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GS Bindra BHEL Ultra Supercritical Power Plants PDF
GS Bindra BHEL Ultra Supercritical Power Plants PDF
International conference
Thermal Power India ‐3
“Ultra Supercritical power plants”
Introduction
Introduction
Worldwide energy and electricity consumption is projected to
grow att an average annuall rate
t off 2‐2.5%
2 2 5% between
b t now and d 2025
caused by increase of population (up to 7.5 billion) and increase
of consumption (mainly of China and India).
Coal Technologies
Coal Technologies
Source : CEA
What is supercritical parameters
p p
As the fluid pressure increases, Latent Heat
((Enthalpy
py of Steam –Enthalpy py of Water))
reduces.
At Critical point it becomes zero.
In physical terms at this pressure water
transforms to steam spontaneously.
4.3
%
SUPER CRITICAL STEAM PARAMETERS:
mprovement
45
40
35
Im
5
0
Super Critical
Subcritical
247 ata / 565 °C / 593 °C
170 ata / 537 °C / 537 °C
INCREASE IN PRESSURE & MAIN AND REHEAT TEMP. > 537 Deg C
RESULTS IN SIGNIFICANT IMPROVEMENT IN HEATRATE
ULTRA SUPER CRITICAL POWER PLANTS
Bharat Heavy Electricals Limited
Parameters of Some SC/USC Plants
/
Country Power Plant Unit Rating Steam Main Reheat RH1 Reheat RH2 Efficiency
Mwe net Pressure Steam Steam Steam (% net
(Gross) (Bar) Temp. (oC) Temp. (oC) Temp. (oC) LHV)
Denmark Avedorevaerket 2 390 300 580 600 ‐‐‐‐‐ 48.3
Typical efficiencies
Typical efficiencies
Pulverized coal option Steam Conditions Typical Efficiency
(% HHV)
Sub critical
Sub critical <22.1 M Pa
<22 1 M Pa 35 0 38 0
35.0 ‐38.0
538oC/538oC
Supercritical (SC)
Supercritical (SC) 24.7 M Pa
24 7 M Pa 38 0 ‐40
38.0 40.0
0
538‐565oC/565oC
Ultra‐supercritical (USC)
p ( ) 27 M Pa 40.0 ‐42.5
565‐625oC
Levelised cost of electricity (CoE) for nominal
cost of electricity (CoE) for nominal
600MWe (A European comparison)
Relative efficiency improvement with
parameters
Evolution of Steam Power Stations
Efficiency Worldwide
• Eight
g units of 660 MW under execution at Sipat
p and Barh
• Two units of 800MW under execution at Krishnapattnam
• Ultra Mega Projects, 4000 MW each, envisaged with
supercritical units.
• 4 projects already awarded to IPPs through tariff based
competitive bidding.
bidding
• Many more supercritical units in pipeline.
ULTRA SUPER CRITICAL POWER PLANTS
Bharat Heavy Electricals Limited
Supercritical Technology – Indian
scenario (Cont..)
• Wid
Widely
l prevalent
l t cycle
l parameters
t (At turbine
t bi end):
d)
– Pressure: 246 ‐250 kg/cm2
– Temperature: 537/566 deg C (In 660MW Sipat & Barh –I TPS)
565/593 deg C (In 660 MW Barh‐II and
2 X 800MW Krishnapattnam)
Identified Ultra Mega Projects
State Project Location Status
g
Chattisgarh Akaltara Pithead ‐
Typical Comparison of Parameters
S b iti l
Subcritical vs. Supercritical
S iti l
2 x 100%
VACUUM PUMPS 2x100%
(For Each Condenser)
CONDENSATE POLISHING
2 x 50% 4 x 25%
UNIT
Reference HBD for 660MW
41.5
41.0
%)
40 5
40.5
Gross Plant efficiency (%
40.0
39.5
39.0
38.5
38.0
37.5
37.0
36.5
500 MW/ 170ATA/
500 MW/ 170ATA/
600 MW/ 170ATA/
600 MW/ 170ATA/
660 MW/ 247ATA/
800 MW/ 247ATA/
800 MW/ 280ATA/
537/537 537/565 537/537 537/565 565/593 565/593 593/593
Parameters
Coal Consumption
Coal Consumption
0.660
0.650
0.640
nsumption kg//KW‐hr
0.630
0.620
0.610
0.600
Coal Con
0.590
0.580
0 570
0.570
0.560
500 MW/ 170ATA/
500 MW/ 170ATA/
600 MW/ 170ATA/
600 MW/ 170ATA/
660 MW/ 247ATA/
800 MW/ 247ATA/
800 MW/ 280ATA/
537/537 537/565 537/537 537/565 565/593 565/593 593/593
Parameters
Supercritical Boilers
Supercritical Boilers
• Supercritical pressure boiler has no drum and heat absorbing
surface being, in effect, one continuous tube, in which the water
& steam generated in the furnace water walls passes through
only once hence called ‘OnceOnce through Supercritical pressure
boilers’
• The water in boiler is pressurized by Boiler Feed Pump, sensible
heat is added in feed heaters, economizer and furnace
tubes, until water attains saturation temperature and flashes
instantaneously to dry saturated steam and super heating
commences.
Supercritical
Separators Steam Generators
Collecting
vessel
Once ‐through
Once through Operating Range
Operating Range
Boiler Parameters
Boiler Parameters
500
Description Unit 800 MW 660 MW
MW
Boiler
B il
- BMCR BMCR BMCR
Parameters
SIEMENS References
SIEMENS References
For Super Critical Steam Turbine
Plant Name Country MW First M.S. Pr.(bar) / MS Temp.
operation (°C) / HRH Temp. (°C)
Kw Schwarze Pumpe1,2 Germany 823 1997 253.08 544 562
Wai Gao Qiao 1,2 China 900 2003 249.60 538 566
Wai Gao Qiao 3,4 China 1000 2007 270 600 600
Yuhuan
h 11,2,3,4
234 Chi
China 1000 2006 262 50
262.50 600 600
Large capacity Supercritical Sets
g p y p
660MW Steam turbine: With Supercritical parameters
Module Combination
• HP : H30-100
• IP : M30-63
• LP : N30-2x12.5
Salient Feature:
247 ata
t MMain
i St
Steam PPressure
• New series of HP & IP modules for 565 0C Main Steam Temperature
supercritical parameters 593 0C Hot reheat Temperature
• Higher size LP module
Order received for NTPC 2x660 MW Barh Extn.
ULTRA SUPER CRITICAL POWER PLANTS
Bharat Heavy Electricals Limited
Large capacity Supercritical Sets
800MW Steam turbine: With Supercritical parameters
Module Combination
• HP : H30-100 (H70-V4)
• IP : M30-100 (I60-V2)
• LP : N30-4x8 (L4x8)
Salient features:
•New series of HP, IP modules for super 246 ata Main Steam Pressure
critical parameters 565 0C Main Steam Temperature
593 0C Hot reheat Temperature
• 4 cylinder turbine (2 LP’s)
LP s)
Parameters -
Voltage - 27 KV
Insulation - Micalastic
Gas Pressure - 5 Bar
Excitation - Brushless
Transport wt. - 443 Tons
Stator Cooling - DM water
Rotor Cooling - Hydrogen
Transportation - By Road
• ONE CONDENSER PER SET
• SINGLE / DOUBLE PASS CONDENSER
SINGLE / DOUBLE PASS CONDENSER
• CONDENSER IS SOLID SUPPORTED
• LP HEATER NO.1 IS LOCATED INSIDE
• CONDENSER NECK
Large capacity Supercritical Sets
DESIGN FEATURES OF CONDENSER FOR 800 MW TG SET
• TWO CONDENSERS CONNECTED TO TWO
LP TURBINES
• SINGLE PASS
Development of Materials for SC/USC
parameters
• For adopting
p g SC/USC/ parameters,, superior
p p material are
required
• Some of the critical materials are Boiler quality plates and
P91 Critical
C iti l piping
i i
• These material are not indigenously available and have to be
essentiallyy imported
p
• There is a need to join hands with the countries which have
already developed these materials
Concluding Remarks
Concluding Remarks
• Electric power generation in India will continue to be
dominated by coalcoal‐fired
fired power generation for at least next
30‐40 years
• Development and application of clean, high efficiency, large
capacity, coal‐fired power generation technology is a long‐
term strategic task for India
• In order to meet our increasing demand for electric power,
power as
well as to improve coal utilization efficiency and reduce
pollutant emissions from coal‐fired power plants, we have to
d l domestic
develop d ti supercritical
iti l / Ultra
Ult supercritical
iti l units
it