Supercritical Steam Generators For Cleaner Environment

Bharat Heavy Electricals Limited, Tiruchirapalli
Power Power Power Power- -- -Gen India, 2012 Gen India, 2012 Gen India, 2012 Gen India, 2012
BHELs Role in Cleaner Environment
Contents
BHEL Steam Generators
Design Features of Supercritical Once Thro Boilers
Major Systems
Startup System
Pressure part Arrangement
Firing System
High Temperature Materials
Major Differences between Supercritical and Subcritical Boilers
BHEL Utility Units - A Summary
Unit Rating, MW
No. MW No. MW
30 4 120 4 120
60 16 960 16 960
67.5 9 607.5 8 540
70 14 980 9 630
80 14 1120 3 240
100 6 600 6 600
110 39 4290 39 4290
120 31 3720 27 3240
125 7 875 1 125
130 2 260 2 260
150 17 2550 0 0
200 24 4800 20 4000
210 116 24360 114 23940
250 58 14500 34 8500
270 34 9180 0 0
300 1 300 0 0
500 82 41000 54 27000
525 6 3150 2 1050
600 22 13200 0 0
660 12 7920 0 0
700 1 700 0 0
800 4 3200 0 0
TOTAL 519 138393 339 75495
Contracted Commissioned
62 % Total
Installed
Capacity of
India is
Contributed by
BHEL Utility
Sets
Unit Contracted Commissioned
VU 40 46 45
VU 40 S 15 15
VU 60 38 19
MU 3 3
VP 23 16
V
2
R 17 17
HRSG 177 121
AFBC 72 59
CFBC 28 10
Others 28 28
Total 447 333
BHEL Industrial Units - A Summary
After supplying more than 950 boilers,
BHEL is currently adopting
Advanced Steam Cycles to Improve the
Environmental & Economic Performance of
Indias Power Generation
Once Through Supercritical Technology for
Higher Unit Ratings 660 MW to 1000 MW
BHEL under license from Alstom offers Once through supercritical
technology to Indian power utilities with the following benefits
Increased efficiency
Lower Fuel consumption
Lower emission levels of CO
2
NO
X
SO
X
Lower operating costs
Greater operational flexibility
These benefits are possible because of the higher steam pressures
and temperatures which are the hallmark of the technology
Reference List of Supercritical Boilers
NTPC / BARH 2 x 660MW
APPDCL / Krishnapatnam 2 x 800 MW
PPGCL / BARA 3 x 660 MW
RPCL / Yermaras 2 x 800 MW
RPCL / Edlapur 1 x 800 MW
KPCL / Bellary 1 x 700 MW
LPGCL/Lalithpur- BHL 3 x 660 MW
DB Power / Singrauli 2 x 660 MW
NTPC / Mouda St. II 2 x 660 MW
18 Boilers
Contracted
Design Features of 660 MW
Supercritical Boilers for
Indian Coal Fired Power Stations
Salient Features of Boiler
Pulverised coal fired
Once through, evaporator suitable for
variable pressure operation
Single reheat
Tilting Tangential firing System
Dry Bottom
Balanced draft furnace
Side mill layout
Dry Bottom
Balanced draft furnace
High performance Bowl Mills
Two Nos. of Axial FD Fans
Two Nos. of Axial PA Fans
Two Nos. of Axial ID Fans
ESP to meet reqd. outlet concentration
Salient Features of Boiler (Contd.)
Boiler Parameters
Description Unit
660 MW
(Supercritical)
500 MW
(Sub critical)
Boiler Parameters - BMCR BMCR
SH steam flow t/h 2120 1625
SHO pressure kg/cm
2
(a) 256 179
SHO/RHO temp.
o
C 568/596 540/540
Feed water temp.
o
C 294 254
Description
(Source/Type)
Unit Design Coal Worst Coal Best Coal
Proximate Analysis
Fixed Carbon % 26.00 23.00 32.00
Volatile matter % 19.00 18.00 22.00
Moisture % 15.00 17.00 12.00
Ash % 40.00 42.00 34.00
Total % 100 100 100
HHV kcal/kg 3300 2800 4000
Ultimate Analysis
Carbon % 31.37 28.93 40.08
Hydrogen % 3.40 2.40 3.50
Sulphur % 0.40 0.5 0.36
Nitrogen % 1.5 1.45 1.78
Oxygen(difference) % 7.75 7.26 8.03
Moisture % 15.0 17.0 12.0
Ash % 40.0 42.0 34.0
Carbonates + Phosphorous % 0.58 0.46 0.25
Hard Grove Index 55 50 60
Fuel Analysis - Coal
General Arrangement of Steam Generator Elevation
General Arrangement of Steam Generator Plan
Plan Area Loading kCal/h/m
2
4.75x10
6
EPRS Loading kCal/h/m
2
190,000
Volumetric Loading kCal/h/m
2
106,920
Furnace Heat Loadings
NTPC / BARH 2 x 660 MW
Coal Fuel
568 / 596
o
C Temperature
255/54.65 kg/cm
2
(g) Pressure
2120/1708.2 t/h. Steam Flow
Customer scope Dust Collector
2 Nos. Axial Reaction ID Fan
2 Nos. Axial Reaction PA Fan
2 Nos. Axial Reaction FD Fan
4 Nos. Airheater
9 Nos. Bowl Mill Mill
Major Auxiliaries
Parameters at SHO / RHO
BARH II 2 x 660 MW Project
National Thermal Power Corporation Customer
Customer Prayagraj Power Generation Company Limited
Project PRAYAGRAJ STPP, PHASE-I, 3x660 MW, BARA
Steam Flow 2095.4/1706.9 t/h.
Pressure 255/54.33 kg/cm
2
(g)
Temperature 568 / 596
o
C
Fuel Coal
Major Auxiliaries
Mill 7 Nos. Bowl Mill
Airheater 2 Nos. Tri-Sector AHs
FD Fan 2 Nos. Axial Reaction
PA Fan 2 Nos. Axial Reaction
ID Fan 2 Nos. Axial Reaction
Dust Collector Customer Scope
PPGCL / PRAYAGRAJ STPP, 3x660 MW, BARA
DB POWER (MP) LIMITED / Gorgi DBP - 2 x 660 MW
Customer DB POWER (Madhya Pradesh) Ltd.
Project
Gorgi DBP(MP)L 2x660 MW STPP, DEOSAR,
Singrauli
Steam Flow 2120.0/1696.1 t/h.
2
(g)
o
C
Fuel Coal
Major Auxiliaries
Dust Collector 4 Nos
Customer
Lalitpur Power Generation Company
Limited
Project Lalitpur Super Critical TPP, 3x660 MW
Steam Flow 2110/1697.8 t/h.
2
(g)
o
C
Fuel Coal
Major Auxiliaries
Dust Collector 4 Nos.
LPGCL / LALITPUR SUPERCRITICAL TPP, 3 x 660 MW
Supercritical Boilers- Major Systems

SC Steam generator
Boiler Steam Pressure
above the critical point Critical Point
221 bar, 374 c
S
T
1
2
3
4
Entropy
T
e
m
p
e
r
a
t
u
r
e

1 - 2 Feed Water Pumping Process
2 - 3 Heat addition in the Feed
Water Heaters & Boiler
3 - 4 Expansion in HP Turbine
4 - 5 Reheating in Boiler
5 - 6 Expansion in IP & LP Turbine
6 - 1 Heat rejection in Condenser
5
6
Supercritical Boilers
Supercritical pressure boiler has no drum and heat absorbing
surface being, in effect, one continuous tube, in which the water &
steam generated in the furnace water walls passes through only
once hence called Once through Supercritical pressure boilers
The water in boiler is pressurized by Boiler Feed Pump, sensible
heat is added in feed heaters, economizer and furnace tubes, until
water attains saturation temperature and flashes instantaneously
to dry saturated steam and super heating commences.
The Concept
The mass flow rate thru all heat transfer circuits from
Eco. inlet to SH outlet is kept same except at low loads
wherein recirculation is resorted to protect the water
wall system
Increased mass flow
through spiral waterwall
tubing, or improved heat
transfer through rifled
vertical wall tubing.
No fixed evaporator end
point
No thick wall components
Features
Once Through Boiler Flow Diagram
Evaporator
Water separator
Feedwater
Economizer
FW-
Pump
Live steam
Superheater
Once through Supercritical Boilers
Major differences from Drum type boiler :
Evaporator system
Low load Recirculation system
Separator
STEAM TO TURBINE
STEAM TO TURBINE
SH
SH
DRUM
SEPERATING
VESSEL
E
V
A
P
O
R
A
T
O
R
E
V
A
P
O
R
A
T
O
R
ECO.
ECO.
(LOW LOAD &
CIRCULATION PUMP
START-UP)
F
E
E
D
F
E
E
D
CIRCULATION TYPE
ASSISTED
Circulation Systems
Drum Type Once-through
Once -through Operating Range
Once -thru Boiler
Requirements :
Stringent water quality
Different control system compared to drum type
Low load circulation system
Special design to support the spiral furnace wall weight
High pressure drop in pressure parts
Higher design pressure for components from feed pump to
separator
Features of Once Through Steam Generator
To ensure adequate mass flow rates through water wall,
spirally wound water wall tubes are used.
Start-up and low load system up to 30-40% BMCR required.
Feed water quality requirements are very stringent.
Can be designed for both sub-critical and super-critical
pressures.
Ideally suited for sliding pressure operation due to the absence
of thick walled components.
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
Reduced number of
tubes with pitch.
Increased mass flow.
Mass flow rate can be
selected by number of
tubes.
Features
Spiral Tube Arrangement
Once -thru Boiler - Furnace Wall
Spiral Water wall Tubing
Lateral Heat Flux Profile
Sliding Pressure Supercritical Design
Spiral Wall
Windbox
Supercritical boiler Separated Over Fire Air (SOFA) assy Supercritical boiler Separated Over Fire Air (SOFA) assy Supercritical boiler Separated Over Fire Air (SOFA) assy Supercritical boiler Separated Over Fire Air (SOFA) assy
Complex Burner Panel using 41.3 mm tubes Complex Burner Panel using 41.3 mm tubes Complex Burner Panel using 41.3 mm tubes Complex Burner Panel using 41.3 mm tubes
2020 complex multi 2020 complex multi 2020 complex multi 2020 complex multi- -- -plane tube bends plane tube bends plane tube bends plane tube bends
12 bends in each 5.4 m length 12 bends in each 5.4 m length 12 bends in each 5.4 m length 12 bends in each 5.4 m length
Fabrication of T22 tubes with Gr 12 scalloped plates Fabrication of T22 tubes with Gr 12 scalloped plates Fabrication of T22 tubes with Gr 12 scalloped plates Fabrication of T22 tubes with Gr 12 scalloped plates
SOFA burner SOFA burner SOFA burner SOFA burner
panel panel panel panel
SPIRAL WALL SUPPORT
Support
Fingers
Spiral to Vertical Transition Area - Load Transfer
Sliding Pressure Supercritical Design
Supercritical boiler Spiral Furnace Wall Assembly Supercritical boiler Spiral Furnace Wall Assembly Supercritical boiler Spiral Furnace Wall Assembly Supercritical boiler Spiral Furnace Wall Assembly
115 membrane wall panels using 41.3 mm tubes 115 membrane wall panels using 41.3 mm tubes 115 membrane wall panels using 41.3 mm tubes 115 membrane wall panels using 41.3 mm tubes
5000 multi 5000 multi 5000 multi 5000 multi- -- -plane tube bends for wall openings plane tube bends for wall openings plane tube bends for wall openings plane tube bends for wall openings
4500 tube butt joints for spiral 4500 tube butt joints for spiral 4500 tube butt joints for spiral 4500 tube butt joints for spiral- -- -vertical transition vertical transition vertical transition vertical transition
Furnace Wall Designs
Spiral Wall Configuration Vertical Wall Configuration
Supercritical Boiler with Vertical wall
Unit Mw
e:
750
Max. Continuous Rating: 2522 t/h
SH Outlet Press: 262 bar
SH Outlet Temp: 568C
RH Outlet Temp: 596 C
Fuel: Sub-bituminous
SCREEN TUBES
SMOOTH TUBING
FRONT WALL
RIFLED TUBING
SMOOTH TUBING
FROM THIS ELEVATION
ALL WALLS
SIDE WALL
RIFLED TUBING
REAR WALL
RIFLED TUBING
ARCH
RIFLED TUBING
HANGER TUBES
SMOOTH TUBING
FRONT WALL
RIFLED TUBING
SIDE WALL
RIFLED TUBING
Vertical Wall Sliding Pressure
Supercritical Design
Vertical Furnace Wall Design
Vertical tube furnace walls will provide all the operational benefits
of the currently popular spiral design while significantly reducing
the cost and construction time for the furnace and providing some
reduction in pressure drop.
Vertical Wall Design - Advantages
The tubes are self supporting.
Transition headers at spiral/vertical interface are avoided.
Ash hopper tubing geometry simplified
Corners are easier to form
Reduced pressure drop, auxiliary power
Spiral Vs. Vertical Wall Comparison
Spiral Furnace System Applicable for all
size units
Benefits from averaging of lateral heat
absorption variation (each tube forms
a part of each furnace wall)
Simplified inlet header arrangement
Large number of operating units
Use of smooth bore tubing throughout
entire furnace wall system
One material utilized throughout
entire waterwall system
No individual tube orifices Less
maintenance & pluggage potential
Vertical Furnace Wall System Limited to
larger capacity units .
Less complicated windbox openings
Traditional furnace water wall support
system
Elimination of intermediate furnace wall
transition header
Less welding in the lower furnace wall
system
Easier to identify and repair tubes leaks
Lower water wall system pressure drop
thereby reducing required feed pump
power
Vertical Wall Wind box
Straight Tubes
Only a Few Bends at the
Top and Bottom
Supercritical Boilers- Start-up and
Low load recirculation Systems
Simplified drain discharge system
Low load system with circulating pump
Start-up System
Separator Separator Separator Separator
vessel for vessel for vessel for vessel for
supercritical supercritical supercritical supercritical
steam generator steam generator steam generator steam generator
Overview of Firing Systems
Close-Coupled
Overfire Air
Close-Coupled
Overfire Air
CFS Air Nozzle Tips
CFS Air Nozzle Tips
Flame Attachment
Coal Nozzle Tip
Flame Attachment
Coal Nozzle Tip
NOx < 0.18 0.30 kg/Mkcal*
NOx < 0.18 0.30 kg/Mkcal*
Furnace
Diagonal
Furnace
Diagonal
Separated
Overfire Air
Separated
Overfire Air
HP Pulverizer
with Dynamic
Classifier
HP Pulverizer
with Dynamic
Classifier
*NOx at furnace outlet
Wind Box arrangement
Upper SOFA
on Walls
Lower SOFA
in Corners
Tilt
+/-30
o
Yaw
+/-20
o
Plan View for SOFA arrangement
Pressure Parts Arrangement
Materials
in 660 MW
(Typical)
Pressure part
660 MW
OTSC (Supercritical)
500 MW
(Sub-critical)
Drum Not applicable SA 299 (Carbon Steel)
Vertical Separator SA 335 P91 Not applicable
Water Walls SA 213 T22 SA 210 Gr C
Economiser SA 210 Gr C Sa 210 Gr C
SH T91, TP 347H T11/T22/T91/ TP 347H
RH
T12/T23/T91/TP347H/
Super 304H
T22, T91, TP 347H
Material Comparison
Air and gas Path
Salient Differences between Supercritical
and subcritical Boilers
Description
660 MW
(Supercritical)
600/500 MW
(Subcritical)
Circulation System
-Startup low load recirculation
System water walls
Once-Through
Vertical separator with One no.
startup Re-circulation pump
Spiral walls with Plain tubing
Controlled Circulation with
3x50%Boiler water circulating
pumps
Not applicable
Vertical walls with rifled tubing
SH / RH / ECONOMISER
system
- Pressure parts arrangement
- 2 stages of SH with SH platen
located above furnace and final
SH in horizontal pass.
- 2 stages of RH with low
temperature RH located in
second pass and RH finish
pendant located in horizontal
pass
- Single stage economizer
located in second pass below
low temperature RH.
- 3 stages of SH with low temp.
SH located in horizontal pass,
SH panel and SH platen located
above furnace.
- Single stage RH located in
horizontal pass
-Single stage economizer
located in second pass below
low temperature SH.
Gas velocity in pressure part,
m/s
10 10
Firing System Tilting tangential firing with
wind box located in four
corners of the furnace
Tilting tangential firing with
wind box located in four
corners of the furnace
Draft System Balanced draft Balanced draft
Description
660 MW
(Supercritical)
600/500 MW
(Subcritical)
Pulverisers 9 nos.HP bowl
mill
9/10 nos. bowl mill
Airheaters 4 nos Bi-sector
air heater system
with 2 nos.
primary&2 nos.
secondary.
2 nos. Regenerative
Trisector air heater
system or 4 nos Bi-sector
air heater system with 2
nos. primary&2 nos.
secondary.
Fans Axial FD, Axial PA
and Axial ID-2nos
each
2 Axial FD, 2 Axial PA and
2 Radial ID with VFD
ESP outlet dust
concentration
18 mg/Nm
3
18 mg/Nm
3
Higher pressure, higher SHO/RHO temperature and higher
feed water temperature has been adopted for improving the
cycle efficiency.
Drum has been eliminated and vertical separator with start-
up recirculation system is used for loads below 40% BMCR.
Two stage SH and two stage RH has been adopted.
Axial ID fans are used in place of radial ID with VFD.
SUMMARY
OTSC plants offer better cycle efficiency
Proven technologies leading to lower GHG emissions and lesser
fuel burnt
BHEL has the technology for offering 660/700/800 MW
supercritical units
Gearing-up to introduce Advanced Ultra
supercritical boilers (AUSC)
AUSC Boilers (300 ata, 700 C / 700 C) will
be developed based on OTSC technology
Test Facility (400 bar, 700 Deg. C) installed
and tests are on to collect critical design
data
BHEL is one among the Five MNCs to have
this facility
Member of the National Technology
Mission program to install AUSC plant by
2017
Advanced Ultra Super Critical Plants

Supercritical Steam Generators For Cleaner Environment

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