ALSTOM BOILERS

DELIVERING
TOTAL EFFICIENCY
 Alstom Power is the number one supplier of boilers
worldwide. Nearly 30% of the world’s boilers
use Alstom technology.

We have developed an unmatched level of

expertise in steam generation and fuel combustion
technology by designing and manufacturing
state-of-the-art systems and equipment that work
cleanly, cost-effectively and reliably.

We also supply full turnkey power plants, with

Alstom’s Plant Integrator™ approach.
Through a unique combination of project
management skills, engineering, procurement
and construction capabilities, we create real
value for our customers throughout the complete
lifecycle of their power plant.

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Proven fuel expertise
Alstom has been making boilers for over 100 years.
Today, almost 30% of all boilers installed or under construction
incorporate our technology.
We offer a wide range of boiler types including pulverised
coal-fired boilers (up to 1,200 MW) in both tower
and two pass configurations, advanced oil and gas-fired
boilers (up to 1,000 MW) and circulating fluidised bed
boilers (up to 660 MW).
We pioneered supercritical steam generation and today lead
the industry in supercritical boiler technology. We have directly
supplied more than 105,000 MW of supercritical boilers
worldwide and trained and licensed other companies to install
an additional 140,000 MW.
We have also developed a range of circulating fluidised bed
(CFB) boilers firing low grade fuel, difficult-to-burn coals,
waste coal and various opportunity fuels. We have developed
a unique expertise in scaling utility size CFB boilers to 660 MW
and larger with supercritical steam cycles.
We are constantly driving towards new improvements in
combustion technology and in material applications which allow
our products to burn a wide range of fuels cleanly while meeting
the most stringent environmental regulations on nitrogen,
sulphur oxides, particulates and greenhouse gas emissions.

Alstom has the largest installed boiler base in the world.

Approximately 30% of all boilers installed or under construction use our technology.

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 EN
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How Alstom is helping SI
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REDUCING LOWERING INCREASING

COST OF ELECTRICITY
It takes competitive assets to keep
electricity affordable. We enable power
companies to compete successfully in
the marketplace and provide affordable
electricity to consumers. We help you
reduce the cost of electricity through:
• Efficiency improvements
• CAPEX reduction / scaling up
• Capacity Factor increase (renewable)
• Lead time reduction
• Competitive O&M
• Competitive financing
ENVIRONMENTAL FOOTPRINT FLEXIBILITY & RELIABILITY
Clean generation is one way of Intermittent power generation is a
demonstrating environmental growing challenge of energy security, as
responsibility. Another is lowering is maintaining an aging installed base
resource usage, visual impact and noise and adapting it to changing market
pollution. In both cases, we can help conditions. We help you tackle both
you meet or exceed regulations and issues so that you can enjoy dependable
environmental standards. That is why operations with:
Alstom innovates in the following areas:
• Maintainability and outage
• Renewable portfolio time reduction
• Natural resource optimisation • Operational and fuel flexibility
• Pollutants control • Lifetime extension and power uplift
(SOx, NOx, PM, mercury) • Designs and service for improved
• CO2 emission reduction & CCS availability and reliability
• Land use, visual impact and noise • Climate packages
• Water intensity reduction & • Energy storage
recyclability

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Alstom boilers
Our promise to customers

Customer benefits

Reducing the cost Lowering the Increasing flexibility

of electricity
We are world leaders in ultra-
supercritical technology – technology
that is already delivering significant
savings to our customers because
of its high efficiency. We have
incorporated other cost-efficient
innovations into our products including
tilting burners for tangential firing
and low maintenance coal-fired boiler
designs. Increased efficiency equals
decreased running costs.
environmental footprint
The higher operational efficiency of our
boilers – especially when combined with
our catalytic reduction systems – means
less wasted fuel, cleaner combustion
and a cleaner environment. Using our
supercritical technology, an efficiency
improvement of one percentage point
equals 2%-4% less CO2 emitted.
& reliability
We offer an unrivalled choice of boiler
products in a number of sizes and
burning a wide variety of fuels. Alstom
technology incorporated into the design
of each of the boilers means that they
are extremely flexible and very efficient
in operation – even at low loads. Our
expertise has produced a boiler design
with very high reliability. This allows
customers to reduce outage time
and maintenance expenses, thereby
minimising lifecycle costs.

Unparalleled fuel expertise

Our key combustion technologies enable our boilers to cover a large spectrum
of fuel, from multiple grades of coal (including anthracite, bituminous, sub-bituminous
and lignite) to oil and gas, heavy residues, biomass and opportunity fuels. In our
extensive portfolio, we will have the product to fit your specific fuel requirements.
05
 The choice of
Different types

Pulverised coal (PC) boilers

Pulverised coal-fired boilers are available in two alternative
configurations. In a tower boiler, the heating surfaces are Tower boiler
arranged directly above the furnace, resulting in a taller Up to 1,200 MW
structure with a small footprint. In a two pass boiler, the Up to 605°C / 621°C / 300 bar
heating surfaces are located both above and adjacent to the
furnace which means the structure is shorter but has a larger
footprint.

Project requirements and customer preferences will determine

which is selected with consideration being given to the fuel
moisture content and ash characteristics as well as site Two pass boiler
restrictions. Up to 1,200 MW
Up to 605°C / 621°C / 300 bar

Oil and gas-fired boilers

We manufacture advanced oil and natural gas-fired boilers, that
are highly reliable and efficient in operation and which deliver
outstanding environmental performance. To date, we have
supplied 228 GW of subcritical and supercritical oil and gas-fired Oil and gas-fired
boilers, either directly or through global licenses. two pass boiler
Up to 1,000 MW
Up to 565°C / 565°C / 250 bar
Circulating fluidised bed (CFB) boilers
As one of the industry leaders in utility-class CFB boilers,
we are scaling up our CFB boilers to 660+ MW ultra-supercritical
steam cycles. These boilers are able to burn a wide range
of fuels, including a variety of low-grade opportunity fuels
in an efficient way and, consequently, produce low emissions Circulating fluidised
which conform to the strictest environmental standards. bed boiler
Up to 660 MW for lignite,
higher for hard coal
Up to 600°C /620°C / 300 bar

Ultra-supercritical technology
Our fifty years of expertise in advanced steam parameters and material testing,
means we can provide state-of-the-art boilers that deliver impressive performance
to maximum efficiency and flexibility and with the lowest possible emissions.

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Alstom boilers
adaptable to your needs

Belchatow, Poland
(858 MW)
This unit, the country’s
largest and most efficient
lignite-fired plant, benefits
from Alstom supercritical
once-through PC tower
boiler technology

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 Ultra-supercritical
Flexible

Understanding the concept HEAT RATE IMPROVEMENTS

VS. STEAM CONDITIONS (SINGLE REHEAT)
Supercritical conditions occur when boiler pressures increase above
3,208 psi / 221.2 bar. Beyond this point, water and steam cease 10%
25ºC (45ºF) = 1.25% improvement
to exist as a distinct liquid and gas and are replaced by a single
Relative heat rate improvement
supercritical fluid.

As the technology of supercritical steam generation emerged

0/1,145ºF)
in the mid-20th century, we realised that it could deliver real benefits 0ºC (1,11
600/6200ºC (1,110/1,100ºF)
600/6 ºC (1,075/1,100ºF)
to plant owners and have pioneered its development ever since. 580/600

C (1,050/1,050ºF)
565/565º

Increased efficiency equals less cost 540/540ºC (

1,000/1,000ºF)
Today, Alstom’s ultra-supercritical boilers can operate at cycle
2,600 psig 3,480 psig 4,350 psig 5,225 psig
efficiencies in excess of 42-45% HHV basis (44-47% LHV basis). 180 bar 240 bar 300 bar 360 bar
subcritical supercritical supercritical supercritical
Because they are more efficient in operation, they consume less fuel
and produce less emissions per kilowatt-hour (kWh). Superheater outlet steam pressure

Supercritical boilers are designed for once-through operation at full

load, avoiding the thick-walled steam drums common in subcritical
boilers and so allowing quicker start-up. As a result of these
ONCE-THROUGH DESIGNS START UP FASTER
efficiencies, the capital cost of supercritical plants is close to those
First fire to turbine
of subcritical plants and overall life cycle costs are often reduced. sync (with bypass
system)
Hot start up after 30 mins
2 hour shutdown
Warm start up after 45 mins
8 hour shutdown
Cold start up after 90 mins
6 hour shutdown

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technology
under pressure

The higher pressures and temperatures which are the hallmark of our
once-through ultra-supercritical technology deliver important benefits including
increased efficiency, greater operating flexibility and lower operating costs
and emissions levels.

Supercritical means operational flexibility SLIDING PRESSURE OPERATION

FOR ONCE-THROUGH BOILERS
Our once-through supercritical boilers operate in a sliding pressure mode, where
pressure is reduced with load. So they can quickly adjust to changes in load demand 4,500/310
1
while maintaining constant first-stage turbine temperature, lessening the thermal

Pressure (psig/bar)
3,750/260
stress on components as the unit is cycled. 3,000/205

2,250/155
variable
1,500/105
2
750/50 3

0
0 20 40 60 80 100
Boiler load (%)
1. Constant pressure operation
2. Modified sliding pressure operation
3. Pure sliding pressure operation

EFFICIENCY IMPROVEMENT WITH INCREASING STEAM CONDITIONS

Steam conditions
Material improvement milestones 350/700/720 350/730/760
280/600/620 (5,075/1,290/1,330) (5,075/1,350/1,400)
bar/ºC/ºC (4,050/1,110/1,150)
(psi/ºF/ºF) R&D ongoing
R&D ongoing
270/580/600 USA USC
(3,900/1,075/1,110) Materials
Consortium
167/540/540 240/540/565 Market & EC AD
(2,400/1,000/1,000) (3,500/1,000/1,050) intro by 700 project
Japan (Ni-base)
Mature technology and
Europe

CONTINUED ADVANCEMENTS

SUPERCRITICAL DOE USC material

SUBCRITICAL DOE steam turbine material
AD 700 project
COMTES 700

1960 1980 2000 2010 2020

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 Boiler
Designed to deliver

Furnace wall
designs: benefits
There are advantages to both spiral
furnace tube and vertical furnace tube
arrangements. Which one is chosen
depends, in part, on the type of project
under construction.

Spiral furnace tube

• Benefits from the averaging of lateral
heat absorption variation in each tube
• Simplified inlet header arrangement
• Use of smooth-bore tubing throughout
entire furnace wall system
• No individual tube orifices
• Large number of operating references

Vertical furnace tube

• Simpler windbox openings
• Simpler furnace water wall support
system
• No intermediate furnace wall
transition header
• Lower construction and maintenance
costs
• Easier to identify and repair tubes leaks
Spiral furnace tube Vertical furnace tube

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features
operational excellence

We are at the forefront of boiler development, designing

highly efficient and reliable products that help your plant
deliver the power you need.

Tangential firing systems

The tangential firing system built into our boilers offers several key advantages over
other firing systems. Tangential firing delivers excellent fuel/air mixing and has a wider
tolerance of fuel fluctuations.

The advanced burner design and staging ensure the use of the furnace volume
is very efficient which results in efficient combustion. As a result, low NOx and slagging
dramatically reduce cleaning and maintenance times allowing the system to work
at maximum efficiency over a sustained period.

Tilting burners
Tilting burners deliver outstanding operation flexibility by allowing the highest cycle
efficiency over the widest load range. They give the operator the ability to control
reheat steam temperature by regulating the furnace outlet temperature.

As a result, there is no need for additional spray attemperation and therefore

no associated reduction in the boiler’s overall efficiency.

Using advanced materials

Materials used for advanced supercritical steam cycles need to combine high
temperature strength with good resistance to oxidation. We use conventional and
advanced ferritic steel, austenitic steel and nickel alloys and are constantly researching
ways to improve the mechanical properties of the materials we use as well as our
welding and manufacturing procedures.

Most materials research is conducted under national or internationally coordinated

programs and Alstom is an active member of many of them, including
the AD 700/COMTES 700 programme funded by the European Commission and the
US Ultra-Supercritical Materials Consortium sponsored by the US Department of Energy.

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 Worldwide
Europe
Global
Massy (France)
North America La Courneuve (France)
Ottawa (Canada) Stuttgart (Germany)
Harrisburg (USA) Neumark (Germany)
Windsor (USA) Ashby (UK) Asia and Oceania
Erlanger (USA) Milan (Italy) Wuhan (China)
Suwanee (USA) Brno (Czech Republic) Xiamen (China)
Chattanooga (USA) Kuala Lumpur (Malaysia)
Tyler (USA) Surabaya (Indonesia)
Denver (USA) Sydney (Australia)
India
Delhi (India)
Kolkata (India)
Durgapur (India)

This map shows our global boiler capabilities, covering the entire product life cycle.

New equipment
• We have centres in charge of project management and engineering
in key locations around the world.

• Our manufacturing sites are also spread around the globe, ensuring
our capability to provide the product you need at the location you want.

Boiler services & retrofits

• Boiler island rehabilitation: an integrated approach for boiler rehabilitation
using process engineered solutions to improve steam parameters to boost
plant efficiency and output.

• Field service includes boiler inspections, plant condition assessment,

outage support & planning and commissioning & start up.

• Spare parts using genuine Original Equipment Manufacturer (OEM)

replacements, plus product upgrades for OEM and other OEM (oOEM)
equipment.

• Subsystem retrofits for biomass co-firing conversions and/or to reduce

NOx or SOx emissions resulting from degraded fuel quality or compliance
with new environmental regulations.

• Construction services for new construction, installation and maintenance

service.

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excellence
projects, global service network
Project highlights worldwide
COMANCHE 3, USA
Sub-bitumous
815 MW two pass PC boiler with vertical
furnace tube walls and the latest low NOx
firing system.
NEURATH, GERMANY
Lignite
2 x 1,100 MW tower PC boilers, the largest
lignite-fired boilers in the world. These
state-of-the-art ultra-supercritical boilers are
replacing older, less efficient units
which will lead to a significant reduction
in CO2 emissions.
BAIMA, CHINA
Anthracite coal with coarse particles
300 MW CFB boiler, commissioned in 2005
and the first utility scale CFB demonstration
unit in China. Designed for an anthracite-
fired power plant, it produces clean,
cost-effective power.
RDK8, GERMANY
Bituminous
1 x 912 MW ultra-supercritical tower PC
boiler. This is one of the highest efficiency
boilers in the world which considerably
reduces CO2 emissions for each kWh
generated.
NARVA, ESTONIA
A variety of fuels including oil shale, wood
chips and peat
1 x 300 MW CFB boiler, making it the largest
oil shale-fired boiler in the world. Commercial
operation is scheduled for October, 2015.
MANJUNG 4, MALAYSIA
Sub-bitumous
1 x 1,000 MW two pass PC boiler with
vertical furnace tube wall. South East Asia’s
first 1,000 MW ultra-supercritical coal-fired
power plant. Commercial operation
is scheduled for 2015.
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Additional boiler products
That stand the test of time

Adding value to your power plant

Grinding Mills
Alstom has extensive experience in grinding technology, having
supplied grinding systems for a wide range of fossil fuels
like coal, petcoke and lignite. For over 90 years, Alstom has
maintained its position as the leading supplier and innovator
of mills for utility and industrial boilers.
Our products are designed to suit boilers up to 1,350 MW,
complying with the highest environmental regulations. We are
also one of the leading suppliers of mills for grinding limestone,
gypsum, minerals, metallic ores, cement and other raw
materials for industrial applications.
Gas-to-Gas Heat Exchangers
Downstream of the Ljungström® Regenerative Air Preheater,
there are several pieces of equipment designed to clean up
the flue gas before it exits the power plant through the stack.
Located just before the stack, the Ljungström® Gas-Gas heater
salvages heat from the flue gas just before it goes into
the scrubber (which removes sulphurs) and then puts it back
into the cleaned flue gas. This reduces corrosion in the stack
and improves flue gas dispersion as it leaves the stack.

Air Preheaters
The Ljungström® Air Preheater is more widely used than
any other type of heat exchanger in the steam generating
industry. Effective leakage control coupled with a compact
design make it adaptable to a wide variety of fuels. Available
in a broad range of sizes, arrangements and materials,
the Ljungström® Air Preheater is custom engineered to meet
the specific requirements and operating conditions of a variety
of applications. To date, Alstom has supplied more than
12,000 Ljungström® Air Preheaters worldwide.

Lifecycle management for competitive advantage

Alstom offers maintenance services and innovative high performance upgrade solutions for Alstom and other OEM boiler
subsystems, including mills/pulverisers, firing systems/ignitors, pressure parts and scanners as well as bottom and ash handling
systems. Reduced emissions, improved operational flexibility, fuel changes and improved performance are just a few of the areas
we can address.

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 Alstom
Alstom is a global leader in the world of power generation,
power transmission and rail infrastructure and sets the benchmark
for innovative and environmentally friendly technologies.

Power generation Alstom builds the fastest train and the highest capacity automated
metro in the world, provides turnkey integrated power plant
solutions and associated services for a wide variety of energy
sources, including hydro, nuclear, gas, coal, wind, solar thermal,
geothermal and ocean energies. Alstom offers a wide range of
solutions for power transmission, with a focus on smart grids.

Power generation
Alstom Power offers solutions which allow their customers to
generate reliable, competitive and eco-friendly power.

Alstom has the industry’s most comprehensive portfolio of thermal

technologies – coal, gas, oil and nuclear – and holds leading positions
in turnkey power plants, power generation services and air quality
control systems. It is also a pioneer in carbon capture technologies.
Electrical grid
Alstom offers the most comprehensive range of renewable power
generation solutions today: hydro power, wind power, geothermal,
biomass and solar. With ocean energies, we are developing solutions
for tomorrow. Alstom is one of the world leaders in hydro power,
the largest source of renewable energy on the planet.

Rail transport
TPWR/PROSOL/ABDTE/EN/11.2013/CHE/1760 © ALSTOM 2013. All rights reserved. Information contained in this document is indicative only. No representation or warranty is given or should be relied on that it is complete or correct or will apply to any particular project.
This will depend on the technical and commercial circumstances. It is provided without liability and is subject to change without notice. Reproduction, use or disclosure to third parties, without express written authority, is strictly prohibited. Photo credits: ALSTOM.
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