super critical presentation

7/31/2019 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


8/46002 065p quer

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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