high performance coal fired thermal power plantthermal ... · pdf fileturbine power plants...

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





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


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)


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


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


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


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


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


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 WｏｒｌｄＥｎｅｒｇｙＯｕｔｌｏｏｋ 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)


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


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


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


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


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.


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


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


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


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





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℃


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


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


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


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

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