Ultra Supercritical Pressure Coal-Fired Boiler
Ultra Supercritical Pressure Coal-Fired Boiler
Ultra Supercritical Pressure Coal-Fired Boiler
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<strong>Ultra</strong> Super Critical <strong>Pressure</strong> <strong>Coal</strong> <strong>Fired</strong> <strong>Boiler</strong>- State of the Art Technology Applications -Yoshio ShimogoriBABCOCK-HITACHI K.K.1
1. Improvement of Steam Conditions2. Improvement of Material andManufacturing Technology3. 1000MW Hitachi-Naka No.14. Next-Generation USC <strong>Boiler</strong>BABCOCK-HITACHI K.K.2
Fig.1 What is Super Critical3,500Super Critical means no distinctionbetween water and steam6003,000Steam(Gas)500Enthalpy*(kJ/kg)2,5002,0001,5001,000500* Thermodynamic quantityMix. Of Steam & WaterSaturated lineCritical (22.06MPa)WaterSub-Critical Super Critical10 20 30<strong>Pressure</strong>(MPa)400300200100Temp.( o C)BABCOCK-HITACHI K.K.3
Fig.2 <strong>Ultra</strong> Super Critical (USC) TechnologyPurposeUSC ConditionHigh Plant EfficiencyHigh Efficiency <strong>Coal</strong> UtilizationLow Emission (CO 2 etc.)USCOver SC ConditionExample25.0MPa/600℃/600℃Super Critical24.1MPa/538℃ or 566℃Critical Pointof Water22.06MPa/374℃* Steam Condition shows Turbine inletBABCOCK-HITACHI K.K.4
Fig.3 Steam Conditions of <strong>Coal</strong> <strong>Fired</strong> <strong>Boiler</strong> Improvement by BHKHitachinaka No.1 (1000MW)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)25.0MPa/600/610 o C24.5MPa/600/600 o C24.1MPa/593/593 o CCanada (495MW)USA (870MW)24.1MPa/566/593 o C<strong>Ultra</strong> Super Critical24.1MPa/538/566 o CSuper Critical1985 1990 1995 2000 2005 2010YearBABCOCK-HITACHI K.K.5
Fig.4 Improvement of Plant EfficiencyGross Plant efficiency (%) HHV base454443424140Sub critical Super critical USC16.6MPa538/538 O C16.6MPa538/566 O C24.1MPa538/566 O C24.1MPa566/566 O C24.1MPa566/593 O C24.1MPa593/593 O C24.5MPa600/600 O CBABCOCK-HITACHI K.K.6
Table 1 <strong>Boiler</strong> Type and Furnace ConstructionNC <strong>Boiler</strong> (Vertical Type)Benson <strong>Boiler</strong>(Spiral Type)FurnaceConstructionSteamDRUMFeedWaterDown ComerOperating <strong>Pressure</strong>Applicable Steam <strong>Pressure</strong>Through Furnace Enclosure TubesTemperature UniformityMass Flow RateSliding <strong>Pressure</strong> Operation ?Allowable Min. Load (%)Load Change RateStart-up Time (min.) (Hot start)Furnace Enclosure ConstructionTube O/D (mm)Max. Unit Capacity in OperationSub-Critical(Constant or Sliding)SubcriticalFeed WaterSub-Critical to <strong>Supercritical</strong> Region(Sliding <strong>Pressure</strong>)<strong>Supercritical</strong> & SubcriticalBetterApprox. 13%YESMuch Better100%YES (Wide Range)15 25 - 35 (OT Mode)15 (Circ. Mode)BaseHigher120 – 150 with TB By-pass 120 – 150 with TB By-passVerticalSpiral57.0 - 63.5 31.8 - 38.1600 MW 1,050 MWNotes NC:Natural Circulation OT:Once-Through Circ.:Circulation O/D:Outside DiameterBABCOCK-HITACHI K.K.7
Fig.5 <strong>Boiler</strong> Types Supplied by BHK GroupNCUPBENSON(Two Pass Type)BENSON(Tower Type)<strong>Boiler</strong> typeCapacity (MW) 50 ~ 600 350 ~ 1000 75 ~ 1050~ 930<strong>Pressure</strong>SubcriticalSubcritical,<strong>Supercritical</strong>Subcritical,<strong>Supercritical</strong>Subcritical,<strong>Supercritical</strong>Steam temp. ( o C)Up to 571Up to 571Up to 613Up to 580<strong>Coal</strong> combustionmethod<strong>Coal</strong> kindPCF PCF(Opposed) (Opposed)Bituminous, Sub-bituminousNotes NC:Natural Circulation UP : Universal <strong>Pressure</strong>PCF (Opposed, Tangential),Slag tapBituminous, Sub-bituminous,Lignite, AnthraciteSupplied by BBPS (Babcock Borsig Power Systems)BABCOCK-HITACHI K.K.8
Fig.6 Wide Range of <strong>Coal</strong> Qualities <strong>Fired</strong>Volatile Matter (dry ash free), %8070605040302010LigniteSub BituminousBItuminousAnthracite00 10 20 30 40Net calorific value, MJ/kgBABCOCK-HITACHI K.K.9
1. Improvement of Steam Conditions2. Improvement of Material andManufacturing Technology3. 1000MW Hitachi-Naka No.14. Next-Generation USC <strong>Boiler</strong>BABCOCK-HITACHI K.K.10
Fig.7 Development Progress of Ferritic CrMo Steel PipesCreep Rupture Strength (600 o C/10 5 h)30 - 40MPa 60MPa 100MPa 140MPa2.25Cr1MoSA335P229Cr1MoSA335P912Cr1MoVX20CrMoV1212.25Cr1.6WVNbSA335P23(HCM2S)9Cr2MoJIS:STPA27(HCM9M)9Cr1MoVNbSA335P91(Mod.9Cr1Mo)12Cr1Mo1WVNbJIS:SUS410J2TP(HCM12)9Cr0.5Mo1.8WVNbSA335P92(NF616)11Cr0.4Mo2WCuVNbSA335P122(HCM12A):Conventional:AdvancedBABCOCK-HITACHI K.K.11
Fig.8 Allowable Stresses of Ferritic CrMo Steel Pipes150Allowable stress (MPa)10050SA335P23(2.25%Cr)SA335P91(9%Cr)SA335P92(9%Cr)SA335P22(2.25%Cr)0500 550 600 650 700Temperature ( o C)SA335P122(11%Cr)BABCOCK-HITACHI K.K.12
Fig.9 Development Progress of Austenitic Stainless Steel TubeCreep Rupture Strength (650 o C/10 5 h)55 - 60MPa 90MPa 110 - 120MPa18Cr8NiSA213TP304H18Cr10NiTiSA213TP321H18Cr10NiNbSA213TP347H18Cr10NiNbTiJIS:SUS321J1HTB(Tempaloy A-1)18Cr9Ni3CuNbNSA213-UNS30432(SUPER304H)21Cr32NiTiAlAlloy800H20Cr25Ni1.5MoNbTiJIS:SUS310J2TB(NF709)25Cr20NiJIS:SUS310TB25Cr20NiNbNSA213TP310HCbN(HR3C): Conventional: AdvancedBABCOCK-HITACHI K.K.13
Fig.10 Allowable Stresses Advanced Stainless Steel TubesAllowable stress (MPa)150100500JIS:SUS321J1TB(18%Cr:Tempaloy A1)SA213TP310HCbN(25%Cr:HR3C)SA213UNS S304 32(18%Cr:Super 304H )SA213TP321H(18%Cr)Temperature ( o C)JIS:SUS310J2TB(20%Cr:NF709)550 600 650 700 750BABCOCK-HITACHI K.K.14
SA213UNS30332SUS310J2TBSA335P92SA335P122SA213TP310HCbNFig.12 Macro Structures ofNarrow Gap TIG WeldFig.11 Macro Structures ofTIG Weld of Tube MaterialsBABCOCK-HITACHI K.K.15
Fig.13 Steam Oxide Scale of Stainless Steel TubesInner scale thickness (micro m)50403020100Time:1,000hSA213UNS S304 32(18%Cr:Super 304H)JIS:SUS310J2TB(20%Cr:NF709)A213TP310HCbN(25%Cr:HR3C)550 600 650 700 750 800Temperature ( o C)SA213TP347HFG(18%Cr:Fine Grain)ShotblastedA213UNS S304 32(18%Cr:Super 304H)BABCOCK-HITACHI K.K.16
Fig.14 Improvement Trend of Hitachi NR Series BurnersAir registerGuide sleeveFlame StabilizingRingSpace CreatorFlame StabilizingRingGuide sleeveFlame StabilizingRing+Baffle PlateSpin VaneDual BurnerSwirlerNR BurnerP.C. Concentrator P.C. ConcentratorNR2 Burner NR3 BurnerDelayed CombustionRapid ignition(In Flame NOx Reduction)NOx (6%O2,ppm)4003002001000300 ppm(100%)Dual Burner(Conventional)175 ppm(60%)NR Burner150 ppm(50%)NR2 Burner1980 1985 1990 1995 2000<strong>Coal</strong> propertyFuel Ratio : 2.2Nitrogen : 1.8%Two Stage Combustion125 ppm(40%)(100 ppm(33%))NR3 Burner<strong>Coal</strong> propertyFuel Ratio:1.8Nitrogen:1.5%Two Stage CombustionBABCOCK-HITACHI K.K.17
1. Improvement of Steam Conditions2. Improvement of Material andManufacturing Technology3. 1000MW Hitachi-Naka No.14. Next-Generation USC <strong>Boiler</strong>BABCOCK-HITACHI K.K.18
Fig.15 Side View of Hitachi-Naka No.1 <strong>Boiler</strong>Secondary SuperheaterTertiary SuperheaterSteam SeparatorReheaterPrimary Superheater<strong>Coal</strong>BunkerEconomizerNO PortsBurners<strong>Coal</strong> FeedersDeNOxSystemAir HeatersMills<strong>Boiler</strong> CirculationPumpForced DraftFansPrimary AirFansBABCOCK-HITACHI K.K.19
Table 2 Main Specification of Hitachi-Naka No.1Generator Output<strong>Boiler</strong> Type1000 MWBabcock Hitachi <strong>Supercritical</strong> Sliding<strong>Pressure</strong> Operation Benson <strong>Boiler</strong>MCRSteam <strong>Pressure</strong> Main 24.5 MPa(g)SteamTemperatureMainReheat600 o C600 o CEconomiser Inlet Feedwater Temp.Combustion System286.9 o CPulverised <strong>Coal</strong> <strong>Fired</strong>Draught SystemSteam TemperatureMainBalanced Draught SystemWater Fuel Ratio Control andStaged Spray AttemperationControl System Reheat Parallel Gas Dampering andSpray AttemperationBABCOCK-HITACHI K.K.20
Fig.15’ Side View of Hitachi-Naka No.1 <strong>Boiler</strong>High strength materialSA335P122, SUPER304HOptimized heatingsurface arrangementSpiral wall withopposed firingParallel gas damper withadequate heating surfaceBABCOCK-HITACHI K.K.21
Fig.16 Steam and Water Temperature30%ECR 50%ECR 75%ECR 100%ECR650600Superheater OutletSteam and Water Temperature ( o C)550500450400350300250Reheater OutletSuperheater InletReheater InletEconomizer OutletEconomizer Inlet2000 1000 2000 3000Main Steam Flow (t/h)BABCOCK-HITACHI K.K.22
Fig.17 Reheater Outlet Steam Temperature during Load Change6503%/min100%Damper opening degree(Reheater side)Load Demand50%550( o C)Previous Designwith Gas RecirculationReheater outletsteam temperature0 30min. 0 30min.Hitachi-Naka No.1without Gas RecirculationBABCOCK-HITACHI K.K.23
Fig.18 Combustion Test Results at 100% LoadUnburned Carbon in Ash (%)100%ECR864Target PointB <strong>Coal</strong>2A <strong>Coal</strong>0100 120 140 160 180 200NOx at <strong>Boiler</strong> Outlet (ppm 6%O2)<strong>Coal</strong>CountryFuel Ratio (-)Ash(dry%)N(dry%)Fuel Ratio =A <strong>Coal</strong>Indonesia1.009.31.3B <strong>Coal</strong>Australia1.997.41.8Fixed CarbonVolatile MatterBABCOCK-HITACHI K.K.24
Fig.19 Flame of Hitachi NR 3 Burner at Minimum LoadFlame of Hitachi NR3Burning B <strong>Coal</strong> at Minimum LoadBABCOCK-HITACHI K.K.25
1. Improvement of Steam Conditions2. Improvement of Material andManufacturing Technology3. 1000MW Hitachi-Naka No.14. Next-Generation USC <strong>Boiler</strong>BABCOCK-HITACHI K.K.26
Fig.20 Target Steam Conditions of Next-Generation USC Developing ProjectMain Steam Temperature ( o C)750700650600550Sub-Critical<strong>Boiler</strong>ExistingUSC <strong>Boiler</strong>USA/VISION21EU/THERMIEAD700’98-’13Germany/MARCKO DE2’99-’03Target fornext generationUSC <strong>Boiler</strong>15 20 25 30 35Main Steam <strong>Pressure</strong> (MPa)BABCOCK-HITACHI K.K.27
Fig.21 Creep Rupture Strength for Material of Next Generation USCCreep Rupture Strength (10 5 hr,N/mm 2 )200150100500PipeAlloy617 (52Ni22Cr)HR6W (40Ni23Cr)NF709 (25Ni20Cr)SA335P122(11Cr2W0.4Mo)Tube600 650 700 750 800 850Temperature ( o C)BABCOCK-HITACHI K.K.28
Summary<strong>Coal</strong> fired USC technology is established up to600 o C class steam conditionImprovement of material and manufacturingtechnology for boiler tubes and pipes increasessteam conditions600 o C class USC <strong>Boiler</strong> , Hitachi-Naka unit No.1,starts commercial operation with advancetechnology such as low NOx, high combustionefficiency and steam temperature control.Investigation for next Generation USC 700 o Cclass is started.BABCOCK-HITACHI K.K.29
Feature of <strong>Supercritical</strong> Sliding <strong>Pressure</strong> OperationSLIDING PRESSURE OPERATIONUnit output control method by sliding pressure is asfollows.By the sliding pressure in proportion to the generatoroutput, steam quantity at turbine inlet can bechanged at a constant volume flow while keepinggoverning valve open.A smaller governing valve loss enables improvementof high pressure turbine internal efficiency : ADecrease of feed water pump throughput : B<strong>Boiler</strong> reheat steam temperature can be maintainedat higher level because of higher temperature inhigh pressure turbine exhaust steam : CIn comparison to constant pressure operations, a slidingtype enables much improvement in plant efficiencyunder partial load operations.Relative comparison ofHeat Rate (%)improvement degradation Main Steam Press. (Mpa )302520151050 0 20 40 60 80 100Turbine Load (%)543210123ABCThermodynamic loss byfalling in pressure0 20 40 60 80 100Turbine Load (%)Improvement of Turbine Heat Ratedue to Sliding <strong>Pressure</strong> OperationBABCOCK-HITACHI K.K.30
High Efficiency <strong>Coal</strong> Utilizations(HHV)55Net Plant Efficiency (%)504540PFBC : Pressurized Fluidized Bed CombustionIGFC : Integrated <strong>Coal</strong> Gasification Fuel <strong>Coal</strong>Combined CycleIGCC : Integrated <strong>Coal</strong> Gasification Combined CycleUSC : <strong>Ultra</strong> Super CriticalPulverized <strong>Coal</strong>24.1MPa538/538 o CBABCOCK-HITACHI K.K.Next Generation USC30MPa 700/700 o CUSC24.5MPa600/600 o CUSC30.6MPa630/630 o CPFBCFrom : NEDO FORUM 2002IGCC/IFGCHyper <strong>Coal</strong>Pulverized <strong>Coal</strong>Bed Fluidized<strong>Coal</strong> GasificationHyper <strong>Coal</strong>1980 1990 2000 2010 2020 203031
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