Modularisation for Clean Coal, CCC/299

ABSTRACT

The basic principle of modularisation is the breaking down of a system or segment, either physically or digitally, into smaller component parts that can be subsequently re-assembled in the required manner. This report focuses on the process of converting the design and construction of monolithic coal-fired power plants into ones that facilitate the factory fabrication of modules, suitable for shipment and installation in the field as complete assemblies. The manufacture and pre-assembly of modules in suppliers’ dedicated off-site production facilities can reduce costs, improve quality and shorten timescales.

As it can provide numerous technical and financial benefits, modularisation of fossil fuel power plants is a particularly attractive and well-established approach for improving the effectiveness and execution of a project. Technology developers and EPC companies frequently strive to modularise as much of a power plant as practicable. However, modularisation will not be suitable for every plant and its degree of application will vary between projects. But even where individual plant components are too large to modularise, it can still provide an effective solution for much balance-of-plant infrastructure.

Modularisation can be applied successfully in many areas of coal-fired power plant operations. This can range from initial coal handling and preparation, through the combustion process, to back-end emission control systems – the report examines each of these stages. Alongside the proven, well-accepted ways of using modularisation, there are ongoing novel developments in areas such as gasification-based applications and small modular coal-fired power plants. Their possible impact on the power sector is discussed.
It is anticipated that the use of modularisation in power plants, in general, will increase wherever feasible. It offers the potential to reduce process costs, speed construction, increase process efficiency, and reduce environmental impacts. In a highly competitive marketplace, the use of modularisation can often provide significant benefits and contribute towards meeting a number of UN Sustainable Development Goals.