SUPER CRITICAL TECHNOLOGY IN NTPC

PRESENTATION CONTENTS
     

What is critical condition?? Types of boilers. Major differences between drum type & once through boilers. Advantages of once through boiler. Effect of advanced cycles on boiler components. Conclusion.

Definition of critical Condition

CRITICAL CONDITION IS THERMODYNAMIC EXPRESSION DESCRIBING THE STATE OF A SUBSTANCE BEYOUND WHICH THERE IS NO CLEAR DISTINCTION BETWEEN THE LIQUID AND GASEOUS PHASE.

SUPERCRITICAL PARAMETERS
Critical Point Pr = 225.56 kg/cm2 T = 374.15 Deg.C

Supercritical

538 Deg C

Subcritical

Entropy

TYPES OF BOILERS
Drum type OnceOnce-through type

Design Types
NATURAL
STEAM DRUM

CONTROLLED
TO SUPERHEATER

ECON.

CIRC. PUMP FURNACE WALLS

ONCE THROUGH
SEPARATOR

Natural circulation - well suited for < 175 kg/cm2 Controlled circulation - optimum solution for reliable high-pressure subcritical operation Once-through technology Suitable for sub and supercritical cycles

ECON.

CIRC. PUMP

DISTRIB. HEADER

DRUM TYPE BOILER

Natural Circulation Boiler Circulation thru water walls by thermothermo-siphon effect Controlled Circulation Boiler At higher operating pressures just below critical pressure levels, thermothermo-siphon effect supplemented by pumps

DRUM TYPE BOILER

Steam generation takes place in furnace water walls. Steam -water separation takes place in the drum. Separated water mixed with incoming feed water.

Supercritical Boilers in NTPC

SIPAT(3 SIPAT(3x660 MW)
Supplier Type Capacity Steam Parameters (at boiler outlet) Coal Firing Order Commissioning Doosan, Korea Two pass,spiralpass,spiralwalled 2225T/hr. 2225T/hr. 256kg/cm2 540/ 256kg/cm2/540/568 deg. deg.C Tangential fired March, 2004 2007

BARH (3x660 MW)

TPE, Russia Two pass,spiralpass,spiralwalled 2225T/hr. 2225T/hr. 256kg/cm2 540/ 256kg/cm2/540/568 deg. deg.C Front & Rear fired March, 2005 2008

ONCE -THRU BOILER

Requirements :
Stringent water quality Sophisticated control system Low load circulation system Special design to support the spiral furnace wall weight Higher design pressure for components from feed pump to separator

ONCE THROUGH BOILER



Water flowing through water walls gets converted into steam in one circulation. Feed pump provides the driving head Suitable for sub critical & super critical pressures

 

ONCEONCE-THRU BOILER
Major differences from Drum type boiler :
 Evaporator

system  Low load circulation system  Separator

ONCE -THRU BOILER

Evaporator system :
 

 

Formed by a number of parallel tubes Tubes spirally wound around the furnace to reduce number of tubes and to increase the mass flow rate thru the tubes Small tube diameter Arrangement ensures high mass velocity thru the tubes

ONCE - THRU BOILER

Low load circulation system :


The excess flow over the onceoncethru flow separated in separator . Recirculated back to the boiler directly by the dedicated circulating pump.

LOW LOAD SYSTEM WITH CIRCIRCULATION PUMP

ONCE -THRU BOILER

Separator :
Separates steam and water during the circulating mode operation Runs dry in once through flow mode. Smaller in size compared to drum in a drum type boiler

ONCE -THROUGH BOILER

Advantages ::Better suited for sliding pressure operation Steam temperature can be maintained over wider load range under sliding pressure Conservation of fuel resources. Shorter start up time Improvement in Efficiency

Advanced Cycles Effect on Boiler Components

 Evaporator (Furnace)  Superheaters  Thickwalled

walls

boiler components

Furnace walls
 Increased

operating pressure increases the medium temperatures. regenerative feed heating increases the fluid temp entering. furnaces required for NOX reduction, increase SH steam temperature at furnace wall outlet.

 Increased

 Larger

Superheaters
 Tube metal temperatures in

final sections increase with outlet steam temperature.  Susceptibility for high temperature corrosion.  Susceptibility to steam side oxidation

Thick walled components

 Higher


pressure & temperature lead to increased thickness of :

Shells of separator, start-up system startcomponents, SHO header.. Main steam piping.

 Higher

thickness results in larger temperature gradients across walls.

Subcritical Vs Supercritical (A Comparison)

500 MW Unit Size (Subcritical) Steam Parameters (ata / Deg.C/ Deg.C) Cost of Boiler & Turbine Generator Block Coal Consumption Plant Efficiency CO2 Emissions SO2 Emissions 169/538/538 Base 660 MW Unit Size (Supercritical) 246/538/566 1.5%

Base Base Base Base

2.1% 2.1% 2.1% 2.1%

Supercritical Technology - Status

More than 500 Units of various sizes operating worldwide Material technology matured up to 600 Deg.C temperature Availability of the order of 88 90% which is comparable with that of subcritical units European union working on program AD 700 which aims at temperature up to 700-720 Deg.C and efficiency target of 50% First supercritical unit in India has commissioned in 2007 by NTPC in sipat.

Thank You