Advanced Supercritical Boiler Technologies Official Opening of the OxyCoalTM Clean Combustion Test Facility Technical Seminar

Dr David Smith Date: 24 July 2009

AGENDA

Why Advanced Supercritical? Advanced Supercritical : State of the Art Next step: Ultra Supercritical

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WHY ADVANCED SUPERCRITICAL?

TRACK 2: Carbon Capture and Storage (CCS) - 95%

CO2 Reduction TRACK 1: Increased Efficiency

Baseline Time Both tracks are required to mitigate CO2 emissions from coal fired generation Primary means to increase efficiency is to increase the steam conditions we use in our power plant cycle
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WHY ADVANCED SUPERCRITICAL?

Efficiency of the Rankine Cycle increases with increasing Turbine inlet Temperature and Pressure Cycle efficiency of typical sub-critical plant is 38% whereas todays supercritical technology increases this to around 45-47%

Sub-Critical

Advanced Ultra Super-Critical Super-Critical Super-Critical

220.89 290 250 Main Steam Pressure (bar)

Supercritical means above the critical point for water / steam (220.89 bar) after which there is no phase change between water and steam Other terms Advanced Supercritical and Ultra Supercritical are loose definitions to indicate steps in technology as opposed to any distinction in thermodynamic Page 3 properties

570 540 610 Main Steam Temperature (C)

DEVELOPMENT IN THERMAL EFFICIENCY

Meaningful CO2 reductions can be achieved by replacing old units with modern advanced supercritical plant

55

Best Available Advanced Supercritical Technology being offered now eg Kingsnorth, Greifswald

Target AD700

50 55% (-29%)

Increasing Efficiency

Lower CO2 emissions

50

Doosan Babcock ASC Plant efficiency % NCV

45

46% (-23%)

Supercritical Boilers

Meri Pori Hemweg

40

New Chinese Orders 38%

42%

UK fleet 32%

38%

Chinese fleet

35

30

Older Plants

Sub Critical Boilers

Year
1960 1980 2000 2020
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STEAM CYCLE AND PLANT EFFICIENCY GAINS

Efficiency gains have mostly been achieved by pushing the steam cycle, lower excess air and lower gas exit temperature have also contributed

55
375-700/700

Target AD700

50

305-585/602 285-580/580

Efficiency (%NCV)

45

275-585/602 274-580/600 260-540/560

Sub-Critical Supercritical

40

239-540/560

169-541/539

35

166-568/568 159-566/566 166-568/568 Main Steam Pressure (barg) Steam Temperature Main / Reheat (C)

30 1960

1970

1980

1990

2000

2010

2020
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Year

AGENDA

Why Advanced Supercritical? Advanced Supercritical : State of the Art Next step: Ultra Supercritical

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WANGQU, SHANXI PROVINCE, CHINA

MAIN STEAM OUTLET REHEATER OUTLET
P ep ar ed by Te r y E van s, J anu ar y 200 4 f or W ang qu r

SEPARATO R VES SEL

REHEAT ER

REHEATER TO S TORAGE VESSEL

FINAL SUPERHEAT ER

PLA TEN SUPERHEAT ER

PRIMARY SUPERHEATER

ECONO MISE R

ECONO MISE R

2 x 600MWe Units Evaporation S/htr Outlet Press S/htr Outlet Temperature R/htr Outlet Temperature Contract Effective Operational 540 kg/s 248 bar 571C 569C 09/03 36 months later
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W ATER IMPO UNDED HOPPER HOPPER KNUCKLE FURNACE ACCES S DOOR

DEPLOYMENT OF SUPERCRITICAL TECHNOLOGY

Chinas deployment of supercritical technology far outstrips other countries and regions UK deployment is zero

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GREIFSWALD, GERMANY

2 x 800MWe Units Evaporation S/htr Outlet Press S/htr Outlet Temperature R/htr Outlet Temperature 588 kg/s 277 bar 600C 605C

PosiflowTM vertical tube furnace

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DEVELOPMENTS IN SUPERCRITICAL BOILERS

PosiflowTM Best Available Technology for Once-Through boiler furnace Lower pressure drop means lower feed-pump power and lower through-life energy consumption Other advantages include better turn-down, simpler construction and improved availability

With a PosiflowTM furnace the supercritical down-shot boiler can be realised: combines the economic and environmental benefits of supercritical steam conditions with anthracite combustion for the first time Doosan Babcock 2 x 600MW supercritical down-shot units for Zhenxiong, Yunnan Province, China.
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DEVELOPMENTS IN SUPERCRITICAL BOILERS: PLANT UPGRADE

Supercritical Retrofit - existing plant can be upgraded to supercritical steam conditions with lower capital cost and more rapid timescale than new plant New boiler within existing structure POSIFLOWTM vertical tube low mass flux furnace Re-use of other equipment (eg fans, airheaters, coal mills) New HP and IP turbine

Doosan Babcock Upgrade of Yaomeng Power Plant in China 2002 Owner chose not to upgrade to supercritical steam conditions.. However, application of PosiflowTM furnace and combustion system modifications gave 10% lower coal consumption and availability of 96%

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AGENDA

Why Advanced Supercritical? Advanced Supercritical : State of the Art Next step: Ultra Supercritical

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ULTRA SUPERCRITICAL

Boiler concept for > 700C Generation Overall cycle efficiency >50% Main Steam Pressure Main Steam Temperature Reheat Steam Temperature 550MW

365 bar-a 705C 720C

Reduction in CO2 emission relative to sub-critical ~30%

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MATERIALS FOR ADVANCED STEAM CYCLES - TUBING

Steam cycle based efficiency gains are constrained by the availability of suitable alloys

Average Stress Rupture (MPa) (100000 Hours)

300

Ferritic Alloys All available now

250
T24

Austenitic Alloys Super 304H, 347HFG available now Sanicro 25 available not yet codified

Nickel Alloys Validation ongoing

200
P92 Super 304H Alloy 617 Alloy 740 Alloy 263 T23 Sanicro 25

150

100
347 HFG

50 Steam Temperature 0 500 550 ~550C 600 ~600C 650 ~650C 700 ~700C 750

Metal Temperature (C)

Note maximum allowable temperatures are also limited by steam-side oxidation
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MATERIALS FOR ADVANCED STEAM CYCLES - TUBING

To put that in context consider a 48mm tube operating at 700C with a design pressure of 380 bar:

HR3C Austenitic Allowable Stress @ 750C (MPa) Calculated thickness t = P.D / 2. (mm) 44.5

Alloy 617mod Nickel Alloy 56.0

Alloy 740 Nickel Alloy 96.0

20.5

16.2

9.5

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MATERIALS FOR ADVANCED STEAM CYCLES HEADERS AND PIPEWORK

Austenitic alloys suffer from thermal fatigue, making them less suitable for thicker wall section components

Average Stress Rupture (MPa) (100000 Hours)

300

Ferritic Alloys All available now Nickel Alloys Validation ongoing

T24

250

200
P92 Alloy 617 Alloy 740 Alloy 263 T23

150

100

50 Steam Temperature 0 500 550 ~600C 600 ~650C 650 ~700C 700 750

Metal Temperature (C)

Note maximum allowable temperatures are also limited by steam-side oxidation
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MATERIALS FOR ADVANCED STEAM CYCLES MANUFACTURING

Manufacturing processes for components from new materials require extensive validation

Bend tests in Sanicro 25 Test bending furnace wall panels in T23 material

Alloy 263 pipe production Alloy 263 weld qualification

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ULTRA SUPERCRITICAL CYCLE OPTIMISATION

In addition to improvements in Rankine Cycle efficiency from increasing steam temperatures we can make better use of low grade heat in our power plant cycle Feedwater heating can be optimised to reduce the quantity of high grade bled steam taken from the turbine and better utilise the low grade heat in the flue gas leaving the boiler

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SUMMARY
Increasing plant efficiency is fundamental to reducing all emissions including CO2 Primary means to increase efficiency is to increase the steam pressure and temperature at the turbine inlet This means using steam at supercritical pressures we use terms such as Advanced Supercritical and Ultra Supercritical to indicate higher ranges of temperatures and pressures We can make improvements to the basic once-through boiler concept like the PosiflowTM furnace to further increase efficiency and operating flexibility Supercritical technology can be readily retrofitted to life-expired existing plant Todays Advanced Supercritical plant will achieve around 46-47% cycle efficiency (LHV basis) and about 20% reduction in CO2 for the same MWe output as existing sub-critical plant Ultra Supercritical plant operating at steam temperatures above 700C is the next step. Together with improved cycles this will achieve a plant efficiency over 50% and about a 30% reduction in CO2 compared to existing sub-critical plant Attainment of 700C is constrained by the availability of suitable materials for the highest temperature components and development programmes are underway
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Commercial Contact Details

Doosan Babcock is committed to delivering unique and advanced supercritical boiler technologies.

Steve Whyley Global Sales Director Doosan Babcock Energy 11 The Boulevard CRAWLEY West Sussex RH10 1UX T +44 (0) 1293 612888 D +44 (0) 1293 584908 E swhyley2@doosanbabcock.com
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