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Modernization of an existing coal-fired power station to comply with European Union regulations.
Modernization of an existing coal-fired power station to comply with European Union regulations.
The Black Triangle: Reducing Air Pollution in Central Europe
Henry Manczyk, C.P.E., C.E.M., Director of Facilities Management, Monroe County, New York
Abstract
Abstract
The coal-fired boilers of public and industrial power generation, cogeneration, and district heating plants are the largest sources of pollution in Central Europe. Dramatic measures to reduce and control this problem on an international scale are illustrated by the joint efforts of Poland, the Czech Republic, and Germany in the highly-polluted "Black Triangle." Ten power plants in this heavily-industrialized, 12,356 square mile region, produce 14,860 MWe and 4000 MWt of energy; yearly burn 80 million tons of lignite coal; make the major contribution to the 3 million tons of SO2 and 1 million tons of NO2 emitted annually in the region. In 1991 environmental ministers of the three countries with a representative from the European Union initiated the "Black Triangle Regional Program" to bring the plants into compliance with European standards, focusing on SO2 in particular. Significant progress has already been made using circulating fluidized-bed boilers, flue gas limestone washing, high-efficiency electrostatic precipitators, coal cleaning technology, denitrification equipment, low-NO2 emission burners, exhaust gas recirculation equipment, improved control systems, and in-plant and regional monitoring systems. Details of the improvements and system replacements being implemented at Poland’s Turów ten-unit, 2000 MWe / 330 MWt plant are presented to illustrate specific measures being applied throughout the region and successes realized from those efforts. The success of the strategies employed provide models for application in other industrial regions of the world where investments in existing resources and facilities cannot be abandoned and simply replaced in toto with alternate fuels and technologies.
Background
The "Black Triangle," where Poland, Germany and the Czech Republic come together, is one of Europe's most heavily industrialized regions. As the name implies, it is also one of the most heavily polluted areas on the continent - plagued for decades by choking coal dust emitted by electric power and district heating plants. The pollution source is primarily lignite, a soft brown coal mined locally. Inexpensive and readily available, its widespread use represents one of the short-sighted energy policies of the area's former communist governments. Since the Cold War ended, efforts have been made to reverse the Black Triangle's air pollution legacy, with promising results already in evidence.
Figure 1
Reliance on Lignite
Roughly half the size of West Virginia (12,356 sq. mi; 32,000 sq. km), the Black Triangle is comprised of the Dresden and Chemnitz districts of Germany, Northern Bohemia in the Czech Republic and the Jelenia Gora and Walbrzych provinces of Poland. (See figure 1) The region is home to Europe's largest basin of lignite coal.
Considered somewhere between peat and hard coal in hardness, lignite has the lowest carbon content of all coal. It has heat values ranging between 4000 and 8,300 Btu/lb (9,298 and 19,294 KJ/kg), depending on which mine it is extracted from. In the Turow Power Plant, the actual calorific value of coal burned is 3,958 and 4,087 Btu/lb (9,200 and 9,500 KJ/kg).
Of the approximately 200 million tons of lignite mined in 1991, 80 million tons were burned in the Black Triangle power plants; the remaining 120 million tons were used in district heating plants or other industries, or sold to other regions. As a result, 3 million tons of sulfur dioxide (SO2) were emitted by area power stations, district heating plants and other industries. That means that an area just half the size of West Virginia accounts for about 30 % of Europe's total SO2 emissions!
Lignite's abundance in the Black Triangle certainly contributed to the rise of the area's industry, which today includes petrochemical plants and refineries, copper mining and processing, textile manufacturing, glassworks and coal extraction. To supply the electricity and heating demanded by these industries, power and district heating plants were created in the region. Today Black Triangle electric power plants produce a total output of 14,860 MWe: 2,000 MWe in Poland, from the Turow Power Plant; 6,860 MWe from three major plants in Germany; and about 6,000 MWe from six power plants in the Czech Republic. Its total thermal capacity is more than 4,000 MWt.
Figure 2. Black Triangle electric power plants, like this one in Turow, Poland, burn lignite coal — the primary cause of the region's air pollution.
(Courtesy of Turow Power Plant.)
In the three Black Triangle countries, where district heating is one of the primary heating methods, there is a maximum district heating output capacity of 144,650 MWt: 52,850 MWt of this is produced in Poland; 50,500 MWt in Germany; and 41,300 MWt in the Czech Republic.
Emissions from these plants - SO2 nitrogen oxides, particulates and other kinds of air pollutants - are a problem not only for the three countries in the Black Triangle itself, but for other European countries as well. Contamination of the air and acidification of soil and water by SO2 and nitrogen dioxide (NO2) have damaged the ecological balance and caused many serious human health problems, including respiratory diseases, cancer, cardiovascular problems, nervous system and immunity disorders.
A study released in 1995 by the firm EEA Corinair showed the Poland, the Czech Republic and the former East Germany released nearly 9.5 million tons of SO2 and more than 2.7 million tons of NO2 in 1990 - before any real progress of post-Cold War environmental cleanup efforts could be made. (See fig. 3 for a breakdown of emissions by each country.) This same study determined that of all the contributing sources of pollution - including, for example, commercial and residential combustion, production processes, road transportation and agriculture - the worst offenders were public power, cogeneration and district heating systems. Most of these systems can be found with in a 93 mi. (150-km) radius of the heart of the Black Triangle (fig. 4).
Figure 3. NO2 and SO2 Emissions. Based on 1990 figures, the former East Germany contributes the highest percent of SO2, while Poland emits the greatest NO2. (Based on data from EEA Corinair 1990. Prepared by Henry Manczyk)
Legacy of Short-Term Planning
While the widespread use of lignite coal is clearly a major cause of Black Triangle pollution, other past practices contributed as well. As outlined in the U.S. Environmental Protection Agency's report Dark Past, Bright Future, effective environmental management was hampered by poor communication among local and national agencies and ministries. Existing environmental protection laws were not effectively enforced. Government subsidies for energy and raw materials held prices at artificially low levels, doing away with incentives to conserve natural resources.
Lacking state-of-the art technology, Black Triangle industries and their outmoded operations wasted resources and released excessive quantities of waste into the environment. There was little concern about the effect of emitted byproducts on people or the land, since industry's prime objective under communism was production in quantity.
Since the end of the communist era in 1989, the countries of the Black Triangle have faced new obstacles regarding the area's environmental problems. Environmental projects must compete for funding with greatly needed infrastructure improvements and social programs. Although economic hardships have led to the closing of many large industrial facilities - and a resulting drop in air pollution - production is gearing back up, and the need to address the issue of air pollution continues.
Emissions Reduction Measures
Since June 1991, the environment ministers of the three Black Triangle countries have been working together under a joint declaration to protect the environment in Central Europe's lignite mining area. Their primary task has been to prepare a transboundary action plan including measures to reduce pollution from power stations, district heating systems and other large industrial plants. The European Commission joined this working group as a fourth partner, providing financial support for the Black Triangle cleanup efforts.
To lower SO2 emissions from both electric power and district heating plants, planners have identified the need to implement coal-cleaning technology, use low-sulfur fuel and install desulfurization equipment. To reduce NO2 emissions they have recommended using available fuels with low nitrogen content, installing denitrifying equipment and low NO2 emission burners, and employing exhaust-gas recirculation methods. Particulate emissions are to be decreased using electrostatic precipitators and coal-cleaning technology. For overall better environmental impact control, boiler emissions and ambient concentration are to be monitored.
Figure 4. Location of Main Sources of Pollution in Black Triangle. Most of the major polluters are electric power plants found within a 93-mi (150 km) radius from the center of the region.
(Courtesy of Turow Power Plant.)
Poland
To support these shared objectives, the individual countries of the Black Triangle are implementing various emissions reduction measures. Poland has chosen to focus on reducing emissions from primary sources to limit its own transboundary impact - even though fully 75% of the pollution produced by Black Triangle Germany and the Czech Republic drifts its way. Plans call for reconstruction of Poland's Turow Power Plant, with emphasis on treating exhaust gases, maintaining capacity and anticipating the exhaustion of local lignite reserves in 2035 (estimated to be 550 million tons). As part of a $1.2 billion renovation program to be completed in 2002, nine of the Turow plant's ten 200 MWe units are being upgraded or replaced in stages with 200 to 235 MWe units. Total plant capacity will be approximately 2,010 MWe and 420 MWt. Three units have already been upgraded with electrostatic precipitators, dry-method flue gas desulfurization and other improvements. One unit will be shut down altogether. The remaining units will be based on electrostatic precipitator technologies and circulating fluidized bed boilers which alone can absorb 90% of the SO2 that would otherwise go into the atmosphere. All these various improvements are expected to reduce Turow's particulate emissions by 88 % and SO2 emissions by 83 % from 1989 levels.
At present, the total thermal capacity produced through cogeneration at the Turow Power Plant is 330 MWt. District heating from the plant is currently utilized by the Town of Bogatynia as well as Turow's coal mine facility for domestic needs. In the near future, an additional 90 MWt or more may be available for potential use in the nearby cities in the Czech Republic and Germany.
Czech Republic
The Czech Republic's focus is on modernizing fossil fuel-burning plants. This strategy includes the six sizable power stations in the Black Triangle: Prunerow, Tusimice, Pocerady, Ledvice, Milnik and Porici. Out of a total 8,447 MW of fossil fuel burning capacity nationwide, 6,427 MW will be desulfurized - 5,710 MW by wet limestone washing, 220 MW by semi-dry washing and 497 MW by replacement of existing boilers with modern fluidized bed boilers. Desulfurization is already completed in facilities representing more than 4,810 MW of production. In addition, the Czech Republic is eliminating the oldest equipment in various power plants. By the end of 1998, equipment totaling 2,020 MWe was to be shut down and most of the other measures completed. This loss in capacity will be supplanted by the 1,962 MWe Temelin Nuclear Power Station, now under construction and slated for completion in 2001-2002. Together with the existing Dukovany Nuclear Power Station, Temelin's addition increases nuclear power's share of the country's electric generation capacity to nearly 40%.
Republic of Germany
In the Republic of Germany, emissions reduction efforts have concentrated on plants located in the eastern part of the former East Germany. Within the Black Triangle region, the 2,260 MWe Boxberg plant has undergone reconstruction of its two 500 MWe units, which included a complete replacement of instrumentation and controls. On the same site, six 210 MWe units were taken out of operation, and an additional six 210 MWe units will be discontinued in December 1998. Plans call, however, for two new 800 MWe units. In another measure to reduce emissions, two relatively large Black Triangle power stations, Hagenverder and Hirschfelde, also fired with lignite coal, have already been decommissioned.
In Schwarze Pumpe, a new 1,600 MWe power plant was recently constructed in place of the old station. It contains state-of-the-art technology, including desulfurization equipment for wet limestone washing. Germany's third Black Triangle plant, Janschwalde, is the largest power-producing station in the region. It has a total capacity of 3,000 MWe produced by six 500 MWe units. All were modernized for long-term operation and equipped with technology for desulfurization and denitrification.
While steps are being taken to reduce pollution from Germany's coal-burning power plants, other factors are at work in that country that may increase air emissions, though not to pre-1989 levels since state-of-the-art technology is in use. As one of the world's largest energy users, Germany consumed 1.342 x 1016 Btu (14,165 PJ) of primary energy in 1995, of which 40% was fuel oil. Nuclear power accounts for 20% of Germany's total electrical power capacity of 112,381 MWe. Since the recently elected coalition of Social Democrats and Greens has announced intentions to eventually close all nuclear power plants, power companies may be forced to rely more on oil and coal. This will likely add to Germany's air pollution problem.
Progress Made
The various actions being taken in Poland, the Czech Republic and Germany are already having positive environmental impact. In 1996, for the first time in years, emissions in the Black Triangle countries actually declined over the previous year. Levels of SO2 were lowered by 14.7%, NO2 was down by 10.2%, and particulates decreased by 33.8%. Eight monitoring stations, locations shown in figure 5, monitor SO2 and other emissions on an ongoing basis.
The renovation plans for Black Triangle region power and district heating plants have been ambitious and aggressive; but given the knowledge, talents and outstanding cooperation of energy professionals in Poland, Germany and the Czech Republic, it comes as no surprise that rapid, significant progress has already been made. With continued government support and access to necessary technology, even more positive progress can be expected toward improving the quality of air, and life in Central Europe.
Figure 5. Black Triangle Region and its SO2 Emissions Monitoring Stations.
(Courtesy of Turow Power Plant.)
Conclusion
Conclusion
The progress being made in the Black Triangle bears significance not only for that Central European Region, but also has important lessons for other industrial areas of the world. Despite the Czech Republic’s increasing use of nuclear power, the primary source of power in all three countries in the Black Triangle region remains locally-produced lignite coal burned in existing, renovated facilities. The extensive, historic investment in existing mines and power plants in the Black Triangle region can no more be abandoned and replaced by alternative sources than elsewhere in the major industrialized countries. Yet the experience in this region demonstrates that major environmental improvements can be achieved through the application of a combination of modern technologies. The strategies adopted in the Black Triangle can be applied as beneficially by North American states, provinces, counties, and municipalities whose financial resources demand that they retain existing facilities and modily them incrementally to achieve improvements. The concentrated effort in this region of Central Europe simply makes the successful results more visible and more easily studied for application by others.
Additional figures
Percentage, by category, of SO2 Emissions of Central Europe: Poland, Czech Republic and East Germany
SO2 Emissions, in Tons, of Central Europe: Poland, Czech Republic, and East Germany
NO2 Emissions, in tons, of Central Europe: Poland, Czech Republic, and East Germany
SO2 and NO2 Emissions of Central Europe: Poland, Czech Republic, and East Germany
Turow Power Plant, Turow Poland
Turow Power Plant Location Map
Turow Power Plant, Existing 210 MW Turbo-Generator Unit
Turow Power Plant, New 235 MW Turbo-Generator Unit 7
Turow Power Plant, New 235 MW Turbo-Generator Unit 8
Turow Power Plant, New 235 MW Turbo-Generator Unit 9
Turow Power Plant, New 235 MW Turbo-Generator Unit 10
Turow Power Plant Open-Pit Coal Mine 12
Turow Power Plant Open-Pit Coal Mine 13
Turow Power Plant Open-Pit Coal Mine 14
Turow Power Plant Open-Pit Coal Mine 15
Komozany Power and Thermo Plant, Engine Hall
Komozany Power and Thermo Plant, Plant Schematic
Henry Manczyk has served as Director of Facilities Management for Monroe County, New York since 1987. He worked previously for the City of Rochester, New York, as manager of HVAC and energy. Manczyk has earned several professional certifications as energy manager and plant engineer, and has been recognized by numerous professional engineering organizations for his application of state-of-the-art technologies and operating practices in municipal facilities. Since 1985 when he first participated in a technical exchange with colleagues in Krakow, Poland, Manczyk has written and consulted on that country's energy issues. His most recent visit to Poland took him to Gliwice in 1998, where he lectured on district heating and energy conservation at Silesia's Technical University. He also toured the black Triangle's Turow Power Plant.
This article was presented and published at the International District Energy Association 90th Annual Conference and Trade Show in Boston, Massachusetts on June 12, 1999.
References
References
European Air Emissions for 1990 issued August 1995, by Corinair 1990
Environmental Pollution in Poland, By: Ltc. Krystauf Marszalik; Director of Environmental Office Ministry of Defense, Poland (NATO Environmental Clearinghouse at Defense and Environmental Conference 1995)
Technical Information on Electric Power Station in Czech Republic, By: The Power Company EEZ, a.s. (CEZ)
Trees Dying in Silence, By: Adam Czygewski
Air Pollution up to 1989 in Poland, By: The State Office of Environment, Poland
Fossil Energy International, By: U.S. Department of Energy
Technical Information on Czech Republic, Poland and Germany, By: United States Energy Information Administration
On a Slow Trip Back From Hell, By: Don Hinrichsen, National Wildlife Federation
Brown Coal in Poland Today and After the 21st Century, By: Dr. Jacek Libicki, Poletgor-Project, Ltd.
13 Power Plant Projects of ABB in Eastern Germany, By: ABB
Sources of Air Pollution, By: The State Office of Environment, Poland
The Environment (in Germany), By: German Information Center
Wroclaw's MPEC Contributes to Poland's National Energy Policy, By Henry Manczyk C.P.E., C.E.M., Rochester Engineer Magazine, January 1998
Brightening the Black Triangle, By: The Regional Environment Center for Central and Eastern Europe
Turow's 1996 Annual Report, By Turow Power Plant, Poland
Turow's Power Plant Informational Booklet, By Turow Power Plant, Poland
Technical Information About Turow Power Station, By: The Engineering and Finance Departments' Staff
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