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Introduction/Background
Summary
Innovations in Supercritical Boiler Design - Coal Gen 2010 - August 10, 2010 - P 2
© ALSTOM 2010. All rights reserved. Information contained in this document is indicative only. No representation or warranty is given or should be relied on that it is complete or correct or will apply to any
particular project. This will depend on the technical and commercial circumstances. It is provided without liability and is subject to change without notice. Reproduction, use or disclosure to third parties, without
express written authority, is strictly prohibited.
Supercritical cycles offer
increased plant efficiency
state of the art
+6.2%
+5.5%
+4.2%
base line
2520 psi 3900 psi 3900 psi 4134 psi
Steam conditions 1005°F 1055°F 1117°F 1117°F
at boiler exit 1005°F 1100°F 1130°F 1150°F
subcritical supercritical ultra-supercritical
cycle cycle cycle
Innovations in Supercritical Boiler Design - Coal Gen 2010 - August 10, 2010 - P 3
© ALSTOM 2010. All rights reserved. Information contained in this document is indicative only. No representation or warranty is given or should be relied on that it is complete or correct or will apply to any
particular project. This will depend on the technical and commercial circumstances. It is provided without liability and is subject to change without notice. Reproduction, use or disclosure to third parties, without
express written authority, is strictly prohibited.
Alstom is a world leader in
supercritical boiler design
Innovations in Supercritical Boiler Design - Coal Gen 2010 - August 10, 2010 - P 4
© ALSTOM 2010. All rights reserved. Information contained in this document is indicative only. No representation or warranty is given or should be relied on that it is complete or correct or will apply to any
particular project. This will depend on the technical and commercial circumstances. It is provided without liability and is subject to change without notice. Reproduction, use or disclosure to third parties, without
express written authority, is strictly prohibited.
Alstom is a world leader in
supercritical boiler design
Supercritical Experience:
Innovations in Supercritical Boiler Design - Coal Gen 2010 - August 10, 2010 - P 5
© ALSTOM 2010. All rights reserved. Information contained in this document is indicative only. No representation or warranty is given or should be relied on that it is complete or correct or will apply to any
particular project. This will depend on the technical and commercial circumstances. It is provided without liability and is subject to change without notice. Reproduction, use or disclosure to third parties, without
express written authority, is strictly prohibited.
Agenda
Introduction/Background
Summary
Innovations in Supercritical Boiler Design - Coal Gen 2010 - August 10, 2010 - P 6
© ALSTOM 2010. All rights reserved. Information contained in this document is indicative only. No representation or warranty is given or should be relied on that it is complete or correct or will apply to any
particular project. This will depend on the technical and commercial circumstances. It is provided without liability and is subject to change without notice. Reproduction, use or disclosure to third parties, without
express written authority, is strictly prohibited.
Alstom continues innovation in
supercritical boiler design
• Key Alstom innovations include;
- Vertical tube furnace wall for sliding pressure
• Combined Circulation PlusTM
- Improved tangential firing system
• TFS XPTM
Innovations in Supercritical Boiler Design - Coal Gen 2010 - August 10, 2010 - P 7
© ALSTOM 2010. All rights reserved. Information contained in this document is indicative only. No representation or warranty is given or should be relied on that it is complete or correct or will apply to any
particular project. This will depend on the technical and commercial circumstances. It is provided without liability and is subject to change without notice. Reproduction, use or disclosure to third parties, without
express written authority, is strictly prohibited.
Modern supercritical boilers:
once-through, sliding pressure
• Once-through provides sufficient cooling at full load
- recirculation required at part load
• Sliding pressure improves part-load efficiency,
plant economics
Operating mode at boiler outlet
4350
3625
1
psi
2900
2175
2
1450
3 1. Constant Pressure
725 2. Modified Sliding Pressure
3. Pure Sliding Pressure
0
Innovations in Supercritical Boiler Design - Coal Gen 2010 - August 10, 2010 - P 8
© ALSTOM 2010. All rights reserved. Information contained in this document is indicative only. No representation or warranty is given or should be relied on that it is complete or correct or will apply to any
particular project. This will depend on the technical and commercial circumstances. It is provided without liability and is subject to change without notice. Reproduction, use or disclosure to third parties, without
express written authority, is strictly prohibited.
Spiral tube furnace walls
allow sliding pressure but add cost *
• More complex furnace support
Spiral to Vertical Transition Area –
Load Transfer
• Spiral tube furnace walls have fewer tubes:
simplifies cooling but adds cost * Support
Fingers
BT Valves
Economizer Recirc. To
Line SH
(smooth tube)
Waterwalls
Feedwater Inlet
Pump
Orifices
Innovations in Supercritical Boiler Design - Coal Gen 2010 - August 10, 2010 - P 10
© ALSTOM 2010. All rights reserved. Information contained in this document is indicative only. No representation or warranty is given or should be relied on that it is complete or correct or will apply to any
particular project. This will depend on the technical and commercial circumstances. It is provided without liability and is subject to change without notice. Reproduction, use or disclosure to third parties, without
express written authority, is strictly prohibited.
Alstom’s new vertical tube furnace design
allows sliding pressure operation
• Combined Circulation PlusTM
Economizer To
SH
Separator
(rifled tube)
Waterwalls
Pump
Feedwater
Inlet
Orifices
Recirculation Line
Innovations in Supercritical Boiler Design - Coal Gen 2010 - August 10, 2010 - P 11
© ALSTOM 2010. All rights reserved. Information contained in this document is indicative only. No representation or warranty is given or should be relied on that it is complete or correct or will apply to any
particular project. This will depend on the technical and commercial circumstances. It is provided without liability and is subject to change without notice. Reproduction, use or disclosure to third parties, without
express written authority, is strictly prohibited.
Vertical tube furnace walls:
Simplified support, construction, maintenance
Features
Features
Simplified furnace
support
Simplified furnace
construction
Simplified furnace
maintenance
Rifled tubing
Innovations in Supercritical Boiler Design - Coal Gen 2010 - August 10, 2010 - P 12
© ALSTOM 2010. All rights reserved. Information contained in this document is indicative only. No representation or warranty is given or should be relied on that it is complete or correct or will apply to any
particular project. This will depend on the technical and commercial circumstances. It is provided without liability and is subject to change without notice. Reproduction, use or disclosure to third parties, without
express written authority, is strictly prohibited.
Vertical tube furnace walls: Orifices ensure
cooling by matching flow to heat flux
• Combined Circulation PlusTM
Innovations in Supercritical Boiler Design - Coal Gen 2010 - August 10, 2010 - P 13
© ALSTOM 2010. All rights reserved. Information contained in this document is indicative only. No representation or warranty is given or should be relied on that it is complete or correct or will apply to any
particular project. This will depend on the technical and commercial circumstances. It is provided without liability and is subject to change without notice. Reproduction, use or disclosure to third parties, without
express written authority, is strictly prohibited.
New tangential firing system
improves furnace performance
• TFS XPTM
Upper level
SOFA nozzles
on furnace walls
Innovations in Supercritical Boiler Design - Coal Gen 2010 - August 10, 2010 - P 14
© ALSTOM 2010. All rights reserved. Information contained in this document is indicative only. No representation or warranty is given or should be relied on that it is complete or correct or will apply to any
particular project. This will depend on the technical and commercial circumstances. It is provided without liability and is subject to change without notice. Reproduction, use or disclosure to third parties, without
express written authority, is strictly prohibited.
New tangential firing system
improves furnace performance
• TFS XPTM
•Reduced furnace outlet swirl can furnace gas temperature unbalance,
improving performance
Gas temp,
C
Introduction/Background
Summary
Innovations in Supercritical Boiler Design - Coal Gen 2010 - August 10, 2010 - P 16
© ALSTOM 2010. All rights reserved. Information contained in this document is indicative only. No representation or warranty is given or should be relied on that it is complete or correct or will apply to any
particular project. This will depend on the technical and commercial circumstances. It is provided without liability and is subject to change without notice. Reproduction, use or disclosure to third parties, without
express written authority, is strictly prohibited.
Comanche Unit 3
Key design parameters
Owner = Xcel Energy
Plant output = 820 MWe (gross)
Innovations in Supercritical Boiler Design - Coal Gen 2010 - August 10, 2010 - P 17 All data at BMCR, operating data
© ALSTOM 2010. All rights reserved. Information contained in this document is indicative only. No representation or warranty is given or should be relied on that it is complete or correct or will apply to any
particular project. This will depend on the technical and commercial circumstances. It is provided without liability and is subject to change without notice. Reproduction, use or disclosure to third parties, without
express written authority, is strictly prohibited.
Comanche Unit 3
Boiler design features
• Design Features
Boiler type Two pass, sliding pressure supercritical
Operating mode Base load and two-shift
Circulation system Once-through
Start-up system Pump recirculation (< 30% load)
Furnace walls Vertical tube (Combined Circulation PlusTM)
Firing system Improved tangential firing (TFS XPTM)
Furnace cleaning Water cannons
Economizer Spiral finned
Coal mills 6 x Alstom HP mills with dynamic classifiers
Air Fans 2 x 60% PA, 2 x 60% FD
NOx reduction SCR
Air Heaters 2 x Alstom regenerative tri-sector
• Alstom Scope
Boiler island supply plus construction
Alstom scope
(boiler, mills, air fans, SCR, air heater, bottom ash, etc. )
Innovations in Supercritical Boiler Design - Coal Gen 2010 - August 10, 2010 - P 18
© ALSTOM 2010. All rights reserved. Information contained in this document is indicative only. No representation or warranty is given or should be relied on that it is complete or correct or will apply to any
particular project. This will depend on the technical and commercial circumstances. It is provided without liability and is subject to change without notice. Reproduction, use or disclosure to third parties, without
express written authority, is strictly prohibited.
Comanche Unit 3
Fuel
Design Range
Proximate, % wt.
Innovations in Supercritical Boiler Design - Coal Gen 2010 - August 10, 2010 - P 19
© ALSTOM 2010. All rights reserved. Information contained in this document is indicative only. No representation or warranty is given or should be relied on that it is complete or correct or will apply to any
particular project. This will depend on the technical and commercial circumstances. It is provided without liability and is subject to change without notice. Reproduction, use or disclosure to third parties, without
express written authority, is strictly prohibited.
Comanche Unit 3
Furnace wall tubing
T-23
• Note: no mixing/pressure
T-12
equalizing headers required
within furnace walls
Innovations in Supercritical Boiler Design - Coal Gen 2010 - August 10, 2010 - P 20
© ALSTOM 2010. All rights reserved. Information contained in this document is indicative only. No representation or warranty is given or should be relied on that it is complete or correct or will apply to any
particular project. This will depend on the technical and commercial circumstances. It is provided without liability and is subject to change without notice. Reproduction, use or disclosure to third parties, without
express written authority, is strictly prohibited.
Comanche Unit 3
Innovations in Supercritical Boiler Design - Coal Gen 2010 - August 10, 2010 - P 21
© ALSTOM 2010. All rights reserved. Information contained in this document is indicative only. No representation or warranty is given or should be relied on that it is complete or correct or will apply to any
particular project. This will depend on the technical and commercial circumstances. It is provided without liability and is subject to change without notice. Reproduction, use or disclosure to third parties, without
express written authority, is strictly prohibited.
Comanche Unit 3:
Boiler performance matches design
• Comanche performance at full load:
Design Actual #1 Actual #2
MWe 820 835 828
SH Steam
- Flow, lb/hr 5,560,000 5,456,000 5,378,000
- Pressure, psi 3935 3596 3601
- Temperature, F 1055 1053 1058
RH Steam
- Pressure, psi 729 693 688
-Temperature, F 1105 1104 1104
Feedwater
- Temperature, F 580 575 574
Emissions
- NOx, lb/mmbtu 0.07 <0.07 <0.07
- CO, lb/mmbtu 0.13 <0.13 <0.13
Innovations in Supercritical Boiler Design - Coal Gen 2010 - August 10, 2010 - P 22
© ALSTOM 2010. All rights reserved. Information contained in this document is indicative only. No representation or warranty is given or should be relied on that it is complete or correct or will apply to any
particular project. This will depend on the technical and commercial circumstances. It is provided without liability and is subject to change without notice. Reproduction, use or disclosure to third parties, without
express written authority, is strictly prohibited.
Comanche Unit 3:
Major milestones achieved
• Substantial completion: May 2010
Innovations in Supercritical Boiler Design - Coal Gen 2010 - August 10, 2010 - P 23
© ALSTOM 2010. All rights reserved. Information contained in this document is indicative only. No representation or warranty is given or should be relied on that it is complete or correct or will apply to any
particular project. This will depend on the technical and commercial circumstances. It is provided without liability and is subject to change without notice. Reproduction, use or disclosure to third parties, without
express written authority, is strictly prohibited.
Agenda
Introduction/Background
Summary
Innovations in Supercritical Boiler Design - Coal Gen 2010 - August 10, 2010 - P 24
© ALSTOM 2010. All rights reserved. Information contained in this document is indicative only. No representation or warranty is given or should be relied on that it is complete or correct or will apply to any
particular project. This will depend on the technical and commercial circumstances. It is provided without liability and is subject to change without notice. Reproduction, use or disclosure to third parties, without
express written authority, is strictly prohibited.
Iatan Unit 2
Key design parameters
Owner = KCP&L
Plant output = 920 MWe (gross)
Innovations in Supercritical Boiler Design - Coal Gen 2010 - August 10, 2010 - P 26
© ALSTOM 2010. All rights reserved. Information contained in this document is indicative only. No representation or warranty is given or should be relied on that it is complete or correct or will apply to any
particular project. This will depend on the technical and commercial circumstances. It is provided without liability and is subject to change without notice. Reproduction, use or disclosure to third parties, without
express written authority, is strictly prohibited.
Agenda
Introduction/Background
Summary
Innovations in Supercritical Boiler Design - Coal Gen 2010 - August 10, 2010 - P 27
© ALSTOM 2010. All rights reserved. Information contained in this document is indicative only. No representation or warranty is given or should be relied on that it is complete or correct or will apply to any
particular project. This will depend on the technical and commercial circumstances. It is provided without liability and is subject to change without notice. Reproduction, use or disclosure to third parties, without
express written authority, is strictly prohibited.
Summary
• Alstom continues to develop innovative design
features for supercritical boilers;
- Combined Circulation PlusTM
- TFS XPTM
• These features provide;
- Reduced capital cost
- Reduced maintenance cost
- Improved performance
• Two recent applications demonstrate these benefits;
- Comanche (in commercial operation)
- Iatan (in commissioning)
• Alstom can bring those benefits to future projects,
worldwide
- Including ultra-supercritical applications
Innovations in Supercritical Boiler Design - Coal Gen 2010 - August 10, 2010 - P 28
© ALSTOM 2010. All rights reserved. Information contained in this document is indicative only. No representation or warranty is given or should be relied on that it is complete or correct or will apply to any
particular project. This will depend on the technical and commercial circumstances. It is provided without liability and is subject to change without notice. Reproduction, use or disclosure to third parties, without
express written authority, is strictly prohibited.
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