Laboratory for Thermal Engineering and Energy

Implementation and verification of plasma technology for fire stabilization in real conditions of thermal power plant boiler TENT-A1

Research Program in the area of Technological development with participation for the period 2005-2007

Energy Engineering and Mining

Dr Predrag Stefanovic, dipl.ing., Laboratory for Thermal Engineering and Energy,Institute of Nuclear Sciences "Vinca", POBox 522, 11001, Belgrade, Tel. +381-11-3443498 Fax. +381-11-2453-670

• Laboratory for Thermal Engineering and Energy, Institute of Nuclear Sciences "Vinca", Belgrade
• JP EPS, Electric Power Company of Serbia Belgrade
• Minel Projektinzenjering, Belgrade

• Dr Predrag Stefanovic, dipl.ing.
• Mr Dejan Cvetinovic, dipl.ing.
• Dr Vukman Bakic, dipl.ing.
• Nikola Zivkovic, dipl.ing.
• Zoran Pavlovic, dipl.ing.
• Mr Zoran Markovic, dipl.ing.
• Dr Goran Zivkovic, dipl.ing.
• Nikola Oka, dipl.ing.
• Mr Trajan Stalevski, dipl.ing.
• Dr Srdjan Belosevic, dipl.ing.
• Dr Miroslav Sijercic, dipl.ing.
• Dr Borislav Grubor, dipl.ing.
• Mr Pavle Pavlovic, dipl.ing.
• Dr Zivota Kostic, dipl.ing.

Liquid fuel consumption for startup and combustion support in JP EPS is about 100.000 t per year with a tendency to increase in future due to decline in coal quality. Fifty percent of the fuel is consumed during startup, and the rest is used for combustion support when a unit is working with lower power production or with low quality coal. It is in the EPS best interest to lower the cost of power production in coal powered units through liquid fuel substitution with the up-to-date plasma technology, which was already proven in Russia and Australia. Earlier preliminary and detailed feasibility studies have shown that with a current heavy oil price of 210 $/t, investment in plasma facility on 210 MW unit in TENT-A will pay itself off in 17 months. In the TR147 project in 2002-2004 period following was done: 1. appropriate thermodinamical and balance calculations 2. mathematical model of a two phase flue gas-coal particles flow, in the fuel mixture channals with and without obstacles, was developed and implemented 3. mathematical model of coal gasification in the plasma process, in the fuel mixture channal before furnice entry, was developed and implemented 4. mathematical models for calculation of thermal stress were developed and implemented 5. complete design documentation (9 volumes) for the industrial pilot plasma facility on the TENT A1 unit boiler was completed 6. during the period 2003-2004 pilot plasma facility was built on the TENT A1 unit boiler, by the consortium of domestic companies under supervision of MINEL Projektinženjering and Institute Vinčа.

Experimental investigation of the functionality and ability to achieve designed parameters of certain components and subsystems of the pilot plasma facility Experimental research of the real life operating parameters of the mills and burner packets of the mills 12 and 15 on the TENT A1 boiler Mill and plasma facility tuning for the use of the plasma technology for combustion support. Experimental investigation of the needed and possible range of the mill and plasma facility work parameters for the combustion support with plasma technology on the real life TENT A1 boiler Determination of the optimal number of plasma burners for the combustion support in the furnice depending on the coal quality, power production level and other technical and technological parameters during boiler operation. Verification and improvement of the mathematical models according to experimental results obtained on the experimental pilot facility, for the further application in the field of plasma technology. Continuous monitoring of the plasma installations usage and long-term application of the plasma technology for combustion support in the TENT A1 boiler in real life conditions. Fitting the plasma facility in the procedures and operating instructions of the boiler system according to security, optimization and efficiency of operation.

Bringing the pilot plasma facility into operation on the TENT A1 boiler. Defining and verification of the ranges and optimal work parameters of the mill and plasma facility for the use of the plasma technology for combustion support. Implementation of the plasma technology in the practice of combustion support with the defined coal quality parameters and defined boiler operating parameters. Verification of the mathematical models for further application of the plasma technology in the power production boilers. Fitting the operating procedures and rules with the plasma installation in real life working conditions of the TENT A1 boiler.

Through the TP-147 in the period 2002-2004, 2 design companies were hired for the design of the electric power supply, cooling water and work gas installations of the plasmatron, and know-how was transferred to them. Also, know-how was transferred and technologies for fully automated, remote monitoring, control and management of the plasma facility with the use of industrial computers (PLC and PC) was acquired. Investing in the pilot plasma facility on the TENT A1 which was made by effort of domestic companies under the supervision of the Institute Vinča (bearer of technology part), and MINEL Projektinženjering (bearer of the engineering part) of the project, know-how and technologies for the production of new electromechanical components, assemblies were transferred to domestic production companies. This will achive a higher employment in the field of electromechanical production. Real benefit for the consortium companies will follow after the verification and implemetation of the plasma technology in real life, planned in this project. The companies will acquire a good reference for production of similar facilities and application of plasma technology on other units in EPS and in neighbouring countries. EPS and its power plants will benefit from the substitution of expensive liquid fuel with plasma technology. Mazout will be replaced with coal through plasma gasification and that will reduce the cost of power production and lowers the import of the expensive liquid fuel.

Liquid fuel consumption for startup and combustion support in JP EPS is about 100.000 t per year with a tendency to increase in future due to decline in coal quality. Fifty percent of the fuel is consumed during startup, and the rest is used for combustion support when a unit is working with lower power production or with low quality coal. It is in the EPS best interest to lower the cost of power production in coal powered units through liquid fuel substitution with the up-to-date plasma technology, which was already proven in Russia and Australia. Earlier preliminary and detailed feasibility studies have shown that with a current heavy oil price of 210 $/t, 135.000 $ investment in plasma facility on 210 MW unit in TENT-A will pay itself off in 17 months. Since great feasibility of plasma technology is expected through substitution of expensive liquid fuel Power Industry of Serbia made an investment in the pilot plasma facility. Proposed project should verify the technology feasibility, and in the same time to acquire a reference for the consortium of domestic companies in the field of plasma facility production in domestic Thermal Power Plant and their export to neighboring countries for their power plants. Through this project an added benefit of increase in employment and increased competitive edge of domestic electromechenical industry in local and international market is expected.