R&D Status & Future Direction of heat resistant materials for efficient power plants
23rd June 2009, NIST, USA
Kyung-Tae HongDirector, Material Science and Technology Division
Korea Institute of Science and Technology
OUTLINE
• World Electricity Need
• Efficiency & Reduction in CO2 Emission
• Development of Heat Resistant Materials
• Issues
• Future R&D direction
World Electricity Portfolio
Sources: 2003: Derived from Energy Information Administration (EIA), International Energy Annual 2003 (May-July 2005), web site www.eia.doe.gov/iea/. 2010-2030: EIA, System for the Analysis of Global Energy Markets (2006).
Fuel Cost Increase
World CO2 Emission
Efficiency & CO2 Reduction
Scenario of CO2 Reduction
Source : IEA ‘Focus on clean coal’ paper, 2006
Improvement in efficiency of fossil-fuel fired powder plants is the most effective solution
Clean Coal Technology
Clean Coal Technology
Conventional Coal-fired
Advanced Efficiency
Coal Gasification
Supercritical(SC)
Sub-critical
Ultra-Supercritical(USC)
Hyper-Supercritical(HSC)
Fluidized Bed Combustion(FBC)
Integrated GasificationCombined Cycle (IGCC)
85% 33~39%
11% 42~45%
2% 44~45%
0% 50~55%(in 2020)
2% ~45%
>0.1% 42%(50% in 2020)
InstalledCapacity
ThermalEfficiency
“Capital costs of IGCC plants today are 20% higher that of PCC plant”(Energy Technology Perspective 2006, IEA)
T & P Increase in PF Power Plant
538oC/538oC/16.7MPa
540oC/560oC/25MPa
560oC/580oC/27MPa
600oC/620oC/29MPa
700oC/720oC/35MPa
1970 1980 1990 2000 2010 2020
EuropeJapan
USA
China
Korea
Sources: COORETEC-Meeting during Enertec 2005, Leipzig, March 11, 2005, Torsten-Ulf Kern, Siemens PG,
Efficiency Improvement
50’s 60’s 70’s 80’s 90’s 00’s 10’s
2400/1005/1005167/540/540
3480/1005/1050 (psi/¡ÆF/¡ÆF)240/540/565 (bar/¡ÆC/¡ÆC)
3600/1050/1085250/565/585
4000/1085/1100280/580/600
4000/1100/1150280/600/620
4000/1165/1200280/630/650
5400/1300/1325/1325375/700/720/720
Mature technology Mature technology
Currentmarketintro.
Market intro.by EU & JapanEf
ficie
ncy
Impr
ovem
ent
Cost Effective Materials are Key
INCREASED
STEAM TEMP. &
PRESSURE
subcritical
supercriticalR&D on-going(COST) inEurope
R&D ongoingUSA USCMaterialsConsortium
EC Thermieproject(Ni-base)
50’s 60’s 70’s 80’s 90’s 00’s 10’s
2400/1005/1005167/540/540
3480/1005/1050 (psi/¡ÆF/¡ÆF)240/540/565 (bar/¡ÆC/¡ÆC)
3600/1050/1085250/565/585
4000/1085/1100280/580/600
4000/1100/1150280/600/620
4000/1165/1200280/630/650
5400/1300/1325/1325375/700/720/720
Mature technology Mature technology
Currentmarketintro.
Market intro.by EU & JapanEf
ficie
ncy
Impr
ovem
ent
Cost Effective Materials are Key
INCREASED
STEAM TEMP. &
PRESSURE
subcritical
supercriticalsubcritical
supercriticalR&D on-going(COST) inEurope
R&D ongoingUSA USCMaterialsConsortium
EC Thermieproject(Ni-base)
USC Materials Program- Target : Alloy Development for 760oC Adv.
Steam Cycle- Schedule of Program : 2001.06 ~ 2006.12- Funding : DOE(15M$), OCDO(2M$), Boiler
Makers(3M$)- Operating Condition :
Higher T and P than EUUse of High Sulfur Containing Coal Efficiency : Adoption of HHV
Vision 21 Program in USA
~2006 : A-USC Material Program ( 5 years) for Advanced Steam Cycle (760�)~2020 : Full Scale Demo Plant of 760�grade PCPP by Novel Design (EPRI)
Completion of Design Concept and Analysis of economical efficiency in 2007Assignment of alloy development and Reliability test (ORNL)
Target : 60% Efficiency, Near Zero Emission, 2020 year DOE* Leading
CCPI (Clean Coal Power Initiative)- Target : 350bar/760oC/760oC/50%HHV/750MW- Relation to CCT, CCS, Hydrogen Program
Program Tasks Program Tasks -- 760760ooC BoilerC Boiler
No. Program Participant
Task 1 Conceptual Design EPRI/Others
Task 2 Mechanical Properties EPRI/ORNL
Task 3 Steamside Oxidation B&W
Task 4 Fireside Corrosion Foster Wheeler
Task 5 Welding Development Alstom
Task 6 Fabricability B&WTask 7 Coatings AlstomTask 8 Design Data Codes B&W
Task 9 Project Management EIO/EPRI/AII
Source: NETL/DOC, D.L.Bonk; NETL's Combustion Technology Program
Time Schedule Time Schedule -- 760760ooC BoilerC Boiler
Items 2000 2005 2010 2015 2020• Reduced Cost 760oC Materials & Fabrication• Develop 760oC Materials
• Code 760oC Materials
• Fabrication of 760oC Materials• Pilot Demo at 760oC
• CCPI Plant at 760oC
• Increased Temperature Material
EU R&D Activities
HSC grade(700oC ~ )
EU
MARCO 700
AD 700
Phase 1 Feasibility
Phase 2 Preparatory work
Phase 3 COMTES 700CTF
ETRPhase 4~6 Full scale dem o
COORETEC
NRWPP700
50plus
Phase 1 Feasibility Study- Jan. 1998- Development new materials- Improved design- Economical viability of AD700
Phase 2 Preparatory Works- 4 years, 11 M€- Funding : FP5 & DG RTD- 10 countries, 34 companies
including Elsam Eng.- Component Test, Facility
design (COMTES700), FSDP preparatin
Phase 3 Component Demo- 5 years, 15 M€- Funded by Emax & RFCS- 13 countries, 40 companies
including Elsam Eng- COMTES700 design,
Component Demonstration
Phase 4~6 Full-scale Demo Plant4 years (+ 3 years)
- FSDP construction & test operation- Feedback - Proposal submitted to FP7
- “Advanced supercritical PF power plant operating at 700oC”
- 13 countries- 40 parteners- Co-ordinated by Elsam
Engineering
Outline
Japanese A-USC Development
Source: Fukuda, NIMS, USC 2009 Symposium
Evolution of Steam Parameters in China
Source: Xie, Univ. S&T Beijing, USC 2009 Symposium
Korean Trend of CF Power Plants
Source: Ryu, Doosan , USC 2007 Symposium
Major Materials Development
JAPAN
EU
USA
1980 1990 2000 2010 2020
USC technology development(600~650oC, Basic & DEMO Plant)
COST (Materials Development & Reliability Test for High temperature)
AD700 (Basic Test & Pilot test of New Materialsfor 700oC Grade USC plant construction)
MARCKO700 (Material Test, analysis and evaluation for 700oC Grade USC plant)
Vision21 (Test and evaluation for 750oC grade USC Materials)
A-USC technology development(700oC grade, Basic & DEMO Plant)JAPAN
EU
USA
1980 1990 2000 2010 2020
USC technology development(600~650oC, Basic & DEMO Plant)
COST (Materials Development & Reliability Test for High temperature)
AD700 (Basic Test & Pilot test of New Materialsfor 700oC Grade USC plant construction)
MARCKO700 (Material Test, analysis and evaluation for 700oC Grade USC plant)
Vision21 (Test and evaluation for 750oC grade USC Materials)
A-USC technology development(700oC grade, Basic & DEMO Plant)
Materials for < 650oC > 700oC Materials
Current CF Power Plant Improvement
Source: Termuehlen and Empsperger 2003
Trend of Materials Development
Source: Speicher, Stuttgart Univ, USC 2009 Symposium
Ni-based Alloys Requirements
Source: Fukuda, NIMS, USC 2009 Symposium
Materials for A-USC Power Plant
Source: Fukuda, NIMS, USC 2009 Symposium
Materials for Steam Boiler
Source: Proceedings of 29th Int’l Conf. on Coal Utilization and Fuel System, US DOE, ASME, (2003)
1995
1998
2005
2010
260550570
270580600
290600620
300630650
350700720
Bar��
Membrane wall Tubes SH outlet header
13CrMo44 X20 CrMoV12 1 Austenite
7CrMoVTiB 10 10HCM2S
Austenite9-12%Crsteel
HCM12 Nickel Alloy
Nickel Alloy
X20 CrMoV12 1 P91
E911,P92,P122
NF12, SAVE12,12CrCoMo
Nickel Alloy
260550570
270580600
290600620
300630650
350700720
260550570
270580600
290600620
300630650
350700720
• Ferritic steels for < 621�applications• Ni-based superalloys for > 700�applications
Boiler Materials Issues
Hig
h te
mpe
ratu
re s
tren
gth
Ther
mal
str
ess
incr
emen
tdu
e to
tem
pera
ture
ther
mal
exp
ansi
on o
f pip
e
Hig
h te
mpe
ratu
re c
orro
sion
Stea
m o
xida
tion
and
scal
eex
pore
atio
nm
anuf
actio
n si
ze li
mita
tion
ofhe
at re
sist
ance
str
eels
Hig
h co
st h
eat r
esis
tanc
est
eel
High temperature properties of Fe-Ni alloy tube materialsEvaluation of Ni base tube materialDevelopment of Fe-Ni, Ni base Thich wall pipe materialDevelopment of austenitic Strainless thick wall pipe material
New 9Cr ferrite thick wall pipe materialDesing Optimization of pipe arrangement - size and thermal stress
Manufacture Welding technology of Fe-Ni and Ni base alloyOperating Optimize operating condition (strat/stop, load variation)
Materials
Break through Point
Development & Inspection Items
Turbine Rotor Candidate Materials
Source: Fukuda, NIMS, USC 2009 Symposium
Steam Turbine Materials Issues
New Alloy Development available to HSC Steam Condition Estimation of Long Term Stability
Turbine material development Breakthrough Point
• Strength ( long term Creep)
• Steam corrosion, oxidation
• Large scale manufacture
• Weldability, Dissimilar weld
• NDT technology
• Low thermal expansion
Experience in A286 rotor for 650� GradeNo Experience in Large Scale Manufacture of Ni base alloys for over 700oC grade
Adoption of Assemble type RotorWelding technology between Dissimilar Materials.
Estimation of Soundness in welded part.Non-destructive Technology of Welding Defects.
Development of Ni Alloy with Low Thermal Expansion Coefficient
• Large scale casting Require same properties as Rotor MaterialsEstimation of Castability and Weldability
Rotor
Casing / Valve
• Steam condition properties Steam oxidation of Ni base alloyBucket
• Long term stability Superior High-Temperature Stress Relaxation PropertiesBolt
Steam Oxidation of Ni base alloy
Breakthrough by New Materials
Efficiency & Economic Design Social & Environmental Demand
Key Issues
- Types of Power Generation- Environmental Regulations- CO2, NOx, SOx
- High Temperature & Pressure - Low Cost Design
MaterialsMaterials
Global Research NetworkGlobal Energy Plan : Define the role of Fossil Power Plants.
- Time Schedule and Market
Reduce the Risk to develop the new materials
- Minimizing the alloying elements
- Low Thermal Expansion Coefficients,
- Good Thermal Conductivity
- Processing tech. to make a large components with reliability
- Data Base for the long term stability
Oxygen burning technology for Near-Zero Emission
Coal
Air
In-furnace deNOx/deSOxIn-furnace
deNOx/deSOx
O2
Power Generation
Flue gas treatment system
OFO/Reburn
Stack
Steam
H2O Sepa-ration
No Stack
CO2
Geological Storage
Geological Storage Ocean
StorageOcean Storage
ASU(Air
SeparationUnit)
Air
N2
Wet FGR Dry FGR
CO2 and/or H2O
Steam turbine
Generator
Steam turbine
Generator
NO need of Flue Gas Treatment System
Germany; Vattenfall AB2008 : 30MWth Schwarze-Pumpe Pilot Plant
2015 : 300~600MWth Demo Plant2020 : 1000MWth Commercial Plant
US DOE3 New Projects
In 2005SRI, B&W, BOC
Spain, CIEMAT2005-
5MW OFC Boiler
Japan; IHI-NEDO1992-2000
1.2MW Boiler Test
1990 2000 2010 2020
1MW
10MW
100MW
USAArgonne NL
EERC3MW Test
forOFC/RFG
Canada; CANMETOn-Going
300kW Oxy-Burner Development
EU-IFRF92-95
150kW↓
35MWOFC
Research
MBELAir ProductUlster U.Napoli U.Imp. Col.
EDP,
Japan-Australia;IHI-CSIRO2004-2011
Retrofit 30MWe Callide A
Jupiter Oxygen25 MWe Orrville
Sask Power 300MWe
KOREA R&D Route to500MWe Class
Commercial Capture-Ready Plant
Global R&D Trend in Oxygen Burning
U.S. Fossil Fuel Reserves / Production Ratio
IGCC
Abundant reserves of CoalEnvironmentally superior coal-based powerEasily adapted for CO2 sequestrationHigh efficiencyFuel & product flexibilityPromising “coal-to-hydrogen” option
USA National Initiatives
Integrated Gasification Combined Cycle, IGCC
Oxygen Separator
O2
Crude coal
Fuel gas
Dust/Gas Purifier
H2 gas
CO gas
+
Syngas
Crude coal/Oil GasificationPurification of Dust/SOx
Production of CO/H2 Gas/Steam Turbine Production of Electricity
Contribution of Energy/Chemical Industry utilizing Syngas
Global R&D Trend in IGCCUSA
• DOE: Construction of Commercial IGCC plants (50% Gov. Funding) - Operating 300MW Grade Demo Plant
• Vision 21 Program: Fuel-Flexible Technology with High Efficiency of 60%
EU • Construction of IGCC Demo Plant (Netherlands, Germany, Spain, Italy)
Japan • Sunshine Project: Construction of IGCC Plant with 250MW Grade
China • Selection of one of National Agenda in 21th • Construction Plan of 200-400 MW Grade IGCC Plants after 2010
Global Production of Syngas by IGCC Technology
Materials Issues for IGCCMaterials Issues for IGCC
Ceramic Gas Turbine
Hydrogen Membrane
�������Membrane
SOFCGas Purifying
Membrane
Oxygen Membrane
High Activity Catalyst
Thank you !