2 x 200 MWel, Bituminous Coal, Tiefstack PS, Germany Germany Study for capacity increase, coke gas firing system, 2 x 307 MWel, RWE AG, Huckingen PS, Germany Essen, Germany Engineering and supply of optimised oil lances, 340 MWel, Knepper PS, E.ON Engineering GmbH, Germany Gelsenkirchen, Germany Supervision of revamping at refinery steam generators, life extension MIRO, and environmental upgrading, Germany Karlsruhe, Germany Supply and implementation of a new oil and gas firing system at steam Shell Deutschland Oil GmbH, generator plus retrofit of a catalytic DeNOX system, 200 t/h, Heavy Fuel Wesseling, Germany Oil and Low-Pressure-Gas, Shell Wesseling, Germany Basic Engineering and supply for gas connection installation, retrofit for Vattenfall Europe Hamburg AG, additional natural gas firing system, Tiefstack PS, Germany Germany Engineering for retrofit of a SCR-DeNOX plant, 200 t/h, Heavy Fuel Oil and Shell Deutschland Oil GmbH, Low-Pressure-Gas, Shell Rheinland Refinery, Germany Wesseling, Germany Babcock Hitachi Europe GmbH, Review of firing concept for BAO Steel, 1170 t/h, Blast Furnace Gas Oberhausen, Germany Legend: PS – Power Station SCR – Selective Catalytic Reduction FGD – Flue Gas Desulphurization PF – Pulverized Fuel STP – Standard Temperature and Pressure CFB – Circulating Fluidized Bed CHP – Heat and power plant HRSG – Heat Recovery Steam Generator ESP – Electrostatic Precipitator www.steinmueller.com Tel. +49 2261 78950-0 Gesamtdarstellung Circulating Fluidized Bed Boiler BUNKER FUEL SCR HANDLING BOILER TURBINE ESP FGD Bereich Kessel BUNKER SCR FUEL HANDLING BOILER TURBINE ESP FGD Bereich Reinigung BUNKER SCR Air Distribution Nozzle TURBINE FUEL HANDLING BOILER Plate Arrangement ESP FGD Tailor Made Design High Efficiency Wide Fuel Range Application Boiler Type Scope of Supply Power Plants and Industrial Boilers • Natural circulation • Consultancy Circulating fluidized bed boiler with direct • Once through • Sophisticated calculation desulfurization tools for flow and heat Fuel Type transfer Benefits • Engineering from • Tailor made design to meet customer • Lignite concept to detail specific requests and space limitations • Bituminous coal • Supply of core • Sub- and super-critical boiler design with • Biomass components and without reheater • Waste fuels • Site supervision and • Advanced nozzle cap design for optimized • Pre-dried lignite commissioning fluidization • Refractory protection for critical zones in • Co-firing of various furnace fuel types • Cyclone configuration for optimal arrangement of plant components • Convective pass with low erosion design www.steinmueller.com Tel. +49 2261 78950-0 Reference List Excerpt Circulating Fluidized Bed Boiler Technology Scope Client Layout and basic engineering for heat and power CFB steam CKD Praha DIZ a.s., generator, 90 t/h, Lignite, Tabor PS, Czech Republic Praha, Czech Republic Basic design review CFB boiler, 330 MWel, Lignite, Stanari PS, EFT Group, Bosnia & Herzegovina Belgrade, Serbia Basic design engineering for a process steam CFBC boiler, 35 t/h, Martech Boiler Company, Bituminous Coal, new-built plant, Vietnam Ho Chi Minh City, Vietnam Basic and partial detail design for 2 x 270 MWel CFBC boilers, Becl PS, AE&E Lentjes GmbH, India Ratingen, Germany Engineering for CFB Boiler, Low Rank Coal, 2 x 80 t/h, PT. ZUG Industrie Indonesia, Indonesia Jakarta, Indonesia Study for CFB operation boiler 6, comparison of operation values RheinEnergie AG, with initial design parameters, Pre-Dried Lignite, 248 MWth, Cologne, Germany Merkenich PS, Germany Know-how transfer and training in the design of CFBC boilers, Eskom Enterprises, Eskom Enterprises, South Africa Johannesburg, South Africa Consultancy and supervision services – Owner’s engineer for the EFT – Rudnik i Thermoelektrana Stanari construction of the 330 MWel lignite-fired thermal power plant Stanari, d.o.o., Belgrade, Serbia Bosnia & Herzegovina Know-how transfer and technical training for circulating fluidized PT. ZUG Industrie Indonesia, bed boilers (CFB) , Indonesia Jakarta, Indonesia Know-how transfer – Engineering for circulating fluidized bed (CFB) PJSC EMAlliance, boiler technology Taganrog, Russian Federation Pressure part layout and design for CFB steam generators, 2 x 250 MWel, AE&E Lentjes GmbH, Lignite, Neyveli PS, India Ratingen, Germany Babcock-Hitachi Europe, CFBC Market study Oberhausen, Germany Legend: PS – Power Station SCR – Selective Catalytic Reduction FGD – Flue Gas Desulphurization PF – Pulverized Fuel STP – Standard Temperature and Pressure CFB – Circulating Fluidized Bed CHP – Heat and power plant HRSG – Heat Recovery Steam Generator ESP – Electrostatic Precipitator www.steinmueller.com Tel. +49 2261 78950-0 BUNKER SCR FUEL HANDLING BOILER TURBINE ESP FGD Bereich Kessel Flue Gas Desulphurization Systems BUNKER FUEL SCR HANDLING BOILER TURBINE ESP FGD Bereich Reinigung BUNKER SCR FUEL HANDLING BOILER TURBINE ESP FGD Tray Basket Flexible Modular System for Retrofit Removal Efficiency Increase Reduction of Power Consumption Application Design Scope of Supply Power Plants and Industrial Boilers • Wet FGD (also with Retrofit, Revamping and tray technology) New Build FGDs SO2 reduction, extension of fuel range • Spray Dryer Absorption • Consultancy System (SDA) • Process engineering Benefits • Circulating Fluidized Bed • CFD-simulations • Reduction of pollutant emissions System (CFB-FGD) (SO2 , SO3 , Dust) • Engineering, supply and • Duct Sorbent Injection (DSI) installation of components • High availability - Nozzle position • Increase of operational flexibility Technical Data - Tray layer retrofit • Optimized consumption of - Oxidation air distribution • SOX < 200 mg/m³ (STP) limestone corresponding to removal • Commissioning • Optimized distribution of efficiencies > 98 % oxidation air • Low pressure drop • Reduction of auxilliary energy consumption www.steinmueller.com Tel. +49 2261 78950-0 Reference List Excerpt FGD Systems Scope Client Retrofit of a tray for FGD scrubber upgrade, 2 x 110 MWel, Slovenské elektrárne, a. s., Lignite, Novaky PS, Slovakia Bratislava, Slovakia Retrofit of a tray for FGD scrubber upgrade, 86 MWel, Mitteldeutsche Braunkohlegesellschaft Lignite, Deuben PS, Germany GmbH, Germany Revamp and optimization of FGD, 660 MWel, Bituminous Coal, Nuon Power Generation B.V., Hemweg PS 8, Netherlands Utrecht, Netherlands Engineering and component supply for a wet FGD, 150 MWel, LAB GmbH Germany, for Electrocentrale Lignite, Paroseni PS, Romania Paroseni S.A., Paroseni, Romania Retrofit of a tray for FGD scrubber upgrade, 600 t/h, Fenne PS, STEAG AG, Bituminous Coal, Völklingen, Germany Saar-Völklingen, Germany Detail engineering for efficiency increase of FGD scrubber, 2 x 227 MWel, ContourGlobal, Lignite, Maritsa East 3 PS, Bulgaria Sofia, Bulgaria Concept design study for SOX emissions reduction 200 – 730 MWel, Eskom Enterprises, Bituminous Coal, ESKOM’S fleet, South Africa Johannesburg, South Africa Technical specification for the FGDs, 6 x 800 MWel, Eskom Enterprises, Bituminous Coal, Medupi PS, South Africa Johannesburg, South Africa Study for efficiency improvement of FGD, 4 x 500 MWel, E.ON, Ratcliffe-on-Soar, Bituminous Coal, Ratcliffe PS, Great Britain Nottinghamshire, UK FGD optimization study, 2 x 110 MWel, Slovenské elektrárne, a. s., Lignite, Novaky PS, Slovakia Bratislava, Slovakia Guizhou XingYun Environment License, know-how transfer and cooperation agreement for FGD plants Protection Co., Ltd., Gyiuang, China FGD Tender evaluation, 6 x 800 MWel, Bituminous Coal, Kusile PS, Eskom Enterprises, South Africa Johannesburg, South Africa Legend: PS – Power Station SCR – Selective Catalytic Reduction FGD – Flue Gas Desulphurization PF – Pulverized Fuel STP – Standard Temperature and Pressure CFB – Circulating Fluidized Bed CHP – Heat and power plant HRSG – Heat Recovery Steam Generator ESP – Electrostatic Precipitator www.steinmueller.com Tel. +49 2261 78950-0 BUNKER SCR FUEL HANDLING BOILER TURBINE ESP FGD Bereich Kessel Electrostatic Precipitator BUNKER FUEL SCR HANDLING BOILER TURBINE ESP FGD Bereich Reinigung BUNKER SCR FUEL HANDLING BOILER TURBINE ESP FGD Emitter Electrode Extremely Low Dust Emissions High Efficiency Reduction of Power Consumption Application Technical Data Scope of Supply Power Plants and Industrial Boilers Type: • Consultancy Dust reduction, extension of fuel • Dry Electrostatic Precipitator • Process engineering range • Wet Electrostatic Precipitator • Concept design • CFD-simulations of flue gas Benefits Emissions: path and flow optimization • Reduction of dust emissions PM < 10 mg/m³ (STP) • Optimization concepts • Extension of fuel range • Commissioning support • Energy savings by optimized high Fuel Type voltage supply • Bituminous coal • High availability • Lignite • Increase of operational flexibility • Co-firing of biomass • Waste • Oil www.steinmueller.com Tel. +49 2261 78950-0 Reference List Excerpt Electrostatic Precipitator Scope Client Boiler and ESP design study and know-how transfer for 6 x 600 MWel, Eskom Enterprises, Bituminous Coal, Tutuka PS, South Africa Johannesburg, South Africa Rehabilitation and optimization of ESP, 610.000 m³/h (STP), Lignite, CET Govora, Govora PS, Romania Râmnicu Vâlcea, Romania Rehabilitation of electrostatic precipitator behind fluidized catalytic Raffineria di Milazzo S.C.p.A., cracker plant, 166.000 m³/h (STP), Milazzo Refinery, Italy Milazzo, Italy Know-how transfer, design tools and training for firing systems, FGD, Eskom Enterprises, DeNOx (SCR) and ESP for bituminous coal-fired power plants, South Africa Johannesburg, South Africa Rehabilitation of electrostatic precipitator behind fluidized catalytic Ruhr Oel GmbH, cracker plant, 90.000 m³/h (STP), BP Refinery Gelsenkirchen, Germany Gelsenkirchen, Germany Concept engineering study for the optimization of ESPs, 6 x 600 MWel, Eskom Enterprises, Bituminous Coal, Tutuka PS, South Africa Johannesburg, South Africa CFD-flow simulation and optimization for ESP downstream pyrite roaster in Ion Blast Ltd., sulfuric acid plant, 30.000 m³/h (STP), Haldor Topsøe Plant, Denmark Helsinki, Finland CFD-flow simulation for ESP, shale oil plant, 119.000 m³/h (STP), Ion Blast Ltd., Eesti Energia Narva, Estonia Helsinki, Finland Legend: PS – Power Station SCR – Selective Catalytic Reduction FGD – Flue Gas Desulphurization PF – Pulverized Fuel STP – Standard Temperature and Pressure CFB – Circulating Fluidized Bed CHP – Heat and power plant HRSG – Heat Recovery Steam Generator ESP – Electrostatic Precipitator www.steinmueller.com Tel. +49 2261 78950-0 BUNKER SCR FUEL HANDLING BOILER TURBINE ESP FGD Bereich Kessel Selective Catalytic Reduction BUNKER FUEL SCR HANDLING BOILER TURBINE ESP FGD Bereich Reinigung BUNKER SCR FUEL HANDLING BOILER TURBINE ESP FGD SCR Shell Wesseling Retrofitted SCR for LowNOX Emissions Application Technical Data Scope of Supply Power Plants and Industrial Boilers Type: • Consultancy NOX reduction Selective Catalytic • Process engineering Reduction Benefits • EPC for SCR installations • With honeycomb catalyst • Reduction of NOX emissions • With plate catalyst • Optimization concepts • Extension of fuel range Selective Non-Catalytic • Adaptation of boiler water- Reduction steam cycle • High availability Emissions: • Adaptation of heating • Increase in operational flexibility NOX < 50 mg/m³ (STP) surfaces • Low pressure loss NH3 slip < 1 mg/m³ • Optimization of flue gas (under high dust conditions) distribution and NH3- injection (CFD simulations) Fuel Type • Bituminous coal • Heavy fuel oil & residues • Waste • Lignite • Co-firing of biomass www.steinmueller.com Tel. +49 2261 78950-0 Reference List Excerpt Selective Catalytic Reduction of NOx Scope Client Concept Design Study: Assessment, comparison and selection of feasible Eskom Enterprises, NOX reduction technologies and concept engineering for a total of 10 Johannesburg, South Africa bituminous coal fired power stations Know-how transfer, design tools and training for DeNOX (SCR) for Eskom Enterprises, bituminous coal-fired power plants, South Africa Johannesburg, South Africa License and know-how transfer agreement for catalytic DeNOX system, Guizhou XingYun Environment Protection China Co., Ltd., Guiyang, China Owner`s engineer for 3 SCR installations, modification of 5 steam MIRO, generators, 75 t/h, 110 t/h, 150 t/h, Refinery Residues, Oil and Gas, Karlsruhe, Germany Mineral Oil Refinery Oberrhein (MIRO), Germany Engineering and supply for retrofit of a SCR-DeNOX plant, 200 t/h, Shell Deutschland Oil GmbH, Heavy Fuel Oil and Low-Pressure-Gas, Shell Rheinland Refinery, Germany Wesseling, Germany Legend: PS – Power Station SCR – Selective Catalytic Reduction FGD – Flue Gas Desulphurization PF – Pulverized Fuel STP – Standard Temperature and Pressure CFB – Circulating Fluidized Bed CHP – Heat and power plant HRSG – Heat Recovery Steam Generator ESP – Electrostatic Precipitator www.steinmueller.com Tel. +49 2261 78950-0 Process Gas Cooler Downstream Secondary Reformer HYDROGEN SYNGAS FOR METHANOL OR AMMONIA PRODUCTON STEAM SECONDARY PGC SUPERHEATER REFORMER REFORMER (PROCESS GAS COOLER) PGC Mopco Ammonia Plant Proven Design High Reliability Application Product Range Scope of Supply Heat Recovery for • Fire tube design • Consultancy (natural circulation) • Optimization concepts Production of ammonia, methanol, • U-tube design hydrogen and similar applications • Process engineering (forced circulation) • Steam superheater • Mechanical design Benefits (option) • Supply of process gas • Tailor made design to meet customer cooler (PGC), superheater specific requirement Technical Data and spare parts • Capacity increase within existing footprint • High availability • Gas temperature: up to 1200°C • Increase in operational flexibility • Gas pressure: • Reliable design based on decades of up to 40 bar experience • Steam pressure: up to 140 bar www.steinmueller.com Tel. +49 2261 78950-0 Reference List Excerpt Process Gas Cooler Downstream Secondary Reformer Scope Client Engineering of a waste heat boiler downstream secondary reformer, YARA Trinidad Ltd., 160 t/h, ammonia plant YAT E 904 B, Trinidad and Tobago Trinidad and Tobago Engineering and supply of a waste heat boiler downstream YARA Trinidad Ltd., secondary reformer, 214 t/h, E 2016 Tringen 1, Trinidad and Tobago Trinidad and Tobago Balcke-Dürr GmbH for ThyssenKrupp Basic and detail engineering for a process gas cooler downstream Industrial Solutions AG secondary reformer, Mopco Ammonia/Urea Plant, Egypt (former Uhde GmbH), Essen, Germany Detail engineering for a waste heat boiler downstream secondary YARA SpA, reformer, U-tube design, 120 t/h, Ferrara plant, Italy Ferrara, Italy Basic and detail engineering for a process gas cooler downstream Babcock Power Espana S.A., secondary reformer, Jinxi plant, China Valle de Trapaga-Vizcaya, Spain Engineering and supply of a waste heat boiler downstream secondary Yara Sluiskil B.V., reformer in ammonia plant, syngas flow: 135 t/h, steam production Sluiskil, Netherlands 118 t/h, E 301 Sluiskil ref C, Netherlands Engineering and supply of a process gas cooler downstream secondary Methanex New Zealand Ltd., reformer E 0205 A&B, Motunui, New Zealand Motunui, New Zealand Engineering and supply of a process gas cooler downstream secondary Krupp Uhde GmbH, reformer 303 E 001 and superheater 303 E 002, Suez, Egypt Dortmund, Germany Engineering and supply of a process gas cooler downstream Tecnimont S.p.A., secondary reformer 303 E 001, Al-Jubail, Saudi Arabia Fertilizer Company, Milano, Italy Saudi Arabia Engineering and supply of a process gas cooler downstream secondary Uhde GmbH, reformer 303 E 001 and superheater 303 E 002, Abu Qir, Egypt Dortmund, Germany Saskferco Products Inc. Regina, Engineering and supply of a process gas cooler downstream secondary Saskatchewan, Canada reformer 03 E 001, Belle Plain, Canada (now Yara Belle Plain) Engineering and supply of a process gas cooler downstream secondary Shell UK, reformer E 2104, Stanlow, Great Britain Stanlow, Great Britain Legend: PS – Power Station SCR – Selective Catalytic Reduction FGD – Flue Gas Desulphurization PF – Pulverized Fuel STP – Standard Temperature and Pressure CFB – Circulating Fluidized Bed CHP – Heat and power plant HRSG – Heat Recovery Steam Generator ESP – Electrostatic Precipitator www.steinmueller.com Tel. +49 2261 78950-0 Waste Heat Boiler Downstream Ammonia Combustion AIR WATER (H 2O) NH 3 AMMONIA (NH 3) REACTOR NITRIC ACID (HNO 3) WASTE HEAT BOILER WHB Leuna Caprolactam Plant Proven Design High Availability Flexibility Increase Application Product Range Scope of Supply Heat Recovery for Catalytic Ammonia • Fire tube design • Consultancy Combustion: (natural circulation) • Optimization concepts • Water tube design, HNO3 and caprolactam production, HCN • Process engineering spiral and meander type synthesis and similar processes (forced circulation) • Mechanical design Benefits • Integrated superheater • Supply of Waste Heat Boiler • Catalyst basket (WHB) including burner • Tailor made design to meet customer hood and catalyst basket specific requirement Technical Data • Pumps & auxiliary • Energy savings equipment • High availability • Gas temperature: up to 1200°C • Increase in operational flexibility • Gas pressure: • Capacity increase within existing footprint up to 10 bar • Reliable design based on decades of • Steam pressure: experience up to 80 bar • Steam temperature: up to 500°C www.steinmueller.com Tel. +49 2261 78950-0 Reference List Excerpt Waste Heat Boiler Downstream Ammonia Combustion Scope Client Engineering and supply of a waste heat boiler in a nitric acid plant down- Grow How UK Ltd., stream catalytic ammonia oxidation, 160 t/h, Ince, Cheshire, Great Britain Ince, Chestershire, Great Britain Engineering and supply of secondary path downstream NH3 combustion Grow How UK Ltd., including superheater, 160 t/h, Ince, Cheshire, Great Britain Ince, Chestershire, Great Britain Engineering and supply of a waste heat boiler for catalytic Solvay/Butachimie, HCN-Synthesis, 156 t/h throughput, Solvay/Butachimie, France Chalampe, France Engineering and supply of heating surface bundles for a capacity Domo Caproleuna GmbH, upgrade to 170 % downstream catalytic ammonia oxidation in Leuna, Germany a caprolactam plant, Leuna, Germany Engineering and supply of a waste heat boiler in a nitric acid plant Balcke-Dürr GmbH, Ratingen, Germany downstream catalytic ammonia oxydation, Glomfjord, Norway for Yara Norge AS, Glomfjord, Norway Engineering and supply of a waste heat boiler in a formaldehyde plant, BASF AG, Ludwigshafen, Germany Ludwigshafen, Germany Engineering and supply of a process gas cooler E 5205 Krupp Uhde GmbH, (vertical fire tube boiler) for nitric acid plant Radici Zeitz, Germany Dortmund, Germany Engineering and supply of a process gas cooler 30 E 005 (horizontal fire Krupp Uhde GmbH, tube boiler) for ammonium nitrate plant, Moura, Queensland, Australia Dortmund, Germany Engineering and supply of a process gas cooler (vertical fire tube boiler) Chemoproject A.S., for nitric acid plant Suslo Sala, Slovenia Prague, Czech Republic Engineering and supply of a process gas cooler (water tube boiler) for ICF Kaiser Engineers Inc., nitric acid plants in Geismar and Baytown, Texas, USA Oakland, USA Engineering and supply of a process gas cooler E 5205 (vertical fire tube Babcock-King-Wilkinson Ltd., boiler) for nitric acid plant Belfast, North Ireland Buckinghamshire, Great Britain Engineering and supply of a waste heat boiler in a nitric acid plant, Didier Engineering, Geleen, Netherlands Essen, Germany Legend: PS – Power Station SCR – Selective Catalytic Reduction FGD – Flue Gas Desulphurization PF – Pulverized Fuel STP – Standard Temperature and Pressure CFB – Circulating Fluidized Bed CHP – Heat and power plant HRSG – Heat Recovery Steam Generator ESP – Electrostatic Precipitator www.steinmueller.com Tel. +49 2261 78950-0 Consulting and Engineering Services Gesamtdarstellung BUNKER SCR FUEL HANDLING BOILER TURBINE ESP FGD Bereich Kessel BUNKER SCR FUEL HANDLING BOILER TURBINE Rely on our Experience! ESP FGD Bereich Reinigung Skills, Engineering Tools BUNKER SCR FUEL and Experts for your TURBINE HANDLING BOILER ESP FGD Project Success Application Scope of Service Thermal Power Plants and Project Development Phase: Industrial Energy Management • Conceptual engineering • Owner’s engineering services • Feasibility studies • Lender’s engineering services • Environmental and social impact assessments (ESIA) • Management support • Fuel supply studies • Engineering solutions • Power evacuation and grid studies Benefits Tender and Contracting Phase: • Concentrated know-how from experienced • Tender specifications and skilled professionals • Bid clarifications and evaluations • Contracting strategy • Inhouse design capabilities and design tools • Contract negotiations for steam generators, heat exchangers and flue gas cleaning plants Project Execution Phase: • Reliable solutions based on decades of • Project management (EPCM) practical experience • Design reviews • QA & QM • Erection and commissioning supervision • Acceptance tests • Training of personnel Know-How Transfer / Licensing • Boiler and heat exchanger design • Flue gas desulfurization and DeNOX plant design www.steinmueller.com Tel. +49 2261 78950-0 Reference List Excerpt Consulting and Engineering Services Scope Client Feasibity study for the retrofit of a flue gas desulphurisation plant, International Paper – Kwidzyn sp. Z.o.o., 3 x 50 MWel, Bituminous Coal, International Paper-Kwidzyn, Poland Kwidzyn, Poland Investigation and recovery scope development support after boiler Eskom Enterprises, damage, 600 MWel, Bituminous Coal, Duvha PS, South Africa Johannesburg, South Africa Plant assessment and life-ex study for a coal-fired power plant, Tübitak MRC, 22.5 MWel, Lignite, Soma A PS, Turkey Ankara, Turkey Know-how transfer and training in the design of CFBC boilers, Eskom Enterprises, Eskom Enterprises, South Africa Johannesburg, South Africa Basic design review, consultancy and supervision services – Owner’s EFT – Rudnik i Thermoelektrana Engineer – for the construction of the 300 MWel lignite-fired thermal Stanari d.o.o., Serbia power plant Stanari, Bosnia & Herzegovina Life time extension assessment for coal-fired boilers, 10 x 200 MWel, Siemens Ltd. South Africa for Eskom Hendrina PS, Bituminous Coal, South Africa Enterprises, South Africa Design study on coal range extension in supercritical utility boilers, Coastal Gujarat Power Generation, 5 x 830 MWel, Bituminous Coal, Mundra PS, India Mumbai, India FGD optimization-study, 2 x 110 MWel, Lignite, Novaky PS, Slovenske elektrarne, a. s., Slovakia Bratislava, Slovakia Design study for boiler with ultra-supercritical steam parameter and Wai Gao Qiao No.3 Power Generation double reheat, 1350 MWel, Bituminous Coal, Co., Ltd., Shanghai, China WaiGaoQiao PS No. 9, Shanghai, China Boiler operation monitoring, 2 x 750 t/h steam generators, Refinery PCK Raffinerie GmbH, Residues, Heavy Fuel Oil and Low-Pressure-Gas, PCK Schwedt, Schwedt, Germany Germany Design review for the steam generators, 12 x 800 MWel coal-fired power Eskom Enterprises, station, Kusile and Medupi PS, South Africa Johannesburg, South Africa Feasibility study for 2 x 660 MWel lignite fired power stations in E.ON Engineering GmbH, Czech Republic Gelsenkirchen, Germany Owner’s Engineer for 800 MWel power plant, Bituminous Coal and Essent Energie B.V., Biomass, Amercentrale PS Unit 10, Netherlands Netherlands Legend: PS – Power Station SCR – Selective Catalytic Reduction FGD – Flue Gas Desulphurization PF – Pulverized Fuel STP – Standard Temperature and Pressure CFB – Circulating Fluidized Bed CHP – Heat and power plant HRSG – Heat Recovery Steam Generator ESP – Electrostatic Precipitator www.steinmueller.com Tel. +49 2261 78950-0 After Sales Services Gesamtdarstellung BUNKER SCR FUEL HANDLING BOILER TURBINE ESP FGD Bereich Kessel BUNKER SCR FUEL HANDLING BOILER TURBINE Rely on our Experience! ESP FGD Bereich Reinigung Skills, Engineering Tools BUNKER SCR FUEL and Experts for your TURBINE HANDLING BOILER ESP FGD Project Success Application Scope of Service Thermal Power Plants and Plant in Service Phase: Industrial Energy Management • Maintenance and repairs • Engineering services • Upgrades • Project Management support • Management support • Engineering solutions • Appropriate supply of spare parts • Sustainable planning and control of outage phases Benefits • Limitation of risks for our clients Optimization Phase: • Concentrated know-how from experienced • Examination of possibilities to optimize operation and skilled professionals • Monitoring of operation • Cost savings by a safe and sound operation • Evaluation of data of your plant • Handling and optimization of wear, fouling • Direct support with hands-on mentality and corrosion behaviour • Reliable communication channel • Improvement of part load behaviour • Reliable solutions based on decades of practical experience • Shortening of start-up times • Free choice of hardware supplier and • Improvement of plant flexibility blue color service • Trouble shooting www.steinmueller.com Tel. +49 2261 78950-0 Reference List Excerpt After Sales Services Scope Owner/Operator Engineering support for the optimization of the combustion system, IHI Corporation, 800 MWel, Bituminous Coal, Trianel Lünen PS, Germany Tokyo, Japan Follow-up of boiler operation monitoring, 2 x 750 t/h steam generators, Refinery PCK Schwedt, Refinery Residues, Heavy Fuel Oil and Low Pressure Gas, PCK Schwedt, Schwedt, Germany Germany Commissioning engineering services, 6 x 800 MWel, Bituminous Coal Eskom Enterprises, Medupi PS, South Africa Johannesburg, South Africa Engineering for repair works of a waste heat boiler in a nitric acid plant Grow How UK Ltd., downstream catalytic ammonia oxydatio, Ince, Cheshire, Great Britain Ince, Cheshire, Great Britain Spare part supply, 200 t/h, Heavy Fuel Oil and Low-Pressure-Gas, Shell Deutschland Oil GmbH, Shell Wesseling, Germany, Germany Wesseling, Germany Overhaul of burners and supply of spare parts, 500 MWel, Bituminous Steag GmbH, Coal, Herne PS Unit 4, Germany Essen, Germany Maintenance service to the owner, 800 MWel, Bituminous Coal, Trianel IHI Corporation, Lünen PS, Germany Tokyo, Japan Re-engineering and supply of coal burner components, 300 MWel, Vattenfall GmbH, Bituminous Coal, Tiefstack CHP, Germany Hamburg, Germany Engineering and supply of 2 evaporator coils for a waste heat boiler CF Industries Nitrogen, LCC, downstream ammonia combustion, 30,5 t/h, Donaldsonville plant, USA Donaldsonville, USA Recalculation a waste heat boiler downstream ammonia combustion, CF Industries Nitrogen, LCC, 30,5 t/h, Donaldsonville plant, USA Donaldsonville, USA Recalculation of gas burners, 117 MWel, Natural Gas, Lingen PS, BP Europe SE, Germany Lingen, Germany Engineering and supply of wall coil header pipework to heating surface Grow How UK Ltd., in a waste heat boiler downstream ammonia combustion, Billingham, Ince, Cheshire, Great Britain Great Britain Engineering and supply of oil atomiser lances and atomiser sprayer, Mainova, Mainova, Germany Frankfurt, Germany Legend: PS – Power Station SCR – Selective Catalytic Reduction FGD – Flue Gas Desulphurization PF – Pulverized Fuel STP – Standard Temperature and Pressure CFB – Circulating Fluidized Bed CHP – Heat and power plant HRSG – Heat Recovery Steam Generator ESP – Electrostatic Precipitator www.steinmueller.com Tel. +49 2261 78950-0 PS Maritsa East 3 4 x 227 MWel, 4 x 730 t/h LowNOx Lignite Firing System Jänschwalde Neurath Turow Niederaußem Vrsany Tabor Voitsberg Sostanj Maritsa East 3 Turceni Kostolac Stanari Can Tufanbeyli Soma Megalopolis Selected Lignite References of Steinmüller Engineering Achievements: Scope of Supply: NOX: 150 – 180 mg/m³ • Process engineering CO: 30 – 80 mg/m³ • 3D CFD modelling (STP @ 6 % O2) • Mechanical design Fuel: Bulgarian Lignite (a.r.): • Lignite burners LCV: 6 – 7 MJ/kg (1.4 – 1.7 Mcal/kg) w: 50 – 60 % • Over fire air system a: 10 – 21 % • Sidewall air system S: 1.5 – 3.0 % N: 0.35 % Literature can be provided on request • VGB PowerTech 10 - 2013 “Revamping of a lignite fired boiler with less NOx emissions” • VGB PowerTech 10 - 2015 “Challenges for a European Utility considering the EU Directive on Industrial Emissions by the end of 2015” Please contact us for further information. www.steinmueller.com Tel. +49 2261 78950-0 CHP Altbach, Unit 2 330 MWel, 1014 t/h LowNOx Firing System for Bituminous Coal Astana KAZAKHSTAN Astana Tiefstack KAZAKHSTAN Mehrum Ibbenbüren Herne 4 Pretoria Duvha Camden RDK7 Altbach Kriel Tutuka Majuba Lesotho SOUTH AFRICA Pretoria Duvha Camden Selected Bituminous Coal References Kriel of Steinmüller Engineering Tutuka Majuba Lesotho SOUTH AFRICA Achievements: Scope of Supply: Capacity increase: 940 to 1014 t/h (+10 %) • Replacement of 12 LowNOx burners NOx: 310 mg/m³ for original coal range • Refurbishment of pulverisers NOx: 420 mg/m³ for new widened coal range • Modification on forced draft (FD) fan CO: 100 mg/m³ (STP @6 % O2) • Replacement of the FD drive motor inclu- ding the addition of a frequency converter Fuel: Bituminous Coal (World Coal) • Refurbishment of air preheater Boiler design: Tower type, Benson steam generator with Steinmüller all-wall firing • All the above considering the system 10 % boiler capacity increase Literature can be provided on request • PowerGen Europe 06 - 2013 “Combustion optimisation, efficiency improvements and emission reduction by installation of modern LowNOX firing systems on existing bituminous coal and lignite coal-fired steam generators” Please contact us for further information. www.steinmueller.com Tel. +49 2261 78950-0 KAZAKHSTAN Shell Rheinland Raffinerie, Wesseling Retrofit and Supply of LowNOx Burners and Flue Gas Treatment Selective Catalytic Reduction (SCR) Plant Medupi (FGD) Kusile Pretoria (FGD) Lesotho Cottam SOUTH AFRICA Ratcliffe on Soar Hemweg (FGD) (FGD) Deuben (FGD) Völklingen- Pocerady Fenne (FGD) Novaky (FGD) Wesseling (SCR) Trbovlje Govora (ESP) Paroseni Fusina (FGD) Maritsa East 3 Selected Flue Gas Treatment References of Steinmüller Engineering Achievements: Scope of Supply: NOx: < 140 mg/m³ • Feasibility study and conceptual design CO: < 40 mg/m³ • Basic engineering for steam generator, NH3 slip: < 1 mg/m³ furnace and SCR plant (STP @ 3 % O2) • Detailed planning NH3 profile: < 3 % maldistribution at SCR inlet • Supply and installation of new burners Fuel: Blended heavy fuel oils and various and SCR plant refinery gases • Commissioning and acceptance test Boiler design: 2-pass boiler, natural circulation with front wall firing system, 8 burners Literature can be provided on request • Presentation on Steinmüller Engineering Conference 2013 Please contact us for further information. www.steinmueller.com Tel. +49 2261 78950-0 KAZAKHSTAN CHP Govora, Unit 7 Retrofit with Efficiency Increase of Electrostatic Flue Gas Treatment Precipitator (ESP) Medupi (FGD) Kusile Pretoria (FGD) Lesotho Cottam SOUTH AFRICA Ratcliffe on Soar Hemweg (FGD) (FGD) Deuben Wesseling (FGD) (SCR) Völklingen- Pocerady Fenne (FGD) Novaky (FGD) Govora (ESP) Trbovlje Paroseni Fusina (FGD) Maritsa East 3 Selected Flue Gas Treatment References of Steinmüller Engineering Achievements: Scope of Supply: Dust: < 50 mg/m³ (originally 180 mg/m³) • Flow cross-section enlarged by introducing (STP @ 6 % O2) new roof design Fuel: Romanian Lignite (a.r.) • Flow distribution improved by installing LCV: 6.7 – 8.3 MJ/kg (1.6 – 2.0 Mcal/kg) guide vanes w: 34 – 43 % • Mechanically more robust electrodes a: 15 – 32 % installed S: 0.9 – 1.5 % • High voltage system replaced Boiler design: 420 t/h, 2-pass boiler Literature can be provided upon request • Presentation on Steinmüller Engineering Conference 2013 • Steinmüller Engineering Workshop 2012 “Retrofit with Efficiency Increase of ESP” Please contact us for further information. www.steinmueller.com Tel. +49 2261 78950-0 KAZAKHSTAN NUON Hemweg 8 Retrofit with Efficiency Increase of Flue Gas Flue Gas Treatment Desulphurization Plant (FGD), 680 MWel, 1980 t/h Medupi (FGD) Kusile Pretoria (FGD) Hemweg (FGD) SOUTH AFRICA Lesotho Cottam Ratcliffe on Soar (FGD) Deuben Wesseling (FGD) (SCR) Völklingen- Pocerady Fenne (FGD) Novaky (FGD) Trbovlje Govora (ESP) Paroseni Fusina (FGD) Selected Flue Gas Treatment References Maritsa East 3 of Steinmüller Engineering Achievements: Scope of Supply: • SO2 removal efficiency increase • Supply of new double hollow cone and full from 92.9 % to 95.2 % cone nozzles • Sulphur dioxide emission reduced by • Nozzle installation based on Advanced more than 30 % Nozzle Positioning (ANP) Technology FGD Design: • Refurbishment of piping system • Diameter of scrubber: 18 m • Further process optimization options identified and proposed in additional • Number of spray levels: 4 engineering study Literature can be provided upon request • VGB Workshop “Flue Gas Cleaning 2008”, Vilnius, Lithuania, 2008 “Flue Gas Cleaning research projects and their application in the NUON Power Plant Hemweg 8” • VDI-Conference “REA-, SCR- and Dust removal in large power plants”, Düsseldorf, 2013 “Retrofit and Process Optimization for FGD” Please contact us for further information. www.steinmueller.com Tel. +49 2261 78950-0 Solvay / Butachimie Chalampé Waste Heat Boiler for Catalytic Steam Generation Technology HCN Synthesis in a Nylon Plant Glomfjord SASKATCHEWAN CANADA Belle Paine Uusikaupunki USA Syra ATLANTIC LOUISIANA OCEAN Donaldsonville MEXICO Billingham Point Lisas Ince TRINIDAD & TOBAGO Sluiskil Leuna Wesseling Chalampé (SCR) Ludwigs- Šaľa hafen Montoir Kikinda Selected Steam Generation References of Steinmüller Engineering Achievements: Scope of Supply: • Replacement of waste heat boiler with • Design of new waste heat boiler for improved design features the existing plant • Capacity increase of boiler by 15 % - Process engineering • Improved cooling of critical components - Mechanical design (basic and detail) Boiler design: • Manufacturing and supply of boiler • Application: catalytic HCN synthesis, steam • Transport to site generation and cooling of hot process gases (> 1100°C) • Supply and installation of refractory • Vertical fire-tube boiler with natural circulation, 121 t/h, 26.5 bar, 227°C • Conical design of tube sheet for improved steam discharge • Engineering and supply by Steinmüller Engineering in 2013 Literature can be provided on request • Presentation on Steinmüller Engineering Conference 2013 Please contact us for further information. www.steinmueller.com Tel. +49 2261 78950-0 CFB Boiler for CHP Tabor Engineering for a Circulating Steam Generation Technology Fluidized Bed BoilerCHINA TAIWAN INDIA PACIFIC OCEAN MYANMAR LAOS Gujarat THAILAND VIETNAM PHILIPPINES India Ho Chi Minh City Sorong Becl Mumbai (Bombay) Merkenich NEW GUINEA MALAYSIA BORNEO Tabor AUSTRALIA Tamil Nadu Neyveli SUMATRA INDONESIA Stanari Lukavac Ankara Mersin Selected CFB References of Steinmüller Engineering Achievements: Scope of Supply: • New build CFB boiler with cyclone separator • Process engineering for CFB steam fired with indigenous lignite generator and auxiliaries Emission limits in mg/m³ • Detailed design of pressure parts NOX: 200 CO: 250 • Design and supply of air distributor nozzles SO2: 200 Dust: 30 • Ash removal system (STP @ 6 % O2) • Field consultancy services during Fuel: Czech Lignite (a.r.): installation and commissioning LCV: 16.9 MJ/kg (4.0 Mcal/kg) w: 29.7 % a: 9.2 % S: 0.8 % Boiler design: Circulating fluidized bed boiler, natural circulation, 88 t/h, 64 bar, 465°C • Commissioning in 2008 Literature can be provided on request • Presentation on Steinmüller Engineering Conference 2013 Please contact us for further information. www.steinmueller.com Tel. +49 2261 78950-0 KAZAKHSTAN CFB Boiler for TPP Stanari Owner´s Engineering for Consulting and Engineering Services CFB Boiler Island Kwidzyn Amercentrale Schwedt Medupi Kusile Pretoria Duvha Niederaußem Kriel Camden Hamborn Tutuka Majuba Novaky Lesotho SOUTH AFRICA Linz Voitsberg Sostanj Stanari Selected Consulting References of Canakkale Steinmüller Engineering Soma Achievements: Scope of Supply: Owner´s engineering for new build • Feasibility study and conceptual design 300 MWel thermal power plant • Expertise in lignite combustion and • Start of concept development: 2006 desulphurization in fluidized bed boilers • Start of site activities: 2012 • Preliminary design and tender specification • Commissioning: 2016 • Tender evaluation and contract drafting Fuel : Bosnian Lignite (a.r.): • Review of Chinese design (basic and detail) LCV: 9.1 MJ/kg (2.2 Mcal/kg) • Chinese vs. European standards compliance w: 49 % check a: 3.8 % S: 0.13 % • QA during manufacturing in China Boiler design: Circulating fluidized bed boiler, • Field advisory services during installation, natural circulation, 1065 t/h, 175 bar/541°C, commissioning and testing reheater 39 bar/541°C Literature can be provided on request • PowerGen Africa 2015 “Experiences with the Construction of a Chinese Power Plant in Europe from an Owner’s Engineer Point of View” Please contact us for further information. www.steinmueller.com Tel. +49 2261 78950-0 PS Herne Unit 4 Astana 500 MWel, 1512 t/h LowNOx Firing System for Bituminous Coal KAZAKHSTAN Astana Tiefstack KAZAKHSTAN Ibbenbüren Mehrum Herne 4 Pretoria Duvha RDK7 Camden Altbach Kriel Tutuka Majuba Lesotho SOUTH AFRICA Pretoria Duvha Selected Bituminous Coal References Camden of Steinmüller Engineering Kriel Tutuka Majuba Lesotho SOUTH AFRICA Achievements: Scope of Supply: Widening of applicable coal range to “world • Process engineering for LowNOx firing system coal” and reduction of primary NOx emissions, • 3D CFD modelling reducing OPEX for SCR reagent. Emission limits: (STP @6 % O2) • Mechanical design of burners and ductwork NOx: < 400 mg/m³ • Manufacturing and installation of CO: < 25 mg/m³ 12 LowNOx burners Fuel: World Coal (a.r.) • Optimization of pulverized fuel distribution LCV: 16.7 – 26.4 MJ/kg (3.9 – 6.3 Mcal/kg) • Installation of over fire air and side wall air w: 7 – 18 % N: 1.2 – 1.9 % system a: 6.0 – 30 % VM: 21 – 36 % • Commissioning and testing Boiler design: Tower type, Benson boiler with opposed firing system, 12 burners, 1512 t/h, 292 bar, 535/541°C (SH/RH) • Commissioning: 1989 revamp by Steinmüller Engineering 2013 Literature can be provided on request • 26. Dt. Flammentag 2013 “Modernization of pulverized coal combustion system of steam generator, Unit 4 at Power Station Herne” (in German) Please contact us for further information. www.steinmueller.com Tel. +49 2261 78950-0 Yara Trinidad Waste Heat Boiler downstream Steam Generation Technology secondary reformer in an ammonia plant SASKATCHEWAN CANADA Belle Plaine USA ATLANTIC OCEAN MEXICO Trinidad & Tobago Point Lisas Sluiskil Kikinda Ravenna Selected Steam Generation References of Steinmüller Engineering Achievements: Scope of Supply: • Replacement of existing waste heat boiler • Basic and detail design of waste heat boiler with design improvements (Bayonette-type • Process design, including CFD optimization replaced by U-Tube heating surface) • Manufacturing of boiler, consisting • Application: WHB downstream secondary of U-Tube bundle incl. water and reformer in TRINGEN 1 ammonia plant steam chamber • Vertical water tube boiler, forced circulation • Pressure vessel 200 t/h, 103 bar, 319 °C, 208 t/h syngas cooled down from 980 °C to 470 °C @ 32 bar • Double layer refractory lining • Engineering and supply in 2014 Steinmüller Engineering Conference 2016 “Customized Process Gas Coolers and Waste Heat Boilers for various applications” page 8–13 Please contact us for further information. www.steinmueller.com Tel. +49 2261 78950-0 PS Ensdorf 120 MWel, 376 t/h Steam Generation Technology Astana KAZAKHSTAN Gujarat India Becl Mumbai (Bombay) Tiefstack Mehrum Neyveli Ibbenbüren Tamil Nadu Herne Ensdorf Pretoria Duvha Camden RDK7 Kriel Altbach Tutuka Majuba Lesotho SOUTH AFRICA Selected utility boiler references of Steinmüller Engineering Achievements: Scope of Supply: Flexible use of the boiler with a shorter • Process engineering for the installation start-up time. of a recirculation on a once-through • Reduction in warm start-up time by 50 % steam generator (<1 hour) • Retrofitting of separation vessel and • Reduction in start-up oil consumption by 25 % circulation system by modifying suction and discharge of pipes, fittings, pump, Boiler design: expander, vents and drains, heat-up and • Once-through steam generator built 1964 evaporation economizer line • Two pass slag-tap furnace • Supplement of steel structure such as platforms, stairs, brackets • 120 MWel • Modification in I & C and boiler protection • Main steam: 376 t/h at 535 °C and 174 bar Literature can be provided on request • not applicable Please contact us for further information. www.steinmueller.com Tel. +49 2261 78950-0 KAZAKHSTAN MIBRAG Deuben Retrofit of a Tray Layer into a Flue Gas Desulphurization Flue Gas Treatment Plant (FGD), 300 MWth Medupi (FGD) Kusile Pretoria (FGD) Lesotho SOUTH AFRICA Cottam (FGD) Deuben Ratcliffe on Soar Hemweg (FGD) (FGD) (FGD) Wesseling (SCR) Völklingen- Pocerady Fenne (FGD) (FGD) Novaky (FGD) Trbovlje Govora (ESP) (FGD) Paroseni Fusina (FGD) (FGD) Selected Flue Gas Treatment References Maritsa East 3 (FGD) of Steinmüller Engineering Achievements: Scope of Supply: • SO2 removal efficiency increase • Tray basket layer and support beams from 95.7 % to 97.3 % • Redesign of 2 spray levels • Sulphur dioxide emission reduced • Supply of new double hollow cone by more than 35 % and full cone nozzles FGD Design: • Nozzle installation based on Advanced • Diameter of scrubber: 9.5 m Nozzle Positioning (ANP) Technology • Number of spray levels: 4 • ID fan upgrade Literature can be provided upon request • Steinmüller Engineering Conference 2016 “Modernization and Optimization of Flue Gas Cleaning Plants” page 23–36 • Kraftwerkstechnisches Kolloquium Dresden 2015, presentation “Operational experience of tray technology for efficiency increase in existing FGDs” Please contact us for further information. www.steinmueller.com Tel. +49 2261 78950-0 International Paper Kwidzyn Technical and Economical Technology Comparison of Flue Gas Treatment Flue Gas Desulphurization (FGD) Plant Retrofit, 420 t/h Medupi (FGD) Kusile Pretoria (FGD) Kwidzyn Lesotho SOUTH AFRICA Cottam (FGD) Ratcliffe on Soar Hemweg (FGD) (FGD) Wesseling(SCR) Deuben (FGD) Völklingen- Pocerady Fenne (FGD) (FGD) Novaky (FGD) Trbovlje Govora (ESP) (FGD) Paroseni Fusina (FGD) (FGD) Maritsa East 3 (FGD) Selected Flue Gas Treatment References of Steinmüller Engineering Requirements: Scope of Supply for all Technologies: • SO2 concentration at stack of 150 mg/m³ • Mass balances and process flow diagrams (STP@6 % O2) • Process description • 33 – 100 % load • Main equipment sizing Technologies: • General arrangement • Circulating Fluidized Bed FGD • Spray Dry Process with burnt lime • Cost estimation • Wet Process with NaOH • Sensitivity Analyses • Wet Process with lime or limestone Literature can be provided upon request • Steinmüller Engineering Conference 2016 ”Modernization and Optimization of Flue Gas Cleaning Plants“ page 23-36 Please contact us for further information. www.steinmueller.com Tel. +49 2261 78950-0 Trianel Lünen PS 813 MWel, 2225 t/h After Sales Services Ince Tiefstack (Hamburg) Lingen (Ems) Schwedt Herne Lünen Shell Wesseling (Köln) Mainova (Frankfurt) Kikinda Selected References of Steinmüller Engineering Technical specifications: Scope of Supply: SH steam pressure: 287,7 MPa • Contact window for the client: SH/RH steam temperature: 600 °C/610 °C IHI via Steinmüller Engineering (SE) Fuel: Bituminous Coal • Spare parts services for TKL via SE Client: Trianel Kraftwerk Lünen • Trouble shooting GmbH & Co. KG (TKL) • Further plant optimization Contractor: Consortium Siemens/IHI (OEM) e.g. combustion tuning, CFD analysis, etc. Benefit: • Direct support by IHI engineers • Short distance to the client • Full access to IHI´s documentation • Optimal communication channel for the client Please contact us for further information. www.steinmueller.com Tel. +49 2261 78950-0 PS Kostolac B1 350 MWel, 1000 t/h LowNOx Lignite Firing System Jänschwalde Neurath Turow Niederaußem Vrsany Tabor Voitsberg Kostolac Sostanj Turceni Stanari Maritsa East III Can Tufanbeyli Soma Selected Lignite References of Steinmüller Engineering Megalopolis Achievements: Scope of Supply: NOx ≤ to 191 mg/m³ (STP) • Process engineering CO < 200 mg/m³ (STP) • 3D CFD modelling Fuel: Serbian Lignite (a.r.) • Mechanical design LCV: 6.5 - 8.4 MJ/kg (1.6 - 2.0 Mcal/kg) • Lignite burners w: 42 - 45 % • PF duct swirler a: 20 - 26 % • Over fire air system S: 1.10 % N: 0.35 - 0.5 % • Commissioning Literature can be provided on request • Kraftwerkstechnisches Kolloquium 2015 “Retrofit of a lignite fired steam generator for NOx emission reduction” Please contact us for further information. www.steinmueller.com Tel. +49 2261 78950-0 GrowHow Ince Waste Heat Boiler downstream Steam Generation Technology catalytic ammonia combustion CANADA Glomfjord USA Uusikaupunki ATLANTIC LOUISIANA OCEAN Donaldsonville Syra MEXICO Ince Ince Leuna Montoir Selected Steam Generation References of Steinmüller Engineering Achievements: Scope of Supply: • Replacement of existing waste heat boiler • Basic and detail design of waste heat boiler in a nitric acid plant downstream catalytic • Manufacturing of boiler, consisting of wall ammonia oxydation coils, spiral type heating surfaces, headers • Application: WHB and a second path, and distributors Ince Cheshire, Great Britain • Pressure vessel • Engineering and supply in 2014 • Second path, consisting of superheater and 2nd evaporator section Literature can be provided on request Please contact us for further information. www.steinmueller.com Tel. +49 2261 78950-0 Concept/Layout: tsitrone medien GmbH & Co. KG, Cologne Steinmüller Engineering GmbH IHI Group Company Fabrikstraße 5 • D-51643 Gummersbach • Germany Tel: +49 2261 78950-0 Fax: +49 2261 78950-199
[email protected] www.steinmueller.com Edition 2016