advantage of usc technology in power generation_l

7/29/2019 ADVANTAGE of USC Technology in Power Generation_L

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Clean Coal Technology, Sardinia May 2005

Group

Burmeister & Wain Energy A/S J gersborg All 164 DK-2820 Gentofte Denmark Tel/fax +45 39 45 20 00/+45 39 45 20 05 [email protected]

Advantages of Ultra SuperCritical Technology in

Power Generation

by

Hans H. Poulsen

Burmeister & Wain Energy A/S


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Burmeister & Wain Energy A/S (I):

Company founded in 1843

First steam boiler supplied1852.

First Benson once-throughboiler supplied in 1952

World record - above 47% in efficiency for acoal fired utility boiler 1999

Part of the Italian STF S.p.A. Group (2002)


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Burmeister & Wain Energy A/S (II):

Advanced Ultra Super Critical steam boilers

FGD Flue Gas Desulphurization plants

Low-NOx firing systems

Regenerative Gas-Gas Heaters

Upgrading of existing boilers to improvedperformance


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Clean Coal technology:

IGCC processes

PFBC processes

USC power cycles


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1950 19701960 19901980 20202000 2010

30

32

34

36

38

40

42

44

46

48

52

50

54

56

58

60

%

Net Efficiency (LHV)

Commissioning Year

Esbjerg 3Nordjyllandsvrket

Avedre 2

Fynsv. 7

250 MW

Studstrup 3/4Ensted 3

Line of Steel

Line of Super Alloys

Efficiency Increase in DK


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BENSON once-through boiler system

Supplied on a licens from Siemens

since 1952

IP1.1

IP2.1

IP2.2

HP2

HP1

ECO

IP1.2

Asnsvrket #2

150MWe, 1958

Asnsvrket #3

250MWe, 1962

Fynsvrket #7

350MWe, 1991

Nordjyllandsvrket #3

415MWe, 1998


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Conventional 2-pass design:

Fynvrket Unit 7 (FV-7):

350MWe

2-Pass Benson boiler, Single Reheat

Tangential firing system

Furnace dimensions

Height of Boiler 66m

Problems related to this design:

Flue gas changes flow direction through the boiler.Flue gas flow direction not perpendicular to the first

heating surfaces

Cracks can appear in the connections between themembrane walls of the first and second pass.

Flue gas flow in the second pass are not uniformcausing problems of erosion as well as thermal

unbalance

Uneven distribution of loads on the top frame

Pressure part not fully drainable


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Tower design (I):

IP1.1

IP2.1

IP2.2

HP2

HP1

ECO

IP1.2

Nordjyllandsvrket Unit 3 (NVV-3):

400MWe

Tower type Benson boiler, Double Reheat

Tangential firing system

Furnace dimensions: 12.2512.25m

Height of Boiler 80m

Problems solved by this design:

The flue gas flows in one direction through theboiler.

Even distribution of loads on the top frame

The main direction of the flue gas is perpendicular tothe tubes in all heating surfaces

The flue gas flow through the convention pass seemsto be uniform. Problems of erosion are not reported.

Heat pick-up are uniform

Pressure part fully drainable


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Tower design (II):

Compared to 2-pass boilers

15-20% additional height

App. 10% reduction ofmaterial consumption

Penthouse not necessary

Ideal for T-firing


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First

tower type

boilersupplied

to STEAGin 1987

Walsum #9

400MWe


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Ultra Super Critical Installations of the World

Power station Cap. Steam parameters Fuel Year of Eff. Boiler/steam Turbine

MW Comm. % line materials materials

Matsuura 2 1000 255bar/598C/596C PC 1997 Super304HP91 TMK1

Skrbk 3 400 290bar/580C/580C/580 NG 1997 49 TP347FG/P91 COST 501 F

Haramachi 2 1000 259bar/604C/602C PC 1998 Super304H/P91 HR1100

Nordjylland 3 400 290bar/580C/580C/580 PC 1998 47 TP347FG/P91 COST 501 F

Nanaoota 2 700 255bar/593C/593C PC 1998 P91 Toshiba 12Cr

Misumi 1 1000 259bar/604C/602C PC 1998 Super304H/P91 TMK2/TMK1

Lippendorf 934 267bar/554C/583C Lignite 1999 42.3 1.4910/P91 COST 501 E

Boxberg 915 267bar/555C/578C Lignite 2000 41.7 1.4910/P91 COST 501 E

Tsuruga 2 700 255bar/597C/597C PC 2000 Super304H/P122 Toshiba 12Cr

Tachibanawan 2 1050 260bar/605C/613C PC 2001 Super304H/P122/P92 TMK2/TMK1

Avedre 2 400 300bar/580C/600C NG 2001 49.7 TP347FG/P92 COST 501 E

Niederaussen 975 265bar/565C/600C Lignite 2002 >43 1.4910/E911 COST 501 E

Isogo 1 600 250bar/600C/610C Coal 2002 Super304/P122 COST 501 E


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400

800

1200

1600

2000

2400

2800

3200

3600

4000

0 50 100 150 200 250 300 350 400

Pressure [bar]

Enthalpy[kJ/kg]

100C

150C

200C

250C

300C

350C

400C

450C

500C

550C

600C

650C

700C

750C

Ultra Super Critical ??

Sub Critical

Super Critical

Ultra Super Critical


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Sub-, Super- and Ultra Super Critical Boilers

0

500

1000

1500

2000

2500

3000

3500

4000

0 50 100 150 200 250 300 350

Pressure [Bara]

ENTHALPY,

H

[kJ/kg]

100C

200C

400C

600C

NVV 3FV 7ASV 5

HT

IP1IP2


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Increasing live steam parameters(temperature and pressure)

Reducing the condenser pressure by

means of a cold and effective cooling

media preferably sea water

Using reheat and maybe double reheat

Optimizing the feed water temperature

Selecting the single train mono

component solution for the air/flue gas

path and thereby reduce aux. power

Increasing boiler efficiency

Increasing Plant Efficiency


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Reducing flue gas exit temperature bymeans of an effective air preheater

reducing Unburned Carbon (UBC) in the

fly ash by effective and improved

combustion

Reducing air excess and thereby areduced flue gas loss

Reducing leakage in the air prehaeter

Reducing pressure loss of the

water/steam cycle

Increasing Boiler Efficiency


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Ultra

Super

Critical

SuperCritical Sub

Critical

Nordjyllandsvrket (I):

3 Generations of Power Plants:


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Unit 3: State of the art Clean Coal Technology

Nordjyllandsvrket (II):

More than 50.000 h of

operational hours has

proven:

Plant efficiency >47%

Availability > 98%


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Generator output 411 MW

Aux. Power consumption incl. DeNOx- and DeSOx plant 26 MW

Aux. Power consumption excl. DeNOx- and DeSOx plant 23 MW

400 kV output to grid, incl. DeNOx- and DeSOx plants 385 MW400 kV output to grid, excl. DeNOx- and DeSOx plants 388 MW

Turbogenerator, heat rate, based on gen. output 6.736,6 kJ/kWh

Boiler efficiency 94,2 %

Power plant, heat rate, based on gen. output 7.151,4 kJ/kWh

Gross calorific value of coal 26 MJ/kg

Specific coal consumption, based on gen. output 275 g/kWh

Specific coal consumption, based on 400 kV output to grid 293 g/kwh

Thermal efficiency, based on 400 kV output to grid 47,2 %

NVV B3 operationdata, Cond. mode

Operational data, power production only100% load, condensing mode, 10 c cooling water.

Operational results: Power production only

Nordjyllandsvrket (III):


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Generator output 339,5 MW

Aux. Power consumption incl. DeNOx- and DeSOx plant 26,5 MW

Aux. Power consumption excl. DeNOx- and DeSOx plant 23,5 MW

400 kV output to grid, incl. DeNOx- and DeSOx plants 313 MW

400 kV output to grid, excl. DeNOx- and DeSOx plants 316 MWDistrict heating output 422 Mj/s

Turbogenerator, heat rate, based on gen. output 8150,3 kJ/kWh

Boiler efficiency 94,2 %

Power plant, heat rate, based on gen. output 8652,1 kJ/kWh

Gross calorific value of coal 26 MJ/kgSpecific coal consumption, based on gen. output + DH output 148 g/kWh

Specific coal consumption, 400 kV output to grid + DH output 154 g/kwh

Thermal efficiency, 400 kV output to grid +DH output 90 %

NVV B3 op CHP mode

Operational data, combined heat and power production100% load, back pressure mode, 4 c cooling water..

Operational results: Combined Heat and Power production:

Nordjyllandsvrket (IV):


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0

50

100

150

200

250

300

0 100 200 300 400 500 600 700

Temperature [C]

Allowablestress

[N/mm

2]

13CrMo4-5

SA-213 T23

7CrMoVTiB10-10

HCM12

Materials for membrane walls:


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Materials for super heaters:

0

50

100

150

200

250

0 100 200 300 400 500 600 700

Temperature [C]

Allowablestre

ss

[N/mm

2]

HR3C

Super304HTP347HFG


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1950 19701960 19901980 20202000 2010

30

32

3436

38

40

42

44

46

48

52

50

54

56

58

60

%

Net Efficiency (LHV)

Commissioning Year

Esbjerg 3Nordjyllandsvrket

Avedre 2

Fynsv. 7

250 MW

Studstrup 3/4Ensted 3

Line of Steel

Line of Super Alloys

Future efficiencies


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NVV B3 op CHP mode

The USC Power Cycle :

Conclusion:

is the current development edge of theconventional Rankine power cycle

has demonstrated high efficiency and has apotential for further efficiency increase

has proved to have high and satisfactoryavailability


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