Download - Super Critical Presentation
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100 % load
100 C
150 C
200 C
250 C
300 C
350C
375C
400C
450C
500C
550C
600C
650C
700C
750C
enthalpy
4 000
3 600
3 200
2 800
2 400
2 000
1 600
1 200
800
400
kJ/ kg
pressure
0 50 100 150 200 250 300 bar 400
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Schwarze Pumpe Heilbronn
Bergkamen Bexbach I
Scholven F GKM, K 18
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H/P-DiagramDifferent Plants
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008 131p
Steam Generator CirculationSystems
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008 406p
Feedwater Control
Natural circulation boiler Once-through boiler
Feedwatercontrol
Level
Feedwater
Steam flowm
EvaEco
T
T
Enthalpy
Feedwatercontrol
Feedwater
TP
Eco
Eva
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Supercritical
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Simplified flow diagram ofCombined Circulation unit
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Constant Pressure Programme forCombined Circulation steam generators
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Sliding Pressure Programme forCombined Circulation steam generators
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Evaporator Tubing (1)
a
t
t1
a
a Furnace side length mm
d Tube diameter m
F Mass flow density kg/ m2s
k Constant mm/m
m Mass flow kg/ s
n No. of tubes
t Tube pitch mm
t1 Horizontal pitch mm
a Angle of inclination
The relation of the tube
system to the tube
diameter is constant for
approx. the same fin head
temperature
dkt
d
tk
sinda
mk
4dn
mF
2
sint
a4
t
a4n
1
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Spiral Wall Design
Reduced number oftubes with pitch.
Increased massflow.
Mass flow rate canbe chosen bynum ber of paralleltubes.
Features
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Evaporator Wall Design
011 104p
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Wall Furnace Supporting Structure
HorizontalBuckstay
Vertical
Buckstay
TensionStrap
TransitionZone
SpiralTubes
FingerStraps
Corner
Assembly
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008 435p
Start-Up and Low-LoadSystem
Separator Separator
Levelingvessel
Levelingvessel
Flash
tank
Flash
tank
Eco Eco
Circulationpump
Feedwaternpump
Start-upheat exchanger
HP feedwater
heater
Deaerator
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Evaporator Temperaturesat Spiral Outlet
at 40 % and 100 % Load
002 502p
0
100
200
300
400
500
Temperatureatspirale
outlet 100 % Load
C
left
side wall front wall
right
side wall rear wall
40 % Load
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Rifled Tube
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Predicted Lateral Water Wall HeatAccumulation
Percent of Wall Dimension, Corner to Corner
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Furnace Waterside Arrangement
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Water / Steam Diagram
Separators
Surroundingwalls
Leveling vessel
SH 1
Evaporator
Economizer
SH 2
SH 3
I 1
I 2
RH 1
RH 2
I RH
I RH
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Modified Tower Arrangement
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Steam-water Separator System and WaterStorage Tank
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Drain Discharge with Indirect HeatRecovery System
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Drain Water return system with low loadcirculation pump
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Drain Water Return System with astart-up Heat Exchanger system
oF
54
36
18
0
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Once-Through Boilers Reference List -Typical Units
Patnow 2004 Brown Coal 4603012/1345 4205/290
Wai Gao Qiao 2003Bituminous
Coal2 x 900 (980)
6247/2789 4045/279 1008/1055
Yonghung 2003Bituminous
Coal2 x 800
5410/2415 3930/271 1056/1056
Niederauem K 2002 Brown Coal 1,012
5860/2662 4205/290 1075/1112
Florina 2002 Lignite 3302278/1017 3800/262 1010/1008
Mai Liao 2000Bituminous
Coal2 x 600
4368/1950 3841/265 1005/1055
Schwarze Pumpe 1997 Brown Coal 2 x 8005420/2420 4135/285 1017/1050
Poryong 3 & 4 1993 ..Bituminous
Coal 2x 500
3852/1720 3840/265 1005/1005
Vestkraft Unit 3 1992Bituminous
Coal400
2420/1080 4000/276 1040/1040
Shidongkou II 1992Bituminous
Coal2 x 600
4250/1897
3885/268
1005/1055
GKM Mannheim
Boiler 181982
Bituminous
Coal475 3068/1370 3990/275
986/1004/986
Scholven, Unit F 1979 .. BituminousCoal
4 x 750 4928/2200 3335/230995/995
544/568
542/568
569/569
580/600
543/542
540/569
541/569
541/541
547/565
1010/1055
560/560
530/540/530
535/535
S
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First Supercritical Monotube
Boiler for China
MHP 527 kg/sPHP 254 barTHP 541
OC
MMP 448 kg/sPMP 45.8 barTMP 569
OC
Coal-Fired, PendantTwo-Pass Design
Main SteamConditions
Reheat Steam
Conditions
Fi t S iti l M t b
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First Supercritical Monotube
Boiler for South Korea
MHP 478 kg/sPHP 251 barTHP 541
OC
MMP 382 kg/sPMP 40.8 barTMP 541
OC
Coal-Fired, HorizontalSingle-Pass Design
Main SteamConditions
Reheat Steam
Conditions
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011 351p quer
NTPC Super Thermal PSTalcher, Unit I + II
Steam output: 1100 t/h
Design pressure: 190 bar
SH steam temperature: 540 C
RH steam temperature: 540 C
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011 350p
Power Station Schwarze Pumpe 2 x 800 MW
The Largest Supercritical Boilers
World-Wide with Brown Coal Firing
Technology - OnceThrough
Fuel - BrownCoal
Capacity t/h 2 x 2,420
Design Pressure bar 285
Temperature C 547/565
Country - Germany
Customer - VEAGBerlin
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011 341p
Power Station Niederauem 1,000 MW
World-Wide Largest Supercritical
Boiler
Technology - OnceThrough
Fuel - Brown Coal
Capacity t/h 2,662
Design Pressure bar 290
Temperature C 580/600 Commissioning - 2002
Country - Germany
Customer - RWEEnergie
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Wai Gao Qiao, 2 x 900 MW
011 414px
Live Steam279 bar (design pressure)542 C774.4 kg/s (2,788 t/h)
Reheater Steam69 bar (design pressure)
568 C687.6 kg/s (2,475 t/h)
Feedwater
273 CFuel
Bituminous coal
Mai Liao Taiwan
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Mai Liao - Taiwan2 x 600 MW
011 456px
Live Steam279 bar (degin pressure)540 C
1,950 t/h
Reheater Steam569 C
Fuel
Bituminous Coal
Year of Commissioning Hours
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001 394p
Year of Commissioning, Hoursof Operation & No. of Start-ups
Commissioning Status Hours of operation No. of start-ups
Scholven F 1979 12/ 2000 137,200 1,830
Bergkamen A 1981 12/2000 147,096 311
GKM K 18 1982 12/2000 140,950 350
Bexbach I 1983 02/2001 106,156 2,007
Heilbronn Unit 7 1985 12/2000 83,230 1,108
Vestkraft 1992 06/2000 58,300 200
Shidongkou 1 & 21) 1992 12/2000 63,842/ 60,474 162/ 112
Poryong 3 & 41) 1993 12/2000 60,685/ 61,025 73/ 71
Poryong 5 & 61) 1993 12/2000 57,378/ 56,818 113/ 74
Schwarze Pumpe A/ B 1997 06/2002 40,457/ 35,050 120/ 124Hadong 1 & 21) 1997 12/2000 27,631/ 25,418 19/ 14
Note: 1) Above data includes only startups after commercial operation, i.e., no commissioning phase startups
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004 252p
0
363
725
1088
1450
1813
2175
2538
2900
3263
3625
psig
32
122
212
302
392
482
572
662
752
842
932
1022
1112F
0
10
20
30
40
50
60
70
80
90
100
110
120
10:00 10:05 10:10 10:15 10:20 10:25 10:30
%
Total firing rate [%] SH Steam temperature [F]
RH Steam temperature [F] SH Steam flow [%]
SH Steam pressure [ psig ] Auxiliary line
64.8 %/10:10:19
6.7 %/min.
95.28 %/10:14:52
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004 251p
8:38:30:2080:248:30:288:30:328:30:368:30:368:30:408:30:448:30:48
8:30:528:30:56
8:31:008:31:04
8:31:088:31:08
8:31:128:31:16
8:31:218:31:24
8:31:288:31:328:31:36
8:31:36
8:31:408:31:448:31:488:31:528:31:56
0
10
20
30
40
50
60
70
80
90
100
8:30 8:45 9:00
Total firing rate [%] SH Steam pressure [psig] SH Steam flow [%]
RH Steam temperature [F] SH Steam temperature [F]
%
0
363
725
1088
1450
1813
2175
2538
2900
3263
3625
psig
932
968
1004
1040
1076
1112
1148
1184
1220
1256
1292
F
Statistics of Forced Outage
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001 381p
Statistics of Forced Outage(Extract)
ca. 750 MWel ca. 475 MWel ca. 750 MWelYear
[h] [%] [h] [%] [h] [%]
1983 128 1.5
1984 682 7.7 93 1.1
1985 215 2.5 146 1.7
1986 19 0.2 95 1.1
1987 73 0.8 147 1.7
1988 252 2.8 89 1.0
1989 60 0.6 21 0.2
1990 244 2.8 28 0.3
1991 276 3.2 0 0 24 0.3
1992 124 1.4 55 0.6 14 0.2
1993 421 4.8 120 1.3 24 0.3
1994 188 2.1 43 0.4 11 0.1
1995 158 1.8 63 0.7 15 0.2
Wall Thickness
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121 078p quer
Wall ThicknessHP-Outlet Headers
Materials: Tungstenalloyed 9 - 12 %Chromium Steels
540 560 580 600 620
SH temperature
20
40
60
80
100
120
140
Headerwallthickness
HP-pressure260 bar/300 bar
E 911/300 bar
NF 616/300 bar
E 911/260 bar
mm
C
i.d.= 200 mm
HCM 12 A/300 bar
HCM 12 A/260 barNF 616/260 bar
Steam Parameter Limits
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Steam Parameter Limits(Superheater Tubes)
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Allowable Stresses for Ferritic Alloys
ALLOWABLE STRESS T91, T22 vs. T23
0
20
40
60
80
100
120
140
370.0 420.0 470.0 520.0 570.0 620.0
Temperature, deg. C
AllowableStress
,MP
T91
T23
T22
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021 147p
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5
180 240 300 360
25 C = 1.25 %improvement
10Relative heat rate (Semi-net) Single reheat
%
bar
Advanced Steam Power Plants
Relative Efficiency Improvement
002 510p
Efficiencies of
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Efficiencies ofSteam Power Stations in Europe
002 636p
30
35
40
45
50
55
1950 1960 1970 1980 1990 2000 2010 2020
Time
Introduction
of
Once-Through
Technology
175/540
/5
40
1stSuperc
riticalPlants
(240-280
bar
EvaporatorPressure)
250
/550
/57
35
0/700
/72
260/580
/60
280/600
/62
Net Efficiency (HHV) vs
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Net Efficiency vs. Design Data
35
36
37
38
39
40
NetEfficiency
(HHV
)
[%]
Live Steam Press. 2407 3625 3915 [ psig ]
Live Steam Temp. 998 1005 1050 998 1005 1050 998 1005 1050 1050 1050 1085 [ F ]Reheat Temp. 1000 1040 1112 1000 1040 1112 1000 1040 1112 1112 1112 1148 [ F ]
Feedwater Temp. 500 525 555 [ F ]
Numb. of Heaters 7 8 7 8
Design Data
(500) - 600 - [700] MW ClassCond. Pressure : 1.23 psi
Net Efficiency (HHV) vs.Steam Cycle Design
Supercritical Boilers
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Supercritical BoilersTypical Emission Advantages
India Coal
Subcritical Supercritical
Plant Efficiency, % 34-37 37-41
Emissions, @ 6%O2 d.v. Total Emissions Rate (g/KWhe)
Plant Efficiency, % 34% 37% 41%
Fuel Consumption Base Base-9% Base-21%
NOx (650 mg/Nm3) 2.41 2.22 2.00
SOx (2000 mg/Nm3) 7.43 6.82 6.16
Particulates (50 mg/Nm3) 0.19 0.17 0.15 CO2 (272,000 mg/NM
3) 1008 926 835
Comparison of Supercritical and
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0
2
4
6
8
10
12
14
EFOR %
Plant (Super) 13.347 12.077 9.668 7.685 7.534 7.482
Plant (Sub) 10.405 9.439 8.16 6.793 7.103 7.013
Blr (Super) 8.441 7.285 5.823 4.872 4.434 4.023Blr (Sub) 5.928 5.464 4.344 3.811 3.926 4.018
1982-1984 1985-1987 1988-1990 1991-1993 1994-1996 1997
Comparison of Supercritical andSupercritical Cycle Availability
Once-through Benefits
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Once through BenefitsSummary
Once-through is the most flexible boiler systemsince it offers
optimum adaptation to various fouling conditions
(fuel flexibility)
best efficiencies due to high steam parameters at fullload and due to low losses at part load (sliding pressure)
max. operational flexibilityeither base loador two-shift or cycling operation mode would be possible
001 699p
C S
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Conclusion Supercritical
Coal is and will stay a fuel with an important contribution topower generation
Worldwide development in steam power plant technology promisesfurther improvementsin economic and environmental performance
Technology trend worldwide is to go for increased steam parameters,
new projects are evaluated / tendered for supercritical technology
The introduction of supercritical technology (once-through boilers)shows highest potential for customers as the most important stepto keep pace with SPP development
Supercritical power plants are state-of-the-art in many countries- as reliable as subcritical- highly efficient with a potential for further improvements- cost-effective in terms of investment and lifetime costs- reducing emissions in regard to worldwide CO2 discussions
- well designed for shift and cycling operation001 812p
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