Innovations in

Supercritical Boiler Design

Coal Gen 2010

Scott L. Darling and Edward S. Sadlon

August 10, 2010
Agenda

Introduction/Background

Supercritical Boiler Design Features

Case Study - Comanche

Case Study - Iatan

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

change in overall plant net efficiency (relative)

+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

ƒ Pioneered the World’s First Ultra-Supercritical Steam Plant (Eddystone Unit 1)

- 1954 design phase to 1960 startup
- Initial steam conditions: 5293 psig/1210/1050/1050F
- Current steam conditions: 5000 psig/1130/1050/1050F
ƒ Fifty years after its initial operation, the steam generator for Eddystone 1
operates at the most advanced conditions of any coal-fired boiler in the world.

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:

• 113 Alstom directly executed

supercritical units in operation or
under construction, worldwide
• Over 70,000 MWe
• Most units in operation for
over 30 years

• 200 units supplied by licensees,

using Alstom technology
• 132,000 MWe

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

Innovative Design Features

Case Study - Comanche

Case Study - Iatan

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

• Other Alstom state-of-the-art features include;

- Alstom HP pulverizers with dynamic classifiers
- Alstom regenerative air heater
- Alstom SSC for bottom ash removal
- Spiral-finned economizer
- Furnace water cannons

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

• More complex windboxes

* Fabrication, construction, maintenance

Innovations in Supercritical Boiler Design - Coal Gen 2010 - August 10, 2010 - P 9
© 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.
Early vertical tube furnace wall designs
required constant pressure operation
• Combined Circulation ®

BT Valves

Economizer Recirc. To
Line SH

(smooth tube)
Waterwalls
Feedwater Inlet
Pump
Orifices

• Insufficient cooling for the 2-phase flow at

part load with sliding pressure
• Supercritical pressure maintained in
furnace walls via valves at furnace outlet;
• Reduced efficiency
• Added complexity

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

• Sufficient cooling for 2-phase flow at

part load with sliding pressure
• No valves required at furnace outlet
• Maximized efficiency
• Reduced complexity

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

• Combined Circulation PlusTM

Features
Features
ƒSimplified furnace
support
ƒSimplified furnace
construction
ƒSimplified furnace
maintenance
ƒRifled 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

• Heat flux varies across

furnace walls
• Orifices match fluid flow
to heat flux
• Proper tube metal
temperatures maintained

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

• Fuel/air nozzles in corners generate counter-clockwise swirl

• Furnace wall SOFA* nozzles add flexibility to adjust furnace outlet swirl

Fuel/air nozzles and

lower level SOFA nozzles
in furnace corners

Upper level
SOFA nozzles
on furnace walls

* Separated Overfire Air

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

With lower SOFA With upper SOFA

(corners) (mid-wall)
Innovations in Supercritical Boiler Design - Coal Gen 2010 - August 10, 2010 - P 15
© 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

Supercritical Boiler Design Features

Case Study - Comanche

Case Study - Iatan

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)

Boiler design parameters;

Main steam:
3935 psi
1055 °F
5,560,000 lb/hr
Reheat steam:
729 psi
1105 °F
4,423,000 lb/hr
Feedwater:
580 °F
Fuel:
Sub-bituminous coal
(PRB)

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

Type PRB PRB

Proximate, % wt.

- Moisture 28.9 25.9-31.1

- Volatiles 31.4 29.5-34.0

- Fixed Carbon 35.2 32.3-36.0

- Ash 4.5 4.3-7.2

- Sulfur 0.26 0.2-0.7

HHV, BTU/lb 8603 8234-8987

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

• Performance tests: May/June 2010

• Reliability run: May/June 2010

• Commercial operation: July 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

Supercritical Boiler Design Features

Case Study - Comanche

Case Study - Iatan

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)

Boiler design parameters

Live steam:
3786 psi
1085 °F
6,246,000 lb/hr
Reheat steam:
1030 psi
1085 °F
5,072,000 lb/hr
Feedwater:
568 °F
Fuel:
Sub-bituminous coal
(PRB)

Same design features as Comanche Unit 3

Innovations in Supercritical Boiler Design - Coal Gen 2010 - August 10, 2010 - P 25 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.
Iatan Unit 2:
Major milestones achieved
• First coal fire: July, 2010

• Commissioning: In progress; currently

operating at 80% load

• Commercial operation Planned late 2010

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

Supercritical Boiler Design Features

Case Study - Comanche

Case Study - Iatan

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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