R&D Status & Future Direction of heat resistant materials for efficient power plants

23rd June 2009, NIST, USA

Kyung-Tae HongDirector, Material Science and Technology Division

Korea Institute of Science and Technology

OUTLINE

• World Electricity Need

• Efficiency & Reduction in CO2 Emission

• Development of Heat Resistant Materials

• Issues

• Future R&D direction

World Electricity Portfolio

Sources: 2003: Derived from Energy Information Administration (EIA), International Energy Annual 2003 (May-July 2005), web site www.eia.doe.gov/iea/. 2010-2030: EIA, System for the Analysis of Global Energy Markets (2006).

Fuel Cost Increase

World CO2 Emission

Efficiency & CO2 Reduction

Scenario of CO2 Reduction

Source : IEA ‘Focus on clean coal’ paper, 2006

Improvement in efficiency of fossil-fuel fired powder plants is the most effective solution

Clean Coal Technology

Clean Coal Technology

Conventional Coal-fired

Advanced Efficiency

Coal Gasification

Supercritical(SC)

Sub-critical

Ultra-Supercritical(USC)

Hyper-Supercritical(HSC)

Fluidized Bed Combustion(FBC)

Integrated GasificationCombined Cycle (IGCC)

85% 33~39%

11% 42~45%

2% 44~45%

0% 50~55%(in 2020)

2% ~45%

>0.1% 42%(50% in 2020)

InstalledCapacity

ThermalEfficiency

“Capital costs of IGCC plants today are 20% higher that of PCC plant”(Energy Technology Perspective 2006, IEA)

T & P Increase in PF Power Plant

538oC/538oC/16.7MPa

540oC/560oC/25MPa

560oC/580oC/27MPa

600oC/620oC/29MPa

700oC/720oC/35MPa

1970 1980 1990 2000 2010 2020

EuropeJapan

USA

China

Korea

Sources: COORETEC-Meeting during Enertec 2005, Leipzig, March 11, 2005, Torsten-Ulf Kern, Siemens PG,

Efficiency Improvement

50’s 60’s 70’s 80’s 90’s 00’s 10’s

2400/1005/1005167/540/540

3480/1005/1050 (psi/¡ÆF/¡ÆF)240/540/565 (bar/¡ÆC/¡ÆC)

3600/1050/1085250/565/585

4000/1085/1100280/580/600

4000/1100/1150280/600/620

4000/1165/1200280/630/650

5400/1300/1325/1325375/700/720/720

Mature technology Mature technology

Currentmarketintro.

Market intro.by EU & JapanEf

ficie

ncy

Impr

ovem

ent

Cost Effective Materials are Key

INCREASED

STEAM TEMP. &

PRESSURE

subcritical

supercriticalR&D on-going(COST) inEurope

R&D ongoingUSA USCMaterialsConsortium

EC Thermieproject(Ni-base)

50’s 60’s 70’s 80’s 90’s 00’s 10’s

2400/1005/1005167/540/540

3480/1005/1050 (psi/¡ÆF/¡ÆF)240/540/565 (bar/¡ÆC/¡ÆC)

3600/1050/1085250/565/585

4000/1085/1100280/580/600

4000/1100/1150280/600/620

4000/1165/1200280/630/650

5400/1300/1325/1325375/700/720/720

Mature technology Mature technology

Currentmarketintro.

Market intro.by EU & JapanEf

ficie

ncy

Impr

ovem

ent

Cost Effective Materials are Key

INCREASED

STEAM TEMP. &

PRESSURE

subcritical

supercriticalsubcritical

supercriticalR&D on-going(COST) inEurope

R&D ongoingUSA USCMaterialsConsortium

EC Thermieproject(Ni-base)

USC Materials Program- Target : Alloy Development for 760oC Adv.

Steam Cycle- Schedule of Program : 2001.06 ~ 2006.12- Funding : DOE(15M$), OCDO(2M$), Boiler

Makers(3M$)- Operating Condition :

Higher T and P than EUUse of High Sulfur Containing Coal Efficiency : Adoption of HHV

Vision 21 Program in USA

~2006 : A-USC Material Program ( 5 years) for Advanced Steam Cycle (760�)~2020 : Full Scale Demo Plant of 760�grade PCPP by Novel Design (EPRI)

Completion of Design Concept and Analysis of economical efficiency in 2007Assignment of alloy development and Reliability test (ORNL)

Target : 60% Efficiency, Near Zero Emission, 2020 year DOE* Leading

CCPI (Clean Coal Power Initiative)- Target : 350bar/760oC/760oC/50%HHV/750MW- Relation to CCT, CCS, Hydrogen Program

Program Tasks Program Tasks -- 760760ooC BoilerC Boiler

No. Program Participant

Task 1 Conceptual Design EPRI/Others

Task 2 Mechanical Properties EPRI/ORNL

Task 3 Steamside Oxidation B&W

Task 4 Fireside Corrosion Foster Wheeler

Task 5 Welding Development Alstom

Task 6 Fabricability B&WTask 7 Coatings AlstomTask 8 Design Data Codes B&W

Task 9 Project Management EIO/EPRI/AII

Source: NETL/DOC, D.L.Bonk; NETL's Combustion Technology Program

Time Schedule Time Schedule -- 760760ooC BoilerC Boiler

Items 2000 2005 2010 2015 2020• Reduced Cost 760oC Materials & Fabrication• Develop 760oC Materials

• Code 760oC Materials

• Fabrication of 760oC Materials• Pilot Demo at 760oC

• CCPI Plant at 760oC

• Increased Temperature Material

EU R&D Activities

HSC grade(700oC ~ )

EU

MARCO 700

AD 700

Phase 1 Feasibility

Phase 2 Preparatory work

Phase 3 COMTES 700CTF

ETRPhase 4~6 Full scale dem o

COORETEC

NRWPP700

50plus

Phase 1 Feasibility Study- Jan. 1998- Development new materials- Improved design- Economical viability of AD700

Phase 2 Preparatory Works- 4 years, 11 M€- Funding : FP5 & DG RTD- 10 countries, 34 companies

including Elsam Eng.- Component Test, Facility

design (COMTES700), FSDP preparatin

Phase 3 Component Demo- 5 years, 15 M€- Funded by Emax & RFCS- 13 countries, 40 companies

including Elsam Eng- COMTES700 design,

Component Demonstration

Phase 4~6 Full-scale Demo Plant4 years (+ 3 years)

- FSDP construction & test operation- Feedback - Proposal submitted to FP7

- “Advanced supercritical PF power plant operating at 700oC”

- 13 countries- 40 parteners- Co-ordinated by Elsam

Engineering

Outline

Japanese A-USC Development

Source: Fukuda, NIMS, USC 2009 Symposium

Evolution of Steam Parameters in China

Source: Xie, Univ. S&T Beijing, USC 2009 Symposium

Korean Trend of CF Power Plants

Source: Ryu, Doosan , USC 2007 Symposium

Major Materials Development

JAPAN

EU

USA

1980 1990 2000 2010 2020

USC technology development(600~650oC, Basic & DEMO Plant)

COST (Materials Development & Reliability Test for High temperature)

AD700 (Basic Test & Pilot test of New Materialsfor 700oC Grade USC plant construction)

MARCKO700 (Material Test, analysis and evaluation for 700oC Grade USC plant)

Vision21 (Test and evaluation for 750oC grade USC Materials)

A-USC technology development(700oC grade, Basic & DEMO Plant)JAPAN

EU

USA

1980 1990 2000 2010 2020

USC technology development(600~650oC, Basic & DEMO Plant)

COST (Materials Development & Reliability Test for High temperature)

AD700 (Basic Test & Pilot test of New Materialsfor 700oC Grade USC plant construction)

MARCKO700 (Material Test, analysis and evaluation for 700oC Grade USC plant)

Vision21 (Test and evaluation for 750oC grade USC Materials)

A-USC technology development(700oC grade, Basic & DEMO Plant)

Materials for < 650oC > 700oC Materials

Current CF Power Plant Improvement

Source: Termuehlen and Empsperger 2003

Trend of Materials Development

Source: Speicher, Stuttgart Univ, USC 2009 Symposium

Ni-based Alloys Requirements

Source: Fukuda, NIMS, USC 2009 Symposium

Materials for A-USC Power Plant

Source: Fukuda, NIMS, USC 2009 Symposium

Materials for Steam Boiler

Source: Proceedings of 29th Int’l Conf. on Coal Utilization and Fuel System, US DOE, ASME, (2003)

1995

1998

2005

2010

260550570

270580600

290600620

300630650

350700720

Bar��

Membrane wall Tubes SH outlet header

13CrMo44 X20 CrMoV12 1 Austenite

7CrMoVTiB 10 10HCM2S

Austenite9-12%Crsteel

HCM12 Nickel Alloy

Nickel Alloy

X20 CrMoV12 1 P91

E911,P92,P122

NF12, SAVE12,12CrCoMo

Nickel Alloy

260550570

270580600

290600620

300630650

350700720

260550570

270580600

290600620

300630650

350700720

• Ferritic steels for < 621�applications• Ni-based superalloys for > 700�applications

Boiler Materials Issues

Hig

h te

mpe

ratu

re s

tren

gth

Ther

mal

str

ess

incr

emen

tdu

e to

tem

pera

ture

ther

mal

exp

ansi

on o

f pip

e

Hig

h te

mpe

ratu

re c

orro

sion

Stea

m o

xida

tion

and

scal

eex

pore

atio

nm

anuf

actio

n si

ze li

mita

tion

ofhe

at re

sist

ance

str

eels

Hig

h co

st h

eat r

esis

tanc

est

eel

High temperature properties of Fe-Ni alloy tube materialsEvaluation of Ni base tube materialDevelopment of Fe-Ni, Ni base Thich wall pipe materialDevelopment of austenitic Strainless thick wall pipe material

New 9Cr ferrite thick wall pipe materialDesing Optimization of pipe arrangement - size and thermal stress

Manufacture Welding technology of Fe-Ni and Ni base alloyOperating Optimize operating condition (strat/stop, load variation)

Materials

Break through Point

Development & Inspection Items

Turbine Rotor Candidate Materials

Source: Fukuda, NIMS, USC 2009 Symposium

Steam Turbine Materials Issues

New Alloy Development available to HSC Steam Condition Estimation of Long Term Stability

Turbine material development Breakthrough Point

• Strength ( long term Creep)

• Steam corrosion, oxidation

• Large scale manufacture

• Weldability, Dissimilar weld

• NDT technology

• Low thermal expansion

Experience in A286 rotor for 650� GradeNo Experience in Large Scale Manufacture of Ni base alloys for over 700oC grade

Adoption of Assemble type RotorWelding technology between Dissimilar Materials.

Estimation of Soundness in welded part.Non-destructive Technology of Welding Defects.

Development of Ni Alloy with Low Thermal Expansion Coefficient

• Large scale casting Require same properties as Rotor MaterialsEstimation of Castability and Weldability

Rotor

Casing / Valve

• Steam condition properties Steam oxidation of Ni base alloyBucket

• Long term stability Superior High-Temperature Stress Relaxation PropertiesBolt

Steam Oxidation of Ni base alloy

Breakthrough by New Materials

Efficiency & Economic Design Social & Environmental Demand

Key Issues

- Types of Power Generation- Environmental Regulations- CO2, NOx, SOx

- High Temperature & Pressure - Low Cost Design

MaterialsMaterials

Global Research NetworkGlobal Energy Plan : Define the role of Fossil Power Plants.

- Time Schedule and Market

Reduce the Risk to develop the new materials

- Minimizing the alloying elements

- Low Thermal Expansion Coefficients,

- Good Thermal Conductivity

- Processing tech. to make a large components with reliability

- Data Base for the long term stability

Oxygen burning technology for Near-Zero Emission

Coal

Air

In-furnace deNOx/deSOxIn-furnace

deNOx/deSOx

O2

Power Generation

Flue gas treatment system

OFO/Reburn

Stack

Steam

H2O Sepa-ration

No Stack

CO2

Geological Storage

Geological Storage Ocean

StorageOcean Storage

ASU(Air

SeparationUnit)

Air

N2

Wet FGR Dry FGR

CO2 and/or H2O

Steam turbine

Generator

Steam turbine

Generator

NO need of Flue Gas Treatment System

Germany; Vattenfall AB2008 : 30MWth Schwarze-Pumpe Pilot Plant

2015 : 300~600MWth Demo Plant2020 : 1000MWth Commercial Plant

US DOE3 New Projects

In 2005SRI, B&W, BOC

Spain, CIEMAT2005-

5MW OFC Boiler

Japan; IHI-NEDO1992-2000

1.2MW Boiler Test

1990 2000 2010 2020

1MW

10MW

100MW

USAArgonne NL

EERC3MW Test

forOFC/RFG

Canada; CANMETOn-Going

300kW Oxy-Burner Development

EU-IFRF92-95

150kW↓

35MWOFC

Research

MBELAir ProductUlster U.Napoli U.Imp. Col.

EDP,

Japan-Australia;IHI-CSIRO2004-2011

Retrofit 30MWe Callide A

Jupiter Oxygen25 MWe Orrville

Sask Power 300MWe

KOREA R&D Route to500MWe Class

Commercial Capture-Ready Plant

Global R&D Trend in Oxygen Burning

U.S. Fossil Fuel Reserves / Production Ratio

IGCC

Abundant reserves of CoalEnvironmentally superior coal-based powerEasily adapted for CO2 sequestrationHigh efficiencyFuel & product flexibilityPromising “coal-to-hydrogen” option

USA National Initiatives

Integrated Gasification Combined Cycle, IGCC

Oxygen Separator

O2

Crude coal

Fuel gas

Dust/Gas Purifier

H2 gas

CO gas

+

Syngas

Crude coal/Oil GasificationPurification of Dust/SOx

Production of CO/H2 Gas/Steam Turbine Production of Electricity

Contribution of Energy/Chemical Industry utilizing Syngas

Global R&D Trend in IGCCUSA

• DOE: Construction of Commercial IGCC plants (50% Gov. Funding) - Operating 300MW Grade Demo Plant

• Vision 21 Program: Fuel-Flexible Technology with High Efficiency of 60%

EU • Construction of IGCC Demo Plant (Netherlands, Germany, Spain, Italy)

Japan • Sunshine Project: Construction of IGCC Plant with 250MW Grade

China • Selection of one of National Agenda in 21th • Construction Plan of 200-400 MW Grade IGCC Plants after 2010

Global Production of Syngas by IGCC Technology

Materials Issues for IGCCMaterials Issues for IGCC

Ceramic Gas Turbine

Hydrogen Membrane

�������Membrane

SOFCGas Purifying

Membrane

Oxygen Membrane

High Activity Catalyst

Thank you !