Super Critical Details
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Transcript of Super Critical Details
1BABCOCK-HITACHI K.K.
Ultra Super Critical Pressure Coal Fired Boiler - State of the Art Technology Applications -
Ultra Super Critical Pressure Coal Fired Boiler - State of the Art Technology Applications -
Yoshio ShimogoriYoshio Shimogori
2BABCOCK-HITACHI K.K.
1. Improvement of Steam Conditions
2. Improvement of Material and Manufacturing Technology
3. 1000MW Hitachi-Naka No.1
4. Next-Generation USC Boiler
1. Improvement of Steam Conditions
2. Improvement of Material and Manufacturing Technology
3. 1000MW Hitachi-Naka No.1
4. Next-Generation USC Boiler
3BABCOCK-HITACHI K.K.
* Thermodynamic quantity
Super Critical means no distinction between water and steam Super Critical means no distinction between water and steam
200
300
400
500
600
1,000
1,500
2,000
2,500
3,000
500
3,500
10 20 30100
Crit
ical
(22.
06M
Pa)
Super CriticalSub-Critical
Steam(Gas)
Mix. Of Steam & Water
Water
Saturated line
Pressure(MPa)
Tem
p.(o
C)
Enth
alpy
*(k
J/kg
)
Fig.1 What is Super Critical
4BABCOCK-HITACHI K.K.
PurposePurpose High Plant EfficiencyHigh Efficiency Coal UtilizationLow Emission (CO2 etc.)
USC ConditionUSC Condition
USCUSCOver SC Condition
Example25.0MPa/600℃/600℃
Super CriticalSuper Critical
24.1MPa/538℃ or 566℃
Critical Point Critical Point of Waterof Water
22.06MPa/374℃
* Steam Condition shows Turbine inlet
Fig.2 Ultra Super Critical (USC) TechnologyFig.2 Ultra Super Critical (USC) Technology
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Fig.3 Steam Conditions of Coal Fired Boiler Improvement by BHK
24.1MPa/538/566oC
24.1MPa/566/593oC
24.5MPa/600/600oC
24.1MPa/593/593oC
1990 20001995 2005
Year
1985 2010
Tachibanawan No.2 (1050MW)Haramachi No.2 (1000MW)
Matsuura No.2 (1000MW)Nanao-Ohta No.1 (500MW)
Shinchi No.1 (1000MW)Noshiro No.1 (600MW)
Hekinan No.2 (700MW)Matsuura No.1 (1000MW)
Takehara No.3 (700MW)
Hitachinaka No.1 (1000MW)
25.0MPa/600/610oC
Ultra Super Critical
Super Critical
Canada (495MW)USA (870MW)
6BABCOCK-HITACHI K.K.
40
41
42
43
44
16.6MPa 538/538OC
16.6MPa 538/566OC
24.1MPa 538/566OC
24.1MPa 566/566OC
24.1MPa 566/593OC
24.1MPa 593/593OC
24.5MPa 600/600OC
Gro
ss P
lant
effi
cien
cy (%
) HH
V ba
se
45
Fig.4 Improvement of Plant Efficiency
Sub critical Super critical USC
7BABCOCK-HITACHI K.K.
Notes NC:Natural Circulation OT:Once-Through Circ.:Circulation O/D:Outside Diameter
FurnaceConstruction
Operating Pressure Sub-Critical(Constant or Sliding)
Benson Boiler(Spiral Type)NC Boiler (Vertical Type)
Sub-Critical to Supercritical Region(Sliding Pressure)
Applicable Steam PressureThrough Furnace Enclosure TubesTemperature UniformityMass Flow RateSliding Pressure Operation ?
Max. Unit Capacity in Operation
Furnace Enclosure ConstructionTube O/D (mm)
Start-up Time (min.) (Hot start)
Allowable Min. Load (%)
Load Change Rate
Subcritical Supercritical & Subcritical
BetterApprox. 13%
YES
Much Better100%
YES (Wide Range)
15 25 - 35 (OT Mode)15 (Circ. Mode)
Base Higher120 – 150 with TB By-pass 120 – 150 with TB By-pass
57.0 - 63.5 31.8 - 38.1600 MW 1,050 MW
Vertical Spiral
Table 1 Boiler Type and Furnace Construction
Feed Water
Down
Com
er
DRUM
Steam FeedWater
8BABCOCK-HITACHI K.K.
Fig.5 Boiler Types Supplied by BHK Group
Capacity (MW)
Pressure
Steam temp. (oC)
Boiler type
Coal combustion method
Coal kind
50 ~ 600
Subcritical
Up to 571
PCF (Opposed)
Bituminous, Sub-bituminous
PCF (Opposed)
~ 930
Subcritical,Supercritical
Up to 580
PCF (Opposed, Tangential), Slag tap
Bituminous, Sub-bituminous, Lignite, Anthracite
NC UP BENSON(Tower Type)
BENSON(Two Pass Type)
350 ~ 1000
Up to 571
Subcritical, Supercritical
75 ~ 1050
Up to 613
Subcritical,Supercritical
Notes NC:Natural Circulation UP : Universal Pressure
Supplied by BBPS (Babcock Borsig Power Systems)
9BABCOCK-HITACHI K.K.
Fig.6 Wide Range of Coal Qualities Fired
0
10
20
30
40
50
60
70
80
0 10 20 30 40Net calorific value, MJ/kg
Vola
tile
Mat
ter (
dry
ash
free
), % Lignite
Anthracite
BItuminous
Sub Bituminous
10BABCOCK-HITACHI K.K.
1. Improvement of Steam Conditions
2. Improvement of Material and Manufacturing Technology
3. 1000MW Hitachi-Naka No.1
4. Next-Generation USC Boiler
1. Improvement of Steam Conditions
2. Improvement of Material and Manufacturing Technology
3. 1000MW Hitachi-Naka No.1
4. Next-Generation USC Boiler
11BABCOCK-HITACHI K.K.
2.25Cr1.6WVNbSA335P23(HCM2S)
2.25Cr1MoSA335P22
9Cr1MoSA335P9
12Cr1MoVX20CrMoV121
9Cr2MoJIS:STPA27(HCM9M)
9Cr1MoVNbSA335P91(Mod.9Cr1Mo)
12Cr1Mo1WVNbJIS:SUS410J2TP(HCM12)
11Cr0.4Mo2WCuVNbSA335P122(HCM12A)
9Cr0.5Mo1.8WVNbSA335P92(NF616)
Creep Rupture Strength (600oC/105h)
30 - 40MPa 60MPa 100MPa 140MPa
:Conventional
Fig.7 Development Progress of Ferritic CrMo Steel Pipes
:Advanced
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0
Temperature (oC)
Allo
wab
le s
tres
s (M
Pa)
SA335P22(2.25%Cr)
SA335P91 (9%Cr)
SA335P92(9%Cr)
SA335P122(11%Cr)
SA335P23(2.25%Cr)
50
100
150
500 550 600 650 700
Fig.8 Allowable Stresses of Ferritic CrMo Steel Pipes
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18Cr10NiTi18Cr8Ni
25Cr20Ni
18Cr10NiNb
25Cr20NiNbNSA213TP310HCbN(HR3C)
20Cr25Ni1.5MoNbTiJIS:SUS310J2TB(NF709)
Creep Rupture Strength (650oC/105h)
55 - 60MPa 90MPa 110 - 120MPa
18Cr10NiNbTiJIS:SUS321J1HTB(Tempaloy A-1)
18Cr9Ni3CuNbNSA213-UNS30432(SUPER304H)
: Conventional: Advanced
SA213TP304H SA213TP321H
SA213TP347H
JIS:SUS310TB
21Cr32NiTiAlAlloy800H
Fig.9 Development Progress of Austenitic Stainless Steel Tube
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0
Temperature (oC)
Allo
wab
le s
tres
s (M
Pa)
SA213TP321H(18%Cr)
SA213UNS S304 32(18%Cr:Super 304H )
SA213TP310HCbN(25%Cr:HR3C)
JIS:SUS310J2TB(20%Cr:NF709)
JIS:SUS321J1TB(18%Cr:Tempaloy A1)
550 600 650 700 750
50
100
150
Fig.10 Allowable Stresses Advanced Stainless Steel TubesFig.10 Allowable Stresses Advanced Stainless Steel Tubes
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SA213UNS30332
SUS310J2TB
SA213TP310HCbN
SA335P92 SA335P122
Fig.12 Macro Structures ofNarrow Gap TIG Weld
Fig.11 Macro Structures ofTIG Weld of Tube Materials
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Temperature (oC)
Inne
r sca
le th
ickn
ess
(mic
ro m
)
0
Time:1,000h
SA213UNS S304 32(18%Cr:Super 304H)
A213TP310HCbN(25%Cr:HR3C)
JIS:SUS310J2TB(20%Cr:NF709)
ShotblastedA213UNS S304 32
(18%Cr:Super 304H)
550 600 650 700 750 800
20
30
40
50
10
SA213TP347HFG(18%Cr:Fine Grain)
Fig.13 Steam Oxide Scale of Stainless Steel Tubes
17BABCOCK-HITACHI K.K.
Fig.14 Improvement Trend of Hitachi NR Series Burners
NR2 BurnerDual Burner NR3 BurnerNR BurnerDelayed Combustion Rapid ignition(In Flame NOx Reduction)
Guide sleeveFlame StabilizingRing
Swirler
Space CreatorFlame StabilizingRing
P.C. Concentrator
Flame StabilizingRing+Baffle Plate
Guide sleeve
Spin Vane
Air register
P.C. Concentrator
Coal propertyFuel Ratio:1.8Nitrogen:1.5%Two Stage Combustion
1980 1985 1990 1995 20000
100
200
300
400
NO
x (6
%O
2,pp
m)
300 ppm(100%)Coal propertyFuel Ratio : 2.2Nitrogen : 1.8%Two Stage Combustion
Dual Burner(Conventional)
NR2 BurnerNR Burner NR3 Burner
175 ppm(60%)150 ppm(50%) 125 ppm(40%)
(100 ppm(33%))
18BABCOCK-HITACHI K.K.
1. Improvement of Steam Conditions
2. Improvement of Material and Manufacturing Technology
3. 1000MW Hitachi-Naka No.1
4. Next-Generation USC Boiler
1. Improvement of Steam Conditions
2. Improvement of Material and Manufacturing Technology
3. 1000MW Hitachi-Naka No.1
4. Next-Generation USC Boiler
19BABCOCK-HITACHI K.K.
Fig.15 Side View of Hitachi-Naka No.1 Boiler
NO Ports
Burners
Steam Separator
Secondary Superheater Tertiary Superheater
Reheater
Primary Superheater
Economizer
DeNOxSystem
Air Heaters
Mills
CoalBunker
Primary AirFans
Forced Draft Fans
Boiler CirculationPump
Coal Feeders
20BABCOCK-HITACHI K.K.
Table 2 Main Specification of Hitachi-Naka No.1
Generator Output 1000 MW
Boiler TypeBabcock Hitachi Supercritical Sliding Pressure Operation Benson Boiler
Steam Pressure Main 24.5 MPa(g)
Main 600 oC Steam Temperature Reheat 600 oC
MCR
Economiser Inlet Feedwater Temp. 286.9 oC
Combustion System Pulverised Coal Fired
Draught System Balanced Draught System
Main Water Fuel Ratio Control andStaged Spray Attemperation Steam Temperature
Control System Reheat Parallel Gas Dampering andSpray Attemperation
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Fig.15’ Side View of Hitachi-Naka No.1 Boiler
Spiral wall with opposed firing
Optimized heating surface arrangement
High strength material SA335P122, SUPER304H
Parallel gas damper with adequate heating surface
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200
250
300
350
400
450
500
550
600
650
0 1000 2000 3000
Main Steam Flow (t/h)
Stea
m a
nd W
ater
Tem
pera
ture
(oC
) Reheater Outlet
Economizer Inlet
Economizer Outlet
Reheater Inlet
Superheater Inlet
Superheater Outlet
30%ECR 50%ECR 75%ECR 100%ECR
Fig.16 Steam and Water Temperature
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Hitachi-Naka No.1 without Gas Recirculation
Previous Design with Gas Recirculation
(oC)550
Load Demand
Reheater outlet steam temperature
50%
3%/min
100%
0 30min. 0 30min.
650Damper opening degree (Reheater side)
Fig.17 Reheater Outlet Steam Temperature during Load Change
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B CoalAustralia
7.41.99
1.8
CoalCountry
Fuel Ratio (-)
N(dry%)
IndonesiaA Coal
1.009.31.3
Ash(dry%)
0
2
4
6
8
100 120 140 160 180 200Unb
urne
d C
arbo
n in
Ash
(%)
Target Point
100%ECR
A Coal
B Coal
NOx at Boiler Outlet (ppm 6%O2)
Fuel Ratio = Fixed Carbon
Volatile Matter
Fig.18 Combustion Test Results at 100% Load
25BABCOCK-HITACHI K.K.
Flame of Hitachi NR3 Burning B Coal at Minimum Load
Fig.19 Flame of Hitachi NR 3 Burner at Minimum Load
26BABCOCK-HITACHI K.K.
1. Improvement of Steam Conditions
2. Improvement of Material and Manufacturing Technology
3. 1000MW Hitachi-Naka No.1
4. Next-Generation USC Boiler
1. Improvement of Steam Conditions
2. Improvement of Material and Manufacturing Technology
3. 1000MW Hitachi-Naka No.1
4. Next-Generation USC Boiler
27BABCOCK-HITACHI K.K.
Main Steam Pressure (MPa)
750
700
650
600
550
15 20 25 30 35
Germany/MARCKO DE2’99-’03
USA/VISION21 EU/THERMIEAD700’98-’13
Sub-Critical Boiler
Target for next generation
USC BoilerExisting USC Boiler
Mai
n St
eam
Tem
pera
ture
(oC
)Fig.20 Target Steam Conditions of Next-Generation USC Developing Project
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Fig.21 Creep Rupture Strength for Material of Next Generation USCFig.21 Creep Rupture Strength for Material of Next Generation USC
Cre
ep R
uptu
re S
tren
gth
(10
5 hr,N
/mm
2 )
0
50
100
150
200
0
50
100
150
200
600 650 700 750 800 850600 650 700 750 800 850
Temperature (oC)
Alloy617 (52Ni22Cr)HR6W (40Ni23Cr)NF709 (25Ni20Cr)SA335P122(11Cr2W0.4Mo)
PipePipe TubeTube
29BABCOCK-HITACHI K.K.
Coal fired USC technology is established up to 600oC class steam conditionImprovement of material and manufacturing technology for boiler tubes and pipes increases steam conditions600oC class USC Boiler , Hitachi-Naka unit No.1, starts commercial operation with advance technology such as low NOx, high combustion efficiency and steam temperature control.Investigation for next Generation USC 700oC class is started.
Coal fired USC technology is established up to 600oC class steam conditionImprovement of material and manufacturing technology for boiler tubes and pipes increases steam conditions600oC class USC Boiler , Hitachi-Naka unit No.1, starts commercial operation with advance technology such as low NOx, high combustion efficiency and steam temperature control.Investigation for next Generation USC 700oC class is started.
SummarySummarySummary
30BABCOCK-HITACHI K.K.
SLIDING PRESSURE OPERATION
Thermodynamic loss byfalling in pressure
51015202530
20 40 60 80 10000Turbine Load (%)
0 20 40 60 80 100Turbine Load (%)
Unit output control method by sliding pressure is as follows.By the sliding pressure in proportion to the generator output, steam quantity at turbine inlet can be changed at a constant volume flow while keeping governing valve open.
A smaller governing valve loss enables improvement of high pressure turbine internal efficiency : A
Decrease of feed water pump throughput : B
Boiler reheat steam temperature can be maintained at higher level because of higher temperature in high pressure turbine exhaust steam : C
Improvement of Turbine Heat Rate due to Sliding Pressure Operation
A
B
C321012345
degr
adat
ion
Rel
ativ
e co
mpa
rison
of
Hea
t Rat
e (%
)im
prov
emen
tM
ain
Stea
m P
ress
. (M
pa )
In comparison to constant pressure operations, a slidingtype enables much improvement in plant efficiencyunder partial load operations.
Feature of Supercritical Sliding Pressure Operation
31BABCOCK-HITACHI K.K.
Next Generation USC30MPa 700/700oC
High Efficiency Coal Utilizations
2010200019901980 20302020
40
45
50
55(HHV)
Net
Pla
nt E
ffici
ency
(%)
Pulverized CoalBed FluidizedCoal GasificationHyper Coal
Pulverized Coal
PFBC
IGCC/IFGC
Hyper Coal
24.1MPa538/538oC
USC24.5MPa
600/600oC
USC30.6MPa
630/630oC
PFBC : Pressurized Fluidized Bed CombustionIGFC : Integrated Coal Gasification Fuel Coal
Combined CycleIGCC : Integrated Coal Gasification Combined CycleUSC : Ultra Super Critical
From : NEDO FORUM 2002