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.
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-2009-02Note to the editor:
Horst Ulrich Reimer | DuPont
Physics, photosynthesis and solar cells
01.12.2016 | University of California - Riverside
New process produces hydrogen at much lower temperature
01.12.2016 | Waseda University
A multi-institutional research collaboration has created a novel approach for fabricating three-dimensional micro-optics through the shape-defined formation of porous silicon (PSi), with broad impacts in integrated optoelectronics, imaging, and photovoltaics.
Working with colleagues at Stanford and The Dow Chemical Company, researchers at the University of Illinois at Urbana-Champaign fabricated 3-D birefringent...
In experiments with magnetic atoms conducted at extremely low temperatures, scientists have demonstrated a unique phase of matter: The atoms form a new type of quantum liquid or quantum droplet state. These so called quantum droplets may preserve their form in absence of external confinement because of quantum effects. The joint team of experimental physicists from Innsbruck and theoretical physicists from Hannover report on their findings in the journal Physical Review X.
“Our Quantum droplets are in the gas phase but they still drop like a rock,” explains experimental physicist Francesca Ferlaino when talking about the...
The Max Planck Institute for Physics (MPP) is opening up a new research field. A workshop from November 21 - 22, 2016 will mark the start of activities for an innovative axion experiment. Axions are still only purely hypothetical particles. Their detection could solve two fundamental problems in particle physics: What dark matter consists of and why it has not yet been possible to directly observe a CP violation for the strong interaction.
The “MADMAX” project is the MPP’s commitment to axion research. Axions are so far only a theoretical prediction and are difficult to detect: on the one hand,...
Broadband rotational spectroscopy unravels structural reshaping of isolated molecules in the gas phase to accommodate water
In two recent publications in the Journal of Chemical Physics and in the Journal of Physical Chemistry Letters, researchers around Melanie Schnell from the Max...
The efficiency of power electronic systems is not solely dependent on electrical efficiency but also on weight, for example, in mobile systems. When the weight of relevant components and devices in airplanes, for instance, is reduced, fuel savings can be achieved and correspondingly greenhouse gas emissions decreased. New materials and components based on gallium nitride (GaN) can help to reduce weight and increase the efficiency. With these new materials, power electronic switches can be operated at higher switching frequency, resulting in higher power density and lower material costs.
Researchers at the Fraunhofer Institute for Solar Energy Systems ISE together with partners have investigated how these materials can be used to make power...
16.11.2016 | Event News
01.11.2016 | Event News
14.10.2016 | Event News
02.12.2016 | Medical Engineering
02.12.2016 | Agricultural and Forestry Science
02.12.2016 | Physics and Astronomy