SYSTEM STUDIES ON ADVANCED POWER GENERATION TECHNOLOGIES FOR 21st CENTURY Dr V K Sethi Director MOP/ CEA

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Super Critical PC Power Plant (15 oC Amb.) 60 Super Critical PC Power Plant (Indian Condition) IGCC (15 oC Amb) IGCC (Indian Condition) Sub Critical PC Power Plant (Indian Condition) 1500 oC 1300o C 623 oC o 600 C

Net Thermal Efficiency (%)

55 50 45 566o C 40

o 1184 C

o 650 C 540o C

Ceramic gas turbine

35 30 1990

1995

2000

2005

2010

Year of commercial use

Fig.1 EFFICIENCY IMPROVEMENT FORECAST CONVENTIONAL Vs IGCC

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PULVERIZED COAL (PC) 100 950* 800* PC+FGD IGCC * mg/m 3

PERCENTAGE OF PC PLANTS

80

60 50* 40 200* 50* 0 SO 2 NO x 200* 100* 5* Particulates 50*

20

Fig.2 COMPARISON OF EMISSIONS FROM VARIOUS COAL FIRED POWER PLANT

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Measures to improve Plant Efficiency And / or Heat Rate

Turbine side measures : Higher steam parameters (Pr. & Temp.) Adoption of double reheat cycle Enhancing Regenerative feed heating Reduced Auxiliary power consumption Increase in condenser vacuum Boiler design to accommodate the first four requirements
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Steam generation process

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Sub-Critical vs Super Critical

Description Full Load Pressure Flow in Water wall Cycle efficiency Fuel saving Boiler weight Stages of reheat Preference on date Sub Critical <190 atm 2-Phase Base Base Base 1 Maintaining Super Critical >240 atm 1-Phase + 2 - 3 % Approx +8 - 10 % Approx + 10 % 2 Preferred Cyclic (Yet to start in India)

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Increase in Efficiency due to steam parameters

SHO/RHO Temp Pressure

538 / 538 Base

538 / 565

565 / 565

580 / 600

600 / 620

175bar 235bar 300bar

+0.75% +1.47% +2.76% +3.74%

+1.72% +2.57% +3.36% +4.72% +5.69% +2.42% +3.37% +4.26% +5.74% +6.77%

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Effect of steam parameters on coal consumption

(500 MWe, 6500 h/a, LHV 13917 kJ/kg) Coal consumption in kg/MWh
SH/RHTemp 175bar 538 / 538 567 538 / 565 572 565 / 565 579 580 / 600 583 600 / 620 587

235bar

556

561

568

572

576

300bar

551

556

563

567

571

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Evolution of Higher steam parameters

1980s: Pressure increased from 175-180 bar to 225 bar ;temp mostly around 540 deg C Pressures raised to 285 bar; temp raised to 565-580-600 Deg C 255 bar 568/568 Deg C commonly used 300 bar & 620 Deg C under development

1990s: Today

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DRUM vs ONCE THROUGH

ECO
DRUM

SH

STEAM TO TURBINE

SH

STEAM TO TURBINE

DOWN COMER CIRC. PUMP

HEAT Water Wall ORIFICE ECO

HEAT Water Wall

Pressure Steam Separation Types Burner Panel Load Change Cold Start Hot Start
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Sub critical Drum Natural / Assisted Straight tube Base 4-5 Hours 1-2 Hours

Sub & super Critical Separator (Low loads) (Sulzer) / (Benson) Spiral Tube / Straight (MHI) Faster 2 Hours 0.5 Hours

Drum type boiler

Steam generation essentially takes place in furnace water walls Fixed evaporation end point - the drum Steam -water separation takes place in the drum Separated water mixed with incoming feed water and fed back to ww lower drum by means of boiler water circulating pumps (BWCPs).
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Drum type boiler

Natural Circulation Boiler Circulation through water walls by thermo-siphon effect Controlled Circulation Boiler At higher operating pressures (just below critical pressure levels), thermo-siphon effect supplemented by pumps to ensure safety of furnace wall tubes.

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THE CONCEPT
The mass flow rate thru all heat transfer circuits from Eco. inlet to SH outlet is kept same except at low loads wherein recirculation is resorted to protect the water wall system

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Once Through Boiler-Concept

Once through system

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Once Through Boiler

Once -through forced flow through all sections of boiler (economiser, water walls & superheater) Feed pump provides the driving head Suitable for sub critical & super critical pressures

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Once -thru Boiler

Advantages:
Quick response to load changes Shorter start up time Better suited for sliding pressure operation Steam temperature can be maintained over wider load range under sliding pressure Higher tolerance to varying coal quality Suitable for sub critical & super critical pressures
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Once -through Boiler

Requirements :
Stringent water quality Sophisticated control system Low load circulation system Special design to support the spiral furnace wall weight High pressure drop in pressure parts Higher design pressure for components from feed pump to separator.
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Once -through Boiler

Characteristics :
Provides Quicker response to TG load changes Supports achievement of better heat rate at lower loads Higher furnace wall pressure drop and consequent higher feed pump auxiliary power consumption Needs ultra pure quality feed water - Cannot operate under conditions of condenser leak

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Once -thru Boiler

Disadvantages : Higher feed pump auxiliary power consumption Cannot operate under conditions of condenser leak

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Furnace Arrangement

SPIRAL TYPE

VERTICAL TYPE
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Once -through Boiler Operating Range

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Sliding Pressure Operation

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Advantages of sliding pressure

Higher efficiency Less auxiliary power Less fatigue of pressure parts

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