MOL GROUP
MODERNIZATION OF
STEAM GENERATORS
341-G-004 & 341-G -005
in Rijeka Refinery Energy Plant
by consumption of natural gas
Opatija 2012.
Svetlana Petrović, Mag.ing.mech; Univ.spec.oec.
MOL GROUP
Rijeka Refinery Utility System – Energy Plant
Boilers
Turbogenerators
Electrical Power System
Large Combustion Plant directive 2001/80/EC
Emission limit values laid down in part A of Annexes III to VII in respect
of sulphur dioxide, nitrogen oxides and dust are respected. Some existing power
plants had a derogation which provided them with 2 options to comply with the
Direktive: either to operate only a limited number of hours or to be upgraded.
The model selected between the two options on a case by case basis. The
upgrading is reflected through higher capital costs.
IPPC Directive 2008/1/EC Costs of filters and other devices necessary for compliance are reflected in the
parameters of the model
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Steam and Electrical Power Production
341-T26
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Energy plant (Steam production)
MOL GROUP
Energy Plant
High pressure steam (37 barg; 450 C)
Production on four steam boilers
- 341-G-001 (2005) 40/50 t/h (nom/max)
- 341-G-002 (2005) 40/50 t/h
- 341-G-004 (1977) 80/100 t/h
- 341-G-005 (1980) 80/100 t/h
- 341-G-003 (1968) Out of service !
Steam production 240 t/h
Steam boilers efficiency (average) 91%
MOL GROUP
Steam Production
Middle pressure steam MPS (13 barg; 280 C) production on:
- Steam extraction turbines
341-T- 010 (16 t/h)
341-T- 021 (100 t/h)
- Steam pressure reduction station
Low pressure steam LPS (5 barg; 200 C)
- Steam extraction turbine
341-T- 010 (45 t/h)
- Steam pressure reduction station
MOL GROUP
Technical description (G1/G2)
1.1.Steam boilers 341-G001/G002
installed: 2005.
producer: Đ.Đ. TEP (Croatia)
number of burners: 2 per boiler
type: DYNASWIRL
medium for dispersion: steam
steam pressure: 6 barg
MOL GROUP
Technical description (G1/G2)
steam temp.: 280ºC
pressure of inlet fuel oil: 12/14 barg
viscosity: 15/20 cSt
temp. of inlet oil: 135 ºC max
temp. of combustion air: 100 ºC
pressure of inlet fuel gas: 1 barg
air glut (λ): 1.05 for fuel gas 1.1 for fuel oil
MOL GROUP
Max. capacity for lighting per burner:
2460 Nm3/h for fuel gas
2040 kg/h for fuel oil
Capacity of fuel oil station: 15m3/h
Heating power: 32.8 MW
Technical description (G1/G2)
MOL GROUP
Technical description (G4/G5)
2.1.Steam boilers 341-G004/G005
installed: 1977. and 1980.
producer: Đ.Đ. (Croatia)
number of burners: 4 per boiler
type: LMF
medium for dispersion: steam
steam pressure: 13 barg
MOL GROUP
steam temp.: 280ºC
pressure of inlet fuel oil: 14/15 barg
viscosity: 15/20 cSt
temp. of inlet oil: 135 ºC max
temp. of combustion air: 100 ºC
pressure of inlet fuel gas: 1 barg
air glut (λ): 1.05 for fuel gas 1.1 for fuel oil
Technical description (G4/G5)
MOL GROUP
Technical description (G4/G5)
Max. capacity for lighting per burner:
2050 Nm3/h for fuel gas
1850 kg/h for fuel oil
Capacity of fuel oil station: 15m3/h
Heating power: 77 MW
MOL GROUP
Steam Production Problems
Low quality liquid fuel (high content of sulphur and heavy metals –vanadium, nickel) causes:
- Hard deposits on the fire side surface of the steam boilers
- 100 day cleaning intervals (out of service for 7 days)
- High temperature corrosion of steam boiler superheaters
- Increased SO2, NOX and particle emission
- High maintenance cost
- Reduced reliability and availability of the steam boilers (steam boiler 341-G-003 out of service -inspection veto:
TK 073-2007/ŽB)
MOL GROUP
Combustion
Fuel oil + Refinery gas
Burners
- Combined (Fuel oil + Refinery gas)
- Proportion of combustion (10-100%)
- Burner types
- 341-G 001/G 002 - John Zink (low NOX)
- 341-G 004/G 005 - LMF Austria
MOL GROUP
Emissions of harmful substances into the environment
(boilers > 50 MW); ISO 10396-1997)
fuel type fuel oil fuel gas
rigid (solid) particles < 50 mg/m3 < 5 mg/m3
CO < 175 mg/m3 < 100 mg/m3
NOx < 450 mg/m3 < 300 mg/m3
SO2 < 1700 mg/m3 < 800 mg/m3
MOL GROUP
G4 G5 GVE
date 19.11.2008. 19.11.2008.
fuel type fuel oil fuel oil
oxygen 2.7% 1.7%
flue gases temp. 225 ºC 215 ºC
SO2 3377 4051 1700(5100)
CO 7 9 175(525)
solid particles 81.77 72.28 50(150)
NOx 775 699 450(1350)
smoke number 0 0
Emissions of harmful substances into the environment; G4 and G5
MOL GROUP
Emissions of harmful substances into the environment; G1 and
G2 (< 50MW)
G1 G2 GVE
date 05.11.2008. 05.11.2008.
fuel type fuel oil fuel oil
oxygen 2.8 % 3.0 %
flue gases temp. 211.5 ºC 207.3 ºC
SO2 3223 3287 1700(5100)
CO 1 0 175(525)
solid particles 66.80 66.11 50(150)
NOx 615 681 450(1350)
smoke number 0 0
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Boiler deposits
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Boiler deposits, analysis
Ashing results:
loss at 500 ºC 5%
loss at 925 ºC 22%
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Boiler deposits, analysis; elemental analysis by X-ray
sodium 3 %
magnesium 3 %
aluminium 5 %
silicon 6 %
Sulphur 18 %
Calcium 1 %
Vanadium 42 %
Iron 7 %
Nical 8 %
Zink < 1 %
Arsenic < 1 %
total oxides (to loss at 500ºC) 95 %
pH of a 1% of slurry 2.8 %
MOL GROUP
Necessary Investments (steam boilers)
Natural gas supply system . Natural gas is also used for firing steam
boilers.
Exchange and modernization of burner system for steam
boilers 341-G-004 and 341-G-005
Exchange and modernization of control system (measurement,
regulation and protection) for steam boilers 341-G-004 and 341-G-
005
Replacement of steam boiler 341-G-003 due to inspection veto: TK
073-2007/ŽB)
MOL GROUP
Necessary Investments (boilers) 2
General remount /replacement of damaged parts on G4/G5 boilers
Periodically burners service (once in two years) by burners producers
Installation of NH4OH injection into combustion chamber
Reconstruction of fuel-oil stations
Installation of on-line monitoring for CO2 and NOx
Additives treatment for fuel-oil
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Operational issues
Steam generators use heavy fuel oil un sustained quality and work
constantly throughout the year with changing load.
Fatigue problems in their work is derived solely from fuel or its poor
quality (increased content of vanadium, nickel and sulfur), and can
in principle be defined as:
Increased content of uncompleted burned out particles in the exit flue
gas,
Creation of the dregs of the heating surfaces (hard to clean) in
containers and fuel pipelines,
Appearance of high-corrosion (on steam heaters) caused by the
creation of low soluble eutectic (vanadium oxides),
High content of SO3 in the flue gas output,
The presence of low temperature corrosion in some parts of steam
generators,
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- || -
9. Fuel feeds for the steam boilers depends on RR
Modernization status: Existing RR:
100% Fuel Oil;
After the 1st Phase of Modernization:
60% Natural Gas & 40% Fuel Oil;
After the 2nd Phase of Modernization:
100% Natural Gas.
MOL GROUP
Case 1 - Rijeka Refinery 1st Phase of Modernization - without TA4
Cost Calculation
The HP and MP steam that is available from 1st Phase of RR Modernization process units is calculated in the model with price 0.0 HRK/t because the steam is surplus in HGU and HCU.
Under normal operation 13.5 MW EP is purchased from HEP: 21.024 MHRK/Mo.
Under normal operation all EP purchase from HEP: 16.878 MHRK/Mo.
Normal operation Model optimization: 19.988 MHRK/Mo.
- A boundary defined to be turbogenerators in operation. Otherwise the minimum cost is when all EP was purchased from HEP.
RR PP EP price is lower than HEP EP price because of “free” steam from HGU and HCU units:
RR PP EP price: 0.4141 HRK/kWh RR steam prices**: HP steam = 133.97 HRK/t
HEP EP with PPL: 0.6326 HRK/kWh MP steam = 120.51 HRK/t
HEP EP price: 0.4730 HRK/kWh LP steam = 117.05 HRK/t
In the case of unplanned stoppage of steam boilers (-80 t/h and -40 t/h) because of PPL and week EP purchase:
- Operation –80 t/h: + 0.0 MHRK/Mo. (No need to purchase EP from HEP!)
- Operation -120t/h with RUS: + 0.0 MHRK/Mo. (No need to purchase EP from HEP!)
- Operation -120t/h with G3: + 0.0 MHRK/Mo. (No need to purchase EP from HEP!)
MOL GROUP
First possibility (explain by now in the presentation)
1. Upgrade existing INA RR Power Plant with:
i. Replacement of the G3 steam Boiler: Capacity: 80/100 t/h (nom/max)
High Pressure Steam: 37bar/450°C
Cost of investment: ~100.0 Mil HRK (18.5 Mil $)
ii. A new substation TS-400: 2 x 63 MVA
110/35 kV
Cost of investment: ~ 100.0 Mil HRK (18.5 Mil $)
iii. Modernistion of G4 / G5 steam Bolier : Capacity: 2 x 80/100 t/h (nom/max)
High Pressure Steam: 37bar/450°C
Cost of investment: ~50.0 Mil HRK (9 Mil $)
MOL GROUP
Other possibilities
2. Build a new Power Plant in Rijeka Refinery
+ New PP on a new location in RR (far from sea side and closed
type building)
+ More reliable solution (new steam boiler and new turbogenerators)
- High investment cost (but cost estimation does not exist)
- Hard to justify the investment because of ongoing projects:
The new turbogenerator TA-4 is under construction,
Other projects in Power Plant (are going to be done during Turnaround 2010 or in 1st Phase of RR Modernization)
- Long time needed to begin the project (government permissions,…)
MOL GROUP
HEP TE Rijeka location
MOL GROUP
HEP TE Rijeka
General data: location: south-east of Rijeka, on the sea coast
type of power plant: regulating/condensing, a boiler and one
steam turbine
type of fuel: oil
total capacity: 320 MW
type of product: electricity
year of construction: 1974 -1978
annual production electricity ~1000 GWh/year
MOL GROUP
Conclusions Existing Energy Supply Strategy for INA RR
1. Upgrade existing INA RR Power Plant:
Goal: To secure enough Energy supply for Rijeka
Refinery ( II Phase of Modernization )
Here are main two options that depend on required level
of RR Energy Independency (To secure Energy supply)
MOL GROUP
Conclusion no. 1.1 Existing Energy Supply Strategy for INA RR ?
1.1 INA RR complete energy independence
with having full energy demand backup from outside:
For steam 80/100 t/h surplus in own RR Power Plant production
Modernisation of G4 and G5 boilers
The new G3 steam boiler is necessary
For electricity in incomers 63 MVA.
The new substation TS-400 is necessary
Secure feed fuels for steam boilers
Alternate fuels existing in RR: oil, refinery gas, or
Natural Gas (NG) inside of RR - done
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Conclusion no. 1.2 Existing Energy Supply Strategy for INA RR ?
1.2 INA RR fully dependent on outside energy supply with having part of capacity backup in own existing production in RR PP:
For steam it is necessary to find other outer source (HEP TE Power Plant Rijeka)
The new steam pipeline to HEP Power Plant Rijeka (an option to be investigate!)
Existing steam boilers will exists as partial backup
For electricity in incomers 63 MVA.
The new substation TS-400 is an option, second
A new incomers directly from HEP TE Power Plant Rijeka (an option to be investigate!)
Secure feed fuels for steam boilers
Highly dependent on Natural Gas from outside of RR
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