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
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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
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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
9© 2011 Electric Power Research Institute, Inc. All rights reserved.
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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