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Bharat Heavy Electricals LimitedBharat Heavy Electricals Limited

International conference Thermal Power India ‐3

“Ultra Supercritical power plants”

ULTRA SUPER CRITICAL POWER PLANTS


Introduction

•Energy, in general, and electricity in particular, plays a vital rolein improving the standard of life•World has abundant proven reserves of coal and thus coal‐based thermal power plants dominatebased thermal power plants dominate• The development of coal fired supercritical power planttechnology can be described as an evolutionary advancement

d i d hi h ffi itowards greater power output per unit and higher efficiency•Energy conversion efficiency of steam turbine cycle can beimproved by increasing the main steam pressure andtemperature



IntroductionIntroduction

Worldwide energy and electricity consumption is projected tot l t f 2 2 5% b t d 2025grow at an average annual rate of 2‐2.5% between now and 2025

caused by increase of population (up to 7.5 billion) and increaseof consumption (mainly of China and India).

Coal offers an abundant, widely spread energy resource at quitebl i f i i l li I ill istable price, from many international suppliers. It will continue to

play a significant role in new generating capacity



Coal TechnologiesCoal Technologies

Integrated gasification combined‐cycle generation technology(IGCC)

Circulating fluidized bed combustion generation technologyCirculating fluidized bed combustion generation technology(CFBC and pressurized circulating fluidized bed combustioncombined‐cycle generation technology (PFBC‐CC）Supercritical and ultra supercritical generation technology(SC/USC)



Advantages of Supercritical unitsAdvantages of Supercritical units

•Reduced fuel costs due to improved plant efficiency

•Significant improvement of environment by reduction in CO2emissions

•Plant costs less than other clean coal technologies•Plant costs less than other clean coal technologies

•Much reduced NOx, SOx and particulate emissionsMuch reduced NOx, SOx and particulate emissions



Efficiency gain due to Supercritical parametersEfficiency gain due to Supercritical parameters

•Supercritical units have higher plant efficiency than that ofsubcritical units because of higher steam parameters.

• The Gross plant efficiency is around 40‐41% for supercritical unitswith steam parameters of 24 7MPa/565 /593 which is aboutwith steam parameters of 24.7MPa/565 /593 , which is about2%‐3% higher than that (38%) of sub‐critical unit with steamparameters of 16.7MPa/537/537•The Gross plant efficiency is around 41‐42% for ultra‐supercritical

units with steam parameters of 28MPa/593 /593 ,which isabout 3‐4% higher than that of the above supercritical unitsabout 3‐4% higher than that of the above supercritical units.

•The advanced ultra supercritical units have reached an overallplant efficiency of 47% to 49% in the world.



National mission on enhanced energy efficiencyNational mission on enhanced energy efficiency

•Increasing efficiency of existing power plants, using cleantechnologies and switching to fuels other than coal

•Adoption of super critical boiler, wherever cost effective andotherwise suitableotherwise suitable

•Adoption of ultra‐super critical boiler when their commercialviability under Indian conditions is establishedy


Source : CEA


What is supercritical parametersp p

As the fluid pressure increases, Latent Heat(Enthalpy of Steam –Enthalpy of Water)( py py )reduces.

At Critical point it becomes zero.

In physical terms at this pressure watertransforms to steam spontaneously.

4.3

1015202530354045SUPER CRITICAL STEAM PARAMETERS:

PARAMETERS MORE THAN CRITICAL STATE• STEAM PRESSURE > 221.2 BAR m

prov

emen

t %

05

500 MW 800 MW

STEAM PRESSURE 221.2 BAR• STEAM TEMPERATURE > 374.15 Deg C

Subcritical170 ata / 537 °C / 537 °C

Super Critical247 ata / 565 °C / 593 °C

Im


INCREASE IN PRESSURE & MAIN AND REHEAT TEMP. > 537 Deg CRESULTS IN SIGNIFICANT IMPROVEMENT IN HEATRATE


Parameters for Ultra supercritical PlantsParameters for Ultra supercritical Plants

•There is no clear definition of ‘ultra‐supercritical’There is no clear definition of ultra supercriticalconditions, However Plants operating above 275 kg/cm2pressure and MS/RH temperatures of 593°C and above aregenerally called ultra super criticalgenerally called ultra super critical.

•World over, many Ultra super critical power plants ranging350MW to 1000MW are under operation/construction.p /


Bharat Heavy Electricals Limited

Development of SC/USC TechnologyDevelopment of SC/USC Technology• Supercritical steam cycle technology has been used for decades and is

becoming the system of choice for new commercial coal‐fired plants in manybecoming the system of choice for new commercial coal‐fired plants in manycountries.

• Recent plant built in Europe and Asia use supercritical boiler‐turbinetechnology and China has made this standard on all new plant 600MWe andtechnology and China has made this standard on all new plant 600MWe andupwards.

• Research and development is under way for ultra‐supercritical units operatingat even higher efficiencies potentially up to around 50%at even higher efficiencies, potentially up to around 50%.

• The introduction of ultra‐supercritical technology has been driven over recentyears in countries such as Denmark, Germany and Japan, in order to achieveimproved plant efficiencies and reduce fuel costsimproved plant efficiencies and reduce fuel costs.

• Research is focusing on the development of new steels for boiler tubes and onhigh alloy steels that minimise corrosion.

• These developments are expected to result in a dramatic increase in the


• These developments are expected to result in a dramatic increase in thenumber of SC plants and USC units installed over coming years.


Present status of SC/USC Coal fired UnitsPresent status of SC/USC Coal‐fired Units

• Supercritical and ultra‐supercritical units have been developedp p pinto proven mature and commercialized advanced technologiesin the world

O 600 iti l l fi d it h b f ll• Over 600 supercritical coal‐fired units have been successfullyinto commercial operation for decades worldwide

• About 60 ultra‐supercritical units in operation worldwidep p

• The 1000MW class ultra‐supercritical units with steamparameters of 31MPa/600 /600 are being developed ini d i l iindustrial economies



Parameters of Some SC/USC Plants/Country Power Plant Unit Rating

Mwe net (Gross)

Steam Pressure (Bar)

Main Steam

Temp. (oC)

Reheat RH1 Steam

Temp. (oC)

Reheat RH2 Steam

Temp. (oC)

Efficiency (% net LHV)

Denmark Avedorevaerket 2 390 300 580 600 ‐‐‐‐‐ 48.3

Denmark Nordjylland 3 411 285 580 580 580 47

Denmark Skaerbeaek 3 411 290 582 580 580 49

Holland Hemweg 8 630 260 540 568 ‐‐‐‐‐ 42

Finland Meri Pori 550 244 540 560 ‐‐‐‐‐ 45

Germany Staudinger 509 262 545 562 ‐‐‐‐‐ 43

Germany Niederaussem K 965 275 580 600 ‐‐‐‐‐ 45.2

Japan Tachibanawan 1050 250 600 610 ‐‐‐‐‐ 43.5

Japan Isogo 600 266 600 610 ‐‐‐‐‐ Not Available

China Changshu 600 259 569 569 ‐‐‐‐‐ 42

China Wangqu 600 247 571 569 ‐‐‐‐‐ 43

USA Tanners Creek 580 241 538 552 566 39.8


USA Duke Power 1120 241 538 538 ‐‐‐‐‐ Not Available


Comparison of some state of the art steam plantsComparison of some state‐of‐the‐art steam plants

Plant Steam ConditionMpa/ oC/oC

Net Thermal efficiency, %

HHV LHV

T hib 24 1/600/610 42 1 44Tachibanawan(Japan)

24.1/600/610 42.1 44

Tanners Creek (USA)

24.1/538/552/566 39.8 42(USA)

Nordjylland 3 (Denmark)

29.0/582/580/580 45 47.0

Niederaussem K (Germany)

27.5/580/600 42.5 45.2



Efficiency vs. EmissionsEfficiency vs. Emissions



Typical efficienciesTypical efficiencies

Pulverized coal option Steam Conditions Typical Efficiency (% HHV)

Sub critical <22 1 M Pa 35 0 38 0Sub critical <22.1 M Pa538oC/538oC

35.0 ‐38.0

Supercritical (SC) 24 7 M Pa 38 0 ‐40 0Supercritical (SC) 24.7 M Pa538‐565oC/565oC

38.0 40.0

Ultra‐supercritical (USC) 27 M Pa 40.0 ‐42.5p ( )565‐625oC

Advanced USC 27 M Pa 42.5 ‐46.0


(not commercial yet) above 625oC


Levelised cost of electricity (CoE) for nominalLevelised cost of electricity (CoE) for nominal 600MWe (A European comparison)



Relative efficiency improvement with parameters



Evolution of Steam Power Stations Efficiency Worldwide



Supercritical Technology Indian scenarioSupercritical Technology – Indian scenario• Supercritical technology being adopted to enhance

efficiency, reduce coal consumption and GHG emission

• 660/ 800 MW units planned in big way.

• Parameters adopted 247 ata / 537/565 OC & 247 ata / 565/ 593• Parameters adopted 247 ata / 537/565 OC & 247 ata / 565/ 593OC

• Eight units of 660 MW under execution at Sipat and Barhg p

• Two units of 800MW under execution at Krishnapattnam

• Ultra Mega Projects, 4000 MW each, envisaged withsupercritical units.

• 4 projects already awarded to IPPs through tariff basedcompetitive bidding


competitive bidding.

• Many more supercritical units in pipeline.


Supercritical Technology – Indian scenario (Cont..)

Wid l l t l t (At t bi d)• Widely prevalent cycle parameters (At turbine end):– Pressure: 246 ‐250 kg/cm2– Temperature: 537/566 deg C (In 660MW Sipat & Barh –I TPS)

565/593 deg C (In 660 MW Barh‐II and2 X 800MW Krishnapattnam)

• Parameters adopted for 800MW are 247kg/cm2 /565/593 deg C.



Ultra Mega Power ProjectsUltra Mega Power Projects

Ministry of Power Central Electricity Authority and PFC areMinistry of Power, Central Electricity Authority and PFC areworking together to facilitate development of Ultra Mega PowerProjects with super critical parameters and capacity of about4000 MW each under Tariff based competitive bidding route.

Being large in size these projects will meet the power needs ofBeing large in size, these projects will meet the power needs ofnumber of states through transmission of power on regional andnational grids.



Identified Ultra Mega Projects State Project Location Status

Chattisgarh Akaltara Pithead ‐g

Gujarat Mundra coastal Awarded to Tata

Karnataka Tadri coastal ‐

Madhya Pradesh Sasan Pithead Awarded to Reliance

Maharashtra Giriye coastal ‐

Andhra Pradesh Krishnapatnam coastal Awarded to RelianceAndhra Pradesh Krishnapatnam coastal Awarded to Reliance

Orissa Bhedabahal(Sundergarh district)

Pithead ‐( g )

Tamil Nadu Cheyyur coastal ‐

Jharkhand Tilaiyya Pithead LOI issued to Reliance



Typical Comparison of ParametersS b iti l S iti lSubcritical vs. Supercritical

Parameter Unit 500MW 660MW 800MW

Main Steam Pressure ATA 170 247 247

M i S T 0C 537 565 565Main Steam Temp. 0C 537 565 565

Main Steam Flow T/Hr 1515 1960 2340

Reheat Pressure ATA 40.5 50.4 56.6

Reheat Temperature 0C 537 593 593

Reheat Flow T/Hr 1335 1625 1940

CRH Pressure ATA 45 56 0 61 5CRH Pressure ATA 45 56.0 61.5

Cold Reheat Temp. 0C 336 336 348

Final FW Temp. oC0C 253 290 290

BMCR Flow T/hr 1625 2120 2600



Power Cycle EquipmentPower Cycle Equipment

EQUIPMENT 500 MW SUB CRITICAL 800 MW SUPER CRITICAL

BOILER Drum Type Once Through Type

TURBINE 1HP + 1IP + 1LP 1HP + 1IP+ 2LP

CONDENSER One Two

GENERATOR 588 MVA 950 MVA

LP HEATERS 3 Nos 4 Nos

HP HEATERS TWO ( 2X50% EACH) THREE ( 2X50% EACH)( ) ( )

DEAERATOR ONE ONE

CONDENSATE EXTN. PUMPS 3 x 50% 3 x 50%

BOILER FEED PUMPS 2 x 50%(TD) / 1 x 50% (MD) 2 x 50 % (TD) / 1 x 35 %MD

VACUUM PUMPS 2x100%2 x 100%

(For Each Condenser)

CONDENSATE POLISHING UNIT 2 x 50% 4 x 25%



Typical 800 MW CycleTypical 800 MW Cycle



Reference HBD for 800MWReference HBD for 800MW


Reference HBD for 660MW



Improvement in Gross plant efficiencyImprovement in Gross plant efficiency

40 5

41.0

41.5

%)

39.0

39.5

40.0

40.5

t efficiency (%

37.0

37.5

38.0

38.5

Gross Plan

36.5

500 MW/ 170ATA/ 537/537

500 MW/ 170ATA/ 537/565

600 MW/ 170ATA/ 537/537

600 MW/ 170ATA/ 537/565

660 MW/ 247ATA/ 565/593

800 MW/ 247ATA/ 565/593

800 MW/ 280ATA/ 593/593

Parameters



Coal ConsumptionCoal Consumption

0.660

0.630

0.640

0.650

/KW‐hr

0.600

0.610

0.620

nsum

ption kg/

0 570

0.580

0.590

Coal Con

0.560

0.570

500 MW/ 170ATA/ 537/537

500 MW/ 170ATA/ 537/565

600 MW/ 170ATA/ 537/537

600 MW/ 170ATA/ 537/565

660 MW/ 247ATA/ 565/593

800 MW/ 247ATA/ 565/593

800 MW/ 280ATA/ 593/593

Parameters


Parameters


Supercritical BoilersSupercritical Boilers

• Supercritical pressure boiler has no drum and heat absorbingsurface being, in effect, one continuous tube, in which the water& steam generated in the furnace water walls passes throughonly once hence called ‘Once through Supercritical pressureonly once hence called Once through Supercritical pressureboilers’

• The water in boiler is pressurized by Boiler Feed Pump, sensibleheat is added in feed heaters, economizer and furnacetubes, until water attains saturation temperature and flashesinstantaneously to dry saturated steam and super heatinginstantaneously to dry saturated steam and super heatingcommences.



Supercritical

Steam GeneratorsSeparators

Collecting vessel vessel



Once ‐through Operating RangeOnce through Operating Range



Low Load System with Circulating Pump


Boiler ParametersBoiler Parameters

B il

Unit 500 MW660 MW800 MWDescription

BMCRBMCRBMCR-Boiler Parameters

162521002585t/hSH steam flow /

kg/cm2(a) 179256256SHO pressure

oC

oC

254291294Feed water temp

540/540568/596568/596SHO/RHO temp.

temp.



SIEMENS ReferencesSIEMENS ReferencesFor Super Critical Steam Turbine

Plant Name Country MW First operation

M.S. Pr.(bar) / MS Temp. (°C) / HRH Temp. (°C)

Kw Schwarze Pumpe1,2 Germany 823 1997 253.08 544 562

Boxberg Q Germany 910 2000 252.58 541 578

Isogo Japan 600 2001 251.00 600 610

NiederauBem K Germany 1027 2002 251.00 576 599

Wai Gao Qiao 1,2 China 900 2003 249.60 538 566

Wai Gao Qiao 3,4 China 1000 2007 270 600 600

Kogan Creek Australia 750 2007 250.00 540 560

h 1 2 3 4 Chi 1000 2006 262 50 600 600Yuhuan 1,2,3,4 China 1000 2006 262.50 600 600



Large capacity Supercritical Sets

660MW Steam turbine: With Supercritical parameters

g p y p

Module Combination• HP : H30-100• IP : M30-63• LP : N30-2x12.5

Salient Feature: 247 t M i St PSalient Feature:

• New series of HP & IP modules for supercritical parameters• Higher size LP module

247 ata Main Steam Pressure565 0C Main Steam Temperature593 0C Hot reheat Temperature

Order received for NTPC 2x660 MW Barh Extn. • Higher size LP module



Large capacity Supercritical Sets800MW Steam turbine: With Supercritical parameters

Module Combination

Salient features:

• HP : H30-100 (H70-V4)• IP : M30-100 (I60-V2)• LP : N30-4x8 (L4x8)

Salient features:•New series of HP, IP modules for super critical parameters• 4 cylinder turbine (2 LP’s)

246 ata Main Steam Pressure565 0C Main Steam Temperature593 0C Hot reheat Temperature4 cylinder turbine (2 LP s)



Large capacity Supercritical SetsRating - 800 MW Generator Module - THDF 125/67


Parameters -

Voltage - 27 KVVoltage 27 KV

Insulation - Micalastic

Gas Pressure - 5 Bar

Excitation - Brushless

Transport wt. - 443 Tons

Stator Cooling - DM water

Rotor Cooling - Hydrogen

Transportation - By Road




STEAM SURFACE CONDENSER


FOR 660 MW TG SET

• ONE CONDENSER PER SET

• SINGLE / DOUBLE PASS CONDENSERSINGLE / DOUBLE PASS CONDENSER

• CONDENSER IS SOLID SUPPORTED

• LP HEATER NO.1 IS LOCATED INSIDE

• CONDENSER NECK




DESIGN FEATURES OF CONDENSER FOR 800 MW TG SET

• TWO CONDENSERS CONNECTED TO TWO

LP TURBINES

• SINGLE PASS

•SOLID SUPPORTED WITHOUT ANY EXPN•SOLID SUPPORTED WITHOUT ANY EXPN.JOINT BETWEEN TURBINE & COND.

•CONDENSERS IN SERIES WITH DIFFERENTBACK PRESSURES (



Pumps for Supercritical Power PlantsPumps for Supercritical Power Plants

• BHEL entered into collaboration with M/S Mitsubishi Heavy/ yIndustries, Japan for

‐BFPs

‐ Booster Pumps

‐ CEPs &

CWPs for Super Critical power plants‐ CWPs for Super Critical power plants.

• Range from 660MW to 1000MW.



Pump Models for 660MWPump Models for 660MW

PUMP MODEL Q(m3/hr) H (mlc) N (rpm)PUMP MODEL Q(m3/hr) H (mlc) N (rpm)

BFP MDG 405 1385 3315 5730

BP MLC 400 1385 160 1475

CEP 145 RND 1015 345 1470

CWP 72 MN 30000 27 370



Pump Models for 800MWPump Models for 800MW

PUMP MODEL Q(m3/hr) H (mlc) N (rpm)PUMP MODEL Q(m /hr) H (mlc) N (rpm)

BFP MDG 455 1605 3310 5100

BP MLC 450 1605 240 1475

CEP 145 RND 1210 350 1470

CWP 78 MN 35000 29 329



Development of Materials for SC/USC parameters

• For adopting SC/USC parameters, superior material arep g / p , prequired

• Some of the critical materials are Boiler quality plates andP91 C iti l i iP91 Critical piping

• These material are not indigenously available and have to beessentially importedy p

• There is a need to join hands with the countries which havealready developed these materials



Concluding RemarksConcluding Remarks• Electric power generation in India will continue to be

dominated by coal‐fired power generation for at least nextdominated by coal fired power generation for at least next30‐40 years

• Development and application of clean, high efficiency, largecapacity, coal‐fired power generation technology is a long‐term strategic task for India

• In order to meet our increasing demand for electric power asIn order to meet our increasing demand for electric power, aswell as to improve coal utilization efficiency and reducepollutant emissions from coal‐fired power plants, we have tod l d ti iti l / Ult iti l itdevelop domestic supercritical / Ultra supercritical units


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