HYBRID SOLAR THERMAL

INTEGRATION AT EXISTING
August 2013

FOSSIL GENERATION FACILITIES

MANAGER OF ENGINEERING,

KEVIN MILLER
BLACK & VEATCH, SOUTH
AFRICA
AGENDA
Solar Thermal Integration at
Existing Rankine Cycle
Generating Facilities [HYBRID
CSP]
Solar Integration with Coal / Oil
Steam Plants
2
CONCEPTS OF COMBINED BRAYTON /
RANKINE CYCLE GENERATION

Brayton Cycle Rankine

Cycle
Integrated Solar Combined Cycle adds
steam to the Rankine Cycle 3
HYBRID CONCEPTS OF INTEGRATED
SOLAR THERMAL (ICSS)

Steam produced from renewable

source
Reduces use of natural gas or
light oil
No additional capacity (MW) will
result from the operation of the
solar thermal facility

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Eskom CSP Workshop August 2013

WHY CONSIDER HYBRID CSP?

Solar energy can be converted to electric
energy at a higher efficiency.
Capital costs are lower than for a CSP-
only facility of similar size.
Minimal additional plant staff is required
A hybrid plant does not suffer from the
thermal inefficiencies associated with
the daily startup and shutdown of the
CSP facility
Potential reduction in fuel costs (fossil
fuel input / MWh will decrease)
Significant reduction in carbon emissions
More
/ MWhefficient with lower
capitol cost 5
Eskom CSP Workshop August 2013

KEY CHARACTERISTICS OF
CANDIDATE FACILITIES FOR
ADDITION OF HYBRID CSP
Located in area of high Direct Normal
Solar Irradiation (DNI)
Adequate space available
Allocation of approximately 2.75 Hectares /
Mw

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Eskom CSP Workshop August 2013

DIRECT NORMAL
IRRADIATION (DNI)

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Eskom CSP Workshop August 2013

INTEGRATION OF CSP AT AN
EXISTING GAS TURBINE
COMBINED CYCLE FACILITY IN
FLORIDA,
Black USA
& Veatch was Owners Engineer
on the addition of 75 MW of CSP steam
generation at Martin Station
Area with high Direct Normal Solar
Irradiation (DNI)
Available adjacent land area (202
hectare)
Available steam turbine capacity
Reduction in associated
fuel cost & carbon emissions

8
 Eskom CSP Workshop August 2013

MARTIN NEXT GENERATION

SOLAR ENERGY CENTER

Source; John Van Beekum for The New York Times

9
Eskom CSP Workshop August 2013

MARTIN NEXT GENERATION

SOLAR ENERGY CENTER
Martin Next Generation Solar Energy Center was,
until recently, the second largest solar-thermal
facility in the world and the largest solar plant of
any kind outside of California
Facility may be the first hybrid facility in the world
to connect a solar facility to an existing combined-
cycle power plant
Provides 75 megawatts of solar thermal capacity
Designed to produce an average of 155,000 MWh
of electricity annually
The expected reduction of system-wide green-
house gas emissions is projected to be
approximately 2.75 million tons over a 30-year
period
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 Eskom CSP Workshop August 2013

COMBINED CYCLE GENERIC

LAYOUT Main Steam
Steam Turbine

HP IP / LP

Air-
Hot Reheat
Cooled
Cold Reheat
Condense
Duct HP Steam IP Steam LP Steam r
Firing

Fuel

Air
H R H H H I I H I L L L
P H P P P P P P P P P P
S E E E S E E E S E E
H V C C H V C C H V C
Gas Turbine

Heat Recovery Steam Generator BFP

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Eskom CSP Workshop August 2013

POTENTIAL SOLAR STEAM

INJECTION POINTS
Admit Steam In LP The most efficient
Circuit use
of solar energy is
Admit Steam Into Cold displacing
Reheat saturated steam
Admit Steam Into Hot production at
the highest
Reheat
pressure.
Admit Steam Into
HRSG HP Circuit The least efficient
Between Evaporator use
and Superheater of solar energy is
feedwater
Admit Main Steam preheating and
steam 12
superheating
Eskom CSP Workshop August 2013

STEAM ADMISSION LOCATIONS

DRIVEN BY SOLAR TECHNOLOGY
TYPICAL ACHIEVABLE STEAM TEMPERATURES
Parabolic Trough
Fluid: Synthetic oil; HTF Temperature: 748F
(398C)
Steam Temperature - ~715 F
Central Receiver
Fluid: Steam, molten salt, air
Steam Temperature: 1025F (550C)
Compact Linear Fresnel Reflector
Fluid: Steam
Steam Temperature: 520F (270C)
Parabolic Trough Technology was
selected by the Client 13
Eskom CSP Workshop August 2013

STEAM ADMISSION LOCATIONS

DRIVEN BY SOLAR TECHNOLOGY
Trough Steam Admission Points:
LP, Cold Reheat, HP Steam Between Evap
and Superheater
Power Tower Steam Admission Points:
Could be same as trough, but also allows
higher temperature admissions to Hot
Reheat or Main Steam
Compact Linear Fresnel Reflector
LP, Cold Reheat
Because parabolic trough systems are
more mature commercially and
technically.
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Eskom CSP Workshop August 2013

STEAM ADMISSION LOCATIONS

DRIVEN BY SOLAR
TECHNOLOGY

but when it is being integrated into

an existing facility, by the
characteristics / capabilities of the
existing steam cycle and equipment
can become overriding considerations

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Eskom CSP Workshop August 2013

TYPICAL FEEDWATER
EXTRACTION LOCATIONS
Boiler Feed Pump (BFP) Discharge
HP Economizer Exit with Booster Pump (A
unique booster pump may be needed to
overcome the additional pressure drop
on the HTF water / steam side)

Extraction point can impact the

feedwater temperature further
influencing the size of the solar field 16
 Eskom CSP Workshop August 2013

FEEDWATER FROM BFP

DISCHARGE + HPSteam
STEAM
ADMISSION USED IN Turbine
THIS CASE
Main Steam

HP IP / LP

Air-
Solar Field /
Cooled
Solar Power Block
Condense
Duct HP Steam r
Firing

Fuel

Air
H R H H H I I H I L L L
P H P P P P P P P P P P
S E E E S E E E S E E
H V C C H V C C H V C
Gas Turbine

BFP Discharge
Heat Recovery Steam Generator BFP
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Eskom CSP Workshop August 2013

REPRESENTATIVE SOLAR STEAM

GENERATOR OUTLINE
Steam Out Steam Out
HTF out

HTF in

The vessel shown is ~ 15 meters long, 3 meters in

diameter
In this design there were (3) vessels for each GT /
HRSG grouping;
Preheater
Steam generator (this vessel)
Superheater
Other configurations are available,
including vertical orientations 18
Eskom CSP Workshop August 2013

SOLAR RESOURCE
INTERMITTENCY
Thermal lag time in solar fields is large, 30
minutes or more, due to the large volume of Heat
transfer fluid (HTF) and variable HTF flow
Cloud cover events result in changing HTF flow as
the solar field responds to control HTF outlet
temperatures
As areas of the solar field see varying levels of
cloud cover and the duration of the cloud passage
is a variable, the degree the power plant output is
impacted is dependant on the magnitude of these
events
Plants operating in regions with frequent cloud
cover should consider these impacts into the
design to mitigate operational impacts and to
maximize daily solar utilization 19
Eskom CSP Workshop August 2013

IMPACT OF CLOUD COVER ON

SOLAR STEAM GENERATION
(SSG) OPERATION
These events can lead to a shut-off of
the solar steam generator train(s)
(SSGs) if the HTF temperature falls near
or below the saturation temperature of
the steam supply generator (SSG)
evaporators
Unlike stand-alone solar plants, the
steam pressure of the SSG is driven by
the operating load of the CC plant CTGs,
not the amount of steam that could be
produced if the evaporator was free to
slide in pressure
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Eskom CSP Workshop August 2013

MARTIN NEXT GENERATION

SOLAR ENERGY CENTER

Array includes 6,864 Units

192,000 Mirrors
Covers approximately 202 ha 21
SOLAR
INTEGRATION
WITH COAL / OIL
STEAM PLANTS

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 Eskom CSP Workshop August 2013

TYPICAL STEAM PLANT GENERIC

SCHEMATIC Steam Turbine
Hot Reheat
Main Steam

Steam HP IP/LP Generator

Generat
or Cold Reheat

(BOILER Condenser
) Final Feedwater

Deaerator

HP FW Heaters BFP LP FW Heaters Condensate

Pump

23
Eskom CSP Workshop August 2013

POTENTIAL INJECTION POINTS

FOR SOLAR-SOURCED THERMAL
ENERGY
CONFIGURATIONS CAN INCLUDE THE
FOLLOWING, ALONE OR IN
COMBINATION
Feedwater heating - External heating
Feedwater heating Provide heating
steam
Generation of Cold Reheat Steam
Generation of Hot Reheat Steam
Generation of HP steam
Generation of Main Steam
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Eskom CSP Workshop August 2013

STEAM ADMISSION LOCATIONS

DRIVEN BY SOLAR TECHNOLOGY
Candidate Trough Steam Admission
Points:
Feedwater Heating, LP, Cold Reheat, HP
Steam Between Evap and Superheater
Candidate Power Tower Steam
Admission Points:
Could be same as trough, but also allows
higher temperature admissions to Hot
Criteria used in the selection of the
Reheat
solar or Main used
technology Steamin a specific
plant should Compact
include not only the
capabilities of the candidate Fresnel
Candidate Linear
Reflector but the steam cycle and
technology,
characteristics of the LP,
Feedwater Heating, existing steam
Cold Reheat
cycle 26
 Eskom CSP Workshop August 2013

EXTERNAL FEEDWATER HEATING

Main Steam Steam Turbine
Hot Reheat

Steam HP IP / LP
Generator
Cold Reheat
Air-Cooled
Condenser
Final Feedwater

Deaerator

Solar Field /
Solar Feedwater Heaters

HP FW Heaters BFP LP FW Heaters Condensate

Pump

27
 Eskom CSP Workshop August 2013

GENERATION OF HP STEAM
HP Steam to HP
Superheater Main Steam Steam Turbine
Hot Reheat

Steam HP IP / LP
Generator
Cold Reheat
Air-Cooled
Condenser
Final Feedwater

Deaerator

Solar Field /
Solar Steam Generators

HP FW Heaters BFP LP FW Heaters Condensate

Pump

28
Eskom CSP Workshop August 2013

SUMMARY

Hybrid Solar thermal has been applied on

large scale basis at an existing combined
cycle facility
The concept has proven to be
operationally acceptable
Application at existing coal or oil-fired
facilities is technically feasible
Designs must consider the steam cycle,
where addition of solar generated energy
is physically possible, as well as the
required temperature and pressure
requirements of the cycle
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