Repowering a Coal Power Plant Steam Cycle Using Modular Light-Water Reactor Technology
<p>Turbine diagram for a nuclear power plant (SG—steam generator, HP—high-pressure section of a turbine, LP—low-pressure section of a turbine, S—moisture separator, R—reheater, G—generator).</p> "> Figure 2
<p>Diagram of the 460 MW condensing turbine (HP—the high-pressure section of the turbine, LP—the intermediate-pressure section of the turbine, LP—the low-pressure section of the turbine).</p> "> Figure 3
<p>Pressure distribution calculation in the IP section of the turbine.</p> "> Figure 4
<p>Temperature distribution calculation in the IP section of the turbine.</p> "> Figure 5
<p>Diagram of the steam cycle with marked calculation points after modernization of the power unit (SG—steam generator, HP—the high-pressure section, LP—the low-pressure section, S—the moisture separator, R—the reheater, G—the generator, (LPH1–LPH4)—the low-pressure feed-water heaters, HPH—the high-pressure feed-water heater, D—the deaerator, ST—the feed-water storage tank). red dashed line—components previously used in the coal-fired power unit.</p> "> Figure 6
<p>Temperature distribution in the steam generator (green line—temperature of water in the reactor coolant system, red line—temperature of working medium in the steam turbine cycle (case without superheater), bleu line—temperature of working medium in the steam turbine cycle (case with superheater).</p> "> Figure 7
<p>Steam expansion line in the turbine of the 460 MW power unit (REF) and post-modernization state (Casa A and Case C).</p> "> Figure 8
<p>Enthalpy drop in the stage groups of the new HP and LP section of the turbine.</p> "> Figure 9
<p>Steam expansion line in the turbine of the 460 MW power unit (REF) and post-modernization state (Case D).</p> "> Figure 10
<p>Cycle efficiency for different parameters of steam feeding the turbine.</p> "> Figure 11
<p>Heat rate for different parameters of steam feeding the turbine.</p> "> Figure 12
<p>Gross electric power output for different parameters of steam feeding the turbine.</p> "> Figure 13
<p>Mass flow rate of steam at the inlet to the turbine for different parameters of steam feeding the turbine.</p> "> Figure 14
<p>Steam mass flow rate to the feed-water heaters (heat exchanger labels as shown in <a href="#energies-16-03083-f005" class="html-fig">Figure 5</a>).</p> "> Figure 15
<p>The velocity ratio of the steam flow in the pipeline to the heat exchangers (heat exchanger labels as shown in <a href="#energies-16-03083-f005" class="html-fig">Figure 5</a>).</p> "> Figure 16
<p>The power of the feed-water pump for different parameters of steam feeding the turbine.</p> "> Figure 17
<p>The turbine bypass system.</p> "> Figure 18
<p><span class="html-italic">NPV</span> as a function of project lifetime for steam cycle modernization cost index <span class="html-italic">MC</span><sub>ST</sub> = 0.5 for average level of <span class="html-italic">RS</span>.</p> "> Figure 19
<p><span class="html-italic">NPV</span> as a function of steam cycle modernization cost index for the three values of retrofit savings factor (<b>left</b>—maximum, <b>central</b>—average, <b>right</b>—minimum).</p> "> Figure 20
<p><span class="html-italic">NPVR</span> as a function of steam cycle modernization cost index for the three values of retrofit savings factor (<b>left</b>—maximum, <b>central</b>—average, <b>right</b>—minimum).</p> "> Figure A1
<p>Axial forces acting on the rotor of IP section.</p> ">
Abstract
:1. Introduction
2. Methods
2.1. Selection of the Turbine for Cooperation with SMRs
2.2. Modelling of the Steam Cycle
2.2.1. Nuclear Retrofit Case with Modernization of the Original IP Section (Case A–C)
2.2.2. Retrofit Case with New HP Section (Case D)
- -
- saturated steam parameters at the turbine inlet: pressure of 7 MPa and corresponding saturation temperature of 285 °C,
- -
- the LP section operating conditions will not change compared to design values: the steam mass flow and parameters upstream the LP section are the same as for the 460 MW turbine,
- -
- the pressure at the HP section exhaust is higher than the pressure at the LP inlet due to pressure losses in the moisture separator and in the steam reheater,
- -
- the deaerator pressure is equal to the design pressure value at the reference load,
- -
- the steam bleed parameters in the HP section make it possible to heat feed water at the inlet the steam generator to the assumed temperature of 230 °C.
2.3. Economic Assessment
2.3.1. Assessment Indicators
2.3.2. Assumptions
3. Results
3.1. Technical and Energy Performance Assessment Results
Flow through Bypass of the IP–LP Section of the Turbine
3.2. Economic Assessment Results
4. Discussion
5. Summary
Author Contributions
Funding
Data Availability Statement
Acknowledgments
Conflicts of Interest
Appendix A
References
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Case | Live Steam Pressure | Live Steam Temperature | Reheated Steam Temperature | Inlet Temperature to Boiler/SG | Boiler/SG Thermal Power |
---|---|---|---|---|---|
Original plant | 28 MPa | 560 °C | 580 °C | 290 °C | 957.1 MW |
Repowered plant | 7 MPa | 285 °C | Varies | Varies | Varies |
Calculation Point | Parameters | Case A, No Reheater | Case B, 1-Stage Reheat | Case C, 2-Stage Reheat |
---|---|---|---|---|
0 | p, MPa | 4.058 | 4.035 | 4.035 |
t, °C | 251.2 | 285.0 | 285.0 | |
x, - | 1.0 | Superheated steam | Superheated steam | |
h, kJ/kg | 2800.6 | 2916.7 | 2916.7 | |
, kg/s | 356.096 | 337.788 | 339.281 | |
1 | p, MPa | 3.997 | 3.974 | 3.974 |
t, °C | 250.2 | 284.2 | 284.2 | |
x, - | 0.999 | Superheated steam | Superheated steam | |
h, kJ/kg | 2800.6 | 2916.7 | 2916.7 | |
, kg/s | 329.5 | 313.0 | 313.0 | |
6 | p, MPa | 0.589 | 0.589 | 0.589 |
t, °C | 158.1 | 158.1 | 158.1 | |
x, - | 0.890 | 0.930 | 0.930 | |
h, kJ/kg | 2525.7 | 2609.2 | 2609.2 | |
, kg/s | 272.003 | 260.257 | 260.488 | |
8 | p, MPa | 0.536 | 0.535 | 0.539 |
t, °C | 230.6 | 230.3 | 235.6 | |
x, - | Superheated steam | Superheated steam | Superheated steam | |
h, kJ/kg | 2919.3 | 2918.6 | 2929.6 | |
, kg/s | 244.533 | 244.489 | 244.706 | |
12 | p, MPa | 0.006 | 0.006 | 0.006 |
t, °C | 35.9 | 35.9 | 35.9 | |
x, - | 0.885 | 0.885 | 0.887 | |
h, kJ/kg | 2288.2 | 2287.8 | 2294.1 | |
, kg/s | 208.924 | 208.886 | 209.102 | |
25 | p, MPa | 4.509 | 4.483 | 4.483 |
t, °C | 212.1 | 211.5 | 211.5 | |
h, kJ/kg | 908.2 | 905.3 | 905.3 | |
, kg/s | 356.096 | 337.788 | 339.281 | |
Gross electric output, MW | 223.242 | 228.788 | 229.989 | |
Heat rate, kJ/kWh | 10,867.1 | 10,690.9 | 10,682.0 |
Based on the Conservation Equation | Based on the Stodola Equation | Absolute Difference | Relative Difference | |
---|---|---|---|---|
Steam pressure at the turbine inlet | 4.035 MPa | 4.356 MPa | 0.321 MPa | 7.96% |
Electric power | 228.8 MW | 234.4 MW | 5.6 MW | 2.45% |
Heat rate | 10,691 kJ/kWh | 10,539 kJ/kWh | 152 kJ/kg | −1.42% |
Calculation Point | p [MPa] | t/x [°C/-] | h [kJ/kg] | m [kg/s] |
---|---|---|---|---|
0 | 7.000 | 285.830 | 2772.6 | 406.865 |
1 | 6.895 | 284.531 | 2772.6 | 365.100 |
2 | 6.930 | 284.959 | 2772.6 | 41.765 |
6 | 0.589 | 0.833 | 2406.1 | 290.584 |
7 | 0.571 | 0.990 | 2733.1 | 244.428 |
8 | 0.554 | 265.151 | 2990.9 | 244.428 |
12 | 0.006 | 0.901 | 2326.7 | 209.031 |
25 | 7.778 | 230.000 | 991.2 | 406.865 |
Gross power output | 267.018 | kW | ||
Heat rate | 9771.5 | kJ/kWh |
Component of Costs | Category | Symbol of Component | Budgeted Share *, % | Minimal Retrofit Savings, % | Mid-Level Retrofit Savings, % | Maximum Retrofit Savings, % |
---|---|---|---|---|---|---|
- | i | or | or | or | or | |
Initial fuels inventory | R | 7.0 | 0.0 | 0.0 | 0.0 | |
Other costs (transmission, owner’s, etc.) | T | 10.0 | 100.0 | 100.0 | 100.0 | |
Land and land rights | R + T | 0(~0) | 100.0 | 100.0 | 100.0 | |
Structure and improvements | R | 15.0 | 0.0 | 12.0 | 24.0 | |
Reactor plant equipment | R | 18.0 | 0.0 | 0.5 | 1.0 | |
Turbine plant equipment | T | 15.0 | 0.0 | 49.5 | 99.0 | |
Electric plant equipment | T | 5.0 | 42.0 | 60.0 | 78.0 | |
Miscellaneous plant equipment | R + T | 2.0 | 6.0 | 48.5 | 91.0 | |
Main condenser and heat rejection system | T | 3.0 | 0.0 | 50.0 | 100.0 | |
Total indirect costs | R + T | 25.0 | 16.0 | 27.5 | 39.0 |
Parameter | Symbol | Value (GF = Greenfield, RE = Repowered) | References |
---|---|---|---|
Lifetime | |||
Construction time, years | CT | 4 | [15] |
Time operational in year, hours | τa | 7884 | [16] |
Total operation time assumed for the NPV analysis, years | TOT | 50 | [17] |
Capital costs | |||
Unit overnight capital cost (GF investment type), €/kW | uOCCGF | 4000 | [15] |
Variable O&M costs | |||
Refuelling costs, €/MWh | uVOMC(RC) | 7 | [18,19] |
Spent nuclear fuel costs, €/MWh | uVOMC(SFC) | 5 | [20,21] |
Electricity average price, €/MWh | 85 | * | |
Non-fuel and non-emission costs for turbine island, €/MWh | uVOMC(nnTI) | 1.50 | * |
Fixed O&M costs, €/MW/y | uFOMC | 100,000 (GF)/104,000 (RET) | [15] |
Turbine island, €/MW/y | uFOMC(TI) | 16,000 (GF)/20,000 (RET) | * |
Nuclear Island, €/MW/y | uFOMC(NI) | 84,000 | [15] |
Others | |||
Discount rate, % | 6 | * | |
Tax rate, % | 19 | * |
Case | |||||
---|---|---|---|---|---|
GF | A | B | C | D | |
NPV, M€ | 1117.75 | 1062.61 | 1096.96 | 1103.12 | 1328.69 |
NPVR, M€ | 0.997 | 1.556 | 1.587 | 1.588 | 1.759 |
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Łukowicz, H.; Bartela, Ł.; Gładysz, P.; Qvist, S. Repowering a Coal Power Plant Steam Cycle Using Modular Light-Water Reactor Technology. Energies 2023, 16, 3083. https://doi.org/10.3390/en16073083
Łukowicz H, Bartela Ł, Gładysz P, Qvist S. Repowering a Coal Power Plant Steam Cycle Using Modular Light-Water Reactor Technology. Energies. 2023; 16(7):3083. https://doi.org/10.3390/en16073083
Chicago/Turabian StyleŁukowicz, Henryk, Łukasz Bartela, Paweł Gładysz, and Staffan Qvist. 2023. "Repowering a Coal Power Plant Steam Cycle Using Modular Light-Water Reactor Technology" Energies 16, no. 7: 3083. https://doi.org/10.3390/en16073083