The purpose of the article was to characterize the international steam coal market based on the latest available data. The information goes back to the first half of 2018. The article focuses on the description of the three largest exporters and importers of steam coal. Representatives in these categories were selected using the latest global statistics on 2017. In 2017, global production of steam coal amounted to 5.68 billion tons and exceeded production in 2016 by 4%. For several years, invariably the world’s leading exporters of steam coal are: Indonesia, Australia and Russia. In total, these three countries in 2017 supplied 73% of steam coal to the international market. However, for the 46% of global steam coal imports (data for 2017), three Asian countries are responsible: China, India and Japan. For each of the six listed countries (i.e. for: three major global exporters and three major global importers), the paper presents volumes related to coal production, export or import. The directions of deliveries or major coal exporters to a given country were also included. At the end of the article, the price situation was presented, as it appeared in the first half of 2018 on the European and Asian markets.
The problem presented in this paper refers to the concepts applied to the design of supercritical steam turbines. The issue under the investigation is the presence of a cooling system. Cooling systems aim to protect the main components of the turbines against overheating. However the cooling flows mix with the main flow and modify the expansion line in the steam path. This affects the expansion process in the turbine and changes the performance when compared to the uncooled turbine. The analysis described here investigates the range of the influence of the cooling system on the turbine cycle. This influence is measured mainly through the change of the power generation efficiency. The paper explains the approach towards the assessment of the cooling effects and presents results of the modeling for three supercritical steam cycles.
The article presents an analysis of Russia’s participation in international steam coal trade, which has been its important participant for years. The research covered the years 2014–2018. The geographical location on two continents and the availability of coal deposits, favors its presence on both the Pacific and Atlantic markets. The article also discusses the main coal producers in Russia and the prices of Russian steam coal directed to the spot market. Due to the significant share of coal exports for the Russian economy, the focus was also on analyzing Russian seaports. In recent years, Asian exports have dominated in Russian steam coal exports. The share of export to this market in the years 2014–2018 was in the range of 49–57% (60–87 million tons). Currently, three countries play an important role among Asian countries: South Korea, China and J apan. They purchased a total of 38–52 million tons of Russian coal. Although in the years under analysis Russia exported 52–67 million tons of steam coal to the European market, the share of this market dropped from almost half to around 40%. T he slow departure from coal energy contributes to reducing the share of recipients from this direction. Among European countries, in 2014 the main direction of export was Great Britain with 19% (24 million tons) of total export share. In 2018, exports fell to 9 million tons (5%). Among European destinations for Russian coal, Poland’s share is growing in importance. In the years 2014–2018, steam coal exports to Poland varied in the range of 5.6–16.2 million tons. In the years 2014–2018 it changed in the range of 5.6–16.2 million tons. The dynamic growth achieved in the last three years is noteworthy. In relation to 2016, imports increased by 10.0 million tons and in 2018 amounted to as much as 16.1 million tons. The article also discusses the geographical structure of coal imports to Poland by railway border crossings and seaports.
The paper presents an analysis of relations describing entropy generation in a condenser of a steam unit. Connections between entropy generation, condenser ratio, and heat exchanger effectiveness, as well as relations implied by them are shown. Theoretical considerations allowed to determine limits of individual parameters which describe the condenser operation. Various relations for average temperature of the cold fluid were compared. All the proposed relations were verified against data obtained using a simulator and actual measurement data from a 200 MW unit condenser. Based on data from a simulator it was examined how the sum of entropy rates, steam condenser effectiveness, terminal temperature difference and condenser ratio vary with the change in the inlet cooling water temperature, mass flow rate of steam and the cooling water mass flow rate.
The paper presents the results of the numerical analyses for the steam turbine rotor, dedicated for the newly-designed 900 MW steam unit with supercritical steam parameters (650 °C, 30.0 MPa). Basing on the design calculations, an optimal design solution was determined. Review of the available literature on materials for turbine rotors with supercritical steam parameters was done. Then the start-ups of the turbine were simulated. Thermal and strength states were analyzed. As a result, an optimal start-up characteristic was obtained.
The paper presents selected issues related to the development of international coal markets. World consumption of coal dropped for the second year in a row in 2016, primarily due to lower demand from China and the U S. The share of coal in global primary energy consumption decreased to 28%. World coal production accounted to 3.66 billion toe and it was lower by 6.2% when compared to the previous year. More than 60% of this decline took place in China. The decline in global production was more than four times higher than the decrease in consumption. The sufficiency of world resources of coal are estimated at 153 years – that is three times more than the sufficiency of oil and gas resources. After several years of decline, coal prices increased by 77% in 2016. The current spot prices are at the level of $80/t and are close to the 2014 prices. In the European market, after the first half of the year, coal prices reached the level of around 66% higher than in the same period of the last year. The average price in the first half amounted to PLN 12.6/GJ, which is close to the 2012 prices. The share of spot trade in the total purchase amount accounted to approx. 20%. Prices in futures contracts can be estimated on the basis of the Japan-Australia contracts prices and prices in supplies to power plants located in Germany. On average, the prices in supplies to these power plants were higher by approximately 9% in the years 2010–2016 and prices in Australia – Japan contracts were 12% higher than CIF ARA prices in 2017. Global energy coal trade reached about 1.012 billion tonnes in 2016. In 2019, a decline by 4.8% is expected primarily due to the expected reduction in the demand in major importing countries in Asia.
The article presents current state of the structure of hard coal enrichment plants in Poland, taking the capacity, the range of grain enrichment and the type of equipment used into account. This data were presented in a tabular format for each Polish Coal Company operating on the Polish market. The article was also present simplified: flow sheet of the steam and coking coal enrichment system. Based on the presented data, the planned needs and trends were described in terms of increasing production efficiency, minimizing water consumption and safety of work. A list of research and development works which must be undertaken were also presented as well as factors determining the technological development of the processing plants.
Turbine stages can be divided into two types: impulse stages and reaction stages. The advantages of one type over the second one are generally known based on the basic physics of turbine stage. In this paper these differences between mentioned two types of turbines were indicated on the example of single stage turbines dedicated to work in organic Rankine cycle (ORC) power systems. The turbines for two ORC cases were analysed: the plant generating up to 30 kW and up to 300 kW of net electric power, respectively. Mentioned ORC systems operate with different working fluids: DMC (dimethyl carbonate) for the 30 kW power plant and MM (hexamethyldisiloxane) for the 300 kW power plant. The turbines were compared according to three major issues: thermodynamic and aerodynamic performance, mechanical and manufacturing aspects. The analysis was performed by means of the 0D turbomachinery theory and 3D computational aerodynamic calculations. As a result of this analysis, the paper indicates conclusions which type of turbine is a recommended choice to use in ORC systems taking into account the features of these systems.
This paper presents the origins of marine steam turbine application on liquefied natural gas carriers. An analysis of alternative propulsion plant trends has been made. The more efficient ones with marine diesel engines gradually began to replace the less efficient plants. However, because of many advantages of the steam turbine, further development research is in progress in order to achieve comparable thermal efficiency. Research has been carried out in order to achieve higher thermal efficiency throughout increasing operational parameters of superheated steam before the turbine unit; improving its efficiency to bring it nearer to the ideal Carnot cycle by applying a reheating system of steam and multi stage regenerative boiler feed water heating. Furthermore, heat losses of the system are reduced by: improving the design of turbine blades, application of turbine casing and bearing cooling, as well as reduction in steam flow resistance in pipe work and maneuvering valves. The article identifies waste energy sources using the energy balance of a steam turbine propulsion plant applied on the liquefied natural gas carrier which was made out basing on results of a passive operation experiment, using the measured and calculated values from behavioral equations for the zero-dimensional model. Thermodynamic functions of state of waste heat fluxes have been identified in terms of their capability to be converted into usable energy fluxes. Thus, new ways of increasing the efficiency of energy conversion of a steam turbine propulsion plant have been addressed.
The study presented here offers an analysis of the heat flow through the wall of the Yankee cylinder when regarded as a thin-walled vessel. The effect of the selected design and process parameters (i.e. cylinder diameter and steam pressure) on density of the heating stream has been analyzed and discussed for both cast iron and steel cylinders. Based on the work presented here, the optimal ranges for steam pressure have been derived and proposed for cylinders mounted at various locations within the drying section.
The paper presents a description of selected models dedicated to steam condensing flow modelling. The models are implemented into an in-house computational fluid dynamics code that has been successfully applied to wet steam flow calculation for many years now. All models use the same condensation model that has been validated against the majority of available experimental data. The state equations for vapour and liquid water, the physical model as well as the numerical techniques of solution to flow governing equations have been presented. For the single-fluid model, the Reynolds-averaged Navier-Stokes equations for vapour/liquid mixture are solved, whereas the two-fluid model solves separate flow governing equations for the compressible, viscous and turbulent vapour phase and for the compressible and inviscid liquid phase. All described models have been compared with relation to the flow through the Laval nozzle.
Superheater is for generating superheated steam from the saturated steam from the evaporator outlet. In the case of pulverized coal fired boiler, a relatively small amount of ash causes problems with ash fouling on the heating surfaces, including the superheaters. In the convection pass of the boiler, the flue gas temperature is lower and ash deposits can be loose or sintered. Ash fouling not only reduces heat transfer from the flue gas to the steam, but also is the cause of a higher pressure drop on the flue gas flow path. In the case the pressure drop is greater than the power consumed by the fan increases. If the superheater surfaces are covered with ash than the steam temperature at the outlet of the superheater stages falls, and the flow rates of the water injected into attemperator should be reduced. There is also an increase in flue gas temperature after the different stages of the superheater. Consequently, this leads to a reduction in boiler efficiency. The paper presents the results of computational fluid dynamics simulations of the first stage superheater of both the boiler OP-210M using the commercial software. The temperature distributions of the steam and flue gas along the way they flow together with temperature of the tube walls and temperature of the ash deposits will be determined. The calculated steam temperature is compared with measurement results. Knowledge of these temperatures is of great practical importance because it allows to choose the grade of steel for a given superheater stage. Using the developed model of the superheater to determine its degree of ash fouling in the on-line mode one can control the activation frequency of steam sootblowers.
Construction elements of supercritical power plants are subjected to high working pressures and high temperatures while operating. Under these conditions high stresses in the construction are created. In order to operate safely, it is important to monitor stresses, especially during start-up and shut-down processes. The maximum stresses in the construction elements should not exceed the allowable stress limit. The goal is to find optimum operating parameters that can assure safe heating and cooling processes [1-5]. The optimum parameters should guarantee that the allowable stresses are not exceeded and the entire process is conducted in the shortest time. In this work new numerical method for determining optimum working parameters is presented. Based on these parameters heating operations were conducted. Stresses were monitored during the entire processes. The results obtained were compared with the German boiler regulations - Technische Regeln für Dampfkessel 301.
This article describes the validation of a supercritical steam cycle. The cycle model was created with the commercial program GateCycle and validated using in-house code of the Institute of Power Engineering and Turbomachinery. The Institute's in-house code has been used extensively for industrial power plants calculations with good results. In the first step of the validation process, assumptions were made about the live steam temperature and pressure, net power, characteristic quantities for high- and low-pressure regenerative heat exchangers and pressure losses in heat exchangers. These assumptions were then used to develop a steam cycle model in Gate-Cycle and a model based on the code developed in-house at the Institute of Power Engineering and Turbomachinery. Properties, such as thermodynamic parameters at characteristic points of the steam cycle, net power values and efficiencies, heat provided to the steam cycle and heat taken from the steam cycle, were compared. The last step of the analysis was calculation of relative errors of compared values. The method used for relative error calculations is presented in the paper. The assigned relative errors are very slight, generally not exceeding 0.1%. Based on our analysis, it can be concluded that using the GateCycle software for calculations of supercritical power plants is possible.
Temperature related decrease of steam turbine components is one of the main transient processes that occur during a typical long-term operation. With a natural cooling (no user interference) it takes more than 14 days before the temperature of components reaches the level that allows to open and repair a turbine. It is then reasonable to apply a forced cooling in order to decrease the time between a shut-down of a power generating unit and a beginning of a repair. This paper presents the analysis of application of a forced cooling process to supercritical steam turbines. The main problems under the investigation are the safety issues of the process and the optimization of cooling conditions. The paper describes the safety restrictions and the optimization criteria. The process is analyzed in numerical simulations conducted for various cooling conditions.
The paper presents a new method of lifetime calculations of steam turbine components operating at high temperatures. Component life is assessed on the basis of creep-fatigue damage calculated using long-term operating data covering the whole operating period instead of representative events only. The data are analysed automatically by a dedicated computer program developed to handle big amount of process data. Lifetime calculations are based on temperature and stress analyses performed by means of finite element method and using automatically generated input files with thermal and mechanical boundary conditions. The advanced lifetime assessment method is illustrated by an example of lifetime calculations of a steam turbine rotor.
The paper presents a thermal-economic analysis of different variants of a hard coal-fired 900 MW ultra-supercritical power unit. The aim of the study was to determine the effect of the parameters of live and reheated steam on the basic thermodynamic and economic indices of the thermal cycle. The subject of the study was the cycle configuration proposed as the "initial thermal cycle structure" during the completion of the project "Advanced Technologies for Energy Generation" with the live and reheated steam parameters of 650/670 °C. At the same time, a new concept of a thermal cycle for ultra-supercritical parameters with live and reheated steam temperature of 700/720 °C was suggested. The analysis of the ultra-supercritical unit concerned a variant with a single and double steam reheat. All solutions presented in the paper were subject to a detailed thermodynamic analysis, as well as an economic one which also included CO2emissions charges. The conducted economic analysis made it possible to determine the maximum value of investment expenditures at which given solutions are profitable.
The paper presents selected issues related to the development of international coal markets. World consumption of coal dropped for the second year in a row in 2016, primarily due to the lower demand from China and the US. The share of coal in global primary energy consumption decreased to 28%. World coal production accounted to 3.66 billion toe and it was lower by 6.2% when compared to the previous year. More than 60% of this decline took place in China. The decline in global production was more than four times higher than the decrease in consumption. The sufficiency of the world resources of coal are estimated at 153 years – that is three times more than the sufficiency of oil and gas resources. After several years of decline, coal prices increased by 77% in 2016. The current spot prices are at the level of $80/ton and are close to the 2014 prices. In the European market, after the first half of the year, coal prices reached the level of around 66% higher than in the same period of the last year. The average price in the first half amounted to PLN 12.6/GJ, which is close to the 2012 prices. The share of spot trade in the total purchase amount accounted to approx. 20%. Prices in futures contracts can be estimated on the basis of the Japan-Australia contracts prices and prices in supplies to power plants located in Germany. On average, the prices in supplies to these power plants were higher by approximately 9% in the years 2010 – 2016 and prices in Australia – Japan contracts were 12% higher than CIF ARA prices in 2017. Global energy coal trade reached about 1.012 billion tons in 2016. A decline by 4.8% is expected in 2019 primarily due to the expected reduction in demand in major importing countries in Asia.
Calculations were performed of the thermal system of a power plant with installed water pressure tanks. The maximum rise in the block electric power resulting from the shut-off of low-pressure regenerative heaters is determined. At that time, the boiler is fed with hot water from water pressure tanks acting as heat accumulators. Accumulation of hot water in water tanks is also proposed in the periods of the power unit small load. In order to lower the plant electric power in the off-peak night hours, water heated in low-pressure regenerative heaters and feed water tank to the nominal temperature is directed to water pressure tanks. The water accumulated during the night is used to feed the boiler during the period of peak demand for electricity. Drops in the power block electric power were determined for different capacities of the tanks and periods when they are charged. A financial and economic profitability analysis (of costs and benefits) is made of the use of tanks for a 200 MW power unit. Operating in the automatic system of frequency and power control, the tanks may also be used to ensure a sudden increase in the electric power of the unit. The results of the performed calculations and analyses indicate that installation of water pressure tanks is well justified. The investment is profitable. Water pressure tanks may not only be used to reduce the power unit power during the off-peak night hours and raise it in the periods of peak demand, but also to increase the power capacity fast at any time. They may also be used to fill the boiler evaporator with hot water during the power unit start-up from the cold state.
The work is a part of research into the reduction of energy consumption in the production of EPSthrough the modernization of technological equipment used. This paper presents the results of research and analysis of heat transfer process between the water vapor that was provided to machine, the mold, the product and the environment. The paper shows the calculation of the heat balance of the production cycle for two types of mold: standard and modernized. The performance tests used an infrared imaging camera. The results were used to develop a computer image analysis and statistical analysis. This paper presents the main stages of the production process and the construction of technological equipment used, changing the mold surface temperature field during the production cycle and the structure of the heat balance for the mold and its instrumentation. It has been shown that the modernization of construction of technological equipment has reduced the temperature field and as a consequence of decreased of demand for process steam production cycle.
In the paper presented is a novel concept to utilize the heat from the turbine bleed to improve the quality of working fluid vapour in the bottoming organic Rankine cycle (ORC). That is a completely novel solution in the literature, which contributes to the increase of ORC efficiency and the overall efficiency of the combined system of the power plant and ORC plant. Calculations have been accomplished for the case when available is a flow rate of low enthalpy hot water at a temperature of 90 °C, which is used for preliminary heating of the working fluid. That hot water is obtained as a result of conversion of exhaust gases in the power plant to the energy of hot water. Then the working fluid is further heated by the bleed steam to reach 120 °C. Such vapour is subsequently directed to the turbine. In the paper 5 possible working fluids were examined, namely R134a, MM, MDM, toluene and ethanol. Only under conditions of 120 °C/40 °C the silicone oil MM showed the best performance, in all other cases the ethanol proved to be best performing fluid of all. Results are compared with the "stand alone" ORC module showing its superiority.
One of the major concerns of the power energy industries is a proper operation of steam power blocks. Pressurized working medium and high temperature cause very high stresses in the construction elements such as collectors, separators or steam valves. They are exposed to sudden temperature and pressure changes that cause high stresses at certain points. Additionally, the cyclic character of loading causes material fatigue, known as low-cyclic fatigue, which may lead to the formation of fracture. Thus, methodologies offered by many companies should ensure reliable and safe operation of steam power blocks. The advanced numerical solutions for determining time-optimum medium temperature changes are presented. They are based on Levenberg-Marquardt and nonlinear programming by quadratic Lagrangian methods. The methods allow us to find parameters for start-up and shut-down operation that can reduce total stresses to limits governed by European regulations. Furthermore, the heating and cooling operations are conducted in a shortest time possible.
Modern supercritical power plants operate at very high temperatures and pressures. Thus the construction elements are subjected to both high thermal and mechanical loads. As a result high stresses in those components are created. In order to operate safely, it is important to monitor stresses, especially during start-up and shut-down processes. The maximum stresses in the construction elements should not exceed the allowable stresses that are defined according to boiler regulations. It is important to find optimum operating parameters, that can assure safe heating and cooling processes. The optimum parameters define temperature and pressure histories that can keep the highest stresses within allowable limit and reduce operation time as much as possible. In this paper a new numerical method for determining optimum working fluid parameters is presented. In this method, properties of steel can be assumed as constant or temperature dependent. The constant value is taken usually at the average temperature of the operation cycle. For both cases optimal parameters are determined. Based on these parameters start-up operations for both cases are conducted. During entire processes stresses in the heated element are monitored. The results obtained are compared with German boiler regulations - Technische Regeln fur Dampfkessel 301.
A mathematical model of the steam superheater exchanger with distributed parameters has been developed. Scale deposits were assumed to be present on the internal tube surfaces. It was assumed that the inner tube surfaces are covered by a thin layer of scale deposits. The finite volume method was used to solve partial differential equations describing flue gas, tube wall and steam temperature. The developed modeling technique can especially be used for modeling tube heat exchangers when detail information on the tube wall temperature distribution is needed. The numerical model of the superheater developed in the paper can be used for modeling of the superheaters with complex flow arrangement accounting scales on the internal tube surfaces. Using the model proposed the detailed steam, wall and flue gas temperature distribution over the entire superheater can be determined. The steam pressure distribution along its path flow and the total heat transfer rate can also be obtained. The calculations showed that the presence of scale on the internal surfaces of the tubes cause the steam temperature decrease and the heat flow rate transferred from the flue gas to the steam. Scale deposits on the inner surfaces of the tubes cause the tube wall temperature growth and can lead to premature wear of tubes due to overheating.
The tubular type instrument (flux tube) was developed to identify boundary conditions in water wall tubes of steam boilers. The meter is constructed from a short length of eccentric tube containing four thermocouples on the fire side below the inner and outer surfaces of the tube. The fifth thermocouple is located at the rear of the tube on the casing side of the water-wall tube. The boundary conditions on the outer and inner surfaces of the water flux-tube are determined based on temperature measurements at the interior locations. Four K-type sheathed thermocouples of 1 mm in diameter, are inserted into holes, which are parallel to the tube axis. The non-linear least squares problem is solved numerically using the Levenberg-Marquardt method. The heat transfer conditions in adjacent boiler tubes have no impact on the temperature distribution in the flux tubes.