Development Deaerator Applications VGB
Development Deaerator Applications VGB
Development Deaerator Applications VGB
Developments in spray-type
deaerator applications
Bart Bramer
4
5 6
11
HP
LP
9
VGB PowerTech - Autorenexemplar - © 2015
8
2
7
10
1
Pump
10
Pump
Author
1 Superheater 5 Alternater 9 Drum
2 Evaporater 6 Transformer 10 Pump
ir. Bart Bramer (M.Sc.)
3 Economiser 7 Condenser 11 Steam boiler
Stork – Process Equipment –- 4 Steam turbine 8 Spray-type deaerator
Department of Process Engineering
Hengelo/The Netherlands
Fig. 1. Typical example of a deaerator in water-steam cycle.
device for controlling this parameter. single vessel deaerator are presented in the water following a by-pass route to the
F i g u r e 2. The deaeration process takes outlet. Finally, the deaerated water leaves
The physical background of deaeration place in two steps: pre-deaeration (step the deaerator at the bottom of the vessel
According to [1], the equilibrium between 1), in which water droplets are sprayed in via a vortex breaker (7) or similar device.
a gas dissolved in water and a gas dis- a steam space; final-deaeration (step 2), in The size of the vessel depends mainly on
solved in steam is described by Henry’s which steam bubbles are injected in a large two factors, namely the residence time
law which, amongst other gases, is valid volume of water, travelling upwards and required to achieve the deaeration target
for oxygen and carbon dioxide. According coming into close contact with water. and the required maximum amount of wa-
to Henry’s law at a given temperature, the Condensate with a temperature below the ter to be stored in the vessel. The latter is
gas concentration in water is proportional deaerator operating temperature must al- normally defined by the entire water-steam
to the partial gas pressure in steam. Here ways enter the deaerator through a spring cycle and is often specified by the system
the partial pressure is the pressure exerted loaded injection nozzle, i.e. the spray noz- designer.
by a particular gas component in a mixture zle (1). The spray nozzle produces a radial Summarising, the functional features of
of gases. Deviating from these equilibrium spray of fine droplets, which are heated dur- the Stork spay-type deaerator in the water-
conditions results in gas transport because ing their flight to saturation temperature steam cycle are:
–– the removal of dissolved oxygen from ing the outlet device, situated at the bottom Steam turbine trip
water to extend boiler service life, of the deaerator in a direction opposite to In sliding pressure mode the deaerator is
–– water storage, required for start-up and the direction of the spray nozzle. connected to a turbine tap and variations
shutdown of the deaerator and allowing in the steam turbine flow pass directly into
Deaerator control
for the collection of various excess con- the deaerator. When a steam turbine trips,
densate streams and The deaerator plays a major role under
the boiler steam flow is halted within a few
–– an efficient direct contact condensate almost every power plant operating condi-
seconds and redirected through a by-pass
preheater. tion; therefore a proper design of its con-
loop. During this period, the deaerator
trol system is important and can be criti- steam flow is halted resulting in a pressure
The emphasis on the individual design as-
cal for the entire power plant. Deaerators and temperature decay in the deaerator.
pects of the deaerator can differ to a great
generally operate in a sliding- or constant Due to the opening time of the by-pass
extent and depend on the specific applica-
pressure regime which is determined by valve and condensation of steam in the pip-
tion.
the steam source. A deaerator obtaining ing, the steam from the by-pass enters the
Design considerations steam from a steam turbine tap is operat- deaerator after approximately one minute.
ing in a sliding pressure regime, in which Simultaneously, the temperature of the
Most spray-type deaerators are installed superheated steam enters the deaerator incoming condensate falls drastically. The
horizontally. This horizontal configuration directly without control. The deaerator deaerator will be fed with steam from this
has a low centre of gravity and requires operating pressure will vary dependent on high-pressure by-pass and in parallel the
only a minimal support structure. It distrib- the load changes in the steam turbine. The pressure will drop. During these pressure
utes the steam perfectly and allows a small water level in the deaerator is controlled by reductions, the saturation temperature in
number of by-pass streams to the deaera- monitoring the incoming condensate flow the deaerator decreases and some portion
tor outlet. Careful attention must be paid to and must be kept at the desired level. The of the water reservoir gets converted into
the layout of the deaerator and its immedi- incoming condensate flow needs to be bal- steam. Consequently, the steam volume in
ate surroundings, the feedwater pumps anced with the amount of water discharged the deaerator increases and pushes up the
and the routing of pipework. Nevertheless from the deaerator. This is achieved by an water column (swell). A spray-type deaera-
this is very flexible. Most of the important external control loop. The water level con- tor can easily handle the sudden flow vari-
design considerations for spray-type de- trol is the only control system for a sliding ations caused by a turbine trip because all
aerators are given in this section. pressure operated deaerator. It can also the flows are balanced against each other
Steam and water sources regulate a separate, relatively small uncon- in the water reservoir.
trolled steam source as long as it does not
This section focuses on the sources re- interfere with the normal control system. Boiler feedwater pump
quired to operate the deaerator, i.e. water For a deaerator operating at constant pres- Reliable performance of the boiler feed-
and steam as shown in Figure 2. Steam is sure, an additional pressure control system water pump is required under all circum-
required to achieve deaeration and for is required in addition to the water level stances. The pressure at the pump inlet is
heating up cold condensate and can be control. Pressure control for spray-type an important factor related to its lifetime in
supplied from a large variety of sources, deaerators is relatively simple because the terms of pump cavitation. If the pressure at
e.g. a boiler, a steam turbine or an external steam is injected into the water reservoir, the pump inlet is close to the local vapour
production facility. The deaerator can op-
making use of the huge buffer. This en- pressure, vapour bubbles could arise which
erate using saturated, superheated or wet
sures smooth continuous pressure control. then have a destructive effect on the inter-
steam. Saturated steam can originate from
To ensure proper control of the deaerator nal components of the pump when they
a low-pressure steam drum, an evapora-
pressure, the steam flow must always be implode. A parameter expressing the safety
tor section of the boiler or a steam turbine.
sufficiently high. margin against pump cavitation is the net
Wet steam often originates from a hot con-
Competing deaerator types require an ad- positive suction head (NPSH), which is de-
densate source from an economiser, which
ditional feed forward control from the fined as the difference between the static
operates at a higher pressure. Superheated
steam inlet, which makes the spray-type pressure at the pump inlet and the local
steam is usually obtained from a low- or
deaerator effective in terms of control. vapour pressure. Here, the static pressure
medium-pressure tap at a steam turbine.
at the pump inlet depends on the deaerator
The steam enters the deaerator through Start-up procedures operating pressure, the hydraulic head cre-
a steam sparger equipped with loading
Deaerator start-up procedures are often de- ated by the water column and the pressure
pipes, located below the water level. The
steam sparger is available in several de- signed in close cooperation with the plant loss in the piping, valves, outlet nozzle,
signs, largely dependent on the operating designer. During a cold start-up, the water vortex breaker and other equipment. The
modes and the deaerator start-up philoso- level in the deaerator should be at least the minimum NPSH (R) required for a pump
phy. Condensate flows with a temperature lowest water level allowed (LLWL). During depends on its design and is specified by
lower than the deaerator operating temper- the start-up period, the deaerator is heated the pump supplier. To overcome pump cav-
VGB PowerTech - Autorenexemplar - © 2015
ature (cold) should be fed into the deaera- and pressurised with steam, until normal itation and achieve maximum NPSH, the
tor using the spray nozzle. On the other operating conditions are achieved. During deaerator needs to be installed at a level
hand, condensate flows with a temperature start-up, steam typically originates from a significantly above the level of the pump, in
higher than the deaerator operating tem- start-up boiler or other steam supply. Air order to obtain sufficient hydraulic head.
perature (hot) should be injected below is removed using start-up vents, while the When designing the pump layout, the fol-
the water level where they will flash into temperature and pressure are rising. When lowing operational aspects should be taken
a water-steam mixture. Hot condensate in- normal operating conditions are achieved into account. For a sliding pressure oper-
jection must take place through a sparger (temperature and pressure), the spray noz- ated deaerator, variations in the deaerator
or perforated pipe, which evenly distrib- zle is used to increase the amount of water pressure travel at the local speed of sound
utes the water-steam mixture in the water to the normal level (NWL). Subsequently, to the suction side of the pump. Accompa-
reservoir. The sizing of the deaerator is the steam feed can be switched to its regu- nying variations in the temperature travel
predominantly determined by the required lar source, setting the deaerator to normal significantly more slowly to the pump and
holdup volume, in order to safely feed the operation mode. Effectively, the deaerator depend on the residence time of a water
boiler feedwater pump in all conditions. delivers deaerated water right from the particle in the suction pipe. Sudden re-
The deaerated condensate is discharged us- start. ductions in the deaerator pressure can be
critical in respect of cavitation, because the which in its turn powers a steam turbine. In Examples of such applications are: para-
pump inlet temperatures can become very such plants, deaerators are often operated bolic trough plants and solar power tow-
close to the local saturation temperature. at a constant pressure, slightly above at- ers. During peak hours thermal energy is
The available NPSH (A) can fall considera- mospheric pressure or into vacuum. Steam extracted from the cycle. Sunlight is not
bly during such an event. To reduce the risk is often supplied from an LP drum or econ- available during the night; therefore much
of cavitation, flow velocities in the suction omiser section. In an HRSG arrangement, attention must be paid to the insulation of
pipe need to be high to increase the tem- efficiency cannot be increased by pre-heat- the CSP cycles. A typical deaerator vessel
perature propagation speed. On the other ing the inlet air of the gas turbine, but is has a relatively low surface-to-volume ratio
hand, the flow velocity needs to be limited, increased by pre-heating the condensate. and can be insulated very effectively. Typi-
in order to reduce the pressure losses. The Preheating the condensate is performed by cal values for overnight cooling are 2 °C or
designer must compromise between those cooling the flue gasses. This takes place at less. The deaerator operates in hot-standby
aspects. Significant pressure losses close the coldest end of the HRSG using a con- mode during the night with automatically
to the deaerator level should be limited as densate pre-heater. For the deaerator feed, operating purge vents kept closed to avoid
much as possible, because here the local the lowest enthalpy heat source must be unwanted steam losses. Thermal segrega-
vapour pressure can be reached relatively used. Due to their versatility, spray-type tion during a long standby mode period
quickly and consequently, evaporation will deaerators can be integrated relatively eas- can always be avoided because, if neces-
occur inside the piping. Pressure losses ily within the HRSG cycle. sary, the medium can be mixed by injecting
due to the flow entering the suction pipe Often, the operating pressure of the de- a small amount of steam which maintains
depend largely on the shape of the inlet aerator is determined by the critical dew homogeneous conditions. No delay is re-
of this pipe and can be a significant fac- point of the flue gas which depends on the quired for deaerating the plant first thing
tor giving rise to cavitation. Consequently, combusted fuel. To avoid external tube cor- in the morning because the water in the
streamlined suction pipe inlets (nozzle) rosion, stack temperatures must not fall be- reservoir is adequately homogenised and
and the vortex breaker are required to low the local water or acid dew point. The up to its start-up level. Likewise pressure
minimise pressure loss. Horizontal pip- most critical section of the boiler in respect and temperature correspond to the start-
ing parts and valves at the deaerator level of flue gas condensation is located at the up conditions.
should be omitted and should be placed at coldest end, where feedwater is supplied.
a level close to the feedwater pump where Nuclear power plants
Critical flue gas dew points are typically
the NPSH is maximal. Water steam-cycles of nuclear and con-
around 60 and 130 °C for gas and oil op-
ventional facilities are quite similar, but
eration, respectively. The boiler feedwater
Deaerator applications temperature is often determined by the
differ typically in the maximum conditions
allowed for temperature and pressure.
deaerator conditions and should have a
Deaeration, preheating and water/steam Consequently, the flow rates of steam and
safety margin relative to the actual dew
storage can be easily combined in the condensate need to be significantly high-
point. Due to its versatility, the same spray-
spray-type deaerator. The emphasis of a er, in order to generate a similar amount
type deaerator can easily fulfil vacuum or of electrical power. For such high con-
functional aspect of the deaerator depends
higher pressure operating requirements densate flows in the nuclear cycle (up to
on the application. Commonly applied de-
and can be easily adapted to meet oil and 6,000 t/h), the preheating function of the
aerator integrations are summarised in this
gas fired power plant requirements. deaerator is much more in demand, often
section.
Closed loop cycle resulting in multiple spray nozzles. Oxy-
Power generation from fossil fuels gen concentrations of condensate flows
In a closed loop cycle, condensate from the
A common application for deaerators is brought into the deaerator are typically
condenser will be directly fed to the boiler
found in fossil fuel powered boilers or less than 50 ppb, because leakage and
heat recovery steam generators (HRSG). feedwater pump without passing through
make-up flow quantities are relatively
Deaerators are situated in the low- or me- the deaerator. In this case, the deaerator is
small. In spite of the high flow rates pre-
dium pressure end of the water-steam cy- installed in a bypass loop and operates only
sent, the water storage capacity can be
cle, in order to reduce investment costs and on demand, i.e. in situations where extra
kept limited, because residence time re-
increase plant efficiency. Efficiency losses make-up water is supplied, oxygen leaks
quirements for nuclear power plants are
due to deaeration are minimised by con- occur or during start-up. Typically the
relatively small (2 to 5 minutes) compared
suming the lowest possible steam quality steam supply originates from a low-pres-
to conventional power plants (5 to 15 min-
for deaeration. sure steam drum and cold condensate orig-
utes). Single vessel spray-type deaerators
inates from the condenser with condensate
In conventional, directly fired power are often applied in nuclear power plants,
preheater. Under normal operating condi-
plants, fossil fuel is combusted in a steam because they combine pre-heating, de-
tions, the deaerator is maintained in hot
generating boiler which powers a steam aeration and water storage aspects by ef-
standby mode. The water storage function-
turbine. The efficiency of such plants can ficiently using the available space.
ality of the deaerator can be shifted to the
VGB PowerTech - Autorenexemplar - © 2015
be improved by preheating the fresh air condenser hot well, leading to a compact In a nuclear power plant all emissions are
used for combustion. The air preheating deaerator size. If the deaerator volume is stringently limited; therefore the water-
takes place by using heat from the exhaust small, it can also be oriented vertically, re- steam cycle needs to be closed. Vent flows
gasses. Returning condensate streams ducing its footprint. This makes its location from the deaerator need to be redirected
from the air pre-heater and the primary HP at the plant highly flexible. to the condenser where the oxygen and
condensate preheater are typically mixed other non-condensables are removed. Risk
in the deaerator. The deaerator operating Solar power plants mitigation is of highest priority in nuclear
conditions are often determined by the In concentrated solar power (CSP) plants plants, therefore extra attention must be
steam turbine tap serving as a steam sup- a large area of sunlight is focused into a paid to non-destructive testing, detailed
ply for the deaerator. concentrated beam, which is used as heat load analysis and proper operation of the
Another efficient manner to generate elec- source for the power generation process. feedwater pump under all conditions.
trical power from fossil fuel is by coupling This heat is often primarily absorbed in
a gas turbine to HRSG. Here, hot exhaust a sodium salt cycle, which acts as heat Internal drum deaerators
gasses from the gas turbine exchange heat source for a parallel operating cycle with In a standard spray-type deaerator, differ-
with the water-steam cycle of the HRSG water and steam containing a deaerator. ent streams can be easily mixed. It offers
LC
1 5
LT TT
LP drum 2 TT
TC
VGB PowerTech - Autorenexemplar - © 2015
3
HP
drum
4 3
6
Economiser/
Superheater Evaporator Economiser Superheater Evaporator condensate
preheater TC
TT
Condensate
3 from
30 to 50 °C condenser
HP section LP section
0 % (-2 %)
80 %
PC LC LC
TT TC
P LT 30 to 50 °C LT 100 °C
Condensate
from condenser
0.2 bar 1.2 bar LT
4 bar
LP
TC
drum
105 °C
LP section A B
Fig. 5. Typical integration of a deaerator in an HRSG operating under a vacuum (a) and under approximately atmospheric conditions (b).
Figure 1 shows a deaerator integration ject to vacuum conditions, extra stiffness is An alternative deaerator integration for an
commonly observed for directly-fired required. Condensate discharged from this HRSG is shown in Figure 5b, making use of
power plants. Here, condensate originates deaerator (black line) is at around 60 °C an external heat exchanger to pre-heat the
directly from the steam condenser and is and can be directly fed into the economis- condensate. In this case, the deaerator op-
distributed to the deaerator using the spray er. As a steam source for the deaerator, hot erates slightly above atmospheric pressure.
nozzle. Steam for the deaeration originates condensate which flashes into low quality The setup of figure 5b is observed in many
from a low-pressure steam turbine tap and steam, can be used. Condensate flashing HRSG’s while the setup of figure 5a has
is directly fed into the deaerator without takes place in the water reservoir similar to several benefits and should be preferred.
control. The deaerator operates at saturat- the deaeration with steam and contributes It has less components, a high availability,
ed conditions and should operate at a tem- to the deaeration process. Hot condensate an easy control philosophy and is very cost
perature at least 10 ˚C above the incoming is typically obtained from an economiser. effective. This deaerator setup is applied in
condensate temperature to safeguard de- In parallel, a small portion of steam (up an HRSG and is typically fed with flashing
aeration quality. If the steam turbine trips, to 2 %) from a low pressure steam drum hot condensate and low-pressure steam
the HP steam produced by the boiler is can be fed through the steam spargers to (purple line). The cold condensate flow
dumped into the condenser and partly into maintain the pressure. During oil firing, from the condenser (blue line) extracts
the deaerator. the deaerator operating pressure must be heat from the relatively hot deaerator out-
A deaerator setup in an HRSG which re- increased to approximately 4 bar to pro- let flow (red line), in order to obtain an
quires a minor level of safeguarding is a vide a safety margin relative to the critical economiser feedwater flow of around 60 °C
deaerator operating under vacuum con- dew point. Under these oil firing operating (black line) which is safely removed from
ditions, as shown in F i g u r e 5. In such conditions, the LP drum water enthalpy is the critical dew point.
cases, cold condensate from the condenser insufficient to provide proper steam distri- Condensate can also be pre-heated inside
of about 30 to 50 °C is brought directly into bution in the deaerator. Consequently, LP the HRSG (F i g u r e 6). The condensate
the deaerator (blue line), which typically steam is used for deaeration by use of the pre-heater is located at the coldest end of
operates at 0.2 bar. As the deaerator is sub- steam sparger. the boiler. Its inlet condition is determined
5
VGB PowerTech - Autorenexemplar - © 2015
TT TC
Supplementary
firing
Drum
4
TT Condensate
3 from
1 condenser
LP section 30 to 50 °C
by the critical dew point, while its outlet oxygen and reduces the rate of corrosion. steam-accumulator. To optimise the de-
condition is determined by the tempera- Spray-type deaerators are highly flex- aerator design, Stork, in conjunction with
ture required to obtain proper deaeration. ible and compact. They combine deaer- its major partners, is currently employing
The condensate inlet temperature (1) ating, preheating and feedwater storage standardisation and “configure to order”
should remain 6 to 8 °C above the critical functionalities in the same device. Due to programmes. This will reduce design cost,
dew point. This could be achieved by mix- their versatility, they can be adapted to a project and quotation lead times.
ing preheated water from the deaerator (2) wide range of plant setups and operating
with cold condensate (3). The latter could requirements. The investment costs of a
result in recirculation rates of 30 to 300 % spray-type deaerator mainly depend on References
depending on the combustion fuel. the amount of condensate which needs
Many HRSG’s are provided with a sup- to be produced as well on the required [1] Coulson, J.M., Richardson, J.F., and Sinnott,
R.K.: Chemical Engineering Volume 6, An In-
plementary firing possibility to increase hold up time of the boiler. The deaerator troduction to Chemical Engineering Design,
steam production, efficiency or separate should operate at a temperature at least 5th edition, Pergamon Press, Oxford ed.
power and process steam requirements. 10 °C higher than the incoming conden- 1983.
HRSG operation with supplementary firing sate temperature to safeguard deaeration [2] Bird, R.B., Stewart, W.E., and Ligthfoot,
changes the critical flue gas dew point and performance. Superheated- or saturated E.N.: Transport Phenomena, 2nd edition,
steam or flashing hot condensate can be John Wiley & Sons, Inc, 2002.
the preheater performance. This will influ-
ence the deaerator operating conditions used as deaeration sources. With the spray- [3] Batchelor, G.K.: An Introduction to Fluid Dy-
type deaerator, oxygen contents of 5 ppb or namics, Cambridge University Press, 1967.
and requires another operating philoso-
phy. Due to the versatility of the spray-type less can easily be obtained. Application of [4] Japikse, D., and Baines, N.C.: An Introduc-
a spray-type deaerator costs a negligible tion to Turbomachinery, Concepts ETI, Inc,
deaerator, combining multiple operating
FIND &and
amount of thermal efficiency GET FOUND! 1994.
oxygen POWERJOBS.VGB.ORG
philosophies can easily be achieved with
the same device. scavenger chemicals are not required. The [5] Budinski, K.G., and Budinski, M.R.: Mate
riaalkunde voor Technici, Prentice Hall,
most common applications of spray-type 1999.
Conclusions deaerators are to be found in directly fired [6] Groen, Ir.: Theoretical Aspects of Physical
plants, HRSG’s for power generation and Deaeration, Stork, 2006.
Boiler life span can be improved by apply- in solar- and nuclear power plants. The [7] Albrink, W.: The Feedwater Deaerator in the
ing a deaerator in the water-steam cycle spray-type deaerator design can also be Water-Steam System, Stork Thermeq B.V.
because it reduces the amount of dissolved used for steam storage, by operation as a | WWW.VGB.ORG/SHOP
ONLINE–SHOP 2010. l
VGB-Standard
!
Selection of impulse pipes and sampling lines NEU !
< 8 >
NE W
for water and steam sectors in thermal power stations
Edition 2015 – VGB-S-170-R-41;2012-07.EN
VGB-Standard
DIN A4, 22 Pages, Price for VGB members € 90.–, for non members € 140.–, plus VAT, shipping and handling. Selection of impulse pipes
and sampling lines for water
This VGB standard was created to adapt the design of measurement and analytical/discharge lines to the and steam sectors in thermal
power stations
increased steam parameters and the updated long-term parameters.
The VGB standard is a set of experiences and recommendations, which although not always able to
VGB PowerTech - Autorenexemplar - © 2015
fully reflect the state of the art, was nevertheless compiled to the best of our knowledge. It is intended to
summarise existing information concerning specific results in this area to facilitate work
for operators. The VGB standard is a key means of harmonisation and helps encour- VGB-S-170-R-41;2012-07.EN
age improved cooperation between the parties concerned. The utilisation, in whole or
in part, must be agreed between the operator and contractor. Any liability, including
for the material accuracy of the information portrayed, is excluded. It is also the user’s
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