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DEPARTMENT OF MECHANICAL
ENGINEERING ShriChhatrapatiShivaji College Of
Engineering
Shrishivajinagar (Rahuri Factory),
Tal: Rahuri, Dist: Ahmednagar.
CERTIFICATE
(Seminar Guide)
(Seminar Co-
ordinator)
Prof.Dongare A.D.
(Head of department)
University of Pune
CERTIFICATE
This is to certify that
Mr. GANESH VASANT NIRGUDE
Student of T.E. Mechanical engineering was examined in the
seminar Presentation entitled
On 23 / 10/ 2012
SUPERCRITICAL TECHNOLOGY IN
POWER PLANT
At
Department of Mechanical Engineering,
Prof.Pandharkar. U.J
(SeminarGuide)
(Seminar Co-ordinator)
ACKNOWLEDGEMENT
Every orientation work has imprint of many people and this work is no
different. This work gives me an opportunity to express deep gratitude for
the same.
While preparing seminar report I received endless help from number of
people. This report would be incomplete if I dont convey my sincere
thanks to all those who were involved.
First and foremost I would like to thank my respected guide Prof. .Seminar
coordinator Prof.Pandharkar U.J. and HOD Prof.Dongare
A.D.
SR
NO
1
TOPIC
ABSTRACT
INTRODUCTION
PAGE
NO
1-5
2.1Supercritical technology
2.2 Efficiency
2.3 Definition
DESIGN AND WORKING
6-8
9-10
3.2 Working
4
MATERIAL SELECTION
4.1 Metallurgical Problems
4.2 Materials used
11-13
SUPERCRITICAL BOILERS
5.1 A typical Supercritical Boilers
14-15
16
Power
7
8
CONCLUSION
17
18
REFERENCES
LIST OF CONTENENT
ABSTRACT
This paper reviews the major technical and performance aspects of a coal fired plan
using the supercritical technology. These include the turbine-generator set, the oncethrough boiler, and operational issues such as load change, fuel flexibility, and water.
Reviewing the possibilities for the design and manufacture of components for
supercritical-fired plants in developing countries, the paper notes that the differences
between sub critical and supercritical power plants are limited to a relatively small
number of components; primarily the feedwater pumps and the high pressure feedwater
train equipment. All of the remaining components, common both types of plants, can be
manufactured in developing countries. The paper concludes with a review of the
Schwarze Pumpe - the world's largest supercritical lignite fired steam power plant.The
primary purpose of the study is to assess whether supercritical thermalplant technology
is a proven and mature commercial technology and whether .They operate at
supercritical pressure. In contrast to a "subcritical boiler", a supercritical steam
generator operates at such a high pressure (over 3,200 psi or 22 MPa) that actual
boiling ceases to occur, the boiler has no liquid water - steam separation. There is no
generation of steam bubbles within the water, because the pressure is above the critical
pressure at which steam bubbles can form. It passes below the critical point as it does
work in a high pressure turbine and enters the generator's condenser. This results in
slightly less fuel use and therefore less greenhouse gas production. The term "boiler"
should not be used for a supercritical pressure steam generator, as no "boiling" actually
occurs in this device.
1 INTRODUCTION
1.1 Basic Rankine Cycle:
The Rankine cycle is the oldest functional heat cycle utilized by man. The
Rankine cycle is the very a basic vapor power cycle which is adopted in all the thermal
power plants. It is a four step process (Figure 1.1) which involves the heating of the
working fluid to its saturation temperature and vaporizing it isothermally, expanding
the vapor on a turbine (work cycle), condensing the steam isothermally to the liquid
phase and pumping it back to the boiler.
Condenser:
Heat rejected in the condenser, Q4-1+h4=h1+W4-1
Since W4-1=0, Q4-1=h1-h4
Thus,
Q4-1=-(h4-h1) kJ/kg
Pump:
Work required to pump water:
Wpump=h1-h2 kJ/kg (-ve work)
Boiler:
Heat added in boiler:
Q2-3=h3-h2 kJ/kg=h3-h1-Wpump kJ/kg
steam. Thus for the same turbine inlet state, more work is obtained at lower
temperatures.
This method though cannot be extensively used as it reduces the dryness
fraction x of the steam. This is highly undesirable as it decreases the turbine efficiency
is reduced due to excessive erosion of the turbine blades.
ii.
Superheating the steam to high temperature:
There is an increase in the work output if superheating of steam is done. It
increases the thermal efficiency as the average temperature at which heat is added
increases.
There is also another benfit of superheating; the steam at the exit of the turbine
is drier than in case of non superheated steam.
10
iii.
added and thereby increases the theramal efficiency. However the dryness fraction
decreases for the same exit temperature of the boiler. This problem can be solved by
employing reheating procedure. If however the boiler pressure is raised to supercritical
point greater efficiency is obtained as the latent heat absorbed during phase change is
reduced to zero.
11
-(eqn 4)
2.2 Definition:
12
Material Concerns:
The primary concern with this cycle, at least for water, is the material limits of
the primary and support equipment. The materials in a boiler can be exposed to
temperatures above their limit, within reason, so long as the rate of heat transfer to the
coolant is sufficient to cool the material below its given limit. The same holds true
for the turbine materials. With the advent of modern materials, i.e. super alloys and
ceramics, not only are the physical limits of the materials being pushed to extremes, but
the systems are functioning much closer to their limits. The current super alloys and
13
coatings are allowing turbine inlet temperatures of up to 700C (973 K). the fourth
generation super alloys with ruthenium mono-crystal structures promise turbine inlet
temperatures up to 1097C (1370 K). Special alloys like Iconel 740, Haynes 230,
CCA617, etc. are used.
Boilers.
The high temperature and pressure in the boiler induce huge amount of stresses
and fatigue in the materials. Also chances of oxidation are very high at such high
should be introduced.
Also they should me machinable and weldable. This is a great metallurgical
challenge.
14
ii.
Location of burners:
The number of burners in the boiler shell is also of prime importance. Amongst
all of them the downfired boilers are most suitable and advantageous. Table 3.2 gives a
clear idea.
iii.
Boiler dimensions:
One of the most important advantages of HTAC applications are high heat
fluxes. Thus, compact combustion chambers can be built and the investment costs can
be lowered. The fourth calculation series was carried out in order to find the
combustion chamber dimensions which can, on one hand, ensure an efficient heat
exchange between combustion gas and water/steam mixture and on the other hand,
ensure high values of firing density. Three different sizes are tested and they are named
in as the small boiler, the medium size boiler and the large boiler .It has been observed
(see Table 3.3) that the small boiler is too short. At the top a region of high
15
temperatures exists and its enthalpy cannot be efficiently used. On the contrary, in the
large boiler although the heat fluxes are uniform, they are two times lower than in the
medium size boiler. Therefore, the medium size boiler configuration is chosen for
further investigations.
Firing Density
Small boiler
774
Large boiler
89
kW/m3
Outlet temperature,
1805
1558
1299
K
Table3.1.1 Results of the boiler size determination
3.2 Working:
As already discussed, the working of Supercritical Boilers is similar to the
working of sub-critical boilers. It works on the supercritical rankine cycle. Most
supercritical boilers are being run at operating pressures above of 235 bars. The
working of ultra supercritical boilers has operating pressures above 273 bars
4
MATERIAL SELECTION
16
program was required to develop new and improved materials and protection methods
necessary for these high temperature steam conditions.
4.2 Materials used:
The materials used should be sustainable to the very high pressure being
developed and should not get oxidized due to the very high temperature. Different high
temperature materials are being used like 9 to 12% ferritic steels T91/P91, T92/P92,
T112/P122 steel, Advanced Austenitic alloys TP347, HFG, Super 304, Nickel and
chrome-nickel super alloys like Inconel 740.
Table 4.2 gives a very brief idea about the boiler materials used for different
parts of the boiler.
Heat surface
Economiser
Furnace Walls
Super
heater/Reheater
Tube material
SA-210 C
SA-213 T12
SA-213 T12
SA-213 T23
SA-213 TP 304H
SA-213
Header material
SA-106 C
SA-106 C
SA-335 P12
SA-335 P91
SA-335 P911
TP347HFG
SUPER 304H
Steam Piping
SA 335 P91
Table 4.2.1 Materials for different boiler parts
The materials for the other parts of the power plant (like turbine) also must be
sustainable for the super critically heated steam. The following table gives a detail idea
on the turbine materials of a plant operating on a supercritical cycle. (Table 4.3)
17
Component
1,050 F
1,150 F
Casings
CrMoV (cast)
910% Cr (W)
(shells, valves,
steam chests,
nozzles)
10CrMoVMb
12CrW (Co)
CrMoWVNbN
1,300 F
CF8CPlus
CCA61
7
CCA617
Inconel
740
Inconel
625
Nimonic
263
Bolting
422
912% CrMoV
912%
CrMoV
CrMoWVNbN
Nimonic 80A
Rotors/Discs
Nozzles/Blade
s
Nimoni
c 105
Nimonic
115
Nimoni
c 115
Waspalo
y
U700
CCA61
7
912 % CrWCo
CCA617
12CrMoVNb
N
12CrMoWVNb
N
Inconel
625
422
912% CrWCo
10CrMoVNb
N
10CrMoVCbN
Wrought
Ni-based
18
CF8CPlus
Nimonic
105
1CrMoV
1,400
F
Inconel
740
Wrough
t
Nibased
The following figures show some of the materials used for SC and USC boilers. Iconel
740 is widely used for steam pipings in almost all of them.
5 SUPERCRITICAL BOILERS
5.1 A typical Supercritical Boilers:
Largest CFB and first supercritical CFB sold to date is the Lagisza 460 MWe
unit Ordered by Poludniowy Koncern Energetyczny SA (PKE) in Poland. The design is
Essentially complete with financial closing expected in the first quarter of 2006 at
which time Fabrication and construction will commence. The largest capacity units in
operation today are the two (2) 300 MWe JEA repowered units which were designed to
fire any Combination of petroleum coke and bituminous coals. The physically largest
Foster Wheeler boilers in operation are the 262 MWe Turow Units 4, 5, and 6 which
were designed to fire a high moisture brown coal. The design and configuration of these
units with Compact solids separators and INTREX heat exchangers were used as the
basis for the Lagisza design as well as for this study. The Lagisza design was adjusted
to accommodate a typical bituminous coal and the steam cycle.
19
Efficiency (%)
Ultra Supercritical
3335
Supercritical
Steam
Typical emissions
pressure/temperature
>242
bar
and
SO2-0.408 kg/MHh
593.33C
NOx-0.286
kg/MWh
3640
>221.2
537C
bar
and
CO2-0.96 T/MWh
SO2-0.431 kg/MHh
NOx-0.304
kg/MWh
20
Subritical
CO2-1.02 T/MWh
SO2-0.445 kg/MHh
NOx-0.31 kg/MWh
CO2-1.02 T/MWh
21
Being a pit head thermal power project, the saving in fuel charges is not justified by
increase in fixed charges.
Here are some upcoming projects in India:
Sholapur 2x660 MW
New Nabinagar-3x660 MW
Many more projects including 800 MW ultra super critical units under
consideration
7
CONCLUSION
22
REFERENCES
1. Design Aspects of the Ultra-Supercritical CFB Boiler; Stephen J.
Goidich, Song Wu, Zhen Fan; Foster Wheeler North America Corp.
2. Novel conceptual design of a supercritical pulverized coal boiler utilizing
high temperature air combustion (HTAC) technology; Natalia SchaffelMancini, Marco Mancini, Andrzej Szlek, Roman Weber; Institute of
Energy Process Engineering and Fuel Technology, Clausthal University of
Technology, Agricolastr. 4, 38678 Clausthal-Zellerfeld, Germany; 6
February 2010.
3. Supercritical (Once Through) Boiler Technology; J.W. Smith, Babcock
& Wilcox, Barberton, Ohio, U.S.A.; May 1998.
4. Steam Generator for Advanced Ultra-Supercritical Power Plants 700 to
760C; P.S. Weitzel; ASME 2011 Power Conference, Denver, Colorado,
U.S.A; July 12-14, 2011.
5. Supercritical boiler technology for future market conditions; Joachim
Franke and Rudolf Kral; Siemens Power Generation; Parsons Conference;
2003.
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