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IN SUPERCRITICAL
BOILER TECHNOLOGY
HIGH-EFFICIENCY
SUPERCRITICAL TECHNOLOGY
Alstom is a global leader in the world of power generation, setting the Alstom pioneered supercritical steam generation and today leads
benchmark for clean, innovative technologies to create customer value. the industry in supercritical boiler technology. We have directly
supplied more than 80,000 MWe of supercritical boilers world-
We supply major equipment in 25% of the installed base worldwide.
wide. In addition weve trained and licensed other companies to
And weve developed an unmatched level of expertise in steam
install an additional 72,000 MWe of Alstom supercritical boiler
generation and fuel combustion technology, having supplied more
technology. Globally, we have unmatched experience in tailoring
than 400 GWe of boilers around the world.
boiler designs to fuel properties.
Our boilers convert fuel into steam for the generation of electricity
cleanly, cost-effectively, reliably. As the No 1 supplier of boilers
worldwide, we can meet your project requirements today and in the
future with the design, manufacture and supply of state-of-the-art
systems and equipment.
FOR CLEAN POWER TODAY!
Superior environmental
Leading Through Technology enables the capture
performance
of CO2 emissions
Today, our advanced high-efficiency pulverized coal supercritical
from fossil fuels, Highest unit efficiency
boilers offer plant owners many benefits. The technologys higher
including pulverized
steam temperature and pressure parameters deliver the most Operating flexibility
coal boilers. Known
economical way to improve plant efficiency and operating
as oxy-fuel firing, Design tailored to fuel choice
flexibility, achieve fuel cost savings, and reduce emissions for each
this technology is
kWh of electricity generated. Alstoms Advanced Supercritical Fuel cost savings
being tested in a 30
technology reduces all emissions, including CO2.
MWth pilot at the
In fact, an efficiency improvement of 1 percentage point equals
Schwarze Pumpe
2%-3% less CO2 emitted.
Power Station in Germany. Oxy-fuel firing is especially promising
Alstom is also driving the development and deployment of the for CO2 -free supercritical generation in the near term.
next generation of clean coal combustion technologies. We are
In addition to our own R&D activities, we participate in a
investing in the future of clean power across 22 development
number of public development projects and partnerships,
centers and 13 laboratories around the world with the express
including those sponsored by the European Union and the US
goal of minimizing environmental impact. One Alstom combustion
Department of Energy, as well as nearly all joint boiler materials
technology currently in the pilot plant demonstration phase
development programs.
THE SUPERCRITICAL
DIFFERENCE
Once-through supercritical technology offers important benefits Increased Efficiency and Lower Emission Levels
to plant owners, including:
Plants that employ todays generation of Alstom supercritical
Increased efficiency boilers can operate at cycle efficiencies in excess of 42-45% HHV
Lower emissions levels (44-47% LHV). As efficiency is increased, less fuel is consumed per
Lower operating costs kilowatt-hour (kWh) with a corresponding decrease in emissions
Greater operating flexibility per kWh. Because these units do not have thick-walled steam
drums, their start-up times are quicker, further enhancing
These benefits are possible because of the higher steam pressures
efficiency and plant economics. We continue to develop increasingly
and temperatures which are a hallmark of the technology.
efficient supercritical cycles for improved efficiency. Alstoms current
technology development will lead to our prototype ultra-supercritical
plant, operating at 1290 F (700 C) / 5075 psi (350 bar).
Understanding Supercritical Technology
Water/steam circulation systems are divided into two main
classifications: once-through, in which the water and steam Lower Operating Costs
generated in the furnace waterwalls passes through only once;
Lower fuel consumption is a direct consequence of higher
and drum-type boilers, in which water/steam separation occurs,
efficiencies. Fuel costs are a power plants largest operating cost
and water is recycled back to the waterwalls.
item. Because the capital cost of supercritical plants is close to
Supercritical conditions occur when the boiler pressure increases those of subcritical plants, overall life cycle costs are often reduced.
above the critical pressure of 3,208 psi / 221.2 bar. Above this
point, two phase mixtures of water and steam cease to exist, and
Heat Rate Improvement vs.
are replaced by a single supercritical fluid. This eliminates the need
Steam Conditions (Single Reheat)
for water/steam separation in drums during operation, and allows
a simpler separator to be employed during start-up conditions.
5075/1350/1400
5075/1290/1330 350/730/760
350/700/720
4050/1110/1150
280/600/620 R&D ongoing
R&D ongoing USA
USC Materials
psi/OF/OF Consortium & EC
(bar/OC/OC) 3900/1075/1110 AD 700 project
270/580/600 (Ni-base)
3500/1000/1050 Market
2400/1000/1000 240/540/565 intro. by
Efficiency Increase
167/540/540 Japan
and
Mature technology Europe
CONTINUED ADVANCEMENTS
SUPERCRITICAL DOE USC Matl.
SUBCRITICAL DOE Steam Turbine Matl.
AD 700 project
COMTES 700
Greater Operational Flexibility Unlike drum boilers, once- Sliding Pressure Operation
through units do not have a for Once-Through Boilers
Todays market realities demand that units are not only designed
fixed evaporative point: the
for baseload operation, but are capable of cycling and/or two-shift
final evaporation occurs in the
operation. Units must be designed for rapid response times.
furnace wall systems with steam
Alstom once-through supercritical boilers have the ability to
that is leaving the furnace
respond and adjust to changes in load demand while maintaining
walls being superheated to a
tight control of steam temperatures.
certain degree. Since the
Alstoms supercritical boilers operate in the sliding pressure evaporation point is not fixed,
mode, where pressure is reduced with load. This allows the heat duties can be shifted
maintenance of relatively constant first-stage turbine temperature, between the furnace and the
reducing the thermal stress on components as the unit is cycled. superheaters, allowing for
Less stress translates into less maintenance and higher availability. adjustment to changing
slagging and fouling 1. Constant pressure operation
Todays generation of supercritical boilers boast high availabilities, 2. Modified sliding pressure operation
comparable to those of subcritical units, as well as improved plant conditions caused by 3. Pure sliding pressure operation
efficiency at lower loads. changing fuel properties.
ADVANCED
BOILER DESIGNS
1 x 750 MWe, US
Furnace Wall Designs For any given furnace size, the spiral wall unit in which the tube is
wrapped around the unit has fewer tubes than the vertical wall unit.
In todays market, two designs dominate for once-through units:
the spiral furnace tube arrangement and the vertical tube arrangement. The vertical waterwall design uses internal ribbing in the tubes to
Design choice is governed by furnace size and customer preference improve heat transfer. The vertical wall option is available for larger
there are advantages to both, depending on project drivers. units where lower perimeter-to-furnace plan area ratios result in
higher fluid flow per tube. The vertically oriented tubes are
The furnace walls are exposed to the greatest heat flux of all
self-supporting within the wall, allowing a simpler
heat-absorbing surfaces. This is because of the intense radiant
support system. In fact, the relative simplicity of a
heat from the fireball.
vertical wall furnace can result in significant
construction cost savings.
Tower and Two-Pass Designs Two-pass is a shorter design which incorporates vertical heating
surface in the radiant section of the furnace, and horizontal
Alstom provides tower and two-pass boiler designs, both of
surface in a parallel backpass. The selection of boiler configuration
which are widespread in power generation applications. In a tower
is project specific, with consideration given to fuel ash
design, all heating surfaces are horizontal and drainable, and
characteristics, site restrictions, and customer preference.
generally in a single vertical configuration within the furnace
bounding walls.
Future
Options
T92 Nickel Alloy Nickel Alloy
Nickel Alloy
Austenitic NF 12,
9-12% SAVE 12, VM12
Cr-Steels
Current
7 CrMo VTiB 10 10 Austenitic E 911, P 92, P 122
HCM 2S
X 20 X 20
CrMoV 121 CrMoV 121
Past
13 CrMo 4 4 Austenitic P 91
Bar SHO 260 270 290 300 350 260 270 290 300 350 260 270 290 300 350
0
C - SH Temp 550 580 600 630 700 550 580 600 630 700 550 580 600 630 700
0
C - RH Temp 570 600 620 650 720 570 600 620 650 720 570 600 620 650 720
A WORLD OF
SUCCESS STORIES
1 x 920 MWe
Powder River Basin coal
Owner: Kansas City Power
COMANCHE 3 US & Light
Commercial operation: 2010
1 x 814 MWe
Features advanced vertical
Powder River Basin coal
wall construction
Owner: Xcel Energy
Commercial operation: 2009
2 x 1100 MWe
Lignite
Owner: RWE Power AG
Commercial operation: 2010
Taean, one of the 20 x 500 MWe sliding pressure supercritical units using Alstom 2 x 800 MWe efficient and highly reliable supercritical steam generation since
technology in Korea. Since 1995, this unit has operated in daily two-shift operation 1996 at the Schwarze Pumpe Station in Germany.
with high reliability.
Alstom An Industry Leader
Alstom has the expertise and experience to make todays energy Renewable targets? Alstoms experts in biomass co-firing can
production as clean and efficient as it can be. We are a world- reduce your carbon footprint and help your bottom-line.
leading provider of integrated environmental solutions for power,
petrochemical and industrial plants including ways to improve Alstoms unparalleled breadth of product offering in Air Quality
the performance and lifespan of your existing units. Control (AQS) systems and Energy Recovery systems means we
can meet your toughest project requirements. With the largest
In addition to high-efficiency boilers, Alstom's supercritical plant installed base in the world for air preheaters and coal pulverizers,
offering includes supercritical turbines, mills, air heaters and post- our customers benefit from superior performance, increased
combustion equipment. Alstoms in-furnace and post-combustion efficiencies, and reliable service. And with more than 70 years
technologies can help meet todays strictest requirements for NOx, of experience in customizing AQS systems for new and existing
SOx, VOCs, mercury, CO and particulates. And our integrated plants, you can depend on Alstom to deliver sustainable,
boiler/backend designs will optimize your units sizing and high-quality solutions at a competitive cost and performance ratio.
performance criteria, all with the lowest installed and operating costs.
Asia Pacific
Sales Region
Tel: +33 (0)1 46 29 15 85
Fax: +33 (0)1 46 29 16 70
North America/Mexico/
Central America/Caribbean
Sales Region
Tel: +1 860 285 2348
Fax: +1 860 285 4172
Ref: PWER/BPROB/BOILERTECHNO/eng/BUBB/
12.07/US/3329 ALSTOM 2007. Alstom, the
Alstom logo and any alternative version thereof
are trademarks and service marks of Alstom.
The other names mentioned, registered or not,
are the property of their respective companies.
Please note: The information in this brochure is
of a general nature, and may not be applicable for
use in any specific application. Reprinted 2007.
www.power.alstom.com