Forum for Science, Industry and Business

Sponsored by:     3M 
Search our Site:

 

Flue gas coolers with AlWaFlon® pressure hoses based on DuPont Teflon® PTFE maximize power plant efficiency

20.05.2009
A new 858 MW-rated generating unit is being built at the site of Europe’s largest lignite-fired power station in Belchatów, Poland.

Upon completion at the end of 2010, it will be one of the country’s most productive and efficient lignite-fired plants with an efficiency rating of around 42 percent, and one of the world’s most modern installations.


Photo: DuPont
Two flue gas coolers with 500,000 metres of heat exchanger pressure hoses, made using the AlWaFlon® system based on DuPont Teflon® PTFE, contribute to the high sustainability of the new 858 MW-rated generating unit for the lignite-fired power plant in Belchatów, Poland.

Two innovative flue gas coolers, equipped with heat exchangers using the AlWaFlon® pressure hose system based on DuPont™ Teflon® PTFE, will make a considerable contribution to the plant’s comparatively low fuel consumption, reduced emissions and high sustainability. The flue gas coolers are developed and supplied by the engineering company Wallstein of Recklinghausen, Germany. The prime contractor for the specification, construction and commissioning of the new power plant is Alstom.

The two units, scheduled for delivery in the first half of 2009, are each equipped with five heat exchanger modules in which a total of approximately 500,000 meters of AlWaFlon® pressure hoses are integrated. After commissioning, they will reduce the temperature of the flue gas by about 50 K and, in doing so, generate two times 32 MW of heat energy. This will contribute towards the feed water heating at the power plant, while the surplus steam will be used for energy production, thereby significantly improving the overall energy balance of the plant.

AlWaFlon® is defined by the interaction of an almost entirely chemically-inert fluoropolymer, designed for use in highly corrosive and reactive gases, and the use of complementary processing methods. Joint developers are Wallstein, DuPont (Geneva/Sweitzerland), as manufacturers of the base material Teflon® PTFE, and Fluortubing (Utrecht/the Netherlands), as the supplier of installation-ready, pre-formed pressure hoses. “We chose AlWaFlon® because – in contrast to the previously all-prevailing nickel-based alloys – it even resists highly corrosive mixed acids of SO2, SO3, HF and HCl, which condense on the hose surface during cooling of the flue gases,” explains Peter Dittmann, technical manager at Wallstein.

“The AlWaFlon® concept combines cost-efficient processing and application benefits with exceptional consistency in terms of its properties over long production periods, from charge to charge and for the entire hose length,” adds Alex Soeterbroek, managing director of Fluortubing. “Compared to many other fluoropolymer grades, the application attributes of AlWaflon® include higher upper service temperatures of up to 260 °C, a significant increase in the Vicat softening temperature to between 130 °C and 140 °C, as well as high flexural fatigue strength and stress cracking resistance.”

Successfully completed internal pressure creep rupture tests, conducted over 10,000 hours at laboratories belonging to BASF, confirm the following: AlWaFlon® pressure hoses provide long-term resistance to the combination of internal pressure, high temperatures and corrosive media, and exceed the performance of comparable products made of a range of other fluoropolymers. For this reason, they can be used at lower wall thicknesses than pressure hoses made, for example, from the equally corrosion-resistant fluoropolymer PFA, whilst providing the same levels of safety and being exposed to the same mechanical stress. Accordingly, larger amounts of heat energy can be coupled out at the same length, or alternatively the number/length of pressure hoses used can be reduced to achieve the same level of heat exchange performance. The German TÜV Süd has produced a positive report on the use of the AlWaFlon® system as a pressure hose at elevated temperatures.

Dittmann finds particular advantage in the excellent non-stick properties and self-cleaning effect of the fluoropolymer: “Compared with metal hoses, considerably fewer deposits form on their exterior, and those that do can be removed both quickly and thoroughly, and therefore cost-efficiently. This extends maintenance intervals and increases the overall availability of the plant.”

Wallstein Ingenieur GmbH is part of the Wallstein network of affiliated companies with a core competency in industrial heat and process engineering. The company is amongst Germany’s leading equipment and plant manufacturers with customers from the waste incineration and power plant sectors, as well as other industries. For the heat-, environmental- and process engineering sectors, Wallstein supplies both individual components and systems for heat displacement and complete flue gas purification plants.

Fluortubing B.V., with headquarters in Utrecht/the Netherlands, is specialized in the extrusion and thermoforming of standard and application-specific pressure hoses and hoses made of PTFE. The company has access to vertical extrusion lines, especially designed for the paste-extrusion of products with an internal diameter of less than 1 mm and up to 150 mm with low wall thicknesses. A specialty product of the company are convoluted PTFE pressure hoses, which can be made available in conductive form and colored to customer requirements.

DuPont Fluoropolymer Solutions is a leading producer of fluoropolymer resins, additives, films, finishes and dispersions, PTFE (polytetrafluoroethylene), PFA (perfluoroalkoxy), FEP (fluorinated ethylene propylene), ETFE (ethylene-tetrafluoroethylene) and PVF (polivinylfluoride), marketed under the registered trademarks DuPont™ Teflon®, DuPont™ Tefzel®, DuPont™ Tedlar® and DuPont™ Zonyl®. Major markets for these fluoropolymer products include the automotive, chemical processing, semiconductor, oil exploration, chemical handling, data communication, aerospace, electronics, housewares, building and renewable energy industries.

DuPont is a science-based products and services company. Founded in 1802, DuPont puts science to work by creating sustainable solutions essential to a better, safer, healthier life for people everywhere. Operating in more than 70 countries, DuPont offers a wide range of innovative products and services for markets including agriculture and food; building and construction; communications; and transportation.

The DuPont Oval Logo, DuPont™, The miracles of science™ and Teflon® are registered trademarks or trademarks of E. I. du Pont de Nemours and Company or its affiliates.

AlWaFlon® is a registered trademark of Wallstein Ingenieur GmbH.

FLP-ACHEMA-2009-02

Note to the editor:
This press release is based on information provided by:
Wallstein Apparate- und Anlagenbau GmbH
Hubertusstr. 50, D-45657 Recklinghausen, Germany
Contact: Peter Dittmann
Telephone: +49 (0) 2361-1047-0
E-Mail: p.dittmann@wallstein.de

Horst Ulrich Reimer | DuPont
Further information:
http://www.dupont.com

More articles from Materials Sciences:

nachricht Watching atoms move in hybrid perovskite crystals reveals clues to improving solar cells
22.11.2017 | University of California - San Diego

nachricht Fine felted nanotubes: CAU research team develops new composite material made of carbon nanotubes
22.11.2017 | Christian-Albrechts-Universität zu Kiel

All articles from Materials Sciences >>>

The most recent press releases about innovation >>>

Die letzten 5 Focus-News des innovations-reports im Überblick:

Im Focus: New proton record: Researchers measure magnetic moment with greatest possible precision

High-precision measurement of the g-factor eleven times more precise than before / Results indicate a strong similarity between protons and antiprotons

The magnetic moment of an individual proton is inconceivably small, but can still be quantified. The basis for undertaking this measurement was laid over ten...

Im Focus: Frictional Heat Powers Hydrothermal Activity on Enceladus

Computer simulation shows how the icy moon heats water in a porous rock core

Heat from the friction of rocks caused by tidal forces could be the “engine” for the hydrothermal activity on Saturn's moon Enceladus. This presupposes that...

Im Focus: Nanoparticles help with malaria diagnosis – new rapid test in development

The WHO reports an estimated 429,000 malaria deaths each year. The disease mostly affects tropical and subtropical regions and in particular the African continent. The Fraunhofer Institute for Silicate Research ISC teamed up with the Fraunhofer Institute for Molecular Biology and Applied Ecology IME and the Institute of Tropical Medicine at the University of Tübingen for a new test method to detect malaria parasites in blood. The idea of the research project “NanoFRET” is to develop a highly sensitive and reliable rapid diagnostic test so that patient treatment can begin as early as possible.

Malaria is caused by parasites transmitted by mosquito bite. The most dangerous form of malaria is malaria tropica. Left untreated, it is fatal in most cases....

Im Focus: A “cosmic snake” reveals the structure of remote galaxies

The formation of stars in distant galaxies is still largely unexplored. For the first time, astron-omers at the University of Geneva have now been able to closely observe a star system six billion light-years away. In doing so, they are confirming earlier simulations made by the University of Zurich. One special effect is made possible by the multiple reflections of images that run through the cosmos like a snake.

Today, astronomers have a pretty accurate idea of how stars were formed in the recent cosmic past. But do these laws also apply to older galaxies? For around a...

Im Focus: Visual intelligence is not the same as IQ

Just because someone is smart and well-motivated doesn't mean he or she can learn the visual skills needed to excel at tasks like matching fingerprints, interpreting medical X-rays, keeping track of aircraft on radar displays or forensic face matching.

That is the implication of a new study which shows for the first time that there is a broad range of differences in people's visual ability and that these...

All Focus news of the innovation-report >>>

Anzeige

Anzeige

Event News

Ecology Across Borders: International conference brings together 1,500 ecologists

15.11.2017 | Event News

Road into laboratory: Users discuss biaxial fatigue-testing for car and truck wheel

15.11.2017 | Event News

#Berlin5GWeek: The right network for Industry 4.0

30.10.2017 | Event News

 
Latest News

Lightning, with a chance of antimatter

24.11.2017 | Earth Sciences

A huge hydrogen generator at the Earth's core-mantle boundary

24.11.2017 | Earth Sciences

Scientists find why CP El Niño is harder to predict than EP El Niño

24.11.2017 | Earth Sciences

VideoLinks
B2B-VideoLinks
More VideoLinks >>>