At the Duisburg-Huckingen gas-fired power plant (HKM / RWE), a recent retrofit of the Boiler Feed Pump (BFP) drive system has significantly outperformed expectations—delivering energy savings well above the guaranteed targets.
The modernization involved replacing a low-efficiency, geared variable-speed fluid coupling with a state-of-the-art SETCON SE6R electro-mechanical variable speed gearbox. This upgrade directly addressed the typical thermal losses associated with fluid couplings, resulting in a marked increase in system efficiency and long-term operational reliability.
The new drive system powers a 5.7 MW Boiler Feed Pump through a planetary gear stage, controlled by low-voltage Servo motors that precisely regulate the gearbox output torque, while reusing existing constant running Main Motor. Unlike fluid couplings—which suffer from increased losses when operating below full load—the SETCON gearbox maintains high and consistent efficiency across the entire load range. Additionally, the SETCON system is optimized for footprint compatibility. It shares the same footprint as the replaced geared variable-speed fluid coupling, utilizing existing anchor points and eliminating the need for any foundation modifications. This significantly reduced downtime during installation. Furthermore, the Booster Pump required no modifications and continues to operate at a constant speed using the existing Main Motor.
Independent measurements conducted by RWE Generation SE confirmed that the SETCON system saves over 1.3 MW on average within the plant’s defined operating conditions—substantially outperforming the legacy setup.
This successful retrofit not only demonstrates the technical and economic advantages of SETCON, but also establishes a proven reference project that can serve as a model for future upgrades in similar applications.
The Duisburg-Huckingen gas-fired power plant, with a net unit output of 2×303 MW, is part of Hüttenwerke Krupp Mannesmann GmbH (HKM)—one of Germany’s leading steel producers, with an annual output of approximately four million tons. The site’s energy supply is managed in partnership with RWE Generation SE (RWE), an international energy company strongly focused on emission reduction targets. RWE Generation is well known for promoting the sustainable transformation of the power generation sector.
The SETCON variable-speed gearbox, developed by the Austrian company SET Sustainable Energy Technologies GmbH, is a proven solution for retrofit projects in power plants and refineries that aim to improve energy efficiency without a complete system overhaul. Thanks to its compact frequency converter and space-optimized gearbox design, SETCON is particularly well suited for upgrading existing systems while offering high system availability.
