This commentary is from USAK’s Energy Review Newsletter
http://www.turkishweekly.net/energy
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In mid- May 2007 we plan to visit Cayirhan Thermal Power Plant. We shall announce the exact date in web site in Ankara Branch of Chamber of Mechanical Engineers. We would like to invite all interested colleagues to join to our technical tours. It is free of charge. All you have to do is call or send an email to Ankara office and register your name, for security procedures of the host company. That is standard procedure at all thermal power plant.
Cayirhan is a good example of successful privatization in the local market. Plant thermal efficiency is high, availability is high, and labor productivity is also high. It is situated at the local indigenous mine mouth lignite reserves.
Cayirhan had a wide range of rehabilitation program covering Instrumentation and controls as well as upgrading flue gas cleaning and desulphurization systems
Our tour will enable us to visualize the latest developments at the site.
Your writer had involved in early proposal works of the FGD system in the plant long time ago. It will be wise to remember those lessons learnt notes at site herein below.
In order to learn the technical and commercial details of “Flue Gas Desulphurization” we had a very good opportunity to work together with a reputable International Company in installing a system in a local thermal power plant. There is nothing difficult, nothing so secret.
To meet our country’s increasing energy demands, the Turkish Electricity Authority’s power plants fire poor quality lignite of low calorific value, high ash and high moisture content, which can not be utilized elsewhere. This operation introduces environmental hazards which have to be avoided. Under the current strict environmental regulations, the Authority considers this their major problem to solve, - avoiding environmental pollution while producing electricity from economic fuel sources. Due to the high sulphur content of the fuel from in its mine, Cayirhan Power Plant was selected for the installation of first Flue Gas Desulphurization (FGD for short) System in year 1987.
Since this installation was an integral part of utility plant, and was the first of its kind in Turkey to apply desulphurization techniques to flue gases, Cayirhan FGD system was regarded by the Authority as a major step in the application of these measures for the control of Environmental Pollution.
The successful initiation of this FGD plant emphasizes the validity of this solution of a technological process applied for a cleaner environment. Even the additional costs of such a solution still allow for economical energy production.
Starting at this point, the Authority decided to make long-term commitment to install similar FGD systems in all other utility power plants.
General Information on the Project
The FGD facility, integrated with the 2x150MW capacity Cayirhan Power plant is 120km from Ankara city center, and is located in Nallihan county, near to Cayirhan town. The Cayirhan Power Plant supplies 1,800,000,000 KW-hr of electric power into the national grid each year while utilizing poor-quality lignite from local mines.
The proximate analysis of the lignite which is based to Cayirhan Power Station is as follows,
Average Lignite Proximate Analysis,
Lower heating Value, 2,800 kcal/kg
Ash 41.3 percent (dry basis)
Moisture 27.5 percent
Total Sulphur 4.65 percent
Combustible Sulphur 4.15 percent
Since the combustible sulphur is quite high at 4.15 percent, under full load of the two units of the power plant, 30 tons of SO2 is calculated to be discharged to the local environment each hour. This is the prime reason for building the FGD plant.
The contract for FGD plant was signed on 3rd July 1987. It is on a turn-key basis, with a consortium formed by Bischoff- Kloecner- Lentjes of Germany and the local partner in Turkey. The contractual lump sum price was 71,638,715 DM, plus 4,387,482,000 TL. By having the credit agreements to cover the project effective as of January 1988, the subject installation has been in operation since November 1991 in parallel with the utility plant.
The financing of the FGD plant was 100% from foreign sources, which also included coverage for the local portion.
Technical Details of the Project
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In Cayirhan FGD plant, conventional cleaning with limestone solution is applied and gypsum is obtained as the byproduct. The plant comprises 2 each 100% operation lines. Flue gases from each utility unit are cleaned in separate cleaning lines.
The Cayirhan FGD plant is split into 3 major sections, which are the limestone preparation unit, the cleaning tower, and the gypsum water extraction unit.
Flue gases passing through the existing Electrostatic filters and newly modified flues are sent to the cleaning tower by booster fans. The cleaning tower is where the SO2 is removed. For each boiler unit, there is one cleaning tower. While the flue gas raises through the tower, it reacts with downcoming pulverized limestone solution. The SO2 in fluegas is thus absorbed by the solution, forming gypsum.
The limestone solution that is passed to the cleaning tower is prepared in the "Limestone Solution Preparation Unit". The raw material for this unit is obtained from the limestone mine only 7 kms (4 miles) from the power plant. It is transported as precrushed particules with maximum size of 6cm (2.5 inches). There is one additional 100% spare unit for the crushing at the location where the limestone solution is prepared and transferred to the cleaning tower.
The flue gas, from which 95% of the SO2 content has been removed, is then discharged to the atmosphere via the "Wet Stack" situated at the top of the cleaning tower.
The gypsum by-product which is removed from the bottom of the cleaning tower is dried and filtered in hydrocyclones and vacuum filters. This dewatered gypsum is then sold on the market as a saleable industrial product.
Our experience was an extraordinary opportunity to teach us the details of an FGD systems. It is our sincere feeling that today in Turkey with local young intellectual and engineering capability, we can repeat the same project in other thermal power plants without or very limited foreign assistance.
All we need is self-confidence as well as confidence of investor who would put money into similar other projects.
Once again we would like to congratulate the Purchasing Authority and the creditors who put money which made the project realized, and to the engineers/employees who make the plant to run smoothly, efficiently at maximum availability
Your comments are always welcome.
Haluk Direskeneli- Energy Analyst
ODTU ME’1973, Ankara MMO 6606
HalukDireskeneli@tr.net
This commentary is from USAK’s Energy Review Newsletter
http://www.turkishweekly.net/energy
To subscribe email to energyreview@turkishweekly.net
2012 National Coal Policy for Turkey
