1c Low Mass Flux Once Through Boiler Design Application and PDF

Doosan Babcock Energy
Low Mass Flux Once Through Boiler Design

Application and Experience
January 11, 2007
Agenda
1. Yaomeng, how ‘low mass flux design’ was applied

2. Yaomeng, commissioning and experience in operation
3. Application to ‘W’ firing in China, 1st new build order,
1st Supercritical order
4. Ongoing activities, retrofit orders in the UK
1
Furnace Design for Yaomeng Power Plant
Features of Original Design
UP-Type Boiler with reheater designed to

generate 935te/h main steam at 570OC but
limited to 545OC by the steam turbine and
superheater.
• Two pass layout with pendent high
temperature surfaces and horizontal multi-
loop low temperature surfaces.
• Multi-loop economiser with twin
longitudinal fin.
• Twin fire-ball T- firing system in a furnace
split by full height part division wall
forming a first water-phase pass.
• Outside membrane walls built from
internally ribbed tubes, water mass flux
approximately 1800kg/m2/s forming second
water pass.
• Cased and insulated boiler roof with
external interconnecting piping.
2
Objectives for Refurbishment
• Improve unit turndown.

• Improve boiler thermal efficiency.
• Reduce air infiltration through boiler roof
and walls.
• Improve turbine heat rate.
• Raise maximum continuous and peak
generation capabilities.
• Reduce start-up times and heat and water
consumptions.
• Upgrade superheater and reheater parts.
• Upgrade boiler envelope framing system.
• Upgrade gallery and stair system.
• Reduce dust build-up with soot-blowers
where needed.
• Reduce stack emissions.
3
Boiler Design Constraints
Retain the Following:

• Main supporting structure.
• All leading dimensions of boiler envelope.
• Division walls.
• Primary superheater parts.
• Primary reheater parts.
• Rear cage pressure parts
• Mills and most parts of milling system.
• Main services pipework.
• Boiler interconnecting pipework where
possible.
• Regenerative gas-air heater.
• Draught plant.
4
Key Features of Refurbished Boiler
• Doosan Babcock LMFVT Benson Boiler.

• More output, better efficiency and
reliability.
• New furnace walls with new casings,
insulation and framing.
• New furnace roof, casings, seals and
insulation.
• New casings, insulation and framing for
rear cage.
• New pendant surfaces with identical
performance. Some new headers.
• New economiser with increased
performance and soot-blowers.
• New burners with staged air admission
and lower NOx emisions.
• New start-up system.
• Addition of steam air pre-heater.
5
New Pressure Parts for the Refurbished Boiler
Boiler Operating Reliability and Availability ensured by

replacing worn out or otherwise defective tubes and
headers in addition to the furnace and economiser parts:
• 50% of the Secondary Reheater tubing replaced without
changing the layout.
• 100% of the Platen Superheater replaced without
changing the layout.
• 100% of the Final Superheater replaced without changing
the layout.
• The Final Superheater Outlet Header replaced.
• New safety valves and exhaust systems and a steam
relief valve installed.
6
Process Design for Refurbished Boiler (1)
Boiler Operating Turn-down and Output improved by

replacing the original water walls:
• The new water walls selected to remove turn-down
limitations.
• The new water walls enable at least 950te/h main steam
flow to be generated.
• The new water walls permit peak load operation at
1000te/h main steam flow.
• The new water wall layout accommodates staged burners
to reduce NOx emissions and enable a higher thermal
efficiency to be met.
• The new water walls insulated and framed to modern
standards.
7
Process Design for Refurbished Boiler (2)
Efficiency improved by reducing heat lost in air-heater exit

gases to the chimney:
• The gas amount reduced by renewing old casings
throughout the boiler.
• The gas temperature reduced by enlarging the
economiser and by reducing the amount of cold air that
enters the milling system and so bypasses the air-heater.
• The amount of cold air used in the milling system
reduced by:
• A larger economiser
• Using lower primary air flows
• Increasing transport air temperatures
• Sootblowers installed with the new economiser and the
air-heater sootblowers refurbished to maintain good heat
transfer and control gas pressure loss.
8
Circuit Layout Option for Division Wall
Temperature, °C
Attachment 2: Enthalpy vs Pressure Diagram
Enthalpy versus Pressure
4000
720
700
650
3500
600
550
500
3000
450
x=0.9
Specific enthalpy, kJ/kg

2500
x=0.7
400
2000
x=0.5 Low er Furnace Side
Wall Outlet 374.1
350
1500 x=0.3
300
x=0.1 250
1000
200
External 500
150
100
walls 50
20
10
0
0 50 100 150 200 250 300
Pressure, bar absolute
100%BMCR 80%ECR 60%BMCR
Division wall in series

With the enlarged Economiser, the
division wall cannot be put in series with
the external walls because the margin to
start of boiling at the inlet to the furnace
60% 80% BMCR walls is too small at 80% load and below.
9
Once Through Options
Vertical Tube Layout:

• The existing furnace for Yaomeng Unit #1 was built with
vertical ribbed bore tubes and this layout gave problems.
• How could a new design, also constructed with vertical ribbed
bore tubes, be a good solution?
• The original design was based on a water flow rate of
approximately 1800kg/m2/s.
• The new design has been based on a low water flow rate
of approximately 700kg/m2/s.
• This lower water flow rate gives the tubes a “positive flow
response” such that more heat results in more flow.
• The new furnace has been built from tubes with an
optimised rib profile according to a technology
developed by Siemens Power Generation and Doosan
Babcock, and manufactured under their supervision in
the United Kingdom.
10
Choice of Furnace Design Water Mass Flow
M = Water flow, kg/s

Q = Heat absorbed by tube, kW
A = Total tube flow area, m2
Water mass flow = M/A, kg/sqm/s
Response ratio = (dM/M)/(dQ/Q)
The optimum water mass flow rate is
obtained by selecting the right
combination of water flow, tube size
and pitching.
Neutral response at BMCR for
Yaomeng would occur at a water
mass flow of 1300-1400kg/sqm/s.
The selected water mass flow of
700kg/sqm/s gives a strong positive
response.
11
Static and Dynamic Pressure Drops in Furnace Design
Static Pressure Drops:

• Static pressure is due to the weight of a column of steam and
water. It therefore depends on density and height.
• At the furnace inlet boxes, the density of water is about
710kg/m3.
• As steam is about to form the density has dropped to about
495kg/m3.
• As steam becomes dry the density is about 170kg/m3.
• The total static pressure drop results from integrating the
heights and densities over the circuit height. More heat
means more steam, lower density and less static pressure.
Dynamic Pressure Losses:
• These arise from friction between the fluid and the tube wall,
from turbulence and by accelerating the flow.
• These losses are functions of specific volume and mass flow.
More heat means more steam and greater dynamic losses.
12
Flow Response of Furnace Tubes
High water flow rates lead to high

High mass flow Low mass flow
dynamic losses. When extra heat is
applied to a tube or group of tubes,
the overall pressure drop increases a
lot. The flows in the effected tubes
have to fall to match the overall circuit
pressure drop.
Circuits designed with low water flow
Dynamic pressure rates are dominated by static pressure
losses drops. When extra heat is applied the
static pressure drop and overall
pressure drop fall.
Static pressure drops
Flow has to increase to
match the overall circuit
pressure drop.
13
Main Features of New Furnace Design
Furnace Wall Design:

• The total furnace heat absorbing wall
area is made up of front, rear and side
outside walls heated from one side only
and two sections of division wall heated
from both sides.
• The water flow for the division wall
would have to be more per tube than the
other walls – this required larger
Outside walls: diameter tubes.
26.9mm od membraned on a 42mm pitch
-- • Division wall edge tubes were selected
Lower division walls: with an even larger diameter for the
26.9/33.7/38.0mm od on a 39mm pitch higher heat input according to their
-- more exposed positions.
Upper division walls:
• At higher elevations all tube have larger
38.0/44.5mm od on a 39mm pitch
bores.
14
Detailed Design of the New Furnace (1)
Flow modelling and checking:

• The water flow through every furnace tube should be
appropriate for the heat supply to prevent overheating or
large temperature differences.
• The concept of positive flow response can deliver that if
the tubes sizes and lengths are correct.
• The flow must also stabilise at the correct amount
during unusual conditions or following a disturbance,
for example during start-up or when conditions are
changed by the boiler DCS.
• Computer modelling of the exact layout is the design
method used to make these checks.
15
3-D Model of Refurbished Boiler
• 3-D modelling provides a true

representation of the plant.
• “Walk Through” allows the access
to be checked effectively.
• Clashes between components can
be spotted and dealt with.
• The true positions of piping
systems are included, and
accurate data is therefore available
for stress checks and pressure
loss calculations.
• The colour scheme is to
differentiate the different systems.
16
Optimised Ribbed Tubing:

• The furnace outside walls and
division walls are manufactured
with cold drawn tubing
incorporating an optimised rib form.
• Rib optimisation has been
completed using a full scale
electrically heated test rig by
Siemens Power Generation, who
own the technology.
Outside walls and vestibule: • The rib form delivers optimum heat
Three different ribbed tube sizes transfer between the tube wall and
the water flow.
Division walls:
Five different ribbed tube sizes
17
Ribbed Tubing:
• Steam forms from saturated water inside the
heated areas of the furnace tubes.
• The rotating water flow induced by the internal
ribs replaces the steam bubbles at the
generation sites by saturated water.
• This action maintains a nucleate boiling type of
heat transfer at much higher steam qualities and
low water flow rates than for standard ribbed
bore tubing.
• The rib lead angle, rib height and other rib
parameters have been optimised for use in low
mass flow furnaces and are different from those
in standard ribbed tubing.
18
Tube wall metal temperature:

• The heat flux used to calculate
Tube wall, OOC
these tube wall temperatures is the
peak which happens only in the
Smaller rib heights burner region.
• In this region the fluid enthalpy is
2150 – 2250 kJ/kg
• If the rib height is made too small
the reduction in heat transfer
causes the tube wall metal
temperature to rise.
Fluid enthalpy, kJ/kg
• Making the tubes with the correct
rib dimensions is important for
long term operation.
Rib height used for
Yaomeng Unit #1
19
Ribbed Tube Manufacture
The specialised ribbed tubes

were manufactured under Doosan
Babcock direction & guidance.
The second cold draw pass was

made with a specially made
grooved plug, held in position in
the die by a rotating bearing.
This critical draw produces the
finished tube dimensions and the
rib pitch and rib flank parameters.
The tubes were drawn in lengths
of about 25m.
On-line checks on every tube
were made to ensure quality.
20
Agenda

3. Application to ‘W’ firing in China, 1st new build order, 1st
Supercritical order
21
Yaomeng Power Plant
Commissioning and Operation
Steam purging required special planning for

the low mass flux design.
Analysis showed that the normal purge
method, by operation of the boiler at low
pressure and high flow rates, would cause
instability in the furnace tubes.
It was necessary to sustain higher boiler
pressures for safety.
However with higher pressures, the
disturbance factors would be too low for an
effective purge.
It was decided to refit the two motorised valves
(MLVs) in the superheater inlet pipework to
give low pressure in the purged circuits and
high pressure in the boiler.
22
Yaomeng Power Plant
Division wall issues During early operation a thermocouple

on one of the division wall tubes in the
front section gave rise to concern.
Tube ‘F65’ forms a non-draining loop to
control alignment of the upper section
and has extra length and heat input.
There was some misalignment of the
lower sections noted.
The lower section had alignment bars
added to keep the tubes in plane.
Additional thermocouples were added to
get a full picture of the temperatures.
Temperatures still ran high for these edge
tubes.
F65 after optimisation
Final solution was to swap tubes from the
edges so that the hottest and coolest
tubes swapped location at the 21.5 meter
level.
Furnace Division wall This kept the temperatures more
consistent.
23
Yaomeng Power Plant
Four years operation

Client extremely pleased
Operation as expected
24
Yaomeng Power Plant
Units Before After

Refurbishment Refurbishment
Peak Output MWe 270 327
Boiler Thermal efficiency %LHV 90.3 91.4
Unburned carbon in flyash % 4.7 1.6
Boiler Turndown without oil support % 70 40
Load change rate MWe/min Virtually Zero 3
Boiler cold start time - - Reduced by 1 hr
Furnace tube failures - ~600 over a 10 yr None

period
Plant availability % 90 99
Plant utilization % 58 79
Downtime for construction only 6 months. Design life 20 years
25
Yaomeng Power Plant
5 0 0
4 8 0
4 6 0
Test Results For Various
Temperature (Deg.C)
4 4 0 Loads Between
4 2 0
4 0 0 203 MWe & 308 MWe
3 8 0
3 6 0
3 4 0
3 2 0
3 0 0
1 2 3 4 5 6 7 8 9 1 0 1 1 1 2 1 3 1 4 1 5 1 6 1 7 H = Hotter Corner
C = Colder Corner
H C C H
C C
500 500
480 480
Temperature (Deg.C)
Temperature (Deg.C)
460 460
440 440
420 420
400 400
380 380
360 360
340 340
320 320
300 300
8
1 27 36 45 5 4 63 7 2 8 1 1 2 3 4 5 6 7 8 9
H H
C H H C
5 0 0
4 8 0
4 6 0
Furnace Tube
Temperature (Deg.C)
4 4 0 Design Temp.
4 2 0
4 0 0
3 8 0
3 6 0
450 °C
3 4 0
3 2 0
3 0 0
1 2 3 4 5 6 7 8 9 1 0 1 1 1 2 1 3 1 4 1 5 1 6 1 7
26
Yaomeng Power Plant
H
Test Results For Front Wall
H C C
Only At
C C 203 MWe & 309 MWe
H = Hotter Corner
C = Colder Corner
H H
C H H C
500
Furnace Tube
480
Design Temp.
460
450 °C
440
420
203 MW e
400
308 MW e
380
360
340
320
300
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17
27
Yaomeng Power Plant
500
480
460
440
420
203 MW e
400
308 MW e
380
360
340
320
300
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 Thermocouple measurements
404 furnace tubes
Maximum measured deviation (415°C to 386°C) = 29°C over 25 tubes
Very Small Average Tube to Tube Variation ~ 1.2 °C
28
Yaomeng Power Plant
• Yaomeng is the first Low Mass Flux Positive Flow Characteristic Once Through Boiler in
the world. After refurbishment, measurements show furnace metal temperatures & fluid
temperatures are even and meet the design requirement, also with good flow stability
characteristic. The load cycle capability meet the design target – 50% to BMCR. The
successful demonstration of this technology at Yaomeng may be applied to similar boiler
refurbishments & other innovative boiler designs in China.
• Boiler BMCR Capacity 954t/h and the peak capacity 1010.3t/h, both exceeds the design.
• The boiler exhaust gas temperature has been reduced by 30degC on average, and the
boiler efficiency has risen to 91.41%, i.e. 1.07% increase comparing with the pre-
modofied boiler.
• Good combustion at part load and minimum turndown ratio 40%BMCR.
• Stable combustion is achieved at all loads and the problem of uneven heat flux in the
combustion zone has been significantly improved. No slagging.
• Good boiler design and free, controlled expansion. Boiler operation is stable at all
normal operating loads with significant reliability improvement.
Note: Extract from Yaomeng Refurbishment Post Evaluation Seminar
29
Agenda

30
‘W’ Firing Boilers
Furnace Design
Octagonal Lower Furnace Plan

Chamfered corners ensure that all
furnace tubes are exposed to similar heat
flux distribution even with extensive
refractory coverage
However, this makes a spiral furnace wall

construction virtually impossible
The solution is to utilise Low Mass Flux

design with vertically arranged tubes
31
Furnace Design –– Flow
Flow Paths
Paths
CFD Modelling Used to

Determine Flow Paths
Models created for each load with

A F differing burner groups firing
75% is close to critical pressure
Front wall penetrating lower furnace

deeper as all burner groups firing
C B
E D
A F
FLUENT Flow Pattern Plan showing Mills

Case 2 75% GHR
32
Furnace Design –– Flow
Flow Paths
Paths
Doosan Babcock program used to determine heat distribution

SURFACE ZONES
ROOF 29 58 87 116 145 174 203
202 173 144 115 86 57 28 1 30 59 88 117 146 175

206 205 204
EXIT
PLANE
201 172 143 114 85 56 27 209 208 207 2 31 60 89 118 147 176
NOSE 200 171 142 113 84 55 26 212 211 210 3 32 61 90 119 148 177
ARCH 199 170 141 112 83 54 25 216 215 214 213 4 33 62 91 120 149 178
198 169 140 111 82 53 24 5 34 63 92 121 150 179

220 219 218 217
197 168 139 110 81 52 23 6 35 64 93 122 151 180

224 223 222 221
196 167 138 109 80 51 22 228 227 226 225 7 36 65 94 123 152 181
195 166 137 108 79 50 21 234 233 232 231 230 229 8 37 66 95 124 153 182
194 165 136 107 78 49 20 240 239 238 237 236 235 9 38 67 96 125 153 183
193 164 135 106 77 48 19 246 245 244 243 242 241 10 39 68 97 126 154 184
192 163 134 105 76 47 18 252 251 250 249 248 247 11 40 69 98 127 155 185
191 162 133 104 75 46 17 258 257 256 255 254 253 12 41 70 99 128 156 186
190 161 132 103 74 45 16 264 263 262 261 260 259 13 42 71 100 129 157 187
189 160 131 102 73 44 15 270 269 268 267 266 265 43 72 101 130 159 188
14
REAR WALL SIDE WALL FRONT WALL
EXTENT OF REFRACTORY 33
Furnace Design –– Heat
Heat Flux
Flux Distribution
Distribution
Heat Flux on Rear w all (Zones 44-55)

75% GHR Load Case 2
200
180
Heat flux (kW/m 2)
160
140
120
100
80
60 Hopper Burner
40 Knuckle arch level
20 Nose level Roof level
Ext ent of ref ract ory
0
0 10 20 30 40 50 60
Height from bottom of hopper (m )
Detailed heat flux distribution is calculated for each load and for
each section of furnace wall
34
Furnace Design –– Wall Temperature and Boiling Crisis
Steam quality 蒸汽干度
Rifled Tube
内罗纹管
Fluid
工质
1.0
Smooth tube
光管
0.8
0.6
Pressure: 150 bar
Mass flux: 500 kg/m²s
0.4
Heat flux: 300 kW/m²
100 200 300 400 500 600

Rifled Smooth
Tube Tube Inside wall temperature (°C)
内罗纹管内侧金属壁温
光管
Furnace Design –– Wall Temperature and Boiling Crisis
Steam quality 蒸汽干度
Rifled Tube
内罗纹管
Fluid
工质
1.0
Smooth tube
光管
0.8
0.6
Pressure: 150 bar
Mass flux: 500 kg/m²s
0.4
Heat flux: 300 kW/m²
100 200 300 400 500 600

Rifled Smooth Inside wall temperature (°C)
tube tube 内侧金属壁温
Furnace Design –– Steam Quality Assessment
N o te : D im e n sio n s a re to T u b e C e n tre lin e
M M C e n tre -lin e o f n o se is a t d im e n sio n 'B ' b e lo w ro o f lin e
L P1 P2
N
A5
Zone 2 Exit
R
B
A3
Q B = 16 .00 0 m
A2 C1 = 11 .49 4 m
C1A = 12 .53 5 m
C /L n o s e U E = N /A m
F = 1 .19 6 m
I A7 G = 10 .00 0 m
• Study identifies
S ta rt o f S up e rh e a tin g
C1A S tart o f S u p erhe a tin g F W & R W C h a m fe rs H = 8 .28 2 m
S id e w a lls I = 12 .51 2 m
J = 23 .66 6 m
S ta rt o f S u p e rh e ating
FW & RW
3 5 .5 m K = 16 .04 5 m
3 4 .8 m R = 13 .23 8 m
exact steam 3 1 .5 m
A1
A1
S
T
U
Kr
=
=
=
=
1 .50 0
13 .80 0
3 .71 8
16 .44 6
m
m
m
m
quality C1 G
Z
UPPER FURNACE DATA
L =
M =
N =
4 .88 8
1 .16 1
0 .95 0
m
m
m
P1 = 0 .63 4 m
S ta rt o f E va p o ra tio n P2 = 3 .71 8 m
• 75% load case

S id e W a lls
Q = 16 .00 0 m ( h e ig h t to p la te n tip )
S ta rt o f E v ap o ra tio n
FW & RW
1 9 .5 m ANG LES
S ta rt o f E va p oratio n O
J z2 A1 = 15
F W & R W C h a m fe rs O
A4 A2 = 35
dry out is in
O
A3 = 35
1 4 .4 m O
1 7 .0 m Ki A4 = 55
O
A5 = 0
O
Kr K A6 = 3 0 .0 0
O
A 7= 25
A4
lower heat flux F F1

z2 =
Z =
1 .0 0 0
6 .0 0 0
R efra ctory C overag e
m
m
D is ta n c e a bo ve ho p p e r k n u c k le a t wh ic h c h a m fe r re fra c to ry e nd s
F ro n t & R e a r w a ll re fra c tory h e ig h t
zone
Ki = 7 .9 6 5 m H e ig h t of C h a m fe r in te rc e p t b elo w h o p p er k n u c k le
A6
BB B o ile r W idth , W = 2 6.6 80 m
N ose R a dius 30 5 mm
H o pp e r R a dius 30 5 mm
BA I BA
BC W BA 5 .57 7 m
BB 3 .22 0 m
BC 20 .24 0 m
C h a m fe r L e n g th 6 .4 4 m
J
NTS
ISSUES & UPDATINGS TO BE MADE ONLY ON THE AUTHORITY OF ENGINEERING PROPOSALS, CRAWLEY
Issue Date Reason For Change By Ch'kd Rev'd/App'd
E
D
C
A 04/03/05 First Issue VKM
37
Furnace Design – Steam Quality Assessment
S ta rt o f S u p e rh e a tin g N o te : D im e n s io n s a r e to T u b e C e n tr e lin e
M M C e n tr e - lin e o f n o s e is a t d im e n s io n 'B ' b e lo w ro o f l
L P1 P2
N
A5
Zone 2 Exit
R
B
A3
B = 1 6 .0 0 0
• At Benson load there

Q m
A2 C1 = 1 1 .4 9 4 m
C 1A = 1 2 .5 3 5 m
C /L n o s e U E = N /A m
F = 1 .1 9 6 m
I A7 G = 1 0 .0 0 0 m
is full circulation so C 1A H
J
K
R
I
=
=
=
=
=
8 .2 8 2
1 2 .5 1 2
2 3 .6 6 6
1 6 .0 4 5
1 3 .2 3 8
m
m
m
m
m
no dry-out in
S = 1 .5 0 0 m
T = 1 3 .8 0 0 m
A1 U = 3 .7 1 8 m
Kr = 1 6 .4 4 6 m
A1
furnace. C1 G
Z
UPPER FURNACE DATA
L =
M =
N =
P1 =
4 .8 8 8
1 .1 6 1
0 .9 5 0
0 .6 3 4
m
m
m
m
P2 = 3 .7 1 8 m
Q = 1 6 .0 0 0 m ( h e ig h t to p la te n tip )
ANG LES
O
J z2 A1 = 15
O
A4 S ta rt o f E v a p o ra tio n A2 = 35
S id e W a lls O
S ta rt o f E v a p o ra tio n S ta rt o f E v a p o ra tio n A3 = 35
F W & R W C h a m fe rs O
FW & RW Ki A4 = 55
1 2 .0 m A5 = 0 O
O
Kr K A6 = 3 0 .0 0
O
9 .0 m 9 .6 m A7= 25
A4
R e f ra c to r y C o v e r a g e
F F1
z2 = 1 .0 0 0 m D is ta n c e a b o v e h o p p e r k n u c k le a t w h ic h c h a m fe r re fra c to ry e n
Z = 6 .0 0 0 m F ro n t & R e a r w a ll re fra c to ry h e ig h t
Ki = 7 .9 6 5 m H e ig h t o f C h a m fe r in te rc e p t b e lo w h o p p e r k n u c k le
A6
BB B o ile r W id th , W = 2 6 .6 8 0 m
N o s e R a d iu s 305 mm
H o p p e r R a d iu s 305 mm
BA I BA
BC W BA 5 .5 7 7 m
BB 3 .2 2 0 m
BC 2 0 .2 4 0 m
C h a m fe r L e n g th 6 .4 4 m
J
NTS
ISSUES & UPDATINGS TO BE MADE ONLY ON THE AUTHORITY OF ENGINEERING PROPOSALS, CRAWLEY
Issue Date Reason For Change By Ch'kd Rev'd/App'd
E
D
C
A 04/03/05 First Issue VKM
38
Furnace Design –– TTube Metal Temperatures, 100% Front Wall
86501 OTSC 'W' FIRED

Lower Furnace Front wall Temperature
100%BMCR Load Case 6
530
100% BMCR
520
Pressure 265.4 bar
510
Mass flux 959 kg/s m2
500 Heat Flux 313 kW/m2
490
480
470
460
Temperature (deg C)
450
440
430
420
410
400
390
380
inner wall temp
370
360
350 Outer wall temp
340
330 Mid-wall temp
320
Enthalpy range in the lower Fluid Temperature
310
furnace
300
1000 1200 1400 1600 1800 2000 2200 2400 2600
Fluid enthalpy (kJ/kg)
39
Furnace Design –– Tube
Tube Meta
Meta Temperature,
Temperature, 75%
75% Front
Front Wall
Wall

Lower Furnace Front wall Temperature
75%GHR Load Case 2
530
75% GHR
520 Pressure 212.5 bar
510 Mass flux 652 kg/s m2
500 Heat Flux 295 kW/m2
490
480
470
460
450
Temperature (deg C)
440
430
420
410
400
390
380
inner wall temp
370
360
350 Outer wall temp
340
330 Mid-wall temp
320
Enthalpy range in the lower
310 Fluid Temperature
furnace
300
1000 1200 1400 1600 1800 2000 2200 2400 2600
Fluid enthalpy (kJ/kg)
40
Furnace Design –– Positive
Positive Flow
Flow Response
Response Verified
Verified
OTSC 'W' FIRED 600MW

Flow Response of Vertical Tube Furnace
BMCR Load Case 1
5
4.5
4
3.5 Side Wall Average Mass Flux 1102 kg/m 2
s
3
2.5
2
1.5 Side Wall SW06 with highest Mass Flux 1143 kg/m 2
s
1
0.5
0
-0.5 0 5 10 15 20 25
-1
-1.5
-2
Additional Heat Input (%)
41
Furnace Design –– Static Stability Checked and Confirmed
OTSC 'W' Fired 600 MW

Static Stability of the Lower Front Wall (38.0 mm o.d x 6.3 thk(min))
35% BMCR Load
2.5
35%BMCR
Lower FW
Pressure drop (bar)
H Inlet 1110 kJ/kg

1.5 Tube o.d 38.0 mm
wall thk 7.0 mm (nom)
0% steam at inlet
0.5
0
0 10 20 30 40 50 60 70 80 90 100 110 120
Mass flow (kg/s)
Good response – No instabilities occur
42
Furnace Design –– Dynamic Stability Calculated and Verified

Dynamic Stability of the Front Wall - Average tube length
35%BMCR
0.4
With Pressure equalising Header at
19m level above hopper inlet
0.35
35% BMCR Benson

0.3
Load
Outlet pressure 110
bara
0.25 h inlet 1107
m in
Mass flow (kg/s)
kJ/kg
Tube o.d 34.92
0.2
m out
0.15
130
0.1
heat input (%)

120
110
0.05
100
0 5 10 15 20
time (s)
0
0 50 100 150 200 250 300
Tim e (s)
43
Furnace Design –– Furnace
Furnace Tubes
Tubes Selected
Selected
Furnace Tube Selection

Zhenxiong
Tube Size Thickness
38 mm OD 7.1 mm Plain
min
34.92 mm OD 6.35 mm Ribbed

min
28.58 mm OD 6.1 mm Ribbed

min
44
Furnace Design –– Validation
Validation of
of selection
selection within
within test
test envelope
envelope
Parameter Range for Investigations performed on Rifled Tubes

Pressure steps: 25,50,70,100,150,175,200,210,212.5,215,217.5,220,230,250,280 bar
900
Tube:
800 100% RR1
Heat flux (kW/m²) (related to tube inside)
lower furnace RR2

700 RR4
75% RR5
600 lower furnace
RR7
500 RR8
* RR9/RR12/RR16
400 * RR18/RR19
300 RR20
200 * Equivalent
* 100% upper furnace Inside diameter:
100
75% upper furnace 13 - 35 mm
0
0 200 400 600 800 1000 1200 1400 1600
Mass flux (kg/m²s)
Furnace Design –– Doosan
Doosan Babcock
Babcock Energy
Energy Study
Study Verified
Verified by
by Siemens
Siemens
Detailed work by Doosan Babcock for the design of 600MW supercritical ‘W’ Fired
Low Mass Flux boiler has been reviewed by Siemens.
46
Agenda

47
International Success - World First ‘POSIFLOW’ Furnace
• Major plant upgrade including 90%

pressure part replacement
• Plant destined for closure now capable
of 20 year life extension
• Outstanding operational availability
since Jun 02
• Positive Flow Characteristics
• Reference for Vertical Tube application
• Additional Posiflow units currently in
negotiation, New Build and Retrofit
Yaomeng, PRC
48
Low Mass Flux Applications
• Yaomeng
– Operational 5 years
• Zhenxiong
– Order for 2 x 600MW supercritical units
• Ferrybridge
– FEED contract for supercritical retrofit
• Tilbury
– FEED contract for supercritical retrofit
• Studies
– DTI 407 based on Ratcliffe including carbon capture
• New build supercritical
– Additional orders in China currently being negotiated
– Potential application in USA for first ‘western’ reference
49
Reference Modern Ultra Supercritical Boiler
Two Pass Design

Divided back pass for Reheat temperature control
Steam conditions, Typically

265bar
600°C Main Steam / 620°C Reheat Steam
Fuel
International traded Bituminous Coal
Performance
- Boiler Efficiency ~ 94.6% (LHV)
(18% XS air, 115ºC Gas Outlet Temp.)
- Plant Efficiency ≥ 46% (LHV)
- Min Load without oil support 25%
Gross Plant Output 800MWe
50
Summary
• Worlds first retrofit application of Low Mass Flux once through

design.
• Close relationship with customer to ensure optimum operation
• Extensive study into ‘W’ fired application.
• Worlds first new build Supercritical ‘W’ fired application of Low

Mass Flux design.
• Doosan Babcock offer Low Mass Flux design for all new build
boilers worldwide as it offers the ‘Best Available Technology’.
• Working with UK Utility companies to promote this solution for

the long terms plans in the UK stations.
51

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Doosan Babcock Energy

Low Mass Flux Once Through Boiler Design

1. Yaomeng, how ‘low mass flux design’ was applied

UP-Type Boiler with reheater designed to

• Improve unit turndown.

Retain the Following:

• Doosan Babcock LMFVT Benson Boiler.

Boiler Operating Reliability and Availability ensured by

Boiler Operating Turn-down and Output improved by

Efficiency improved by reducing heat lost in air-heater exit

Specific enthalpy, kJ/kg

100%BMCR 80%ECR 60%BMCR

Division wall in series

Vertical Tube Layout:

M = Water flow, kg/s

Static Pressure Drops:

High water flow rates lead to high

Furnace Wall Design:

Flow modelling and checking:

• 3-D modelling provides a true

Optimised Ribbed Tubing:

Tube wall metal temperature:

The specialised ribbed tubes

The second cold draw pass was

1. Yaomeng, how ‘low mass flux design’ was applied

Steam purging required special planning for

Division wall issues During early operation a thermocouple

Four years operation

Units Before After

Peak Output MWe 270 327

Boiler Thermal efficiency %LHV 90.3 91.4

Unburned carbon in flyash % 4.7 1.6

Boiler Turndown without oil support % 70 40

Load change rate MWe/min Virtually Zero 3

Boiler cold start time - - Reduced by 1 hr

Furnace tube failures - ~600 over a 10 yr None

Downtime for construction only 6 months. Design life 20 years

404 furnace tubes

Maximum measured deviation (415°C to 386°C) = 29°C over 25 tubes

Very Small Average Tube to Tube Variation ~ 1.2 °C

• Good combustion at part load and minimum turndown ratio 40%BMCR.

Note: Extract from Yaomeng Refurbishment Post Evaluation Seminar

1. Yaomeng, how ‘low mass flux design’ was applied

Octagonal Lower Furnace Plan

However, this makes a spiral furnace wall

The solution is to utilise Low Mass Flux

CFD Modelling Used to

Models created for each load with

75% is close to critical pressure

Front wall penetrating lower furnace

FLUENT Flow Pattern Plan showing Mills

Doosan Babcock program used to determine heat distribution

ROOF 29 58 87 116 145 174 203

202 173 144 115 86 57 28 1 30 59 88 117 146 175

198 169 140 111 82 53 24 5 34 63 92 121 150 179

197 168 139 110 81 52 23 6 35 64 93 122 151 180

REAR WALL SIDE WALL FRONT WALL