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oster Wheeler was awarded an COGEN, two package boilers recently installed by
engineering, procurement and Dow and the rearrangement of the existing primary
construction management (EPCm) electrical distribution network of the Plant. The new
contract by Dow Deutschland facility is required to continuously supply steam and
Anlagengesellschaft mbH for a new electric power to the electrical network of the Plant,
FCogeneration Facility (COGEN) to be in parallel with the 220 kV public grid.
installed within Dow’s existing chemical complex at
Stade, Germany.
The new COGEN consists of three gas turbine New COGEN
generators, three heat recovery steam generators The new COGEN consists of 3 new gas turbine
(HRSG), a combined steam turbo generator and generators (GTG), each coupled to a new HRSG,
required infrastructure to connect to the existing supplementary fred, producing HP (High Pressure)
site. The new plant is currently being started up. steam at a single pressure level (45 bara and 410
This article describes some challenges in the °C). It also includes one new back pressure steam
execution of this project, namely: turbine generator (STG), capable of expanding
• integration with the existing facilities; steam from HP to MP (Medium Pressure) level
• HRSG post-fring with natural gas and and producing 15 MWe. The overall electric power
hydrogen; production capacity of the new COGEN is 150
• permitting and certifcations; MWe. The overall HP steam production capacity
• KKS Power Plant Identifcation System. is 420 t/h.
The COGEN and the package boilers (190 t/h
Integration with the existing HP steam each) constitute an integrated energy
generation system aimed at satisfying frm electric
facilities power and steam supply to the plant in normal
conditions and in emergency situations, such as
the trip of important equipment (gas turbine, boiler
Stade Energy Transformation or steam turbine) or disconnection of the Plant’s
Program electrical system from the external public grid.
To satisfy these stringent requirements in terms of
The new COGEN is part of the Stade Energy reliability, the combined confguration of COGEN
Transformation Program developed by Dow to and package boilers is based on the N-2 logic. That
ensure the supply of steam and electric power to means that the design of the overall steam system
the Stade Dow Chemical Complex and maximize is such that the outage of the two largest steam
effciency in the production of energy. producers will not cause an unplanned outage or
This Program includes three elements: the new process curtailment to the Dow Plant.

Fig. 1 – New COGEN
scheme

Impiantistica Italiana - Novembre-Dicembre 2013 61