Chinese Electric Power Industry Under Developing

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Chinese Electric Power Industry Under Developing

Hongqiang Yan
Secretary in General of CSPE, President of SPERI

1 INTRODUCTION
Chinese economy has grown dramatically in the first six years of 21st century, GDP increased from 9921.5 billion (RMB, ditto) to 20940.7 billion, at annual growth rate of 9.77%. The economy growth has promoted the development of electric power industry. During the period of past six years Chinese electric power industry grown very rapidly, electricity generated increased from 1368.5 TWh to 2834.4 TWh, at annual growth rate of 12.94%, and the installed generating capacity increased from 319.32GW to 622GW, at annual growth rate of 11.89%. Elasticity ratio of electricity in average is 1.31, much higher than the average figure (0.8) got in the period of 1981 to 2000. In recent years many kinds of electric power generating units, including thermal, hydro, nuclear, wind, solar and biomass energy, have rapidly and simultaneously developed in China. China is one of the few countries in the world where main energy resource depends on coal, hence coal plays an

important role in domestic economic and social development, and this scenario of energy resource structure relying mainly on coal wont be changed in coming certain years. This paper therefore, has only elaborated the thermal power equipment development in China.

2 GENERAL
To the end of 2006, the installed electricity capacity in China was 622GW, and the general electricity generated was 2834.4 TWh, both the electricity capacity and generated occupied the second place in the world, among them thermal power capacity installed was 484GW, taking up 78.22%, thermal electricity generated was 2357.3 TWh, and taking 83.17%. The domestic made capacity took 85% and more in the entire installed capacity (Table 1).

Table 1 The growth of installed and generated electricity during 2001 ~ 2006 Installed Year GW 2000 2001 2002 2003 2004 2005 2006 319.32 338.49 356.57 391.41 442.39 517 622 Rate % 6.88 6.00 5.34 9.77 13.02 16.87 20.31 TWh 1368.5 1483.9 1654.2 1905.2 2194.4 2474.7 2834.4 Rate % 10.98 8.43 11.47 15.18 15.18 12.77 14.54 237.54 253.01 265.55 289.77 329.48 384.13 484.05 Annual Generated Annual Installed Thermal GW % 74.39 74.75 74.47 74.03 74.48 74.30 77.82 Thermal TWh 1107.9 1204.5 1352.2 1579 1810.4 2018 2357.3 % 80.96 81.17 81.74 82.88 82.50 81.55 83.17 Ratio Generated Ratio

The current status of thermal power plant operation reflected continual improvement of reliability, economic gain and emission cut down effect. In 2006 the equivalent availability factor for 100MW and larger units was 92.67%, The number of unplanned stop times and time lasted per unit were 1.15 and 63.67 hours, respectively. Undergo more than 50 year development, Chinese electric power equipment manufacturing industry has formed a completed production system, the comprehensive manufacturing capacity of power equipment extends 50GW annually (Table 2).

Since the 300MW and 600MW subcritical thermal power generating units were imported, the technical performance and economical factor of those units has been dramatically raised and their several technical and economical records have attained to international levels for the same units due to efforts on the investigation of imported technology, join venture of manufacturing, localization and technical optimization. At present those units become the main units in national electric grids.

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International Conference on Power Engineering-2007, October 23-27, 2007, Hangzhou, China Table 2 Manufacturing capacity of power equipment 2004~2006 Production of power equipment Year GW 2004 2005 2006 2007 52.7 92 110 Estimated 100 3.1 Boiler BMCR 1945.3t/h ( designed 1913 t/h) Efficiency 94.12% (designed 93.90%) Average leakage of air preheater: 5.42% (A side) and 5.48% (B side), respectively (designed 6%) 3.2 NOx emission in flue gas: 204mg/m3 (A side) and 216 mg/m3 ( B side) both lower the design value. Main steam temperature can be maintained at designed value ( 5715)ranging from 35%~100% BMCR, Reheat steam temperature can be maintained at designed value ( 5695) ranging from 50%~100% BMCR, Boiler minimum output without oil firing is 517.4t/h, lower than 30%MBCR 3.3 Turbine Heat rate: 7527.9 kJ/kWh Efficiency of high pressure cylinder: 86.41% Efficiency of middle pressure cylinder: 92.71% Efficiency of low pressure cylinder: 84.55% In the second half of 2003, extra supercritical unit construction started in China. Undergo sufficient analysis and evaluation it was decided the first step to develop 1000MW sized unit, then three largest Power Equipment Groups , Harbin, Shanghai and Dongfang, had transferred technique for 1000MW extra supercritical units from Mitsubishi, Hitachi, Alstom and Siemens, based on a cooperation mode that the performance and quantity guaranteed by foreign companies, and the 1000MW extra supercritical units has been manufactured by Chinese Groups. At present some extra supercritical units had been put into operation, namely: The first phase of Huaneng Yuhuan 2h1000MW ( 26.25MPa, 600/600), and the forth phase of Zou County 2h1000MW ( 26.25MPa, 600/600), the gloss electric generating efficiency is basically within about 45%, the gloss coal special consumption is almost 275 g/kWh. The localization ratio of those four units is about 60%, such ratio would be more than 85%, as the manufactured units increase. The limestone - gypsum method desulphurization system is adopted in supercritical units, The capture rate of sulphur is about 95%. The annual average capture ratio is not less 90%, SO2 emission concentration is not higher than 400mg/m3, which is much lower than that stipulated in current national regulation. It is up to repeatedly efforts expected after another ten year or longer time, the 600MW and 1000MW supercritical and extra supercritical units would be the main electric power units in China

In 2000 and later, in order to meet the electric demand, taking the points for saving energy, enhancing efficiency and reducing emission of view, a versatile forms of development has been established such as technology transfer, join venture manufacturing, re-innovation and bonded bidding for transferring technology by marketing. Up to now China is able to produce 600MW and 1000MW two series extra supercritical units and to produce a batch of 600MW supercritical units, 600MW directly air cooling units, 300MW CFB units, 300MW thermo - electricity co-generation units and gas turbine unit of E and F classes. In the end of 2006, three domestic 1000MW extra supercritical units have put into operation one after another; this is the symbol of a new era of development for the technical and manufacturing capability of Chinese electric power industry.

3 SUPERCRITICAL & EXTRA SUPERCRITICAL UNITS

China had imported larger supercritical units from abroad since the end of 1980s. There are totally 18 supercritical units up to now, the sum capacity is 10000MW, among them the largest unit is 900MW, the longest operation time is more than 80000 hours, Lots operational experience has been obtained. Since 2002, domestic power equipment manufacturing enterprises had commence to produce 600MW supercritical units decided by Chinese government to develop supercritical and extra super critical units for enhancing unit efficiency and reducing the coal special consumption. Those units are with the parameters of 24.2MPa 538/538, and 24.2MPa 566/566. The previous several units were bided on behalf of Chinese enterprises while foreign partners guaranteed the performance targets. However the later units were designed and manufactured by Chinese enterprises themselves based on their own ability. For the time being the total orders for 600MW supercritical unit is up to 203, among them 104 units had been delivered to customers and 70 or more has put into operation, connected to electric grids. It is to take the measured operational data during testing of #5 unit in Zhengjiang Power Plant, as a example for showing the performance of Chinese made 600MW supercritical units close to international advanced level.

4 THE GAS TURBINE AND COMBINED CYCLE UNITS

There are totally 280 gas turbine units with capacity of 16 GW in China according to statistical figures collected in the

Chinese Electric Power Industry Under Developing end of 2006. Gas turbine units occupy a very small portion (3.36%) of the entire thermal electric power capacity installed and usually burn gaseous fuel and take liquid fuel as supplemental. Most of gas turbine units are formed into combined cycle and then undertake peak load. The R&D for stationary heavy gas turbine can be traced back to 60s of last century, Turbine and Boiler Research Institute (the former name of SPERI) had developed prototypes of 3000 ~ 25000 kW gas turbine. However this hopeful tendency couldnt be continuous due to the liquid and gaseous fuel resource in China werent discovered in that time. To resume the development of gas turbine seems in 80s, when Nanjin Turbo-Generator Works had join ventured with General Electric for cooperation of production of 6B set, except some important components including rotor of compressor & turbine, stationary vane of compressor, nozzle of turbine and high temperature part in combustor as well as turning gear control system are still delivered by GE. At present there are totally 60 sets of 6B manufactured already, their performance and quality have attained to the GE standard, among them some had been exported to Middle East and Africa. The localization ratio, if calculated by sales price, is 67%. Along with the large-scaled exploration of natural gas filed and carrying on Transportation of NG from West to East of China, NRDC had organized three times Bonded bidding meetings for transferring technique by marketing, and had consequently, transferred gas turbine manufacturing technology of F and E classes from GE, Mitsubishi, Siemens, and had built up some join-ventured factories for fabrication of high temperature component of gas turbine in secession. In the end of 2006, there were four E class and thirty F class gas turbine units fabricated, the localization ratio is 30 - 60%, The preparation of heat component manufacturing is under going now Currently there are 10.9 GW of single and combined cycle gas turbine units under operation and connected to electric grids, besides there are 9.1GW capacity under construction. F class gas turbine efficiency is up to about 57%, the gross and net fuel special consumption are 127g/kWh and 130g/kWh (NG) , if converted into coal, are 215g/kWh and 220g/kWh, respectively. The equivalent availability of gas turbine unit of 100MW or more is 86.36%.

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bed combustion, SPERI used to be one of the leading research institutes in the world. A successful transition from high pressure CFB to extra high pressure CFB has been lasted 10 years since the first 50MW CFB had put into operation in 1995. Since 2002 it has been developed CFB units of 100MW and 200MW in China, and meantime, both 300MW CFB units either transferred from Alstom or solely designed are appeared in parallel in Chinese market. The former 20 units were ordered (9 units in operation), the latter 17 units ordered. The 600MW supercritical CFB was sponsored by Chinese government as a demo power plant, it is expected to put into operation by the end of 2010. The efficiency of CFB is equal to that of PC unit, basically is higher than 90%. If burn deteriorated fuel or fuel with low volatile, the efficiency of CFB would be better than that of PC unit. Because the desulphurization process can be carried on in CFB furnace with addition of limestone, the emission of SO2 is reduced to 400mg/Nm3 approximately. The NOx emission is usually lower than 250 mg/Nm3. The reliability of CFB seems to be lower that that of PC unit nowadays, the statistical data has shown the longest continuous operation time lasted 200 days and the shortest period was 74 days for 135MW CFB in 2005, but one year later, the data has revealed the longest operation was extended to 297 days, the reliability of CFB was getting better year by year. Unfortunately there is lack of statistical data for reliability of 300MW CFB unit, because those units havent longer enough in operation. Full localization is for 200MW and smaller CFB units as well as solely developed 300MW CFB, regarding technique transferred 300MW CFB, the localization part is about 85%

6 THE INTEGRATED GASIFICATION COMBINED CYCLE UNIT (IGCC)

The condition for construction of IGCC project seems to be mature at present, owing to long term technological R&D efforts and the designing and manufacturing ability improved. In 2005 an 80MW IGCC demo unit was built up in Yanzhou Mineral Bureau of Shangdong Province, which adopted 1150t/d own-designed aqueous gasifier and 6B low heat value gas turbine. It operated several thousand hours already. More than twenty IGCC projects preliminary works are under going now aimed at Yantai, Tianjin and Hongzhou, respectively. For where as soon as the preliminary work finished the feasibility study starts. The program of Green Coal Electricity began in 2006, one target is to retrofit the 50MW coal fired plant into IGCC, the other is to build 250MW demo IGCC in coming year and to prepare the 300MW~400MW IGCC demo units as the second phase project.

5 THE LARGE CFB UNIT

According to uncompleted statistics, there are almost 2000 units of 35-1100t/h CFB in China. Of course, China is the only country in the world, where CFB units are very popular and even more new units will be installed in the coming years. The R&D of CFB in China has experienced several stages through many rounds of solely R&D and technique transfer alternatively. As shown in recorded historical engagement on investigation of fluidized

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International Conference on Power Engineering-2007, October 23-27, 2007, Hangzhou, China

7 THE LARGE AIR COOLING ELECTRIC GENERATING UNIT

To the end of 2006 there were 16GW of air cooling units under operation, performance of which is attained to world best record. China possesses the maximum capacity of air cooling electric generating units in the world. The largest is 600MW subcritical unit, which is also the largest one in the world. As early in 80s of last century, China had imported mixture typed air indirectly cooling unit from Hungary and has solely and successfully developed 200MW air cooling turbo-generator unit, which was installed in Datong of Shanxi Province. After that more similar units were manufactured. In 90s the 200MW mixture typed condenser and surface typed condenser air indirectly cooling units had been developed. At present the technology of manufacturing 300MW and 600MW air directly cooling units has been grasped. In the end of 2006, there were few decade units of 300MW and 600MW air cooling units under operation, and another decade units are under fabrication. The first 600MW subcritical air indirectly cooling unit in Yangcheng Power Plant of Shanxi Province will be put into operation by the end of 2007, the 600MW supercritical mixture typed condenser air indirectly cooling unit is under stage of engineering design; the preliminary study for extra supercritical air cooling unit has been completed. The average net coal special consumption of air directly cooling unit is higher than that of water cooling by 10g/kWh to 16g/kWh. The net coal special consumption of air indirectly cooling unit is lower than that of air directly cooling unit, difference of them is 5g/kWh to 8g/kWh. The emission records of particulate, NOx and SOx of air cooling unit is similar to PC units, but the average water consumption is 0.15 m3/s.GW taking up 21% of regular coal fired water cooling unit ( 0.71 m3/s.GW).

largest condensing and district heating dual purpose unit is 300MW, the extra large 600MW condensing and district heating dual purpose unit is under construction now. The gross coal special consumption of co-generation unit is similar or lower than that of extra supercritical unit ( 275 g/kWh or lower). The reliability of such unit is consistent with the condensing unit of same sized.

9 THE ENVIRONMENTAL PROTECTION EQUIPMENT FOR THERMAL ELECTRIC GENERATING UNITS

Chinese coal features high ash content, almost 28% in average. The harmful matters (particulate, NOx, SOx etc.) in flue gas emitted by coal fired electric generating units take up a major part of that by other industrial sources of emission. There is an obvious gap between China and the developed countries on emission control regulation and real emission level. However things had been changed a lot when the severe emission situation drawn public more and more attention. 1980s the electric precipitator became popular in Chinese power plant and since 1990s the industrial scale testing of desulphurization devices had started in some power plant burning high sulfur content coal. The development of dust collector, de-nitrogen and desulphurization devices are simultaneously in line with the growth of thermal electric power plants. A great success has been got as described in the following: 9.1 Dust collector technique The designing, manufacturing and assembling of electric precipitator for 1000MW and less units has been grasped, besides the baghouse has also been applied in 200MW, 300MW units and assembled in 600MW now, the baghouse electric precipitator hybrid device has been used in middle and small units. 9.2 Desulphurization facilities In recent years to industrialize desulphurization facilities is progressing obviously. To the end of 2006 the thermal electric generating units with capacity of 150GW has been equipped with desulphurization facilities. There are more than ten types of limestone gypsum desulphurization methods in application. The independent intellectual property for limestone gypsum desulphurization method used in 300MW and 600MW units has been possessed. Some other desulphurization methods such as flue gas semi - dried for CFB, NID (Novel Integrated Desulphurization), spray calcium plus humidity actuation and electronic bean etc. are applicable in some cases. 9.3 De-nitrogen technology In new units constructed the low NOx combustion technology are applied. To the end of 2006, there were totally 9 power plants

8 THE LARGE ELECTRIC AND THERMAL CO-GENERATION UNIT

To the end of 2006, there were 2500 of 6000KW or larger co-generation units all over China, which average capacity is 35MW/unit, the total installed capacity extends 70GW, taking up 15% of entire installed thermal generating capacity, which undertakes 80.5% of industrial heating load and 26% of district heating load in China. The coal special consumption of heating unit is 40.22kg/GJ normally. The scale of co-generation is small and distribution is unevenly in China, in western area the district heating covers territory less than 30%, among them co-generation takes up only 2% roughly. Since 2003 the 100MW or larger co generation units, especially the 300MW with extra parameters large capacity condensing and district heating dual purpose units are up to 30 sets. The energy saving effect is obviously higher. The largest operated steam extracting and condensing unit is 142MW, the largest back pressure unit is 50MW. The

Chinese Electric Power Industry Under Developing equipped SCR or SNCR put into operation. The capacity of 6000MW units are equipped with de-nitrogen facilities. The capture ratio of NOx is ranging in 50%~80%.

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10 CONCLUSION
The first six years of the 21st century is the period when electric power industry has developed very rapidly in China, the electric power equipment manufactured and the generating capacity installed both occupy the first place in the world. However there are still some unsolved, needed to be improved problems such as unreasonable structure of power supply, less amount of large units, higher net coal special consumption, less portion of gas steam combined cycle units, insufficient capacity undertaking peak load, not enough water saving units installed in water resource shortage area in our country. Although the electric power industry has gotten great progress. owing to huge amount of population (1.3billion), in 2006 only 2180 kWh electric power generated and 0.48KW installed capacity per capita in China, havent reached the world average level in 2000 (2540kWh, 0.575kW). In pace with the sustainable development of Chinese economy and further improvement of living standard of Chinese people, a big moving forward of electric power industry is expected. The estimated development of Chinese electric power is shown in Table 3 Table 3 Estimated development of electric power of China in 2006~2020 Year 2006 2010 2020 Annual electric power generatedTWh In which Hydro Thermal Nuclear Others Total installed capacity GW In which Hydro Thermal Nuclear Others 2834.4 416.7 2357.3 54.3 2.7 622 128.57 484.05 6.85 1.87 3764.0 627 2958.2 78.8 20 820 190 610 10.50 10 6070.0 1000 4487 308 100 1290 300 910 40 40

As shown in Table.3, in period of fourteen years from 2006 to 2020, the annual generating capacity installed is 51.28GW in average, with moderately growth rate. Elasticity ratio of electricity will be dropped to 0.8. The thermal electric power generating sector will still dominate the total capacity, nevertheless which ratio will be reduced. The following countermeasure would be carried on for optimization Chinese electric power structure in coming four year: 1) To close small thermal electric coal fired power plants of 50 GW and oil fired of 7-10 GW entirely in order to reduce coal ( standard) consumption by 50,000,000 tons and cut down dioxide carbon emission by 1,600,000 tons. 2) To deeply reform electric power system of organization, improve the dispatch approach of electric production, arrange electric production according to coal special consumption: the units with lower coal consumption have priority connected to electric grids and units with higher coal consumption will be sifted out gradually. Foreseeing in 2020, it is planned: 1) The 600MW or larger units will be the main units, the average net coal (standard) special consumption will be reduced to 335g/kWh, 2) The 600MW CFB burning low grade coal, 1000MW air directly cooling units, 600MW air indirectly cooling units will be preferable to be installed, 3) The 400MW IGCC will start commercial demonstration operation, localization of which will be 85%, 4) The gas steam combined cycle units should occupy certain ratio in peak load electric power units, 5) The localization ratio of F class gas turbine should be 85%, 6) The co-generation system will be built up in the large and middle sized cities, 7) The desulphurization technology will be fully of the independent intellectual property of China. Above mentioned is, of course, a very heavy task in front of us, but all who is engaged in the field of electric power generating and power equipment manufacturing will work hard together for fulfillment of this glorious target.