1. Combined Heat and Power ITT experience in Coal Technologies Andrzej Ziębik Institute of Thermal Technology, SUT

2. Andrzej Ziębik Combined Heat and Power, ITT experience Gliwice, November 22, 2005 Institute of Thermal Technology Silesian University of Technology Staff: - 11 full professors - 3 associate professors - 17 assistant professors - 26 masters of science (assistants, PhD students) Divisions: Division of Thermodynamics and Gas Energy Division of Energy Management and Refrigeration Division of Combustion Technology and Internal Combustion Engines Division of Heat Transfer, Nuclear Engineering and Renewable Energy Resources Group of Computer Methods in Thermal Engineering Selected activities: exergy – theory and practice cogeneration simulation and optimisation of power units numerical heat transfer computational fluid dynamics HTAC (High Temperature Air Combustion)

3. Andrzej Ziębik Combined Heat and Power, ITT experience Gliwice, November 22, 2005 Institute of Thermal Technology – selected books

4. Andrzej Ziębik Combined Heat and Power, ITT experience Gliwice, November 22, 2005 Gliwice TU Berlin UMSICHT Oberhausen TU Clausthal INternational Cooperation on Research in EnvironmentAl protection, process Safety and Energy Technology Optimization of the Application of gas and steam CPH Plants in Polish Industial Control Systems of Operation of Power and CPH Units Investigation of the Combustion Processes in Highly Preheated Air Optimization of Energy Management of Industrial Furnaces Coal Mine Gas from Abandoned Mines in Upper Silesian Basin Polish – German scientific network 1997-2003

5. Andrzej Ziębik Combined Heat and Power, ITT experience Gliwice, November 22, 2005 Centre of Excellence OPTI_Energy (V Framewrok Progamme of European Commission) Optimization, simulation and environmental impact of energy systems and processes summer schools international conferences international workshops for PhD students seminars for the industry 2003 - 2006

6. Andrzej Ziębik Combined Heat and Power, ITT experience Gliwice, November 22, 2005 INTRODUCTION TRADITIONS OF CO-GENERATION IN POLAND First back-pressure steam turbine – 1939 After the second world war – repowering of pre-war power stations – condenser operating in a deteriorated vacuum as the first stage of preheating the district heating water 60’s – 70’s CHP’s equipped with special bleed-condensation and back-pressure turbines

7. Andrzej Ziębik Combined Heat and Power, ITT experience Gliwice, November 22, 2005 The latest 20 years CHP’s with heating units Heating units with fluidisation boilers Power units adapted to district heating purposes Some medium- and small-scale CHP’s fired with natural gas Industrial CHP’s fired with hard coal and technological fuel gases or liquid waste fuels Fundamental fuel in Polish CHP’s - hard coal

8. Andrzej Ziębik Combined Heat and Power, ITT experience Gliwice, November 22, 2005 The share of electricity produced in district heating and industrial CHP’s 19 % (together with the condensing part) 15 – 16 % (only co-generation) Production of electricity in CHP’s Production of heat in CHP’s = 27.5 %

9. Andrzej Ziębik Combined Heat and Power, ITT experience Gliwice, November 22, 2005

10. Andrzej Ziębik Combined Heat and Power, ITT experience Gliwice, November 22, 2005 Unit 2 Unit 1 Unit 3 and 4

11. Andrzej Ziębik Combined Heat and Power, ITT experience Gliwice, November 22, 2005

12. Andrzej Ziębik Combined Heat and Power, ITT experience Gliwice, November 22, 2005 INDUSTRIAL CHP’s – SPECIFIC PROBLEMS Short statistical information Power rating – 3 GWel (~9 % of global power rating of NES) The share of electricity production in global national demand 5 ~ 5.5 % (in co-generation – 4.5 %) The largest industrial CHP 300 MW el

13. Andrzej Ziębik Combined Heat and Power, ITT experience Gliwice, November 22, 2005 PROBABILISTIC APPROACH TO THE DETERMINATION OF THE OPTIMAL STRUCTURE OF A METALLURGICAL CHP FIRED WITH TECHNOLOGICAL FUEL GASES Net present value of modernisation of CHP plant COAL&STEEL Repowering of traditional CHP by realization of gas and steam cycle

14. Andrzej Ziębik Combined Heat and Power, ITT experience Gliwice, November 22, 2005 CHP system integrated with metallurgical process Corex The Corex process: coal gasification Pig iron and export gas Production. District heat demand: -ironworks, -nearby city. Ambient temperature duration curve Process steam demand: 0.6 MPa, 270 O C Fuel supply Design Optimization Simulation COAL&STEEL

15. Andrzej Ziębik Combined Heat and Power, ITT experience Gliwice, November 22, 2005 CO 2 Removal from Corex Export Gas The COREX process The CO 2 removal process (physical absorption with the Selexol solvent) 35% CO 2 42% CO 18% H 2 7600 kJ/m 3 n 5,2% CO 2 62,2% CO 26,7% H 2 11300 kJ/m 3 n COAL&STEEL

16. Andrzej Ziębik Combined Heat and Power, ITT experience Gliwice, November 22, 2005 Blast furnace process Characteristic features: production of pig-iron in big amount high exergy efficiency basic fuel – coke (rather high thermoecological cost) Main purpose of rationalization of energy management of blast-furnace plant decrease of coke consumption Ways of rationalization injection of pulverized coal as auxiliary fuel increase of blast temperature enrichment of blast with oxygen increase of top gas pressure COAL&STEEL

17. Andrzej Ziębik Combined Heat and Power, ITT experience Gliwice, November 22, 2005 Energy indices Blast furnace process COAL&STEEL Thermoecological cost

18. Andrzej Ziębik Combined Heat and Power, ITT experience Gliwice, November 22, 2005 Biomass co-firing – ITT and Power Plant „Opole” Impact on boiler and overall plant efficiency - simulation analysis for existing big power units Method for calculation of „green” energy production Moisture content in biomass, % Net power unit efficiency