Case Study
Rheinhafen Steam Power Plant RDK 7 in Karlsruhe, Germany: Fit for Efficient Energy Production - Now and in the Future

For the modernization of the largest power plant unit RDK 7, an amount of approx. 40 million euros was invested by EnBW Kraftwerke AG

OPTIMUM VALUE CREATION – FUTURE-PROOF POWER GENERATION
For more than 50 years, the Rheinhafen steam power plant has been reliably supplying the region of Karlsruhe with power and district heat. The active units of the hard-coal-fired power plant provide a total output of 1,260 megawatts. In order to make the largest unit RDK 7 fit for efficient energy production, extensive modernizations were carried out in 2010 by the operator EnBW Kraftwerke AG.

EXTENSIVE RETROFIT AND MAJOR OVERHAUL
The retrofit focused on the modification of the pulverized coal firing system and on the optimization of the two low pressure turbines. Balcke-Dürr carried out the modification of the firing system of the hard-coal-fired boiler. The aim: essential optimization of the combustion process. The challenges for Balcke-Dürr also included a clear reduction in the development of nitrogen oxides, a reduction in the excess air and improved operational reliability.

OPTIMIZED OVERALL SERVICE
By the modernization of the regenerative air preheater, the Balcke-Dürr team of experts reduced primary and secondary air leakages. The measures not only decreased the dust load of the burner air but also reduced the maintenance requirements of the air preheaters to a minimum. The replacement of the header-type high pressure heater, refurbishment work on a low pressure heater as well as the general overhaul work completed the total scope of services.

Modernization of the Regenerative Air Preheater in the RDK7 power plant in Germany

JUST-IN-TIME WITHIN ONLY 35 DAYS
Since downtime is always very expensive for power plant operators, it was important to finish all measures within the shortest possible time. In preparation of the work, our experts planned the entire workflow down to the last detail. The benefit to EnBW was not only the proven specialized knowledge of the Balcke-Dürr experts with regard to the various power plant components and equipment but also the full service without any interfaces: engineering, design, own manufacture and supply of components, installation and upgrade – Balcke-Dürr provided everything from one source. The greatest challenge – the extreme time pressure – was mastered by the team of 500 experts in spite of partly difficult general conditions. Especially with regard to the modification of the firing system, our experts even exceeded the goals set.

OUR SCOPE OF SUPPLY: