imteag.comimteag ag/2.1-pga-2008.pdf · 2 1895 cambridge power station produced 3 x 100 kw using...

1

imteag.comimteag.comimteag.com

CONTENTCONTENT�� History History

�� Asia related Facts Asia related Facts

�� Energy ConsumptionEnergy Consumption

�� Efficiency EvolutionEfficiency Evolution

�� Coal ReservesCoal Reserves

�� Cost SavingCost Saving

�� ST Unit Size EvolutionST Unit Size Evolution

�� SC / USC TechnologySC / USC Technology

�� SC / USC Power PlantsSC / USC Power Plants

Worldwide SummaryWorldwide Summary

�� Efficiency ImprovementEfficiency Improvement

�� 50 Hz RPP50 Hz RPP

�� 60 Hz RPP60 Hz RPP

�� OT BoilerOT Boiler

�� Boiler MaterialsBoiler Materials

�� ST ConfigurationsST Configurations

�� ST MaterialsST Materials

�� Selected SC / USC Selected SC / USC

Power PlantsPower Plants

2

�1895 �� Cambridge Power Station produced 3 x 100 kW using Parsons STGs

�1896 �� Niagara Falls Hydro Power Plant produced 3.7 MW at 2.35 kV / 25Hz

�1900 �� First 1 MW Parsons STG units put in operation in England (10bar / 200ºC)

�1903 �� 1st Commonwealth Edison Power Plant ST produced 5 MW (12.5bar/275ºC)

�1900–1920 �� STGs operated at 1,200rpm (20Hz); Unit Capacity up to 65 MW

�1914-1915 �� STs for Military Cargo Ships 6-20MW (10-16bar / 300-350ºC)

�1915 ��Establishment of ASME Code

�1930 �� Pulverized Coal Technology

�1920 – 1935 �� ST operated at 1,500-1,800rpm; Unit Capacity up to 200 MW

�1935–1953 �� ST operated at 3,000-3,600rpm; Unit Capacity up to 200 MW

�1957 �� 1st USC Power Plant, 120MW Philo 6 (310bar / 612ºC)

�1960 �� Eddystone USC Power Plant, 325 MW (345bar / 650-565-565ºC)

�1960 – 1963 �� 1st Commercial Nuclear Power Plants produce Electric Power

�1980 �� Large STs reached Unit Capacity up to 1,300MW

�1900 – 1980

� kWh-Costs decreased every decade + Generating Capacity doubled every 8 – 12 years

�Last Decade of 20th century �� Golden Times for NG fired CCGT Power Plants

�First Decade of 21th Century Renaissance of SC / USC Technology

�2008 �� Worldwide Power Generation Capacity ≈≈≈≈3,200GW (≈≈≈≈1,300GW from Coal)

113 years

Powergen Asia Powergen Asia

20082008

Electricity Power Generation Electricity Power Generation History History

IMTE AGIMTE AG Power Consulting EngineersPower Consulting Engineerswww.imteag.comwww.imteag.com

© IMTE

3

China

&

India

Main driving force in Asia

PowergenPowergen Asia Asia

20082008

ASIAASIA


© IMTE

�� In 2030 the primary energy consumed by China & India will

represent around 25% of the world consumption.

�� Majority of SC unit are being built in Asia, especially in

China & India.

�� China & India will be responsible for around 40% of the

growth in the world’s primary energy consumption.

�� China is planning to install 90GW of new power generation

capacity over next 2-3 years.

�� Indian demand will grow from 130 GW to 280 GW over the

next decade, an increase of 150 GW .

�� CO2 emissions are expected to grow by factor 2 in 2030.

�� In the period from now until 2030 Asia will require of about

8 trillion USD on energy infrastructure (350 billion USD/Year).

�� Indonesia is also planning first SC power plants.

�� Coal demand from electric power generation sector is

expected to grow fast in Asia.

4

Technology

&

Fuel


20082008

Main Concerns with Energy Main Concerns with Energy �� Electricity Electricity SupplySupply


��AffordabilityAffordability

Investment Investment -- Technology Technology –– Fuel Fuel –– O&M O&M �� TariffTariff

��ReliabilityReliability

Technology Technology –– Fuel Fuel –– O&M O&M �� AvailabilityAvailability

��AccessibilityAccessibility

Grid Connections Grid Connections �� Distribution NetworkDistribution Network

��Environmental AcceptabilityEnvironmental Acceptability

Technology Technology –– Fuel Fuel –– O&M O&M �� EmissionsEmissions© IMTE

5

1Exajoule (EJ) = 1018 Joule

0.948 x 1015 Btu


20082008

Worldwide Overall Energy ConsumptionWorldwide Overall Energy Consumption


© IMTE

0

100

200

300

400

500

600

700

1890 1900 1910 1920 1930 1940 1950 1960 1970 1980 1990 2000 2010 2020 2030

EJ

2.5%/Year

2.0%/Year

1.6%/YearForecast

Average

20 Century

2.2 %/Year

Average

1890-2030

2.15 %/Year

1973 Energy Crisis

± 60% for Power

Generation

2008/09?

30

450

6


20082008

Worldwide Overall Energy Consumption for Power GenerationWorldwide Overall Energy Consumption for Power Generation


© IMTE

1950Coal 59.6%

Oil 14.5%

NG 5.2%

Nuclear 0.0%

Renewable20.7%

2000Coal 40.5%

Oil 5.1%

NG 27.8%

Nuclear 10.1%

Renewable16.8%

2050Coal 54.5%

Oil 1.5%

NG 23.7%

Nuclear 7.3%

Renewable13.0%

0

100

200

300

400

500

600

1950 1960 1970 1980 1990 2000 2010 2020 2030 2040 2050

EJ

Coal

OilNG

NuclearRenewable

FORECAST

547

241

59

1950 2000 2050

7


20082008

Crude Oil Price Status 2005 Crude Oil Price Status 2005 ((PowergenPowergen Asia 2005)Asia 2005)


© IMTE

0

10

20

30

40

50

60

70

80

*19

70

*19

73

*19

76

*19

79

*19

82

*19

85

*19

88

*19

91

*19

94

*19

97

*20

00

*20

03

*20

06

*20

09

*20

12

*20

15

*20

18

*20

21

*20

24

Year

US

D /

Ba

rre

l

EIA 2004 Projection Past Prices & 2005 Situation

IMTE AG Projection

8


20082008

Crude Oil Price vs. Natural Gas & CoalCrude Oil Price vs. Natural Gas & Coal


© IMTE

-

20.0

40.0

60.0

80.0

100.0

120.0

140.0

*1965 *1970 *1975 *1980 *1985 *1990 *1995 *2000 *2005 *2006 *2007 *2008

Year

US

D/B

arr

el

Actual Money Value

Today's Money Value

18. 10.2008** 70 USD/Barrel

15.07.2008 ** 145USD / Barrel

15.08.2008 ** 120USD / Barrel

2 Months ** - 50 USD/Barrel

3 Months ** - 75 USD/Barrel

-

5.00

10.00

15.00

20.00

25.00

30.00

*19

85

*19

90

*19

95

*20

00

*20

05

*20

06

*20

07

*20

08

*20

09

Year

US

D /

Mio

BT

U

Crude Oil Steam Coal Dry Natural Gas

Status 15.08.2008

-

5.00

10.00

15.00

20.00

25.00

*19

85

*19

90

*19

95

*20

00

*20

05

*20

06

*20

07

*20

08

*20

09

Year

US

D /

Mio

BT

U

Crude Oil Steam Coal Dry Natural Gas

Status 18.10.2008

9


20082008

Worldwide Power Generation Energy SourcesWorldwide Power Generation Energy Sources


FossilFossil

�� CoalCoal

�� Natural GasNatural Gas

�� Fuel OilFuel Oil

OthersOthers

�� NuclearNuclear

�� GeothermalGeothermal

�� HydroHydro

�� Other RenewableOther Renewable

© IMTE

Others

25%

Fossil

75%

Others

25%

Coal

41%

NG & Oil

34%

20082008

10


20082008

Coal Fired Power Generation Capacity vs. ProductionCoal Fired Power Generation Capacity vs. Production


© IMTE

200

400

600

800

1000

1200

1400

1600

1800

2000

2200

*2000 *2005 *2008 *2010 *2015 *2020 *2025 *2030

Year

GW

60.0

62.0

64.0

66.0

68.0

70.0

72.0

74.0

76.0

78.0

80.0

%

Capacity World Capacity Asia Production World Production Asia

PLF World PLF Asia PLF China

11


20082008

Coal Fired Power Generation Efficiency EvolutionCoal Fired Power Generation Efficiency Evolution


0

10

20

30

40

50

60

*1900 *1915 *1930 *1950 *1970 *2005 *2020

Year

%

Current Worldwide Average

33%

© IMTE

Pulverized Coal

Technology

Single

Reheat

Ultra-Supercritical

Technology

Supercritical

Technology

33%

European Average 36%

12

1 Short Ton=1 Short Ton=

0.907 M Ton0.907 M Ton


20082008

Worldwide Present & Projected Future Coal ReservesWorldwide Present & Projected Future Coal Reserves


Reserves in 2007Reserves in 2007

1,000 Billions Short Tons1,000 Billions Short Tons

Annual Consumption (2007)Annual Consumption (2007)

4 Billions Short Tons4 Billions Short Tons

250 Years250 Years

Projected Reserves in 2030Projected Reserves in 203030% Efficiency Scenario30% Efficiency Scenario

138 Years 138 Years

Projected Reserves in 2030Projected Reserves in 203040% Efficiency Scenario40% Efficiency Scenario

190 Years190 Years© IMTE

13


20082008

1,000MW ** 6,000 kcal / kg (25,120 kJ / kJ)1,000MW ** 6,000 kcal / kg (25,120 kJ / kJ)

50USD/ton (2.1 USD / Mio Btu) ** PLF=80%50USD/ton (2.1 USD / Mio Btu) ** PLF=80%


1%1% ImprovementImprovement

40%40%��41%41%Coal Savings vs. Efficiency Improvement

0

200

400

600

800

1000

1200

30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45

Efficiency (%)

10

00

to

n /

Ye

ar

0

10

20

30

40

50

60

Mio

US

D /

Ye

ar

ton USD

61 Mton/Year

3.06 Mio USD/Year

© IMTE

14


20082008

Evolution of ST Unit SizeEvolution of ST Unit Size


© IMTE

15


20082008

ST Unit ConfigurationST Unit Configuration


© IMTE

60Hz

50Hz

50Hz

60Hz

50/60Hz

5060

Hz

16

SupercriticalSupercritical

WaterWater--SteamSteam

CycleCycle

TechnologyTechnologyPowergenPowergen Asia Asia

20082008


© IMTE

17

Supercritical is a thermodynamic expression Supercritical is a thermodynamic expression

describing the state of a fluid above a certain describing the state of a fluid above a certain

pressure when there exists no clear distinction pressure when there exists no clear distinction

between the liquid and gaseous phasesbetween the liquid and gaseous phases. .

≥≥≥≥≥≥≥≥ 22.064 MPa (220.64 bar)22.064 MPa (220.64 bar)

≥≥≥≥≥≥≥≥ 374.81 374.81 ººCC

One of the primary means of increasing the One of the primary means of increasing the

efficiency of steam power plants is to increase efficiency of steam power plants is to increase

live steam pressures to superlive steam pressures to super-- or ultraor ultra--

supercritical conditionssupercritical conditions.PowergenPowergen Asia Asia

20082008


© IMTE

18


20082008

Heat Transfer Heat Transfer SubcriticalSubcritical vs. vs. SupercriticalSupercritical CycleCycle


© IMTE

6

3 5

4

1

2

19


20082008

Worldwide Number and Capacity of Coal FiredWorldwide Number and Capacity of Coal Fired

SC/USC Power Plants in Operation (2008)SC/USC Power Plants in Operation (2008)


0

20

40

60

80

100

120

140

160

180

USA Japan Russia Germany Korea China Other

Counties

No

. o

f U

nit

s

© IMTE

0

20

40

60

80

100

120

140

160

180

USA Japan Russia Germany Korea China Other

Counties

No

. o

f U

nit

s

0

20

40

60

80

100

120

GW

No. of Units Power Output

Total

< 570 Units

< 350 GW

20


20082008

Potential in Increase in Net EfficiencyPotential in Increase in Net Efficiency


30

35

40

45

50

55

F12 F12 P91 P92 Austenitic

Steel

Inconel

Material

Eff

icie

nc

y (

%)

16.8 MPa

538°°°°C

25.0MPa

540 - 560°°°°C

+ 1 - 2%

26.5 MPa

585 - 600°°°°C

+ 2 - 3%

30.0 MPa

600 - 620°°°°C

+ 4 - 5%

32.5 MPa

620 - 620°°°°C

+ 6 - 7%

35.0 MPa

700 - 720°°°°C

+ 10 - 12%

10-12%

© IMTE

21


20082008

1,000MW ** 6,000 kcal / kg (25,120 kJ / kJ)1,000MW ** 6,000 kcal / kg (25,120 kJ / kJ)

50USD/ton (2.1 USD / Mio Btu) ** PLF=80%50USD/ton (2.1 USD / Mio Btu) ** PLF=80%


1%1%

3.06MioUSD/Y3.06MioUSD/Y

10%10%

30.6MioUSDY30.6MioUSDY

Coal Savings vs. Efficiency Improvement

0

200

400

600

800

1000

1200

30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45

Efficiency (%)

10

00

to

n /

Ye

ar

0

10

20

30

40

50

60

Mio

US

D /

Ye

ar

ton USD

61 Mton/Year

3.06 Mio USD/Year

© IMTE

22


20082008

50Hz RPP 50Hz RPP –– Main ParametersMain Parameters


�� Plant Gross CapacityPlant Gross Capacity 600 MW600 MW

�� Plant Net CapacityPlant Net Capacity 552 MW552 MW

�� Live Steam PressureLive Steam Pressure 28.5 28.5 MPaMPa

�� Live Steam TemperatureLive Steam Temperature 600 600 ººCC

�� Reheat PressureReheat Pressure 6.0 6.0 MPaMPa

�� Condenser PressureCondenser Pressure 4.5 4.5 kPakPa

�� Feed Water TemperatureFeed Water Temperature 303 303 ººCC

�� Reheat TemperatureReheat Temperature 620 620 ººCC

�� Heat RateHeat RateNET/LHVNET/LHV––Efficiency 45.9 % Efficiency 45.9 % �� 7,843 kJ / kWh7,843 kJ / kWh

�� Boiler TypeBoiler Type OTOT--BensonBenson

�� STST TypeType 3 Casing 3 Casing –– Single ReheatSingle Reheat

1SF HP1SF HP--1DF IP1DF IP--1DF LP1DF LP© IMTE

23


20082008

600MW600MWGROSS GROSS 33--Casing (50Hz) USC Steam TurbineCasing (50Hz) USC Steam Turbine


© IMTE

Concept study reference power plant North Rhine-Westphalia (RPP NRW), Project 85.65.69 – T-138, VGB PowerTech e.V., 2004

Source: Siemens AG

24


20082008

50 Hz RPP 50 Hz RPP –– Water Steam Cycle DiagramWater Steam Cycle Diagram


W715-

NOT BINDING FOR EXECUTION Power Generation PG

P KZ /P C UA/ Type o f Doc.

UN ID

XG 0 2

Ind e x

R e v.

S iemens

Inha lts ke nnz e ic he n / C on te n ts C ode Zhl.-Nr./Re g .No .

Die ns ts t./De pt.

Da tum /Da te

LZDK00 6 RKW NRWMODULES OF

WATER STEAM CYCLE

vgl_RKW NRW_basis_8_engl.dsf

12 HP FEEDWATER HEATER A713 HP FEEDWATER HEATER A814 MAKE-UP WATER15 EVACUATION16 LP BYPASS STATION17 GENERATOR18 LP TURBINE19 IP TURBINE20 HP TURBINE21 WARM-UP STATION22 HP BYPASS STATION23 EXTERNAL DESUPERHEATER

1 CONDENSER WITH STANDPIPES 2 CONDENSATE POLISHING PLANT 3 CONDENSATE POLISHING PUMP 4 GLAND STEAM CONDENSER 5 LP DRAINS COOLERS 6 LP FEEDWATER HEATER A1/A2 7 LP FEEDWATER HEATER A3 8 LP FEEDWATER HEATER A4 9 LP HEATER DRAINS PUMP10 CONNECTION AUXILIARY STEAM11 HP FEEDWATER HEATER A6

Condensate SupplyLP Feedwater Heating

Feedwater Storage / DeaerationFeedwater SupplyFeedwater Preheating

Main Steam Piping SystemCold Reheat Piping System

Hot Reheat Piping SystemAuxiliary Steam Piping System

5

1

1415

G

1718

4

1x60%

7

8

9

10

FEEDWATER TANK

FEEDWATERPUMPS 3x50%

12

11

13

A8

10 21

16

DE

SU

PE

RH

EA

TIN

G

A7 20

A5A6

A4

19

A1 A1A3A2

6

PREFERRED VARIANT

2

MAINCONDENSATEPUMPS2x100%

3

DESUPERHEATING

2x50%22

2x50%

23

REHEATER

SUPERHEATER

ECO

FROMPULVERIZERAIR HEATER

FROM STEAM COILAIR HEATER

2003-09-30

TO PULVERIZERAIR HEATER

TO STEAM COILAIR HEATER

© IMTE

25


20082008

60Hz Varioplant 60Hz Varioplant –– Main ParametersMain Parameters


�� Plant Gross CapacityPlant Gross Capacity 800 MW800 MW

�� Plant Net CapacityPlant Net Capacity 725 MW725 MW

�� Live Steam PressureLive Steam Pressure 28.5 28.5 MPaMPa

�� Live Steam TemperatureLive Steam Temperature 600 600 ººCC

�� Reheat PressureReheat Pressure 6.0 6.0 MPaMPa

�� Condenser PressureCondenser Pressure 4.5 4.5 kPakPa

�� Feed Water TemperatureFeed Water Temperature 303 303 ººCC

�� Reheat TemperatureReheat Temperature 610 610 ººCC

�� Heat RateHeat RateNET/LHVNET/LHV––Efficiency 45.8 % Efficiency 45.8 % �� 7,844 kJ / kWh 7,844 kJ / kWh

�� Boiler TypeBoiler Type OTOT--BensonBenson

�� STST TypeType 4 Casing 4 Casing –– Single ReheatSingle Reheat

1SF HP1SF HP--1DF IP1DF IP--2DF LP2DF LP© IMTE

26


20082008

800MW800MWGROSS GROSS 44--Casing (60Hz) USC Steam TurbineCasing (60Hz) USC Steam Turbine


© IMTE

Siemens AGPower Generation

27


20082008

50 Hz vs. 60 Hz50 Hz vs. 60 Hz


© IMTE


Source: Siemens AG


Source: Siemens AG

Siemens AG

Power Generation

50Hz

60HzMach 2.2 (∼∼∼∼720m / sec) at Last Stage Blade End allows

55” Blade for 50Hz (Titanium)

43” Blade for 60Hz (Titanium)

28


20082008

Drum vs. OT BoilerDrum vs. OT Boiler


Drum Type BoilerDrum Type Boiler

Operational PressureOperational Pressure

1.0 1.0 –– 18.0 MPa18.0 MPa

OT Type BoilerOT Type Boiler

Operational PressureOperational Pressure

2.0 2.0 –– 40.0 MPa40.0 MPa

© IMTE

29


20082008

Drum vs. OT BoilerDrum vs. OT Boiler


OT BoilerOT Boiler

�� Both SubBoth Sub-- & Super& Super--Critical Critical PressuresPressures

�� Highest Efficiency at Part Highest Efficiency at Part & Full Load& Full Load

�� Short StartShort Start--up Timesup Times

�� Thermoelastic Thermoelastic Construction Construction ��Lower Lower Thermal StressesThermal Stresses

�� Feed Water Flow Control Feed Water Flow Control by after Evaporator by after Evaporator Temperature / Enthalpy Temperature / Enthalpy ControlControl

�� Higher Load Transients Higher Load Transients (6(6--8%)8%)

© IMTE

Drum BoilerDrum Boiler

�� Restricted to SubRestricted to Sub--Critical Critical

PressuresPressures

�� Low Efficiency at Part Load Low Efficiency at Part Load

�� Long StartLong Start--up Timesup Times

�� Thick Walled Components Thick Walled Components

((HP DrumHP Drum) ) ��Higher Thermal Higher Thermal

StressesStresses

�� Feed Water Flow Control by Feed Water Flow Control by

Drum Water Level ControlDrum Water Level Control

�� Lower Load Transients Lower Load Transients (4(4--5%)5%)

30


20082008

OT Boiler Furnace ArrangementsOT Boiler Furnace Arrangements


Vertical Tube Vertical Tube

ArrangementArrangement

High Mass FluxHigh Mass Flux

Spiral Tube Spiral Tube

ArrangementArrangement

High Mass FluxHigh Mass Flux

Advanced Vertical Advanced Vertical

Tube ArrangementTube Arrangement

Low Mass FluxLow Mass Flux© IMTE

Water

Inlet

First

Pass

Down

First

Pass

Up

Second

Pass

Up

Third

Pass

Mix

Headers

Water

Inlet

Mix

Header

Third

Pass

Spiral

Tubes

Water

Inlet

Third

Pass

Mix

Header

Advanced

Vertical

Tubes

31


20082008

Advantages of Vertical vs. Spiral ArrangementAdvantages of Vertical vs. Spiral Arrangement


�� Cheaper Manufacture & AssemblyCheaper Manufacture & Assembly

�� Maintenance FriendlyMaintenance Friendly

�� Part Load up to 20% at highest Main Steam Part Load up to 20% at highest Main Steam

TemperaturesTemperatures

�� Reduced Slagging of Furnace WallsReduced Slagging of Furnace Walls

�� Lower Evaporator Pressure LossLower Evaporator Pressure Loss

�� Lower Auxiliary Power RequirementLower Auxiliary Power Requirement

�� Simple StartSimple Start--up System.up System.© IMTE

32


20082008

Low Mass Flux Design (LMFD)Low Mass Flux Design (LMFD)


��Current OT boilers use Furnace Tube Current OT boilers use Furnace Tube Mass Fluxes (FTMF) designs >1,500Mass Fluxes (FTMF) designs >1,500--1,800kg/m1,800kg/m²²s. s.

��FTMF levels below 1,000FTMF levels below 1,000--1,200kg/m1,200kg/m²²s s �� (LMFD) minimize the furnace (LMFD) minimize the furnace dynamic pressure losses.dynamic pressure losses.

��ThermoThermo--hydraulic behavior of the hydraulic behavior of the LMFD becomes similar to natural LMFD becomes similar to natural circulation boilers.circulation boilers.

© IMTE

33


20082008

Low Mass Flux Design (LMFD)Low Mass Flux Design (LMFD)


Combination Vertical Tube Arrangement Combination Vertical Tube Arrangement

with Low Mass Flux Design with Low Mass Flux Design

��

Highly Efficient & Reliable Boiler with Highly Efficient & Reliable Boiler with

Outstanding Operating Characteristics at Outstanding Operating Characteristics at

any Load from 20% part Load up to any Load from 20% part Load up to

Design Base Load.Design Base Load.

© IMTE

34


20082008

OT Boiler Design AlternativesOT Boiler Design Alternatives


Floor space: 2,975 m²

Volume: 166,000 m3

Efficiency: 95%


Volume: 197,000 m3

Efficiency: 95%


Volume: 209,000 m3

Efficiency: 95%


Volume: 166,000 m3

Efficiency: 95%


Volume: 197,000 m3

Efficiency: 95%


Volume: 209,000 m3

Efficiency: 95%


So

urc

e:

Sie

me

ns

AG

Tower BoilerTower Boiler TwoTwo--Pass BoilerPass Boiler Horizontal BoilerHorizontal Boiler

© IMTE

Courtesy of Siemens PG

Milan

Cathedral

Height ratio3 : 2 : 1

Height Comparison of 500MW Coal Fired OT Boilers

108 m

35


20082008




Volume: 166,000 m3

Efficiency: 95%


Volume: 197,000 m3

Efficiency: 95%


Volume: 209,000 m3

Efficiency: 95%


Volume: 166,000 m3

Efficiency: 95%


Volume: 197,000 m3

Efficiency: 95%


Volume: 209,000 m3

Efficiency: 95%


So

urc

e:

Sie

me

ns

AG


© IMTE

Tower BoilerTower Boiler ��

Lowest Steel & Pressure Parts Lowest Steel & Pressure Parts

& Floor Space Requirement. & Floor Space Requirement.

Allows Multilevel Coal Feeders.Allows Multilevel Coal Feeders.

High High HightHight..

36


20082008




Volume: 166,000 m3

Efficiency: 95%


Volume: 197,000 m3

Efficiency: 95%


Volume: 209,000 m3

Efficiency: 95%


Volume: 166,000 m3

Efficiency: 95%


Volume: 197,000 m3

Efficiency: 95%


Volume: 209,000 m3

Efficiency: 95%


So

urc

e:

Sie

me

ns

AG


© IMTE

TwoTwo--Pass Boiler Pass Boiler ��

High Steel, External High Steel, External

Piping, Pressure Piping, Pressure

Parts & Floor Space Parts & Floor Space

Requirement. Requirement.

Short Assembly Short Assembly

Time.Time.

Low Height.Low Height.

37


20082008




Volume: 166,000 m3

Efficiency: 95%


Volume: 197,000 m3

Efficiency: 95%


Volume: 209,000 m3

Efficiency: 95%


Volume: 166,000 m3

Efficiency: 95%


Volume: 197,000 m3

Efficiency: 95%


Volume: 209,000 m3

Efficiency: 95%


So

urc

e:

Sie

me

ns

AG


© IMTE

Horizontal Boiler Horizontal Boiler ��

Lowest External Piping Lowest External Piping

Requirement, High Steel & Requirement, High Steel &

Floor Space Requirement. Floor Space Requirement.

Low Height.Low Height.

38


20082008

Boiler Temperature & Material DevelopmentBoiler Temperature & Material Development


CCA 617 CCA 617 -- IN 740 IN 740 –– Haynes 230 Haynes 230

–– Save 12 Save 12 Super Super

AlloysAlloysStart Start

20102010<700 <700 <35.0<35.0

X10CrWMoVNb9X10CrWMoVNb9--1 EUROPE1 EUROPE

STBA29STBA29--STPA29 JAPAN STPA29 JAPAN P 92P 92Since Since

20042004<620 <620 <33.0<33.0

9Cr 9Cr –– 1Mo 1Mo P 91P 91Since Late Since Late

8080’’ss

<560 <560 <30.0<30.0

2 2 ¼¼ Cr Mo Cr Mo P 22P 22Since Early Since Early

8080’’ss<540 <540 <25.0<25.0

Cr Mo V 11 1 Cr Mo V 11 1 X 20X 20Since Early Since Early

6060’’ss<520 <520 <20.0<20.0

Equivalent toEquivalent toMaterialMaterialDateDate

Live SteamLive Steam

TemperatureTemperature

°°C C

Live SteamLive Steam

PressurePressure

MPa MPa

© IMTE

39


20082008

Design Features (50Hz) 16mDesign Features (50Hz) 16m22 Last Stage BladeLast Stage Blade


• Rotor diameter ~ 1900 mm

• Blade length 1400 mm (55´´)

• Velocity at blade end 750 m/s (~ Ma = 2.0)

• Mach-number Supersonic at blade end

• Blade connection Shroud & snubber

• Exit losses 3D effects

Design features 16 m 2 - last stage blade


Source: Siemens AG

��Rotor DiameterRotor Diameter 1,900 mm 1,900 mm

��Blade LengthBlade Length 1,400 mm (551,400 mm (55””))

��Speed at Blade EndSpeed at Blade End 738 m/s 738 m/s

��Mach No at Blade EndMach No at Blade End 2.242.24

��Blade ConnectionBlade Connection Shroud & SnubberShroud & Snubber

��Blade MaterialBlade Material TitaniumTitanium

© IMTE

40


20082008

Design Features (60Hz) 10.3 mDesign Features (60Hz) 10.3 m22 Last Stage BladeLast Stage Blade


• Rotor diameter ~ 1900 mm

• Blade length 1400 mm (55´´)

• Velocity at blade end 750 m/s (~ Ma = 2.0)

• Mach-number Supersonic at blade end

• Blade connection Shroud & snubber

• Exit losses 3D effects

Design features 16 m 2 - last stage blade


Source: Siemens AG

� Rotor Diameter 1,700 mm

�Blade Length 1,067 mm (42.0’’)

�Speed at Blade End 722 m/s

�Mach No at Blade End 2.18

�Blade Connection Shroud & Snubber

�Blade Material Titanium

© IMTE

41


20082008

ST Common ConfigurationsST Common Configurations


33--Casing * 4Casing * 4--Flow 400Flow 400--700 MW700 MW 44--Casing * 4Casing * 4--Flow 700Flow 700--1000 MW1000 MW

Double Shell * 1Double Shell * 1--Flow <50MWFlow <50MW 22--Casing * 2Casing * 2--Flow 300Flow 300--600 MW600 MW

© IMTE

Steam turbine tandem compound configuration:Five-casing, six-flow, with single reheat,

> 1200 MW, 310 bar

42


20082008

ST Material Development (50Hz)ST Material Development (50Hz)


Nimonic105 / 115 / Nimonic105 / 115 /

718Allvac 718 Plus 718Allvac 718 Plus

WaspaloyWaspaloy

99--12% Cr Mo VIN 71812% Cr Mo VIN 71899--12% Cr Mo V12% Cr Mo V

NI 80A; IN 718NI 80A; IN 718BoltingBolting

Wrought NiWrought Ni--BaseBase

Titanium (last rotor Titanium (last rotor

row)row)

99--12% Cr W Co 12% Cr W Co


row)row)

10Cr Mo V Nb N 10Cr Mo V Nb N


row)row)BladingBlading

CCA 617CCA 617

IN 625 IN 625

IN 740 (up to 760IN 740 (up to 760°°°°°°°°C)C)

99--12% Cr (W) 12% Cr (W)

Cast12Cr W (Co)Cast12Cr W (Co)11--2 Cr Mo Cast2 Cr Mo Cast

Cr Mo V CastCr Mo V Cast

9Cr 1 Mo V Nb 9Cr 1 Mo V Nb

(up to 590(up to 590°°°°°°°°C)C)

Inner CasingInner Casing

ShellsShells

CCA 617CCA 617

IN 625 / IN 714IN 625 / IN 714

99--10% Cr (W) 10% Cr (W)

Cast12Cr W (Co)Cast12Cr W (Co)Cr Mo V CastCr Mo V Cast

10Cr Mo V Nb10Cr Mo V Nb

NozzlesNozzles

ValvesValves

IN 625 / IN 740IN 625 / IN 740

CCA 617CCA 617

Haynes 230Haynes 230

99--12Cr W Co forging12Cr W Co forging

12Cr Mo W V Nb N12Cr Mo W V Nb N

1Cr Mo V forging1Cr Mo V forging

12Cr Mo V Nb N12Cr Mo V Nb N

26Ni Cr Mo V11 526Ni Cr Mo V11 5RotorRotor

≤≤700700°°CC≤≤620620°°CC≤≤560560°°CCSteam Steam

TemperatureTemperature

© IMTE

43


20082008

Creep Strength of Materials Creep Strength of Materials –– Typical ExampleTypical Example


© IMTE <7501,000Super Alloys

Materials for applications above 700°°°°C

<7001,000Austenitic Steel

<6501,000Martensitic Steel

Materials for applications between 620 and 700°°°°C

<6203,000Supper Alloys

<6201,2009 Cr Steel �� P 92

<62060012% Cr Steel �� X 20

Max. Temperature (°°°°C)Creep Strength (kN/cm2)Material

Materials for applications below 600°°°°C

44

xCOAL2008CON750.000CS ENERGY CORP LTDKOGAN CREEKKOGAN CREEK 1

xCOAL2008CON660.000NTPC LTDSIPATSIPAT 1

xCOAL2008CON660.000ENEL SPATORREVALDALIGA NORDTORREVALDALIGA NORD 7



BITCOAL2008CON600.000CHINA POWER INTL DEVELOP LTDYAOMENGYAOMENG-2 NO 2

BITCOAL2008CON600.000CHINA POWER INTL DEVELOP LTDYAOMENGYAOMENG-2 NO 1

xCOAL2008CON600.000CHINA POWER INVESTMENT CORPQINGHEQINGHE 11

xCOAL2008CON600.000CHINA POWER INTL DEVELOP LTDHUANGGANG DABIESHANHUANGGANG DABIESHAN 2

xCOAL2008CON600.000CHINA POWER INTL DEVELOP LTDHUANGGANG DABIESHANHUANGGANG DABIESHAN 1

BITCOAL2008CON600.000DATANG INTL POWER GEN CONINGDENINGDE 2

BIT/SUBCOAL2008CON500.000KOREA MIDLAND POWER (KOMIPO)PORYONGPORYONG 8

BIT/SUBCOAL2008CON500.000KOREA MIDLAND POWER (KOMIPO)PORYONGPORYONG 7

xCOAL2008CON500.000WISCONSIN PUBLIC SERVICE CORPWESTON (WI)WESTON (WI) 4

LIGCOAL2008CON464.000ZES ELEK PATNOW-ADAMOW-KONINPATNOWPATNOW 9

BITCOAL2009CON1000.000HUADIAN POWER INTL CORPZOUXIANZOUXIAN 8

BITCOAL2009CON1000.000SHENERGY COMPANY LTDWAIGAOQIAOWAIGAOQIAO-3 NO 2

xCOAL2009CON1000.000TIANJIN BEIJIANG POWER PLANTTIANJIN BEIJIANGTIANJIN BEIJIANG 2

xCOAL2009CON1000.000TIANJIN BEIJIANG POWER PLANTTIANJIN BEIJIANGTIANJIN BEIJIANG 1

BITCOAL2009CON870.000KOREA SOUTH-EAST POWER COYONGHUNGDOYONGHUNGDO 4

xCOAL2009CON816.000PUBLIC SERVICE COLORADOCOMANCHE (CO)COMANCHE (CO) 3

xCOAL2009CON660.000NTPC LTDSIPATSIPAT 2

xCOAL2009CON660.000NTPC LTDBARHBARH 1

BITCOAL2009CON615.000WE POWER LLCELM ROADELM ROAD 1

BITCOAL2009CON460.000PKE ELEKTROWNIA LAGISZA SALAGISZALAGISZA 8

LIGCOAL2009PND 860.000TXU POWER CO LLCOAK GROVE (TX)OAK GROVE (TX) 2

LIGCOAL2009PND 860.000TXU POWER CO LLCOAK GROVE (TX)OAK GROVE (TX) 1

LIGCOAL2010CON1100.000RWE POWER AGNEURATHNEURATH G

SC /

USC

PO

WER

PLA

NT D

ATA BASE

45


20082008


SC & USC Data BaseSC & USC Data Base

�� Total SC / USC Power Plants Total SC / USC Power Plants �� 717 717 (COD 1959(COD 1959--2016)2016)

�� Coal: 460 Coal: 460 �� Gas: 178 Gas: 178 �� Oil: 79Oil: 79

�� Last 140 SC/USC PP (from 2005) only Last 140 SC/USC PP (from 2005) only coal firedcoal fired

�� Retired: Retired: 23 23 �� Operational: 574 Operational: 574 ��Construction: 64 Construction: 64 �� Design & Planning: 48Design & Planning: 48

�� USA USA �� 190190

�� Japan Japan �� 130 130

�� Russia & Ukraine Russia & Ukraine �� 1118 18

�� Europe Europe �� 8282

�� China & India China & India �� 7777

�� Former SU Countries Former SU Countries �� 4545

�� South Korea South Korea �� 3434

�� Rest of the World Rest of the World �� 2626

�� Rest of Asia Rest of Asia �� 1515© IMTE

46

200925.0 / 600 / 620 60050JapanIsogo 224

200524.1 / 537 / 56570060JapanKobe 223

200325.4 / 604 / 602 (1000)50JapanHitachi-Naka 122

200225.0 / 603 / 602(700)50JapanTomato-Atsuma21

2001/0225.0 / 571 / 5962 x 100060JapanHekinan 4 & 520

200225.0 / 600 / 610 43.060050JapanIsogo 119

2001/0225.0 / 571 / 59642.0(2 x 1000)60JapanHekinan 4 & 518

200126.4 / 605 / 613 43.1105060JapanTachibana-wan 217

200024.1 / 565 / 593 (700)60JapanTachibana-wan 116

200025.5 / 597 / 59570050JapanTsuruga 215

199825.5 / 600 / 605100060JapanMisumi14

200927.5 / 560 / 58043.346050PolandLagisza (CFB Boiler)13

>201028.5 / 600 / 610>46.02 x 78050NetherlandsEmshaven 1 & 212

200525.0 / 570 / 568 49560CanadaGenesee 311

201025.5 / 585 / 585 85060USAIatan 210

2009/1026.2 / 570 / 570 2 x 60060USAElm Road 1 & 29

200926.2 / 570 / 570 75060USAComanche 38

200826.2 / 580 / 580 50060USA Weston 47

200725.3 / 566 / 59379060USACouncil Bluffs6

2010/1127.2 / 600 / 605 45.22 x 105050GermanyNiederaussem 2&35

>201028.5 / 600 / 61046.02 x 76550GermanyWestfalen 1 & 24

201026.0 / 595 / 595 >43.02 x 110050GermanyBoa 2 & 3 Neurath3

200326.0 / 580 / 600 43.296550GermanyNiederaussem 12

200026.7 / 555 / 57841.791550GermanyBoxberg1

%LHV/NET

(%LHV/GROSS

)

(MWGROSS

)

47


20082008

LagiszaLagisza 460 MW USC Power Plant 460 MW USC Power Plant -- PolandPoland


© IMTE

� World’s largest and first supercritical CFB boiler with OT- technology.

� Lower total plant investment, better net plant efficiency and fuel firing flexibility.

� Boiler designed for bituminous coal or mixture of bituminous coal with wet coal slurry (30%) and/or biomass (10%).

� Staged low temperature combustion & limestone feeding � SO2 & NOx < 100mg/Nm3

� Low furnace heat flux & low mass flux with vertical tubes � lower tube stress & pressure drop.

� Flue gas temperature of 85°C � combustion air preheating � efficiency improvement

� Net plant LHV efficiency of 43.3%.

� Scheduled COD in 2009.

48

2012(5 x 800)50IndiaMundra42

2011(3 x 800)50IndiaShahapur41

200825.0 / 540 / 56839.0(3 x 660)50IndiaSipat40

200825.5 / 569 / 569(5 x 800)50IndiaSasan39

200925.5 / 569 / 5962 x 50060S. KoreaHadong 7 & 838

2008(2 x 550)60S. KoreaTaean 7 & 837

200825.5 / 569 / 5962 x 50060S. KoreaPoryong 7 & 836

2008/0925.5 / 569 / 596(2 x 870)60S. KoreaYonghung 3 & 435

200525.5 / 569 / 5962 x 50060S. KoreaTangjin 5 & 634

200425.5 / 569 / 569(2 x 800)60S. KoreaYonghung 1 & 233

200827.0 / 600 / 600 2 x 100050PR ChinaZouxian IV32

2006/0827.5 / 605 / 60043.0 - 45.04 x 100050PR ChinaYuhuan31

2006/0826.5 / 600 / 600 4 x 100050PR ChinaHuaneng30

200727.0 / 600 / 600100050PR ChinaWaigaoqiao II29

200724.7 / 571 / 569 43.02 x 60050PR ChinaWangqu28

200625.9 / 569 / 569 42.03 x 60050PR ChinaChangshu27

200425.8 / 542 / 568 2 x 90050PR ChinaWaigaoqiao I26

25.0 / 540 / 560 75050AustraliaCogan Creek 25

CODMain Steam

MPa /°°°°C /°°°°C

Thermal

Efficiency

%LHV/NET

(%LHV/GROSS

)

Power Output

MWNET

(MWGROSS

)

HzCountryPower Plant NamePos

49

Photographs courtesy

of Siemens Power

Generation AG


20082008

Boxberg 907 MW USC Power Plant Boxberg 907 MW USC Power Plant -- GermanyGermany


26.6 26.6 26.6 26.6 26.6 26.6 26.6 26.6 MPaMPaMPaMPaMPaMPaMPaMPa / 545 / 545 / 545 / 545 / 545 / 545 / 545 / 545 ººººººººCCCCCCCC / 581 / 581 / 581 / 581 / 581 / 581 / 581 / 581 ººººººººCCCCCCCC

© IMTE

50

Photograph courtesy

of Siemens Power

Generation AG


20082008

NiederaussemNiederaussem 1 1 –– 965 MW USC Power Plant 965 MW USC Power Plant

GermanyGermany



© IMTE

51


of IHI Ltd


20082008

TachibanaTachibana--Wan 1050 MW SC Power Plant Wan 1050 MW SC Power Plant –– Japan Japan

. .


25.9 MPa25.9 MPa25.9 MPa25.9 MPa25.9 MPa25.9 MPa25.9 MPa25.9 MPa

600 600 600 600 600 600 600 600 ººººCCCC / 610 / 610 / 610 / 610 / 610 / 610 / 610 / 610 ººººººººCCCCCCCC

© IMTE

52


of Electric Power

Development Co &

Siemens AG


20082008

ShinShin--Isogo 600 MW USC Power Plant Isogo 600 MW USC Power Plant -- JapanJapan


28.0 28.0 28.0 28.0 MPaMPaMPaMPa / 605 / 605 / 605 / 605 ººººCCCC / 613 / 613 / 613 / 613 ººººCCCC

© IMTE

53


20082008

Misumi 1000 MW SC Power Plant Misumi 1000 MW SC Power Plant -- JapanJapan


25.0 25.0 25.0 25.0 25.0 25.0 25.0 25.0 MPaMPaMPaMPaMPaMPaMPaMPa / / / / / / / / 600 600 600 600 600 600 600 600 ººººººººCCCCCCCC / 605 / 605 / 605 / 605 / 605 / 605 / 605 / 605 ººººººººCCCCCCCC© IMTE

54


of Siemens Power

Generation AG


20082008

Waigaoqiao 2x900 MW USC Power PlantWaigaoqiao 2x900 MW USC Power Plant––PR ChinaPR China



© IMTE

55


of Ministry of

Construction PR China


20082008

Huaneng Yuhuan 4x1000 MW USC Power Plant Huaneng Yuhuan 4x1000 MW USC Power Plant ––

PR ChinaPR China


26.5 26.5 26.5 26.5 26.5 26.5 26.5 26.5 MPaMPaMPaMPaMPaMPaMPaMPa / 600 / 600 / 600 / 600 / 600 / 600 / 600 / 600 ººººººººCCCCCCCC / 600 / 600 / 600 / 600 / 600 / 600 / 600 / 600 ººººººººCCCCCCCCIMTE AG

57


20082008


According to the World Coal According to the World Coal

Institute, more than 40% coal is Institute, more than 40% coal is

worldwide used for power worldwide used for power

generation and it is expected to generation and it is expected to

be the fuel of choice for the be the fuel of choice for the

foreseeable future as power foreseeable future as power

producing companies deploy producing companies deploy

technologies that offer cleaner, technologies that offer cleaner,

more efficient coalmore efficient coal--fired based fired based

electric power production.electric power production.

© IMTE

58


20082008


Most of the coal fired power plants to Most of the coal fired power plants to

be build worldwide during next be build worldwide during next

decades will be of:decades will be of:--

IGCC Technology; andIGCC Technology; and

Pulverized Coal Fired SC/USC Pulverized Coal Fired SC/USC

TechnologyTechnology

© IMTE

59


20082008


�� Both IGCC and SC & USC Technologies Both IGCC and SC & USC Technologies

are enjoying a steeply growing market are enjoying a steeply growing market

share.share.

�� However, IGCC market specifically, is However, IGCC market specifically, is

not following this bullish trend yetnot following this bullish trend yet--

reason is higher investment costs than reason is higher investment costs than

the cost of SC & USC Technology.the cost of SC & USC Technology.

© IMTE

60


20082008


SC & USC Power Generation Technology will SC & USC Power Generation Technology will

gain superiority over conventional (subgain superiority over conventional (sub--critical) critical)

power plants from the following reasons:power plants from the following reasons:--

Higher EfficiencyHigher Efficiency

Excellent Load BehaviorExcellent Load Behavior

CompactnessCompactness

Lower Specific WeightLower Specific Weight

Environmental FriendlinessEnvironmental Friendliness

© IMTE

61


20082008


Double reheat cycles are being more often implemented to improve

efficiency and reduce the problems concerning erosion by water drops

of the LP ST last stage blades.

© IMTE

62


20082008


Vertical Tube Arrangement with Low Mass Flux Design is the preferable, highly efficient & reliable option for

boiler design.

© IMTE

63


20082008


Current SC pulverized coal based Current SC pulverized coal based

power plants are working with net power plants are working with net

efficiencies in the range of:efficiencies in the range of:--

44 44 -- 46% 46%

8,180 8,180 -- 7,830 kJ / kWh7,830 kJ / kWh

© IMTE

64


20082008


Options to increase efficiency above Options to increase efficiency above

5050 % %

7,200 kJ / kWh 7,200 kJ / kWh

in in

USC Power Plants USC Power Plants

rely on elevated steam conditions as well as on rely on elevated steam conditions as well as on

future process improved future process improved

and and

quality of used high pressure quality of used high pressure

andand

high temperature materials.high temperature materials.

© IMTE

65


20082008


Steam conditions up to Steam conditions up to

30 MPa/60030 MPa/600°°C/620C/620°°C C are achieved using steels with are achieved using steels with

1212 % Cr content% Cr content

Steam conditions up to Steam conditions up to

32.532.5 MPa/620MPa/620°°C/620C/620°°C C can be achieved with Austenite can be achieved with Austenite

steels.steels.

© IMTE

66


20082008


NickelNickel--based alloys may permitbased alloys may permit

37.5 37.5 MPaMPa / 720/ 720°°C / 720C / 720°°C C

yielding efficiencies of:yielding efficiencies of:--

50 50 -- 52% 52%

7,200 7,200 –– 6,900 kJ / kWh6,900 kJ / kWh

in 2020in 2020

© IMTE

67


20082008


Early problems experienced with the first and second generation of SC and USC power

plants have been overcomed.

Overall outlook for pulverized coalOverall outlook for pulverized coal--fired SC/USC fired SC/USC power plant technology is promising and its power plant technology is promising and its

further growth lies ahead.further growth lies ahead.

Intensity of this growth will depend on the Intensity of this growth will depend on the

following factors:following factors:

© IMTE

68


20082008


�� Worldwide acceptance of USC technology.Worldwide acceptance of USC technology.

�� Further development of NG vs. Coal price.Further development of NG vs. Coal price.

�� Reduction of investment & life cycle costs.Reduction of investment & life cycle costs.

�� Further Improvement of availability & reliability.Further Improvement of availability & reliability.

�� Efficiency improvement.Efficiency improvement.

�� Further reduction of specific emissions.Further reduction of specific emissions.

© IMTE

69


20082008

New technologies have an impact on New technologies have an impact on

everything everything —— from environmental quality to from environmental quality to

costs that consumers will ultimately have costs that consumers will ultimately have

to pay.to pay.

THANK YOUTHANK YOU

IMTE AGIMTE AGPower Consulting Engineers, SwitzerlandPower Consulting Engineers, Switzerland

imteag.comimteag.comimteag.com

imteag.comimteag ag/2.1-pga-2008.pdf · 2 1895 cambridge power station produced 3 x 100 kw using...

Documents