Oberhausen-Sterkrade thermal power station

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Oberhausen-Sterkrade thermal power station
Oberhausen-Sterkrade thermal power station, in the foreground the HP rotor of the old 50 MW helium turbine
Oberhausen-Sterkrade thermal power station, in the foreground the HP rotor of the old 50 MW helium turbine
location
Oberhausen-Sterkrade thermal power station (North Rhine-Westphalia)
Oberhausen-Sterkrade thermal power station
Coordinates 51 ° 30 '42 "  N , 6 ° 55' 47"  E Coordinates: 51 ° 30 '42 "  N , 6 ° 55' 47"  E
country GermanyGermany Germany
Data
Type Gas turbine heating plant, steam heating plant, biomass heating plant
Primary energy fossil and renewable energy
fuel Natural gas / EL heating oil / wood chips
power gross electrical output: 28.6 MW thermal CHP output: 44.2 MW fresh heat output: 49.5 MW
owner evo (Energieversorgung Oberhausen AG)
operator evo
Start of operations 1974 (thermal power plant with helium gas turbine, HTR test facility)
Shutdown 1988 (50 MW helium gas turbine)
turbine 1 open gas turbine (25.45 MW),

1 condensing turbine with heating condenser (3.15 MW)

boiler 1 district heating waste heat boiler behind the gas turbine (35 MW),

1 high pressure natural circulation steam generator (60 t / h), 1 high pressure biomass natural circulation boiler (15.5 t / h), 1 saturated steam boiler (18 t / h)

Firing GT: LowNOx with water injection; Steam: LowNOx overpressure combustion
Website www.evo-energie.de
f2

The HKW 2 - Oberhausen-Sterkrade thermal power station is located in the center of Oberhausen-Sterkrade on the premises of Energieversorgung Oberhausen AG, directly on Friedrichstrasse. The main energy sources are natural gas and wood chips . EL heating oil can also be used to safeguard district heating .

Operating basis

review

Planning for the Oberhausen Sterkrade cogeneration plant began as early as 1965. Due to the good operating experience with the Alt-Oberhausen cogeneration plant, a closed gas turbine with pulverized coal firing (hot air turbine) was also favored for the new cogeneration plant.

However, the implementation of the project initially failed due to contractual difficulties. The power supply for the Oberhausen-Sterkrade district was previously mostly in the RWE network area and there was no interest in taking the electrical energy from the new thermal power station. To solve the problem, the energy companies of Stadtwerke Oberhausen were spun off and Energieversorgung Oberhausen AG (evo) was founded together with RWE. The previous RWE supply area has now also been incorporated into the new company.

On the initiative of the CEO of Stadtwerke Oberhausen and what would later become evo AG, Gerhardt Deuster, the project was further developed with regard to the development of high-temperature reactors in conjunction with closed helium-based gas turbines and initially included in the Federal Ministry of Research's third nuclear program.

A closed gas turbine with a net electrical output of 50 MW and helium as the working medium was now in the planning stage. The operating experience gained in this plant with conventional coke oven gas was later incorporated into the development of a high-temperature nuclear power plant with a helium turbine. At the same time, with the THTR-300, a demonstration power plant in Hamm-Uentrop was planned on the basis of a pebble bed reactor, in order to gain operational experience in operation with a conventional steam power process.

In conjunction with the high-temperature reactor, the electrical efficiency of the THTR-300 has already been increased to over 40%. With the usual light water reactors, the maximum achievable electrical efficiency is limited to 35–36% by the upper process temperature of approx. 300 ° C. By combining the high-temperature reactor with a helium gas turbine process with a process temperature of up to 930 ° C above and 20 ° C below, an electrical efficiency of 50% was expected. In addition, part of the waste heat could also be extracted at a high temperature level and fed into a district heating network, for example, without reducing the electrical power.

This high-temperature reactor with helium turbine was then continued as an HHT project after the 4th atomic program of the Federal Ministry of Research. The Oberhausen helium turbine was also assigned to the HHT project. Energieversorgung Oberhausen AG was responsible for the overall planning of the heating power plant, which also led to the founding of the later consulting department. The turbine system was designed in cooperation between GHH-Sterkrade AG (today MAN-Diesel & Turbo) and the Institute for Turbomachines at the TU Hannover, under the direction of Karl Bammert. The manufacture and assembly of the turbo group, the heat exchanger and the cooler was also taken over by GHH-Sterkrade AG.

Commissioning of the largest closed gas turbine in the world

After construction, the entire system was handed over to its intended use with the commissioning of the helium turbine on December 19, 1974. In addition to the research work with extensive test drives and further optimizations, the generated electrical and thermal energy could be taken over into the distribution networks of evo AG to supply the Oberhausen population. With a maximum electrical output of 50 MW, up to 53.5 MW of heat should be extracted for the Sterkrade district heating network, with a fuel efficiency of 65% being projected. A higher output could not be sold due to the limited expansion possibilities of the Sterkrade district heating network. Simple changes in the circuit design would also have made it possible to extract 75 MW of district heating with a fuel utilization of over 82%.

The design of the turbo group was also carried out taking into account a later interpolation / extrapolation for systems with greater performance. For example, the dimensions of the low-pressure turbine and the mechanical loads on the high-pressure turbine corresponded to those of a 300 MW turbine.

After the Chernobyl disaster and the problems with the operation of the THTR-300, a massive rethinking of German nuclear energy policy was initiated. Research into high-temperature reactor technology, which is considered “inherently safe”, has also suffered and will be discontinued. This also ends the research work on the Oberhausen helium turbine.

The system is also being taken out of operation due to increasing economic problems, since the projected performance data could not be fully achieved despite the many optimization attempts. The heat supply of the Sterkrad district heating network is ensured by the waste heat from Ruhrchemie, by the network system and, at peak times, also by the steam heating plant.

Conversion to a gas turbine system with open circuit

The planned district heating supply for the "Neue Mitte" Oberhausen increases the heat requirement for supplying the district heating networks in Oberhausen, which are linked to one another via the interconnected system. To ensure that the proportion of combined heat and power in district heating does not decrease any further, a new gas turbine is installed instead of the helium turbine that is no longer operational.

With continued use of the generator, the helium turbine set was replaced by a MAN FT-8 industrial gas turbine, which was derived from the Pratt & Whittney JT8D aircraft engine. To use waste heat, a hot water waste heat boiler was installed behind the payload turbine that drives the generator to generate electricity. The entire system was located in the machine hall and was put into operation in November 1995 after a construction period of 42 weeks. Energieversorgung Oberhausen AG thus secured an entry in the Guinness Book of Records for the shortest construction time for a gas turbine system.

In addition to the high electrical and thermal efficiency, the new system is highly flexible and is one of the fastest controllable conventional power plants. This also makes it possible to use the system as a control reserve in the power grid.

Current operating mode

Today, the power plant mainly serves to supply heat to the Oberhausen-Sterkrade / Oberhausen-Osterfeld district heating network and to generate heat on the basis of combined heat and power via the gas turbine system. The heating output (CHP and fresh heat) of the power plant is sufficient to cover the total heat demand of the connected district heating networks. In addition, after extensive renovations from 1986 to 1988, the power plant is connected to the HKW 1 - Alt-Oberhausen combined heat and power plant and the GMVA - Lower Rhine joint waste incineration system via a high-pressure district heating system. In addition, since 1986 the power plant has been connected to the Ruhrchemie plant of Oxea GmbH in Oberhausen-Holten via another district heating rail .

The heating network enables the feeding of CHP heat from the waste incineration plant and industrial waste heat from Ruhrchemie, which contributes to considerable savings in the main fossil fuel natural gas. The district heating network of the Neue Mitte Oberhausen (Centro / O-Vision) is also supplied directly via the network.

In addition, the steam heating plant supplies a neighboring turbo machine manufacturer with process steam for the operation of several steam turbine test stands.

fuel

The power plant has been fired with coke oven gas since commissioning. From 1980, more light heating oil had to be used in the cogeneration plant, since so-called interruptible deliveries were offered in the gas supply contracts in the mid-1970s. On the one hand, this allowed the fluctuating and shrinking coke oven gas production, which is influenced by economic influences in the steel sector, to be taken into account and, on the other hand, the service price was reduced.

The shutdown of the coking plants at the beginning of the 1980s impaired the supply of gas to the thermal power station to such an extent that a switch to natural gas from 1984 onwards became inevitable for reasons of security of supply.

Biomass cogeneration plant - Biostrom Oberhausen

An integrated biomass cogeneration plant has been operated at the site since 2011, which is mainly used in base load operation. Since this system works with combined heat and power, the base heat load of the district heating networks Alt-Oberhausen , Oberhausen-Sterkrade, Oberhausen-Osterfeld and Neue Mitte Oberhausen is covered at the same time .

Annually, around 20,000 MWh of electricity and around 60,000 MWh of district heating are generated here by burning 40,000 tonnes of landscape conservation wood by means of combined heat and power. This means that around 6,000 households can be supplied with electricity and around 3,500 with district heating. This saves around 20,000 tons of CO 2 emissions every year .

The plant is the first biomass cogeneration plant in the Ruhr area that is fired exclusively with renewable raw materials and achieves an average share of 12% of the annual district heating supply. This leads to a saving of the fossil primary energy carrier natural gas.

Current dissipation

The derivation of the electrical energy is carried out by the Oberhausener Netzgesellschaft and fed into the 10 kV medium-voltage network to supply the city of Oberhausen. This reduces the upstream electricity consumption from the 110 kV high-voltage level by a corresponding amount and thus makes an important contribution to the decentralization of electricity generation. The Oberhausener Netzgesellschaft is a wholly-owned subsidiary of Energieversorgung Oberhausen AG.

Performance data of the individual power plant boilers / turbines since 1973

Steam generator / heater Boiler 1 Boiler 2 Helium heater Boiler 3 Boiler 4 Gas turbine plant Biomass plant with grate firing
status in operation dismantled dismantled dismantled in operation in operation in operation
Installation 1973 1973 1974 1975 1976 1995 2011
Max. Combustion heat output 13.2 MW 13.2 MW 159.6 MW 38 MW 58.1 MW 71 MW 14.3 MW
Steam output 18 t / h 18 t / h - 51 t / h 60 t / h - 15.5 t / h
Steam parameters 200 ° C / 11 bar 200 ° C / 11 bar 750 ° C / 27 bar (helium) 300 ° C / 13 bar 500 ° C / 58 bar open gas turbine 430 ° C / 60 bar
Turbines Feed water preheating / degassing closed Gas turbine /

Helium as a working medium (dismantled)

- Process steam for

Test bench operation

Gas turbine ( aero-derivative ) Heating turbine -

Condensing turbine with heating condenser

status in operation dismantled dismantled dismantled in operation in operation in operation
el. gross efficiency - - 32% - - 36% 22%
Fuel efficiency > 93% > 93% > 65% > 93% > 93% > 85% > 85%
el. gross output - - 51.2 MW - - 25.45 MW 3.15 MW
CHP heating capacity - - 53.5 MW - - 35 MW 9.2 MW
Fresh heat output

(without combined heat and power)

12.5 MW 12.5 MW - 35 MW 49.5 MW - up to 10 MW when starting up via heating condenser
Chimney (height) 45 m steel chimney from boiler 3/4 45 m steel chimney (dismantled) 45 m steel chimney 50 m steel chimney 35.4 m steel chimney
Cooling tower - 2 fan wet cooling towers

(dismantled)

- only for unit cooling via two fan cell coolers

Operator of the thermal power station

The operator of the thermal power station is Energieversorgung Oberhausen AG - evo for short. Evo is owned by Stadtwerke Oberhausen AG (STOAG) and RWE Rhein-Ruhr AG, each of which holds 50 percent in FSO GmbH & Co. KG (Fahrzeugservice Oberhausen) and half in evo's share capital . 10 percent of the evo shares are held directly by STOAG and RWE Rhein-Ruhr AG. The remaining 80 percent of the shares are held by FSO GmbH & Co. KG. The parent company of RWE Rhein-Ruhr AG is RWE Energy AG.

history

prehistory

1964: On February 14th, the former company and municipal office became the "Stadtwerke Oberhausen Aktiengesellschaft".

1965: The first preliminary planning for a district heating supply for the Sterkrade district on the basis of combined heat and power was started. Here too, another hot air turbine with pulverized coal combustion was favored.

1970: City, STOAG and RWE signed a preliminary agreement on the establishment of "Energieversorgung Oberhausen Aktiengesellschaft" (evo). In addition to supplying electricity, gas and district heating, evo also took on the planning and operational management of the newly established community waste incineration plant GMVA.

1971: The new company was entered in the commercial register in January. The transport company remained in the STOAG.

1972: In Sterkrade, the construction of the heating power station 2 began with another closed gas turbine with helium as the working medium. Contrary to the original plan, the facility has now become part of the 4th nuclear program of the Federal Republic of Germany and served as a prototype for high-temperature reactor research. However, the helium heater in the new plant was conventionally heated with coke oven gas.

District heating supply begins in Oberhausen-Sterkrade

1973: The district heating network in Sterkrade went into operation and was initially supplied by the steam heating plant integrated into the new heating power plant.

1974: The world's first helium turbine system went into trial operation with a net electrical output of 50 MW. Similar to the Oberhausen hot-air turbine in HKW 1, up to 53.5 MW of heat could be extracted for the Sterkrade district heating network.

1975: The saturated steam boiler 3 is put into operation so that the growing district heating network in Sterkrade can be supplied with heat if the helium turbine fails.

1976: Commissioning of the 60 t / h high pressure steam boiler for process steam generation for a neighboring turbo machine manufacturer. In addition, the high-pressure steam can also be used with the installed heat exchanger to heat the district heating network after it has been expanded through conversion and reducing stations.

1983: evo developed an energy supply concept for the city of Oberhausen, taking into account all three line-bound forms of energy such as district heating, gas and electricity. Future plans for a district heating network between the two power plant locations Oberhausen and Sterkrade and the GMVA waste incineration plant were presented.

1982: The heating power station 2 was gradually converted to natural gas, as a sufficient supply of coke oven gas could no longer be guaranteed.

1985: With a total order value of DM 120 million, one of the largest investment programs in the history of Energieversorgung Oberhausen AG was started in order to ensure a long-term and sustainable energy supply for the city of Oberhausen. In addition to the new district heating network, which runs across the city through mostly underground pipelines, the CO 2 -free heat extraction from the waste incineration plant, the waste heat utilization by Ruhrchemie and Messer Griesheim GmbH, will contribute to a very low primary energy factor for Oberhausen district heating in the future

1986: Completion of the district heating transport line between the premises of Hoechst AG, the Ruhrchemie plant and the heating power station 2. At the same time, the transfer of industrial waste heat for the Oberhausen-Sterkrade district heating network began.

1986: The biggest accident in the use of nuclear energy to date shook the world in 1986. After experiments on reactor block 4 of the Chernobyl nuclear power plant, the operating team immediately triggered overcriticality through a grossly negligent "blackfall" attempt, which was made possible in particular by the reactor design of the RBMK with its positive vapor bubble coefficient. The sudden power excursion triggered the explosion of the reactor core and thus the worst-case scenario (greatest accident to be assumed). Radioactive particles rose into the air and spread around the globe.

1987: The Chernobyl catastrophe initiated a massive rethink in German nuclear energy policy. Research work on high-temperature reactor technology, which is considered to be “inherently safe”, also suffered and was discontinued. This also ended the research activities in CHP 2.

1988: The helium turbine plant was also taken out of service due to increasing economic and technical problems. The heat supply of the Sterkrad district heating network was ensured by the waste heat from Ruhrchemie, by the new network system and, at peak times, also by the steam heating plant.

Extensions through the connection of the New Center Oberhausen (Centro)

1993: The "New Center" in Oberhausen is being built heavily. Evo is also involved. A 100/25/10 kV substation in the middle of the site had to be relocated. The construction of a high-pressure transport spur and the construction of a pumping station created the basis for connecting the planned area to the district heating network.

1994: The reintroduction of the tram meant for evo the laying of numerous power cables along the planned track. Independently of this, a change was prepared in the heating power station 2 in Sterkrade. The helium gas turbine, which was no longer in operation, was to be replaced by a modern, open gas turbine system with 25.45 MW electrical output and 35 MW heating output. Natural gas or light heating oil should be used as fuel.

1995: In December, the new MAN FT-8 gas turbine plant could be put into operation for the first time with the "First Firing". With this, evo received an entry in the Guinness Book of Records for the shortest construction time of a gas turbine system.

1996: evo celebrated its 25th anniversary.

2001: The power supply in Oberhausen has existed for 100 years. EVO can look back on 30 years of business activity.

2007: Planning studies for a renewal of the generation plants on the basis of a combined cycle plant with the fuels natural gas and lignite at the location of the heating power plant 2 in Sterkrade or on the Ruhrchemie plant as a replacement for the existing plants were developed, but not for political and economic reasons pursued further. As a domestic energy source, lignite fuel can be obtained economically over long periods of time, but in direct comparison with today's natural gas combustion it has a negative environmental balance, especially when taking into account CO 2 emissions.

Invest in the future

2008: In order to adapt the existing system to future requirements of the energy markets, an extensive upgrade program was started. Important peripheral systems were partially rebuilt and the so-called internal and external power plant control systems were replaced. The work was carried out during ongoing operations over a period of five years.

2010: In order to reduce the proportion of fossil fuels in the existing energy concept through the use of regenerative energies, it was decided to build a biomass cogeneration plant at the location of HKW 2. Most of the system components could be integrated into the existing halls of the old helium heater.

2011: The new biomass cogeneration plant was put into operation for the first time in February. The plant can feed an electrical output of 3.145 MW and a thermal output of 9.2 MW into the existing supply networks. Thanks to the burning of wood chips, CO 2 -neutral energy generation is possible. The system is operated all year round and thus generates the base heat load, which also has to be fed in in the summer months for reasons of hot water preparation. The share of the total heat supply is around 12%.

In addition, the existing boiler systems that were still in operation were equipped with LowNOx burners in order to keep them below the current emission limit values . In addition, the two full desalination plants, which are very important for the feed water supply to the steam power plants and for feeding the district heating network, were replaced by new, highly automated systems.

2013: After extensive redesign of the power plant control room, all retrofits and new installations were completed before the beginning of the heating season, so that the generation plants meet the current requirements and safe operation of the district heating network can continue to be achieved.

Footnotes

  1. ↑ Art. Helium turbine. In: Otto Ahlhaus, Gerhard Boldt, Klaus Klein (eds.): Pocket dictionary environmental protection. Schwann, Düsseldorf, 10th edition 1986, ISBN 3-590-14362-2 , p. 101.
  2. ↑ History - 111 years of municipal electricity generation

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