8.4-capacity-increase-4-86ab8141320f8e0c.pdf

This report section details the technical requirements and cost projections for increasing the capacity of the Hendrina Power Station. It focuses on necessary upgrades to generators, boiler plants (Units 1-5 and 6-10), and auxiliary systems to support higher power output and ensure operational reliability through 2035.

• Upgrading existing gas/water-cooled generators to increase capacity is impossible due to design limitations in the excitation system and geometrical constraints of the slip rings. A capacity increase is only possible through a replacement strategy using air-cooled Footprint generators, which can provide up to 35 MW of additional power beyond the installed 200 MW output.
• Scenario C proposes replacing all ten gas/water-cooled generators with air-cooled Footprint generators. This would allow for enhanced performance to support boiler or turbine power uprates, reduce maintenance costs, and allow for the decommissioning of existing generator auxiliary systems.
• For Boiler Units 1-5, a conversion to a tower boiler design is recommended to improve reliability. This configuration halves the velocity in the convection pass compared to El-Paso units, which is expected to increase nominal tube life by nearly ten times and reduce air ingress through the use of membrane walls.
• A low NOx burner retrofit is recommended for the boiler plants to comply with future emissions legislation. This solution is particularly suited for South African coal and includes balancing pulverized fuel distribution to address unequal burner firing.
• Mill upgrades are identified as critical for reliable operation during capacity increases, especially when using lower quality coal (20-22 MJ/kg with over 28% ash). The proposed upgrade using high performance rotating throats and static classifiers would increase mill throughput by 20% and product fineness by 15%.
• For Boiler Units 6-10, several components require replacement to support a 110% capacity increase scenario, including the Superheater 2 outlet header (upgraded to EN10216 10CrMo9-10) and Attemperators I and II, which require a new 'spray water ring design' because the current systems are inadequate.

APA

Centre for Environmental Rights (n.d.). 8.4-capacity-increase-4-86ab8141320f8e0c.pdf. https://cer.org.za/wp-content/uploads/2017/07/8.4-Capacity-Increase-4.pdf?x21779

Chicago

Centre for Environmental Rights. 8.4-capacity-increase-4-86ab8141320f8e0c.pdf. n.d. https://cer.org.za/wp-content/uploads/2017/07/8.4-Capacity-Increase-4.pdf?x21779.

Wikipedia

{{cite report |author=Centre for Environmental Rights |title=8.4-capacity-increase-4-86ab8141320f8e0c.pdf |url=https://cer.org.za/wp-content/uploads/2017/07/8.4-Capacity-Increase-4.pdf?x21779 |access-date=17 August 2026 |via=Climate Insights Directory}}

BibTeX

@techreport{centreforenvironmentalrightsnd84capacityincrease486ab8141320f8e0cpdf, author = {{Centre for Environmental Rights}}, title = {{8.4-capacity-increase-4-86ab8141320f8e0c.pdf}}, institution = {Centre for Environmental Rights}, url = {https://cer.org.za/wp-content/uploads/2017/07/8.4-Capacity-Increase-4.pdf?x21779}, urldate = {2026-08-17}, note = {Indexed by Climate Insights Directory} }