HRSG Power Plant Project Proposal

for 5xWartsila Gas Genset

1. Project overview 

一、工程概述

The existing 5 gas/dual fuel generating sets discharge smoke 76320kg/h(18V34SGx2) and 114480kg/h(18V32DFx3) at 450℃ directly into the atmosphere , which are both environmental pollution and waste of energy. We advise to install exhaust heat recovery boilers at exhaust of gensets, and the boilers adopt double-pressure forced-circulation mode--high-pressure steam to drive a steam turbine power generation system and the low-pressure steam to heat the fuel oil of diesel genset. 5 sets of waste heat boiler and a 3MW turbine generator set is proposed in this proposal, which can not only make full use of energy and reduce emissions to solve environmental problems, but also bring considerable economic benefits to the plant. Meanwhile this HRSG(heat recovery steam generation) power plant project can increase the power generation amount by 6%~8% of existing power plant , that equals to reduce fuel consumption by ~5%, which means reducing ~5% of sulfur content in sulfur-bearing gases(SO2) , so the benefit of HRSG project has a greater improvement on the environment impact than the existing power plant. 
5台燃气或双燃料发电机组,每小时直接排到大气中76320kg/h(18V34SGx2)和114480kg/h(18V32DFx3)的烟气,既污染环境又浪费能源,因此我们推荐在发电机组排气位置安装余热锅炉,锅炉采用双压强制循环方式,高压系统产生的蒸汽用来驱动汽轮机发电,低压系统产生的蒸汽用于柴油机供油系统重油加热。项目方案设计采用我公司5套余热锅炉和1台3MW汽轮发电机组,该方案不仅能充分利用能源,降低排放解决环境保护问题,还会给电厂带来可观的经济效益。另外, 由于余热发电可使整个电厂发电量提高6%~8%, 折算原电厂发电油耗降低5%左右, 即原单位发电量所排放的含硫气体(SO2)含量相应降低5%左右。因而余热发电工程的投入对环境的影响比原来有了更大的改善。
 
2. Solution proposed
二、方案构成
 
This waste heat utilization project construction scale is of 1×3MW grade, with 5 sets of HRSG boiler supporting a steam turbine generator sets and related auxiliary equipments, power generated directly access to the plant bus bar. In order to maximize the use of waste heat according to exhaust parameters provided , waste heat boiler steam production parameters are designed to meet low-conditions of steam turbine generator set. 
turbine inlet steam parameters: temperature 340 ℃, pressure 1.60MPa; 
boiler outlet steam parameters designed: temperature 340 ℃, pressure 1.6MPa;
The additional low-pressure steam production is designed at 0.6MPa to heat the HFO for fuel oil supply system of diesel genset. 
High-frequency-resistance-welding-finned-tube is adopted in the HRSG boiler, smoke emissions from diesel genset is filtered greatly as well as exhaust chimney noise is attenuated by 15dB. The boiler features at high stability, high shock-resistance, low technical requirements for running, easy operation and maintenance.
该余热利用工程建设规模为1×3MW级,采用5台余热锅炉配套1台套汽轮发电机及相关辅助设备,发电直接接入电厂母线上网。根据客户提供的发电机的废气参数和最大限度利用废气余热的原则,余热锅炉产汽参数设计为满足低参数汽轮发电机的运行,汽轮机入口蒸汽参数为:温度340℃,压力1.60MPa,余热锅炉出口蒸汽温度设计为340℃,压力为1.6MPa。另外产生0.6MPa饱和蒸汽用于电厂的重油加热。
余热锅炉采用高频电阻焊翅片管作为受热面,既大大地过滤了柴油发电机排放的烟尘,同时又使原柴油机烟囱排气噪音降低15dB,锅炉稳定性好,抗震性强,锅炉的主要部件钢架支承,锅炉运行技术要求低,操作管理方便。
 
3. Necessary conditions for project construction
三、项目建设的必要条件
 
3.1 5 gas gensets in the existing power plant, each genset is equipped HRSG boiler, foundation of boilers is designed according to requirements of boilers.
3.2 Steam turbine room can be designed to locate at one side of existing genset room.
3.3 Enough water supply available from existing power plant, therefore water cooling steam turbine is adopted, position for cooling towers should be reserved nearby the cooling towers of existing power plant.
3.4 Auxiliary load of HRSG power plant is ~407.7KW, and total capacity of HRSG power generation is 3047KW, so aux. load is ~13.38% of total, it can be supplied by standby genset of existing power plant.
3.5 The power generated by HRSG power plant is 6KV which will be directly connected to bus bar of existing power plant.
3.6 ~825 tons fresh water each day will be used for this HRSG power project, this should be guaranteed.
In the layout, well deal with whole (whole plant) and local (HRSG power plant) relationship, make the process more reasonable. The systems for whole power plant such as industrial water, sewage, fire, rain water and fuel system should be shared, to reduce the engineering investment.
      
 3.1电厂5台机组,全部配套余热锅炉,在厂房设计时按余热锅炉提供的条件进行基础设计。
3.2汽轮机房可设计在柴油发电机房一端。
3.3电厂地点有足够的淡水资源,所以汽机冷却系统采用水冷,冷却塔位于柴油机冷却塔的旁边的空地上,要求位置预留。
3.4整个系统的自用电约为407.7KW左右,而余热发电功率3047KW,自用电约占余热发电13.38%。系统的低压用电可由电厂的自备电源提供,无需增加原电厂的设施。
3.5汽轮机组利用余热发出的电量,直接接入电厂6KV母线上网。
3.6整个余热发电系统每天要增加用水量825吨左右,柴油机电厂的供水系统可满足需求。
在布局上处理好整体(整个电厂)与局部(余热回收电厂)的关系,使其工艺路线更为合理。对于全厂性的系统,如工业水、消防、排污、雨排水和燃油等系统应尽可能共用,以减少工程投资。
综上所述,余热发电项目的建设,利用电厂的条件及资源(场地、水、电、汽等),均能满足。

4. Major technical specifications of equipments

四、设备性能指标

4.1 HRSG(designed according to 90% load factor)余热锅炉(锅炉按90%负荷设计)

existing genset model

柴油机组型号

Wartsila 18V34SG

Wartsila 18V32DF

existing genset power

柴油机100%负荷kw

6000

5229~5597

existing genset load factor

柴油机负荷率%

90

90

existing genset power output

柴油机运行负荷kw

5400

4700~5030

Exhaust flow

烟气流量kg/s(100% power)

38160

38160

Exhaust flow

烟气流量kg/s(90% power)

34344

34344

Exhaust temperature

烟气温度℃

450

450

max. back pressure of exhaust allowed

烟气允许最大背压

2500

2500

Evaporation amount of boiler-High pressure superheated 

锅炉高压过热蒸发量Kg/h acc. to genset load factor 90%)

3200

 

3200

Evaporation amount of boiler-Low-pressure saturated锅炉低压饱和蒸发量 Kg/h

450

450

Boiler resistance

锅炉烟气阻力Pa

2400

2400

Boiler exhaust temp.

锅炉排烟温度℃

168

169

Boiler dry weight

锅炉空重(tons

~60

~60

Boiler qty.

锅炉台数

2

3

 

Steam amount-high pressure

高压部分总蒸汽量Kg/h

6400

9600

16000

Steam amount-low pressure

低压部分总蒸汽量Kg/h

2250

Steam consum. of turbine gen.

发电机汽耗Kg/kw.h

5.25

HRSG power capacity

计算余热发电功率KW

16000/5.25=3047

Steam turbine gen. power

配套汽轮发电机组功率KW

3000

Steam turbine gen. qty

配套汽轮发电机组台数(台套)

1

 


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