high performance coal fired thermal power...
TRANSCRIPT
Session Theme:Clean Coal saving the Earth and Economy
High Performance Coal Fired Thermal Power PlantThermal Power Plant,
Achievement and R&D for Future
8th September, 2010Toshiba Corporation
Copyright 2007, Toshiba Corporation.
Contents
11. Introduction of Steam Turbine & Generator Achievements. Introduction of Steam Turbine & Generator Achievements
2. Efficiency Improvement by Innovative Thermal Cycle2. Efficiency Improvement by Innovative Thermal Cycle
3. Development of Advanced3. Development of Advanced--USC & CCS technologies USC & CCS technologies pp gg
2© TOSHIBA CORPORATION 2010, All rights reserved.
Contents
11. Introduction of Steam Turbine & Generator Achievements. Introduction of Steam Turbine & Generator Achievements
2. Efficiency Improvement by Innovative Thermal Cycle2. Efficiency Improvement by Innovative Thermal Cycle
3. Development of Advanced3. Development of Advanced--USC & CCS technologies USC & CCS technologies pp gg
3© TOSHIBA CORPORATION 2010, All rights reserved.
Iran Pakistan
Turbine Power Plants supplied by ToshibaAs of March 2010
Canada10 Units
1,427 MW
USA96 Units
29,370 MW
Thailand8 Units
348 MW
India10 Units
2,458 MW
Kuwait22 Units
4,470 MW
4 Units255 MW
China(i l T i R i )
Pakistan3 Units
137 MW
Bulgaria
As of March 2010
348 MW (incl. Taiwan Region) 49 Units
12,037 MW
3 Units532 MW
Iceland1 Unit
Mexico30 Units Antigua
Korea28 Units
2,138 MW
Cyprus
Puerto Rico1 Unit
214 MW
Japan1,447 Units
81 134 MW
Italy4 Units
994 MW
UK1 Unit
210 MW
34 MW
2,512 MWg
2 Units18 MW
Venezuela7 Units
1,418 MW
Philippines27 Units
1,114 MW
Nigeria
Egypt6 Units
1,764 MW
2 Units120 MW
Nauru1 Unit
0.1 MW
81,134 MW
UAE4 Units
968 MW
Costa Rica1 Unit
55 MW
Brazil3 Units
155 MW
Argentina
Indonesia15 Units
2,328 MW
Sri Lanka1 Unit6 MW
B
Nigeria4 Units
56 MW Lebanon4 Units
130 MW
BahrainBangladesh
5 Units
3 UnitsPapua New Guinea
135 MW
968 MW
3 Units14 MW
Australia55 Units
11,672MW
Malaysia22 Units
4556 MW2 Units118 MW
Botswana1 Unit
33 MW
Bahrain1 Unit
65 MW
5 Units41 MW
Myanmar2 Units
0.9 MW
South Africa
T t l 1 890 U it 160GW i 37 t i i 1927
4© TOSHIBA CORPORATION 2010, All rights reserved.
Total: 1,890 Units, 160GW in 37countries since 1927
Recent EPC Thermal Power Projects in the WorldUSA I tJ M i #2Bulgaria – Maritsa East 2
#1,3,4 3x177MW Coal FiredPlant Rehabilitation
(COD:#1 Sep.2007, #3 Nov.2008, #4 Feb.2009)
China - Taizhou #1,#22x1000MW Coal FiredUSC 25MPa600/600℃
(COD:#1 Dec.2007/#2 Mar.2008)
USA - Iatan2x1000MW Coal Fired
USC 25.5MPa582/582℃(Under Construction)
Japan – Maizuru #2900MW Coal Fired
USC 24.5MPa595/595℃(COD: Aug. 2010)
, )
Indonesia - Tanjung Jati B Extension
2x660MW Coal Fired
(Under Construction)Rumania – Paroseni #4 1x150MW Coal Fired
India - Mundra5x800MW Coal Fired
USC 24.2MPa565/593℃(Under Construction)
Malaysia - Jimah 2x700MW Coal Fired
(COD:#1 Jan./#2 Jul.2009)
Malaysia - Tanjung Bin 3x700MW Coal Fired(COD:#1 Oct.2006/
#2 Feb./#3 Aug.2007)
Plant Rehabilitation(COD: Aug.2007)
( ) #2 Feb./#3 Aug.2007)
5© TOSHIBA CORPORATION 2010, All rights reserved.
Profile of the Project (1)KEPCO M i #2 P Pl (COD A 2010)KEPCO Maizuru #2 Power Plant (COD August, 2010)
Customer: Kansai Electric Power Co., JapanTurbine: Cross Compound Four Flow( CC4F 43”)Turbine: Cross Compound, Four Flow( CC4F-43 )Generator: Pri./Sec.:670MVA/370MVAOutput: 900 MWM i St 25 MP 595℃Main Steam: 25 MPag、595℃Reheat Steam: 595℃Rotation Speed: Pri./Sec.:3,600rpm/1,800rpm
FeaturesTop Level Plant PerformanceV i C l A il blVarious Coals AvailableHigh-efficiency on Various CoalsSustainability and Landscape-Reserve, considering
the Location adjacent to the quasi-national park
C l Fi d Pl t ith th L t t T h l i6© TOSHIBA CORPORATION 2010, All rights reserved.
Coal Fired Plant with the Latest Technologies
Profile of the Project (2)
Eraring 660MW Thermal Power Station, Australia
The record of continuous operation in the World (at 2003)Eraring Unit 4 & 10 (Australia): manufactured by Toshiba
The continuous operation : 673 days (from Feb 26, 1995 to Dec31,1996) Availability : 99.63%
&7© TOSHIBA CORPORATION 2010, All rights reserved.
The most reliable turbine & generator in the world
Profile of the Project (3)
Anpara #4,#5 Power Station, India 8 years continuous commercial
Customer: Uttar Pradesh State
operation without major overhaul
Custo e Utta ades StateElectricity Board, India
Taking over: Unit # 4: Feb 1994Unit # 5: Oct 1994Unit # 5: Oct 1994
Turbine: Tandem Compound, Double Flow, Reheat Type (TCDF 42”)Reheat Type (TCDF-42”)
Output: 500 MWMain Steam: 166 barg, 538 ℃R h t St 538 ℃Reheat Steam: 538 ℃Rotation Speed: 3000 rpm
R b t D i d T bi f B kd M i t8© TOSHIBA CORPORATION 2010, All rights reserved.
Robust-Designed Turbine for Breakdown Maintenance
Contents
11. Introduction of Steam Turbine & Generator Achievements. Introduction of Steam Turbine & Generator Achievements
2 Efficiency Improvement by Innovative Thermal Cycle2 Efficiency Improvement by Innovative Thermal Cycle2. Efficiency Improvement by Innovative Thermal Cycle2. Efficiency Improvement by Innovative Thermal Cycle
3. Development of Advanced3. Development of Advanced--USC & CCS technologiesUSC & CCS technologies
9© TOSHIBA CORPORATION 2010, All rights reserved.
Growth of Thermal Power Plant (2007→2015)
【China】
【Europe】 Shift to Low Emission Power Plants
371GW
42GW
【China】 Mega Market more than 50% in the World
Local Manufactures Supplied Equipment
371GW
35GW76GW 15GW
【America】【Japan】C【Middle East】
80GW
71GW
【America】 Shift from Coal to CC in North America
Large Scale Thermal Plant
in South America
Construction of
Combined Cycle
Plant
【Middle East】 Shift from Oil Fired to
Natural Gas Fired
【India】
39GW
【Asia & Oceania】 Large Scale Thermal Power Plant
Geo Thermal
【Africa】
【India】
Large Scale Coal
Fired Thermal Plant
【Africa】
Coal Firing Unit
& Combined Cycle
Plant Source: IEA World Energy Outlook 2009
10© TOSHIBA CORPORATION 2010, All rights reserved.
Towards Clean Coal Thermal Power Plants
TOSHIBA activities
Hi h ffi iAdvanced
Methods40 Gt
PerformanceImprovement(57%)
• High-efficiencyEquipment supplyBaseline
Temperature Increase
Emerging Countries
Countries
• Rehabilitation Advanced
Renewable • Hydro CSP
6 deg C of decrepit plantsAdvanced Countries
Advanced CountriesRenewable
Energy(23%)Neucler(10%)CCS(10%)
• Hydro, CSP,Geothermal
450ppm Stabilization Scenario temperature Increase 2 0 – 2 4 deg C
Countries
Emerging Countries
CCS(10%)
(Source: World Energy Outlook 2009)
• Thermal Plantwith CCS
temperature Increase 2.0 2.4 deg C
26 Gt@2030
Advanced Countries
(Source: World Energy Outlook 2009)
Efficiency Improvement for CO2 Reduction
@2030
11© TOSHIBA CORPORATION 2010, All rights reserved.
Efficiency Improvement for CO2 Reduction
Coal-Fired Plant Efficiency in the World
43 %
45 % The Latest Plant Efficiency Level
37 %
39 %
41 % Japan
UK&Ireland
(L
HV
)
33 %
35 %
37 % German
USA
Australiaffici
ency
27 %
29 %
31 %
Australia
China
IndiaGro
ss E
ff
25 %
27 %
1990 1992 1994 1996 1998 2000 2002 2004 2006
G
T L l Effi i C l Fi d Th l Pl t
Source: Ecofys International Comparison of Fossil Power Efficiency and CO2 Intensity 2009
12© TOSHIBA CORPORATION 2010, All rights reserved.
Top Level Efficiency as Coal Fired Thermal Plant
CO2 Reduction by Efficiency ImprovementW ld T t l l fi d th l l t
Efficiency and CO2 emissions of C l Fi d Th l Pl t
World Total coal-fired thermal plant capacity: 1,440GW
(1/3 of entire power plants capacity) Coal-Fired Thermal Plants
Coal-Fired Thermal Plantsin the World
(1/3 of entire power plants capacity)
(%)
The Latest Plant Efficiency Level
China35%
Others37%
40
41 6%
(%)
BaseEffi
+760kt +1690kt +1760kt
CO
2e
USAIndia5%
1,440GW 3541.6%
36.7%
icie
ncy
*
em
issions
*
*Gross efficiency (LHV)
USA23%
5%
Source: IEA World Energy Outlook 2009・ECOFYS INTERNATIONAL COMPARISON
30Japan USA China India
31.8%32.1%
Efficiency Improvement Technology
G y ( )
*CO2 emissions from a 1,000MW plant
・ECOFYS, INTERNATIONAL COMPARISON OF FOSSIL POWER EFFICIENCY(2008)
13© TOSHIBA CORPORATION 2010, All rights reserved.
Contributes to Reduction of CO2 emissions
Steam Cycles and Efficiency Gains
elat
ive)
6
7600/610℃
ent (
% re
4
5
6
566/566℃
593/593℃
566/593℃
prov
eme
2
3
4 566/566℃
538/566℃
538/538℃
ency
Imp
0
1
2MST/RST Temperature
15 20 25 30 35Main Steam Pressure (MPa)Ef
ficie 0
Higher the Pressure, Higher the TemperatureMore Gains on Efficiency and Subsequent CO2 Reduction
14© TOSHIBA CORPORATION 2010, All rights reserved.
O 81 it f T hib ’ S C iti l STG h b
Super Critical Turbine ExperienceOver 81 units of Toshiba’s Super Critical STG have beenoperating since 1969. (except China)
World Share of Supercritical Steam Turbine(Among Major Manufactures, Past 20 Years)
TOSHIBATOSHIBA27%27%
Company ECompany E9%9%Company DCompany D
14%14%14%14%
Company CCompany C16%16%
Company BCompany B16%16%
Company ACompany A18%18%
16%16%
as of 2009
Top Level efficiency Steam Turbines Supplied to the Markets
15© TOSHIBA CORPORATION 2010, All rights reserved.
Top Level efficiency Steam Turbines Supplied to the Markets
Transition of Steam Conditions
MST/RSTJ-Power TACHIBANA BAY #1
KAWAGOE #1,#2700MW (TC)
NANAO OTA #2700MW (TC)
J Power TACHIBANA BAY #11050MW (CC) (25MPag 600/610℃)
600/610℃
TAIZOH #1&21000MW (TC)(25MPag 600/600℃)
MAIZURU #2900MW (CC)
(24 5MP 595/595℃)700MW (TC)(31MPag 566/566/566℃)
NOSHIRO #2600MW (TC)(24 1MP 566/593℃)
700MW (TC)(24.1MPag 593/593℃)
HEKINAN #4,#51000MW (TC)(24.1MPag 566/593℃)
593/593℃ IATAN 914MW (TC)(24.6MPag 582/582℃)
(24.5MPag 595/595℃)
TSURUGA #1500MW (TC)(24.1MPag 566/566℃)
(24.1MPag 566/593℃)
HARAMACHI #11000MW (CC)(24.5MPag 566/593℃)
566/593℃TACHIBANA BAY700MW (TC)(24.1MPag 566/593℃)
WESTON #4 5834MW (TC)(24.7MPag 582/582℃)
TC : TANDEM COMPOUND
538/566℃
( g )
HEKINAN #1700MW (TC)(24.1MPag 538/566℃)
566/566℃CALLIDE #3,#4 420MW(TC)(25MPag 566/566℃)
TC : TANDEM COMPOUNDCC : CROSS COMPOUND
: 60Hz: 50Hz
1990 1995 2000538/566℃
2005 2010
Towards to Top Level Steam Conditions16© TOSHIBA CORPORATION 2010, All rights reserved.
Towards to Top Level Steam Conditions
Steam Turbine Development based on CFD
Cross-Over PipingHP Turbine 1st Stage NozzleHP Steam Valve
Nozzle
Lead PipingIP Exhaust LP InletBox
IP InletIP Inlet
RH Steam Valve LP Exhaust Casing
Abradable Seal
17© TOSHIBA CORPORATION 2010, All rights reserved.
RH Steam Valve LP Exhaust Casing
High efficiency large capacityEfficiency Improvement of Generator
High-efficiency, large-capacity indirectly hydrogen-cooled turbine generator
Reduce losses compared to water-cooled generatorsReduce losses compared to water cooled generators
Award fromThe Japan Machinery
Federationas
Excellent Energy-saving Equipment
in 2009
Generators: Primary 670MVA(600MW) Secondary 370MVA(300MW)
Achieved the largest capacity and highest-efficiency
18© TOSHIBA CORPORATION 2010, All rights reserved.
in the world by indirectly hydrogen-cooled method
Steam Turbine Efficiency Improvement■ St T bi T t F ilit
Mikawa Power StationUnit2 Turbine Test Facility
( i J 2008)
■ Steam Turbine Test Facility
(since June 2008)
LP Turbine
HP Turbine GeneratorHP Turbine
MSV/CVCondenser
Generator
Bypass valve
Condenser
HP Turbine LP Turbine
Condenser
Generator
Boiler
Speed: 6,000rpmStages: 16
HP Turbine BoilerSpeed: 3,600rpmStages: 6LSB: up to 50 in.
19© TOSHIBA CORPORATION 2010, All rights reserved.
Full-scaled Turbine Test Facility for R&D to Boost Up
New Technology R&D PlanningNew Technology R&D Planning Verification PhaseVerification PhasePerformance Improvement R&D Process
Rotational direction① Blade loss reduction
O S
New Technology R&D PlanningNew Technology R&D Planning Verification PhaseVerification PhaseAnalysis & Simulation
Bucket
nozzle
② Pressure drop loss reduction
・Optimized Reaction Stage Design・Surface friction loss reduction・Longitudinal flow distribution control
② Pressure drop loss reduction・Inlet/Exhaust scroll・Steam valve・piping connection part・Section joint piping, duct
Practical Operation
Performance Performance ImprovementImprovement
C lC l③ Leakage loss reduction・Seal fin profile improvement・Clearance reduction
p
Mikawa P/S Unit #2Mikawa P/S Unit #2Actual size test facilityActual size test facility
CycleCycle
④ Last stage blade development・High efficiency LSB series
Increased annulus area=> Exhaust steam speed reduction=> Loss reduction・High mach number blades・Smaller radical clearance
20© TOSHIBA CORPORATION 2010, All rights reserved.
Utilization of the test results for Analysis & Simulation
OO
Latest Development – Steam Turbine TechnologyOptimal Reaction BladeVerified High EfficiencyOptimal Reaction BladeVerified High Efficiency
Drum-type RotorDrum-type Rotor
Direct LubricatedBearingsConfirm 30% Loss
Direct LubricatedBearingsConfirm 30% Loss
35in LSBMeasure Moisture35in LSBMeasure MoistureDrum-type Rotor
Confirm Rotor DynamicsDrum-type RotorConfirm Rotor Dynamics
Confirm 30% LossReductionConfirm 30% LossReduction CoefficientCoefficient
Abradable Coating SealConfirm Low LeakageAbradable Coating SealConfirm Low Leakage Welded Rotor
GWelded RotorG
Corrosion-ResistantCoatingCorrosion-ResistantCoatingLoss and good Shaved
SurfaceLoss and good ShavedSurface
Good Inspection Resultafter Long OperationGood Inspection Resultafter Long Operation
CoatingConfirm Coating EffectCoatingConfirm Coating Effect
V i T h i l I t f B th P f & R li bilit
21© TOSHIBA CORPORATION 2010, All rights reserved.
Various Technical Improvements for Both Performance & Reliability
Steam Turbine World Market Share
100%
Worldwide US Market%(Yr03-09 Except China, >100MW)
AA
50%
Others
日立
三菱
BBOthersOthers
F
D
Alstom
Siemens
GE37% 40%
64%
46%EE
CC
DD61%
B
C
E
0%
GE
Toshiba
37% 36% 32%40%
TOSHIBA8%
TOSHIBA8%
E
0%
03 04 05 06 07 08 09
No 1 Share in US for 7 yearsNo 1 Share in US for 7 yearsNo 4 Share worldwideNo 4 Share worldwide
Total:362,393MW
22© TOSHIBA CORPORATION 2010, All rights reserved.
No.1 Share in US for 7 yearsNo.1 Share in US for 7 yearsNo. 4 Share worldwideNo. 4 Share worldwide
■ 450MW 169atg 538/538degC TC4F 26”Advanced Technology for Plant Rehabilitation
■ 450MW 169atg - 538/538degC TC4F-26”HIP Section Replace = Increased Heat Rate 0.8%
1% efficiency iimprovement on 1,000MW rating coal-fired plant means about 46,000t CO2 reduction per year.
LP Section Replace = Increased Power Output 18.6MW■ 780MW 246atg - 538/538degC TC4F-30”
L t t T h l f Hi h ffi i & Lif E t i23© TOSHIBA CORPORATION 2010, All rights reserved.
Latest Technology for High-efficiency & Life Extension
Profile of the latest Project (4)Bulgaria – Maritsa East 2 #1-#6 6x177MW Plant Rehabilitation
Customer Maritsa East II TPPCusto e a tsa ast Taking Over #1 Sep.2007, #2 Jan.2007
#3 Nov.2008, #4 Feb.2009
( ) ( )#5 (Mar.2011), #6 (Aug.2010)(under construction) (under construction)
#1-4:4x150 MW STG Replacement#1 4:4x150 MW STG ReplacementTurbine:LMZ Make → Toshiba Latest TurbineGenerator:LMZ Make →
T hib Ai C li G t f it2Toshiba Air Cooling Generator for unit2→40 Years old Machine to Latest
#3,4: 2x210 MW LMZ Make Turbine RehabilitationHP IP LP Blade Nozzle, LP Rotor Replacement→24 Years old Machine to renewal
R h bilit ti f d it U it t I Effi i24© TOSHIBA CORPORATION 2010, All rights reserved.
Rehabilitation of decrepit Units to Improve Efficiency
Contents
11. Introduction of Steam Turbine & Generator Achievements. Introduction of Steam Turbine & Generator Achievements
2. Efficiency Improvement by Innovative Thermal Cycle2. Efficiency Improvement by Innovative Thermal Cycle
3. Development of Advanced3. Development of Advanced--USC & CCS technologies USC & CCS technologies pp gg
25© TOSHIBA CORPORATION 2010, All rights reserved.
Turbine material for High Temperature Parts
750
Further material development is underway to meet 700℃ condition
725700
A-USC
NewM t i l
650675 700MW
24.1MPa593/593℃
USC
375MW16.7MPa
Materialfor A-USC
600575
625
Modified 12Cr
Advanced 12Cr
12Cr alloy
USC566/538℃
575550525
Modified 12Cr
CrMoV alloy
12Cr alloy
500MW24.1MPa525
5001960 1970 1980 1990 2000 2010 20201950 (year)
Sub / Super Critical 566/566℃
26© TOSHIBA CORPORATION 2010, All rights reserved.
Material Development as National Project
A-USC (Advanced Ultra Super Critical) TurbinesMain steam
η/η
(%
)
Generator
Steam turbine
Main steam (35MPa 700C)
16 700/720/720℃ A-USCD bl R h t
Effic
ienc
y ⊿η
LP LPVHP HP IPReheat steam(750C)
10
12
14 Double Reheat
ovem
ent o
f E
CondenserFWHBoiler
6
8
10
600/700C A-USC
Steam Turbine●High temperature material●Turbine Structure / Flowpath
Overall system●Steam condition●Heat balance
Steam Valve●High temperature
material
elat
ive
Impr
o
0
2
4
538/566C
566/566/566C USCDual Reheat
600/610CUSC
Re
20 30 40Main Steam Pressure (MPa)
USC
VHP Cross Section VHP Rotor TPReheat Valves
(φ850mm, 7.7ton)(φ400mm, 3.9ton)
Drive towards Advanced USC technology for future low CO2 emissions
27© TOSHIBA CORPORATION 2010, All rights reserved.
Drive towards Advanced USC technology for future low CO2 emissions
CCS Pilot Plant
Plant Overview- Location: Sigma Power Mikawa,
Omuta, Fukuoka, Japan- Post Combustion Method- Capacity:2,100Nm3/hr (Feed)
(10t CO /d )(10t-CO2/day)- Exhaust Flow: 2,100 Nm3/h- Commenced: September, 2009
Objectives- Testing using the actual flue gas oflive thermal power plantlive thermal power plant
- Verification of performance, operability, maintainability, etc.i i f l d l t d iin view of scaled up plant design.
D l t i P f F ll S l d Pl t28© TOSHIBA CORPORATION 2010, All rights reserved.
Development in Progress for Full-Scaled Plant
Thermal Power Plant with CCSBoilerSteam Turbine
Generator
Carbon Capture System Stack
FGD
EP
DeNOx
CO2
Abs
orbe
r
Strip
per
Condenser CompressorReboiler CO2
Steam Extractions Exhaust
e (t
/ MW
h)O
2D
isch
arge
R&D f Hi h P f S l t
Comparison of CO2 Discharge
CO
29© TOSHIBA CORPORATION 2010, All rights reserved.
R&D for High Performance Solvent
Towards Clean Coal Thermal Power Plant1400
1200
1400kW
h)
800
1000
gram
s /
A USC
Sub Critical
USC
600
800
ssio
ns (g A-USC
USC+CCS
200
400
CO
2 Em
is A-USC+CCS( 50% CO2 Capture )
USC CCS( 50% CO2 Capture )
0
200
30 35 40 45 50 55 60
C
USC+CCS( 90% CO2 Capture )
A-USC+CCS( 90% CO2 Capture )
30 35 40 45 50 55 60Plant Net Efficiency (LHV)
Clean Coal Thermal Power Plant is realized by Integration and
30© TOSHIBA CORPORATION 2010, All rights reserved.
Optimization of both High efficiency Turbine Cycles and CCS technology
Toshiba Steam Turbine for Solar Power Plant
Axial Flow Turbine(Below 100-150MW)
Double Flow Turbine(Over 100-150MW)
MEB from Geothermal TechnologyDrain Catcher Drain Removal
GFour Flow Turbine
Moisture Extraction Blade (MEB)
GroovesFour Flow Turbine(Over 400MW)
St t bi li f R bl E Pl t31© TOSHIBA CORPORATION 2010, All rights reserved.
Steam turbine line-up for Renewable Energy Plant