The record-breaking Dubai 700MW CSP+250 MW PV Hybrid Project developed by ACWA POWER, with Shanghai Electric Group Corporation as EPC, will use the Steam Generation Systems based on header-and-coil technology from Aalborg CSP after signature of a 600 MWe order for delivery of 42 heat exchangers and pressure vessels. The header-and-coil technology from Aalborg CSP has operated since 2009 in Spain without any leakages in the tube bundles and will provide value-add for the project with a much higher availability and significantly lower operation and maintenance cost.
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Aalborg CSP has received the largest order in terms of megawatt power to deliver steam generator systems based on the leakage-free header-and-coil technology for three CSP plants in Dubai, each providing 200 MWe totalling 600 MWe for the largest CSP project in the world. When completed, the solar park will provide clean energy to more than 270,000 residences in Dubai, while reducing the carbon emissions by 1.4 million tonnes per year.
Header-and-coil technology preferred over standard shell-and-tube type
With the steam generator systems from Aalborg CSP, the Dubai 700 MWe CSP Project will benefit from state-of-the-art boiler designed heat exchangers based on the header-and-coil technology. The header-and-coil design from Aalborg CSP originates from traditional boiler technology and is a 100 % welded coils type based on steam boiler technology, rather than a conventional TEMA-type based steam generator using U-tube design. The header-and-coil design has a higher availability from the no leakages design and thus lower operation and maintenance cost. Since Aalborg CSP’s entry on the CSP market, the company’s steam generator technology has won several international awards, due to its no-leakage design and higher performance features. In 2019, Aalborg CSP celebrates its 10-year anniversary for no leaks in header-and-coil.
Eliminating leakages with header-and-coil technology
Leakages are one of the main causes for breakdowns causing unplanned downtime for CSP plants and is considered a major quality issue within heat exchangers and steam generation systems for CSP plants. During repairs, the steam generator is drained and cooled down resulting in massive loss of revenue, as the system cannot produce steam while repairs are made. The majority of TEMA U-tube type equipment has leaking issues, as it is not suited for the frequent system starts/stops and load changes in large-scale CSP plants.
The header and coil type equipment on the other hand possesses the ability of absorbing the dynamic loads and thermal stress of large-scale CSP plants. This technology eliminates leakages, avoiding unnecessary maintenance and system downtime.
Due to the patented header-and-coil design for CSP applications, Aalborg CSP is capable of demonstrating a proven track record of 10 years leakage-free operation, which presents the client with the optimal amount of availability and thereby productivity, electricity revenue and the general payback time of the power plant are greatly improved to lower the cost of energy.
“In a few years, I firmly believe all CSP plants should use header-and-coil technology from Aalborg CSP or other header-and-coil suppliers like Balcke-Dürr from Germany. The advantages for owners and financiers in terms of revenue and lower risk as well as the advantages to EPC in terms of reduced risk during commissioning and guarantee period are too great to ignore. Actually, there should be a premium cost to this, but we are committed to being cost leaders to lower levelized cost of energy and make CSP competitive” – says Svante Bundgaard, CEO of Aalborg CSP.