U.S. Program for Advanced Ultrasupercritical (A-USC) Coal Fired Power Plants

Dr. Jeffrey Phillips

Senior Program Manager, Advanced Generation

McIlvaine Company “Hot Topic” Webcast: Next Generation of Coal Combustion Technologies

March 24, 2011

2© 2011 Electric Power Research Institute, Inc. All rights reserved.

Definitions

Nomenclature ConditionsNet Plant Efficiency

Net Plant Heat Rate (HHV)

Subcritical2400 psig (16.5 MPa)

1050ºF/1050ºF (565ºC/565ºC)35% 9751 Btu/kWh

Supercritical

(SC)

>3600 psig (24.8 MPa)

1050ºF/1075ºF (565ºC/585ºC)38% 8981 Btu/kWh

Ultrasupercritical

(USC)

>3600 psig (24.8 MPa)

1100ºF/1150ºF (593ºC/621ºC) and above

>42% 8126 Btu/kWh

“Advanced”

UltraSupercritical

(A-USC)

5000 psig (34.5 MPa)

1250ºF (677ºC)

and above

>45% 7757 Btu/kWh

3© 2011 Electric Power Research Institute, Inc. All rights reserved.

1500

1400

1300

1200

1100

1000

900

800

700

600

500

400

750

700

650

600

550

500

450

400

350

300

250

200

1900 ’10 ’20 ’30 ’40 ’50 ’60 ’70 ’80 ’90 2000 ’10

Year

Tem

pera

ture

, D

eg

rees F

Tem

pera

ture

, D

eg

rees C

Eddystone 1

Philo 6

Materials for A-USC Coal Power Plants – U.S. Department of Energy (DOE) and Ohio Funded Project

• During 1st 60 years of the 20th century, steam turbine temperatures rose from 500 F to 1200 F

– Thermal efficiency rose from 4% to 40% (HHV)

• Eddystone experienced several materials issues

– Derated from 1200 F to 1135 F

• No improvements for 50 years!

Maximum Steam Turbine Inlet

Temperature History

Provides 20% lower CO2 emissions than existing fleet average

4© 2011 Electric Power Research Institute, Inc. All rights reserved.

Heat Rate Improvement Technologies

5© 2011 Electric Power Research Institute, Inc. All rights reserved.

Acknowledgements: U.S. DOE / Ohio Coal Development Office (OCDO) A-USC Steam Boiler and Turbine Consortia

Federal – State – National Laboratory

Non Profit – For Profit

Cost Sharing Consortium

6© 2011 Electric Power Research Institute, Inc. All rights reserved.

Primary Technical Goals of the U.S. A-USC Materials Program

• Materials Technology Evaluation

• Focus on nickel-based alloys

• Development of fabrication and joining technology for new alloys

•Unique Conditions for U.S. Program Considerations

• Higher temperatures than European Program (760 C versus 700 C) means additional alloys are being evaluated

• Corrosion resistance for U.S. coals

• Data for ASME code acceptance of new materials

• Phase II Boiler work includes Oxycombustion

7© 2011 Electric Power Research Institute, Inc. All rights reserved.

40

60

80

100

300

500

550 600 650 700 750 800

1100 1200 1300 1400

6

8

10

30

50

70

Str

ess (

MP

a)

Average Temperature for Rupture in 100,000 hours (oC)

9-12Cr Creep-Strength

Enhanced Ferritic Steels

(Gr. 91, 92, 122)

Nickel-Based

Alloys

Std. 617CCA617

Inconel 740

Haynes 230

Advanced Austenitic

Alloys (Super 304H,

347HFG, NF709, etc.)

Haynes 282

Average Temperature for Rupture in 100,000 hours (oF)

Str

ess (

ksi)

Materials Limit the Current Technology

°

Steels = USC

620 C (1150°F) Solid Soln’ = A-USC

~700 C (1300°F)

Age Hardenable = A-USC

760 C (1400°F)

Minimum

Desired

Strength at

Application

Temperature

ksi =

10

00

psi

8© 2011 Electric Power Research Institute, Inc. All rights reserved.

U.S. DOE – OCDO Advanced USC Project

Accomplishments over the past 10 years

General design studies show

favorable economics

Welding Technology Developments

Fabrication Processes

Fireside Corrosion (High-Sulfur Coal

& In-Plant Testing)

Steam-Side

Oxidation

HP Turbine Concept

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Successes: Air-cooled Probes

Cleaned surface of an air-cooled probe exposed for 2 years in a coal-fired boiler at A-USC temperatures

Inconel 740 shows lower wastage than a high-chromium cladding(50/50), a 23% Cr wrought alloy (HR6W), and weld overlays (WO)

10© 2011 Electric Power Research Institute, Inc. All rights reserved.

Successes: Welding Technology

Original Inconel 740 weld trials

(Liquation cracking in heat affected zone)

Today: Repeatable 3” (75-mm) thick Inconel 740

welds without cracking

Consortium

Research

Consortium research has demonstrated revolutionaryprogress in nickel-based alloy welding

11© 2011 Electric Power Research Institute, Inc. All rights reserved.

A-USC Research & Development (R&D)

• Current Boiler & Turbine Materials R&D

– Effect of oxycombustion on materials

– Improved weld/weldment performance

– Code approval of new alloys

– Long-term high-temperature material property databases

– Production of larger forgings

– Scale-up and repair of nickel-based castings

Air , Low O2 , High O2

April 7 – Workshop in Washington, DC

Hotel Monaco

“Events” on EPRI.com for more information

12© 2011 Electric Power Research Institute, Inc. All rights reserved.

Timelines of Advanced USC Development

2011 2012 2013 2014 2015 2016 2017 2018 2019 2020 2021 2022 2023 2024 2025

Current Materials Development Program

“Last Lap”

Component Test Facility

Supplier Development

A-USC 600 MW Demonstration Plant

>1300 F Demo Plant

Build

Operate

Design

Permit

Other R&D

R&D

Build

Build OperateDesign

Design

Permit

Build Operate

Build Test Pieces

Provides 5 Years of Commercial-scale Experience by 2025

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Together…Shaping the Future of Electricity