EDP and Corporación Masaveu complete conversion of Aboño power plant to natural gas
- Unit 2 of the plant, located in the Spanish region of Asturias, is already generating electricity for the grid, ensuring supply to heavy industry.
- It exceeds initial forecasts, reaching over 500 MW of capacity.
- The project involved more than 600 people and over 80 companies working simultaneously at peak construction.
- The results of this ambitious project translate into a significant reduction in emissions.
The conversion to natural gas of the main power generation facility in Asturias, Spain, is now a reality. Following 16 weeks of intervention, preceded by over a year of preparation and around 400,000 hours of work, Unit 2 of the Aboño power plant – essential for supplying electricity to Asturias’ heavy industry and the Spanish power system – is back in operation and generating energy. This follows the ambitious project carried out by EDP and Corporación Masaveu, making a significant contribution to the energy transition of the Iberian Peninsula and Europe.
The project lasted a total of 18 months, with fieldwork concentrated between the shutdown of the unit on 1 March this year and its reconnection to the grid on 25 June. These were intense weeks during which, in addition to converting the boiler to burn natural gas and blast furnace gases, a general overhaul of the turbine was carried out. This included inspection and fine-tuning of all equipment, systems, and infrastructure, which – like the thermal unit itself – is now set for a new lease of life.
Highlights of the overhaul include the turbine group and auxiliary turbines, after 73,000 hours of operation since the last overhaul in 2016; interventions in the denitrification unit to ensure optimal reduction of nitrogen oxide emissions; and the inspection of the gasometer and pipelines transporting blast furnace gases.
Blast furnace gases will continue to be used for power generation – a clear example of EDP and Corporación Masaveu’s commitment to the circular economy, which already avoids the annual emission of one million tonnes of CO₂ into the atmosphere.
In addition, specific conversion works were carried out, including a complete overhaul of the fuel system. As a result, the plant has eliminated coal use for power generation, replacing it with natural gas and preparing for the potential future integration of renewable hydrogen.
In total, 30 coal burners were replaced with new burners capable of using natural gas and hydrogen. The blast furnace gas burners were also adapted to the new boiler configuration. Over 3,000 welds were made on the boiler alone, with a total of 15,000 across the entire conversion project.
In terms of emissions, the conversion has a significant impact on air quality improvement. It reduces particulate emissions by nearly 100%, sulphur oxides by 90%, and nitrogen oxides by 80%. As for CO₂ emissions, the conversion project will reduce them by an average of 30%.
Following tests carried out between June and July, the unit’s capacity now exceeds 500 MW, surpassing the project’s initial forecasts.
At peak construction, the project involved more than 600 workers on-site and over 80 companies. These figures represent a major organisational challenge due to the technical, preventive, and environmental complexities of carrying out a high volume of tasks and managing a large workforce simultaneously. All of this was coordinated alongside the operation of Unit 1, which remained available to meet the needs of the Asturian power system.
Risk prevention and worker safety were top priorities from day one, with strong engagement from teams and all companies involved. Over 800 safety inspections were carried out, a key factor in the project’s success in this area.
Unit 2 of Aboño celebrates its 40th anniversary in 2025. From September 1985 until this past March, when the conversion works began, the unit generated 131,625 GWh – enough energy to power all households in Gijón for 250 years or the entire Portuguese territory for nearly three years.