Ultra Super Critical Pressure Coal Fired Boiler

- State of the Art Technology Applications -

Yoshio Shimogori
BABCOCK-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
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Fig.1 What is Super Critical

Super Critical means no distinction between water and steam
3,500 600

3,000

Steam(Gas)

500

Enthalpy(kJ/kg)

Critical (22.06MPa)

2,000

Mix. Of Steam & Water

400

1,500

Saturated line
1,000

300

Water Sub-Critical
10

200

Super Critical
30 100

500

* Thermodynamic quantity
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20 Pressure(MPa)

Temp.(oC )

2,500

Fig.2 Ultra Super Critical (USC) Technology Purpose

High Plant Efficiency High Efficiency Coal Utilization Low Emission (CO2 etc.)

USC Condition
USC Over SC Condition Example 25.0MPa/ 600/600 Super Critical 24.1MPa/ 538 or 566 Critical Point of Water 22.06MPa/ 374

* Steam Condition shows Turbine inlet

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Fig.3 Steam Conditions of Coal Fired Boiler Improvement by BHK

Hitachinaka 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) 24.1MPa/538/566oC 1985 1990 1995 Year
5

25.0MPa/600/610oC 24.5MPa/600/600oC 24.1MPa/593/593oC 24.1MPa/566/593oC Ultra Super Critical Super Critical 2005 2010 Canada (495MW) USA (870MW)

2000

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Fig.4 Improvement of Plant Efficiency

45

Gross Plant efficiency (%) HHV base

Sub critical

Super critical

USC

44

43

42

41

40
16.6MPa 16.6MPa 24.1MPa 24.1MPa 24.1MPa 24.1MPa 24.5MPa 538/538OC 538/566OC 538/566OC 566/566OC 566/593OC 593/593OC 600/600OC

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Table 1 Boiler Type and Furnace Construction

NC Boiler (Vertical Type)
Steam DRUM Feed Water

Benson Boiler(Spiral Type)

Down Comer

Furnace Construction

Feed Water

Operating Pressure Applicable Steam Pressure Through Furnace Enclosure Tubes Temperature Uniformity Mass Flow Rate Sliding Pressure Operation ? Allowable Min. Load (%) Load Change Rate Start-up Time (min.) (Hot start) Furnace Enclosure Construction Tube O/D (mm) Max. Unit Capacity in Operation

Sub-Critical (Constant or Sliding) Subcritical Better Approx. 13% YES 15 Base 120 150 with TB By-pass Vertical 57.0 - 63.5 600 MW

Sub-Critical to Supercritical Region (Sliding Pressure) Supercritical & Subcritical Much Better 100% YES (Wide Range) 25 - 35 (OT Mode) 15 (Circ. Mode) Higher 120 150 with TB By-pass Spiral 31.8 - 38.1 1,050 MW

Notes NC:Natural Circulation OT:Once-Through Circ.:Circulation O/D:Outside Diameter

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Fig.5 Boiler Types Supplied by BHK Group

NC UP BENSON (Two Pass Type) BENSON (Tower Type)

Boiler type

Capacity (MW) Pressure Steam temp. (oC) Coal combustion method Coal kind

50 ~ 600 Subcritical Up to 571

350 ~ 1000 Subcritical, Supercritical Up to 571

75 ~ 1050 Subcritical, Supercritical Up to 613

~ 930 Subcritical, Supercritical Up to 580

PCF PCF (Opposed)(Opposed) Bituminous, Sub-bituminous UP : Universal Pressure

PCF (Opposed, Tangential), Slag tap Bituminous, Sub-bituminous, Lignite, Anthracite

Notes NC:Natural Circulation

Supplied by BBPS (Babcock Borsig Power Systems)

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Fig.6 Wide Range of Coal Qualities Fired

Volatile Matter (dry ash free), %

80 70 60 50 40 30 20 10 0 0

Lignite Sub Bituminous BItuminous

Anthracite

10

20 Net calorific value, MJ/kg

30

40

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1. Improvement of Steam Conditions 2. Improvement of Material and Manufacturing Technology 3. 1000MW Hitachi-Naka No.1 4. Next-Generation USC Boiler
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Fig.7 Development Progress of Ferritic CrMo Steel Pipes

Creep Rupture Strength (600oC/105h) 30 - 40MPa 2.25Cr1Mo SA335P22 9Cr1Mo SA335P9 60MPa 100MPa 140MPa

2.25Cr1.6WVNb SA335P23 (HCM2S) 9Cr2Mo JIS:STPA27 (HCM9M)

9Cr1MoVNb SA335P91 (Mod.9Cr1Mo) 12Cr1Mo1WVNb JIS:SUS410J2TP (HCM12)

9Cr0.5Mo1.8WVNb SA335P92 (NF616) 11Cr0.4Mo2WCuVNb SA335P122 (HCM12A)

12Cr1MoV X20CrMoV121 :Conventional :Advanced

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Fig.8 Allowable Stresses of Ferritic CrMo Steel Pipes

150

Allowable stress (MPa)

SA335P91 (9%Cr) 100 SA335P23 (2.25%Cr) 50 SA335P22 (2.25%Cr) 0 500 550 600 650 700 SA335P92 (9%Cr) SA335P122 (11%Cr)

Temperature (oC)
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Fig.9 Development Progress of Austenitic Stainless Steel Tube

Creep Rupture Strength (650oC/105h) 55 - 60MPa 18Cr8Ni SA213TP304H 18Cr10NiTi SA213TP321H 18Cr10NiNb SA213TP347H 21Cr32NiTiAl Alloy800H 25Cr20Ni JIS:SUS310TB : Conventional : Advanced
13

90MPa 18Cr10NiNbTi JIS:SUS321J1HTB (Tempaloy A-1)

110 - 120MPa

18Cr9Ni3CuNbN SA213-UNS30432 (SUPER304H) 20Cr25Ni1.5MoNbTi JIS:SUS310J2TB (NF709) 25Cr20NiNbN SA213TP310HCbN (HR3C)

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Fig.10 Allowable Stresses Advanced Stainless Steel Tubes

150

Allowable stress (MPa)

SA213TP310HCbN (25%Cr:HR3C) SA213UNS S304 32 (18%Cr:Super 304H ) JIS:SUS310J2TB (20%Cr:NF709)

100

50

JIS:SUS321J1TB
(18%Cr:Tempaloy A1)

0 550 600

SA213TP321H (18%Cr) 650 700 750

Temperature (oC)
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SA213UNS30332

SUS310J2TB SA335P92

SA335P122

SA213TP310HCbN

Fig.12 Macro Structures of Narrow Gap TIG Weld

Fig.11 Macro Structures of TIG Weld of Tube Materials

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Fig.13 Steam Oxide Scale of Stainless Steel Tubes

Inner scale thickness (micro m)

50
Time:1,000h

40
SA213UNS S304 32 (18%Cr:Super 304H) JIS:SUS310J2TB (20%Cr:NF709) SA213TP347HFG (18%Cr:Fine Grain) A213TP310HCbN (25%Cr:HR3C) Shotblasted A213UNS S304 32 (18%Cr:Super 304H)

30

20 10
0

550

600

650

700

750

800

Temperature (oC)
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Fig.14 Improvement Trend of Hitachi NR Series Burners

Guide sleeve Air register Guide sleeve
Flame Stabilizing Ring

Space Creator
Flame Stabilizing Ring

Flame Stabilizing RingBaffle Plate

Spin Vane

Swirler P.C. Concentrator

P.C. Concentrator

Dual Burner
Delayed Combustion

NR Burner

NR2 Burner

NR3 Burner

Rapid ignition(In Flame NOx Reduction)

300 ppm(100%)

400 NOx (6%O2,ppm) 300 200 100 0

Dual Burner (Conventional) NR Burner NR2 Burner 175 ppm(60%) 150 ppm(50%)

Coal property Fuel Ratio : 2.2 Nitrogen : 1.8% Two Stage Combustion 125 ppm(40%) 100 ppm(33%) NR3 Burner Coal property Fuel Ratio1.8 Nitrogen:1.5% Two Stage Combustion

1980

1985

1990

1995

2000

BABCOCK-HITACHI K.K.

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1. Improvement of Steam Conditions 2. Improvement of Material and Manufacturing Technology 3. 1000MW Hitachi-Naka No.1 4. Next-Generation USC Boiler
18

BABCOCK-HITACHI K.K.

Fig.15 Side View of Hitachi-Naka No.1 Boiler

Secondary Superheater Tertiary Superheater

Steam Separator

Reheater Primary Superheater Economizer

Coal Bunker NO Ports Burners Coal Feeders DeNOx System

Air Heaters

Mills

Boiler Circulation Forced Draft Pump Fans

Primary Air Fans 19

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Table 2 Main Specification of Hitachi-Naka No.1

Generator Output Boiler Type MCR Steam Pressure Steam Temperature Main Main Reheat 1000 MW Babcock Hitachi Supercritical Sliding Pressure Operation Benson Boiler 24.5 MPa(g) 600 oC 600 oC 286.9 oC Pulverised Coal Fired Balanced Draught System Main Steam Temperature Control System Reheat Water Fuel Ratio Control and Staged Spray Attemperation Parallel Gas Dampering and Spray Attemperation
20

Economiser Inlet Feedwater Temp. Combustion System Draught System

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Fig.15 Side View of Hitachi-Naka No.1 Boiler

High strength material SA335P122, SUPER304H Optimized heating surface arrangement

Spiral wall with opposed firing

Parallel gas damper with adequate heating surface

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Fig.16 Steam and Water Temperature

30%ECR 50%ECR 75%ECR 100%ECR

650

Superheater Outlet
600

Steam and Water Temperature (oC)

550 500 450

Reheater Outlet

Superheater Inlet
400 350 300 250 200 0 1000 2000 3000

Reheater Inlet Economizer Outlet Economizer Inlet

Main Steam Flow (t/h

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Fig.17 Reheater Outlet Steam Temperature during Load Change

650 3%/min 50%

100% Damper opening degree (Reheater side)

Load Demand

550 (oC) 0

Reheater outlet steam temperature

30min.
Previous Design with Gas Recirculation

30min.
Hitachi-Naka No.1 without Gas Recirculation

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Fig.18 Combustion Test Results at 100% Load

Unburned Carbon in Ash (%)

100%ECR 8 6 4 2 A Coal 0 100 120 140 160 180 200 Fuel Ratio = Fixed Carbon Volatile Matter Target Point B Coal
Coal Country Fuel Ratio (-) Ash(dry%) N(dry%) A Coal Indonesia 1.00 9.3 1.3 B Coal Australia 1.99 7.4 1.8

NOx at Boiler Outlet (ppm 6%O2)

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Fig.19 Flame of Hitachi NR 3 Burner at Minimum Load

Flame of Hitachi NR3 Burning B Coal at Minimum Load

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1. Improvement of Steam Conditions 2. Improvement of Material and Manufacturing Technology 3. 1000MW Hitachi-Naka No.1 4. Next-Generation USC Boiler
26

BABCOCK-HITACHI K.K.

Fig.20 Target Steam Conditions of Next-Generation USC Developing Project

Main Steam Temperature (oC)

USA/VISION21

750

EU/THERMIE AD700 98-13

700
Germany/MARCKO DE2 99-03

650

600

Existing USC Boiler

Sub-Critical Boiler

Target for next generation USC Boiler

550

15

20

25

30

35

Main Steam Pressure (MPa)

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Fig.21 Creep Rupture Strength for Material of Next Generation USC

Creep Rupture Strength (105hr,N/mm2 )

200

Alloy617 (52Ni22Cr) HR6W (40Ni23Cr) NF709 (25Ni20Cr) SA335P122(11Cr2W0.4Mo)

150

Pipe
100

Tube

50

0 600 650 700 750 800 850 Temperature (oC)

28

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Summary
Coal fired USC technology is established up to o 600oC class steam condition Improvement of material and manufacturing technology for boiler tubes and pipes increases steam conditions
o 600oC 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. o Investigation for next Generation USC 700oC class is started.

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Feature of Supercritical Sliding Pressure Operation

SLIDING PRESSURE OPERATION 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 In comparison to constant pressure operations, a sliding type enables much improvement in plant efficiency under partial load operations.
Main Steam Press. (Mpa ) 30 25 20 15 10 5 0 0 5 4 3 2 1 0 1 2 3 0

20

Relative comparison of Heat Rate (%) improvement degradation

40 60 80 100 Turbine Load (%) Thermodynamic loss by falling in pressure

B C
20 40 60 80 100 Turbine Load (%)

Improvement of Turbine Heat Rate due to Sliding Pressure Operation

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High Efficiency Coal Utilizations

(HHV) 55 Net Plant Efficiency (%)
PFBC : Pressurized Fluidized Bed Combustion IGFC : Integrated Coal Gasification Fuel Coal Combined Cycle IGCC : Integrated Coal Gasification Combined Cycle USC : Ultra Super Critical
From : NEDO FORUM 2002

IGCC/IFGC

50
Next Generation USC 30MPa 700/700oC

Hyper Coal PFBC Pulverized Coal Bed Fluidized

45
Pulverized Coal

40
24.1MPa 538/538oC

USC 24.5MPa 600/600oC

USC 30.6MPa 630/630oC

Coal Gasification Hyper Coal

1980

1990

2000

2010

2020

2030
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