Materials: Steps towards 700°C power plantfiles.messe.de/cmsdb/001/14491.pdf · ·...

Materials:

Steps towards 700°C power plant

C. Stolzenberger

VGB PowerTech e.V.

User Forum

of the

Power Plant Technology, 21.-25.4.2008

24. April 2008 Power Plants - Technology in Dialogue 2

• Motivation

• Actual high efficient Power Plants

• Activities towards 700°C Ultra Super

Critical Coal Generation

• 700°C-Demonstration Power Plant

• Summary


30%

35%

40%

45%

50%

55%

1950 1970 1990 2010 2030

Efficiency Development (Hard Coal Power Station)N

et

Eff

icie

ncy

Nickel basis material

(350 bar, > 700°C)

Austenites(290 bar, 600°C)

Ferrites und Martensites(260 bar, 545°C)

CCS needsEfficiency Increase

1950 1970 1990 2010 2030


• Motivation





• Summary


New Power Plant

Total capacity 3 x 660 MW ~2000 MW

Live-steam 604°C / 250 bar / 1915 t/h

Reheater-steam 612°C / 56 bar / 1591 t/h

Efficiency increased more than 10% 44,7%

Boiler Material

- Martensite: P91, P92,

- Austenite: Super 304 (shot blasted)

Emissions (mg/Nm3)

Design values European limits

- NOx 100 200

- SO2 100 200

- Particulate 15 30

Commercial operationend 2008/ mid 2009 / end 2009

Actual high efficient Power Plants (Hard Coal)

ENEL’s conversion project

Torrevaldaliga Nord from oil to coal

Before conversion

After conversion


• Motivation





• Summary


700°C - Boiler Test Programme

COMTES700 –

Component Test Facility for a 700°C Power Plant

Objectives

- Manufacturing, bending and welding of the components in real plant dimensions for a power plant with efficiency higher than50%,

- Operational behaviour of all components especially operational testing of Ni-based alloys for tubes, pipes and valves,

- Flue gas corrosion and steam oxidation behaviour of the materials and erosion effects due to sootblowing,

- Operation started in summer 2005

- Approximately min. 20.000 operation hours, end expected 2009/11


Membrane

Wall

Superheater

Host Plant - Scholven F, Germany, E.ON

► Net output

– 676 MW

► Live-steam

– 220 bar

– 540 °C

– 2,250 t/h

► Reheater-steam

– 44 bar

– 540 °C

– 2,044 t/h

► Fuel

– Hard coal

COMTES700 - Implementation into Host Boiler


COMTES700 - Flow Diagram

M

Mass Flow ~ 12 kg/s

from SH1

Inlet Header

from

Injection

SuperheaterMembrane Wall

Safety Valve

Turbine

Valve

to SH4

Outlet

Header

to Reheater 1

Outlet Header

410°C

222 bar 610°C 705°C

536°C

210 bar

410°C

44 bar

HP-Bypass


8,800 mm

43 x

48

=

2,0

46

mm

Outlet

44 parallel tubes

7 CrMoVTiB 10 10/T 24

13 CrMo44

P 92Alloy 617

Inlet

HCM 12

Membrane Wall

Tube diameter 33,7 x 7,1 mm

COMTES700 - Material Concepts

Superheater 1 & 2

Tube diameter 44,5 x 10 mm

1) 2)


Project Budget: € 23.2mEmax Partners

– DONG Energy

– E.ON

– EdF

– Electrabel

– EnBW

– Enel

– PPC

– RWE

– Vattenfall Europe

– Vattenfall Nordic

Industrial Partners

– Alstom

– BWE

– HPE

– Siemens

Know-how Access

– EVN

– Evonik Energie

– GKM

26% - (EC) RFCS € 6.1m

3% - Know-howAccess € 0.7m

4% - IndustrialPartners € 0.8m

67% - Emax Partners € 15.6m

COMTES700 - Budget, Financing & Partner


Steam

700°C - Turbine Test Programme

COMTES700 - Turbine Valve

Target

• Testing most critical components of a 700 °C turboset

• Integration in COMTES700 and operation time > 20,000 h

• Evaluation of

- metal temperatures

- deformation and

- expansionSteam


700°C - Material Test Programme

Esbjerg Test Rig (720°C), Esbjerg, Denmark

• Precursor of COMTES700 and maturity test of materials

• Materials tested over > 30,000 h

Austenite Ni-based Material

- Sanicro 25 - Alloy 740

- HR3C - Alloy 617

- TP347HFG


MARCKO700 - Boiler

Material Qualification for the 700 / 720 °C Power Plant

Evaluation of long-term characteristics u. operation conditions

• 7CrMoVTiB 10-10

• T/P92

• 12CrCoMo

• Alloy 617

MARCKO III - Turbine

Optimized materials and material compounds behaviour

for 700 / 720 °C steam turbine components

• Development of models for the description of the thermal

cyclical behaviour

• Analytical and numeric assessment of dissimilar weldments



COORETEC - Projects

• Fireside corrosion and steam side oxidation behaviour of

materials for the 700 °C power plant

• Characterisation of superheater materials for 700°C power

plant after cold deformation

• Characterisation of strength and deformation of pipes and

forgings made of Ni-base alloys

• Qualification of dissimilar weldings between 10 % Cr-steels

and Ni-based alloys

• Fracture mechanics approaches for life time assessment of

components operating in 700°C temperature regime

• Optimisation of non-destructive testing methods for thick

walled components made of Ni-base alloys



AD700-1 Creep Tests

Targets

Creep rupture strength after 100,000 h (expected)

- Sanicro 25 for 700 °C 96 MPa

- Inconel 740 for 750 °C 107 MPa

- Nimonic 263 for 750 °C 89 MPa

Sanicro 25

Nimonic 263

Alloy 740



• Live Steam Pressure 250/350 bar

• Live Steam Temperature 700°C

• Reheat Temperature 720°C

• Gross Power

Demo Plant ~ 500 MW

Full Scale Plant 700 – 1100 MW

• Fuel

Demo Plant Hard Coal

Full Scale Plant Hard Coal/Lignite

Specification NRW 700°C Power Plant (NRW PP700)

700°C - Power Plant Feasibility Study


Defining BoundaryConditions

Basic DesignBoiler Variants

Scale-Up1,000 MW

Detailed Design

Boiler Turbine BoP

Transferto Lignite

Tim

e

Step by stepprocedure

Target (NRW PP700)

• Technical and economical viability of a 700 °C Power Plant

700°C - Power Plant Feasibility Study


• Motivation





• Summary


E.ON‘s Project

“….50plus“

Efficiency: ≥ 50 % LHV

Capacity: ≥ 500 MWbr

Investment: ≥ 1 bn. €

Location: Wilhelmshaven, E.ON, Germany

700°C - Demonstration Power Plant

until 2009 20152011

Pre-Engineeringsize and site

ErectionStart-up

Material issues, tenderorder, approval


• Motivation





• Summary


700°C-Material Tests . . . . . .

700°C-PP Feasibility Study .

700°C-Boiler- & Turbine

Component Tests . . .

700°C-Power Plant ≥ 50 % . .

600°C-Power Plant ~ 46 % . .

2008 2010 2012Year 2014 2016

Wilhelmshaven (DE)

Torrevaldaliga (IT), Datteln (DE), etc.

Pathway to 700°C-Power Plant


Thank you for your attention !

[email protected]

COMTES700 is funded by the Research Fund for Coal and Steel of the European Commission (project number RFC-CP-04003),

European Power Plant Operators, Manufacturers andco-ordinated by VGB PowerTech e. V.

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