Académique Documents
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CONTENTS
The DTI drives our ambition of
prosperity for all by working to
create the best environment for
business success in the UK.
We help people and companies
become more productive by
promoting enterprise, innovation
and creativity.
We champion UK business at home
and abroad. We invest heavily in
world-class science and technology.
We protect the rights of working
people and consumers. And we
stand up for fair and open markets
in the UK, Europe and the world.
Overview ...............................................1
1.
Introduction...........................................2
2.
State-of-the-art .....................................2
3.
4.
5.
6.
7.
8.
Conclusions .........................................23
9.
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Advanced Power
Plant Using High
Efficiency
Boiler/ Turbine
OVERVIEW
This Best Practice Brochure describes the best
commercially available, pulverised fuel combustion
advanced supercritical (ASC) boiler/steam turbine
power plant technologies suitable for clean coal
power generation, in home and export markets, for
both new build and retrofits. It describes the
performance of such plants, including efficiency,
carbon dioxide emissions, air pollution
controls/emission levels, and their flexibility and
availability. It demonstrates
how these technologies are
based on many reference plants
worldwide for a wide range of
coal types (from semi-lignite to
semi-anthracite) and explains
how these best practice
technologies can be adapted for
biomass co-firing and carbon
dioxide capture and storage.
The best available technology
(BAT) with steam conditions of
300 bar / 600C / 620C gives an
efficiency of 46-48% net (LHV
basis). This limit is primarily
determined by the combination
of best practice boiler and
turbine technologies, with the
best commercially available
materials for the higher
temperature parts of the boiler,
turbine and pipework. Site
specific requirements such as
location, ie inland or coastal,
also being a factor in
determining how high an
efficiency can be achieved.
Such a BAT PF-fired power plant
would be fitted with high-quality
selective catalytic reduction
(SCR) for NOx reduction, flue gas
desulphurisation (FGD) for SO2
reduction and an electrostatic
precipitator (ESP) or baghouse
filter, as appropriate, for
particulates removal. The BAT
PF-fired ASC power plant would
meet or better the EU Large
Combustion Plant Directive
(LCPD) on emission level values
applicable from 2008.
For these BAT temperatures
ferritic, martensitic and
austenitic steels are utilised,
building on the growing
experience base of these
materials over the last 15 years.
Future plant currently under
development in the Advanced
(700C) PF Power Plant Project
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1.
INTRODUCTION
2.
STATE-OF-THE-ART
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Figure 2. Progressive improvement of net efficiency of boiler turbine coal-fired (PF-fired) power plant
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chromium martensitic steels for headers, mainsteam and reheat pipework, first in the UK for
plant retrofits, then in Denmark for the plants
described above, has allowed steam conditions
to be increased.
A consensus has emerged among
boilermakers and turbine-makers, including
Mitsui Babcock and Alstom Power, that the
BAT for supercritical boiler/turbine power plant
using the best commercially available materials
would have steam conditions at the boiler
superheater/reheater outlets of approximately
300 bar / 600C / 620C and, for example, at an
inland Northern European location, would have
an overall plant efficiency of about 46% net
(LHV). Such a plant would be fitted with
selective catalytic reduction (SCR) for NOx
reduction, flue gas desulphurisation (FGD) for
SO2 reduction and an electrostatic precipitator
(ESP) for reduction of particulates, and would
meet or better the EU Large Combustion Plant
Fossil Fuel Power Generation The State of the Art, published by the EU PowerClean R, D and D Thematic Network,
30 July 2004, Section 3
3 DTI Best Practice Brochure No. BPB003, Supercritical Boiler Technology at Hemweg Power Station DTI/Pub URN
01/699, March 2001
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Country
Power Plant
Unit
Rating
MWe
net
(gross)
Steam
Press
(bar)
Main
Steam
Temp (oC)
Reheat
RH1
Steam
Temp
(oC)
Reheat
RH2
Steam
Temp
(oC)
Efficiency
(% net LHV)
Denmark
Denmark
Denmark
Holland
Finland
Germany
Germany
Japan
Japan
China
China
USA
USA
Avedorevrket 2
Nordjylland 3
Skrbk 3
Hemweg 8
Meri Pori
Staudinger
Niederaussem K
Tachibanawan
Isogo
Changshu
Wangqu
Tanners Creek
Duke Power
390
411
411
630
550
509
965
1050
600
600
600
580
(1120)
300
285
290
260
244
262
275
250
266
259
247
241
241
580
580
582
540
540
545
580
600
600
569
571
538
538
600
580
580
568
560
562
600
610
610
569
569
552
538
580
580
566
48.3
47
49
42
45
43
45.2
43.5
Not Available ?
42
43
39.8
Not Available ?
3.
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16
700/720C
14
12
10
8
600/620C
600/600C
565/565C
540/540C
2
0
160
200
240
280
320
Figure 4. Effect of steam conditions on cycle efficiency (for single reheat units)
360
400
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4.
ADVANCED SUPERCRITICAL
BOILERS
BOILER DESIGN
The state-of-the-art ASC PF-fired boiler design
is based on the established Mitsui Babcock
two-pass layout once-through supercritical unit
utilising the Benson principle (see Figure 5).
The two-pass opposed wall-fired furnace/boiler
layout has been widely used in subcritical and
supercritical boilers built by Mitsui Babcock and
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J F Henry, J M Tanzosh, M Gold, Issue of Concern to ASME Boiler & Pressure Vessel Committee TG on Creep
Strength Enhanced Ferritic Steels and Remedies Under Consolidation
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Heating
surface
Material
Design
temp (C)
Furnace roof
Rear cage
W M Ham, B S Greenwell, The Application of P91 Steel to Boiler Components in the UK, ECSC Information Day,
November 1992
10
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Emission
(@6% oxygen dry vol basis)
Units are mg/Nm3
EU LCPD
limit existing
plant
(from 2008)
EU LCPD
limit new
plant
(from 2008)
Levels
currently
offered
NOx
500
200
38
SO2
400
200
100
Particulates
50
30
20
PM10
20
Mercury
VOC
38
CO
11
H2SO4
3.75
= Typical values being offered for new plant: exact figures depend on coal composition.
11
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ADVANCED SUPERCRITICAL
TURBINES
BACKGROUND
The basic construction of single reheat large
steam turbines for coal-fired power plant was
established over 30 years ago. This
construction, designed originally for operating at
conventional steam conditions, has achieved
very high standards of reliability and operability
through continuing development and feedback
of operating experience. The same basic design
therefore provides a very sound reference base
for high output applications at ASC operating
conditions taking advantage of advanced
materials and design refinements (see
Figure 7).
ADVANCES IN MATERIALS
Steam turbines for ASC steam conditions
require application of advanced alloy steels for
the HP and IP turbines and for the main and
reheat steam admission valves.
The maximum metal temperatures in high
temperature steam turbine components are
limited by the applied stress and the
requirement for a component lifetime of at
least 200,000 hours. The principal material
property determining the maximum
temperature is the long-term creep rupture
strength.
12
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13
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Figure 8. HP and IP turbines with welded rotors using 10% Cr steel in hottest regions
14
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BENEFITS OF ADVANCED
SUPERCRITICAL
TECHNOLOGY
Table 2.
DTI Best Practice Brochure No. BPB005, Refurbishment of Yaomeng Power Plant, DTI/Pub URN 03/1065, August
2003
15
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Table 3. Levelised CoE for nominal 600MWe gross bituminous coal-fired power plant
Parameter
Units
Subcritical
power plant
Supercritical
power plant
Plant size
MWe gross
600
600
% LHV
38.0
46.0
Euros/kWe gross
874
920
Fuel price
Euros/GJ
1.6
1.6
Load factor
85
85
c/kWh
3.5
3.3
UK p/kWh
2.3
2.2
Fuel
c/kWh
1.5
1.2
Capital
c/kWh
1.3
1.4
O&M
c/kWh
0.7
0.7
Breakdown of CoE
Reference Power Plant North Rhine-Westphalia (RPP NRW) VGB PowerTech 5/2004
G Booras and N Holt, EPRI, Pulverised Coal and IGCC Plant Cost and Performance Estimates Gasification
Technologies 2004, Washington DC, October 3-6, 2004
9 Francisca Garcia Pena, Advanced Gasification Systems, presented at PowerClean / EPPSA Seminar, Brussels, 12
April 2005
8
16
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7.
CURRENT DEVELOPMENTS
OF BEST PRACTICE FOR
SUPERCRITICAL
TECHNOLOGY
17
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J Bugge, S Kjr, R Vanstone, F Klauke, C Stolzemberger, F Bregani, S Concari, Review of the AD700 technology: a
European route to clean combustion of coal, CCT 2005 Second International Conference on Clean Coal Technologies
for our Future, Castiadas (Cagliari), Sardinia, Italy, 10-12 May 2005
20
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21
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stream from the absorber is highly energyintensive. Care again is required in the design
and plant integration activities to minimise
significant export power loss.
Figure 15 opposite presents an indicative
diagram for an oxyfuel CO2 capture system.
Note that, as shown, the oxyfuel flue gas
recycle (FGR) is taken from downstream of the
flue gas desulphurisation (FGD) plant, which
assumes a high sulphur coal. For low sulphur
coals, the FGD plant can be removed and the
FGR stream may be taken from further
upstream. For oxyfuel firing, an air separation
unit is used to ensure that only oxygen is
admitted to the furnace for combustion.
This has the advantage of significantly reducing
the flue gas volumes, but the separation
process has a performance penalty.
Mitsui Babcock and Alstom Power, together
with Fluor, Air Products and Imperial College,
provide further information on the application
and process integration of the above CO2
capture technologies for new-build ASC
PF-fired CO2 capture power plant.11,12
C A Roberts, J Gibbins, R Panesar and G Kelsall, Potential for Improvement in Power Generation with PostCombustion Capture of CO2, Proceedings of the 7th International Conference on Greenhouse Gas Control
Technologies. Peer-reviewed Papers, Vancouver, BC, September 5-9, 2004
12 D J Dillon, R S Panesar, R A Wall, R J Allam, V White, J Gibbins & M R Haines, Oxy-combustion Processes for CO
2
Capture from Advanced Supercritical PF and NGCC Power Plant, Proceedings of the 7th International Conference on
Greenhouse Gas Control Technologies. Peer-reviewed Papers, Vancouver, BC, September 5-9, 2004
22
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Figure 15. Indicative oxyfuel capture process (as shown for high sulphur coal hence FGD included)
8.
CONCLUSIONS
23
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UK COMPANIES: BEST
PRACTICE TECHNOLOGY
CONTACTS
11 The Boulevard
Crawley
West Sussex
RH10 1UX
UK
Contact: S N (Neil) Harrison
Tel:
+44 (0)1293 584731
Fax:
+44 (0)1293 584331
E-mail: nharrison@mitsuibabcock.com
Web:
www.mitsuibabcock.com
Porterfield Road
Renfrew
PA4 8DJ
UK
Contact: J M (Mike) Farley
Tel:
+44 (0)141 886 4141
Fax:
+44 (0)141 885 3338
E-mail: mfarley@mitsuibabcock.com
Web:
www.mitsuibabcock.com
Willans Works
Newbold Road
Rugby
Warwickshire
CV21 2NH
UK
Contact: John McCoach
Tel:
+44 (0)1788 531602
Fax:
+44 (0)1788 531387
E-mail: john.mccoach@power.alstom.com
Web:
www.alstom.com
24
Hersham Place
Molesey Road
Walton-on-Thames
Surrey
KT12 4RZ
UK
Contact: Vince White
Tel:
+44 (0)1932 249948
Fax:
+44 (0)1932 257954
E-mail: whitev@airproducts.com
Web:
www.airproducts.com
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Steam conditions
MPa / C / C
LHV %
Tachibanawan (Japan)
42.1
44
39.8
42
Nordjylland 3 (Denmark)
45
47.0
Niederaussem K (Germany)
42-43
45.2
25
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E-mail: helpline@cleanerfossilfuels.org.uk
Web: www.dti.gov.uk/cct/
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