Super Critical Technology

Supercritical Technology ?

IN MHI TERMINOLOGY
Ultra Supercritical
Subcritical Supercritical
(USC)
Pressure 16.7 24.1 24.1 to 31.0
M pa (kg/cm2) (170.29) (245.75) (245.75 - 316.11)
Temperature 538/538 or 538/560 to 593/593 to
Deg. C 538/560 566/593 600/620

Pressure range : Super Critical - 221 bar (225.37 kg/cm2) and above

1 bar = 1.02 kg/cm2

 Benefits of Supercritical technology
• Large size units mean
• Rapid Capacity addition
• Reduced land requirement
• Reduced manpower requirement
• Higher cycle efficiency means primarily
• Less fuel consumption
• Less per MW infrastructure investments
• Less emission
• Less auxiliary power consumption
• Less water consumption
• Operational flexibility
• Shorter start-up time, Suitable for variable pressure operation
• Better temp. control and load change flexibility
WHY SUPERCRITICAL TECHNOLOGY?

ηPower Plant = ηBoiler * ηTG Cycle * ηTurbine * ηGenerator

37.5-43% 85-88% 48-50% 89-92% 98-98.6%
-Sub-Critical

51-53%
- Super-critical

 ηBoiler , ηTurbine , ηGenerator have almost peaked,

only incremental improvements taking place.

 ηTG Cycle depends on MS and RHS Temperature

(and Pressure) and Condenser Vacuum

Turbine Generators 4
 Thermodynamic Cycle

Critical point

Salient points

 Series of processes,working fluid goes change of phase alternately

 Maximum temperature limitation for a cycle
 Quality of steam at later stage of expansion in a turbine is important.
 Phase diagram

Critical Point parameters for water P = 22.064 Mpa and T= 374oC

Actual cycle

Entropy is a measure of magnitude of irreversibility in the system

On a T-S diagram, the area under process curve represents the heat transfer
Process can occur in a direction where S>0
7
 Effect of Pressure and temp

Pressure increase : 0.005 % per bar

Temp increase : 0.011 % per deg K

8
Reheat cycle

9
 Regenerative cycle

NPL: Single reheat and regenerative cycle

HP heaters - 3 Closed heaters
LP heaters - 4
Deaerator - Open heater

10
 Supercritical cycle
Plant operating above critical point i.e. 221.2 bar are supercritical cycles

Improves efficiency by increasing the working fluid pressure

and superheating of the steam to higher temperatures which
provides significant further efficiency improvement.
NPL parameters:
P- 247 bar at turbine inlet, SH/RH temp-
12 565 /593 deg C
 Improvement of thermal efficiency
•Increasing the steam temperature (ή increases 0.31%
every 100C of increase of main steam temperature &
0.24% every 100C of increase of reheat steam
temperature )
•Increasing in the steam pressure (ή increases 0.1%
increase with increase of 10 bar pressure)

COMPARISION OF THERMAL CYCLE EFFICIENCIES.

• OPEN CYCLE EFFICIENCY - 14.68 %

• WITH CONDENSER - 26.2 %
• WITH SUPER HEAT – 30.75 TO 34.15 %
• WITH REHEAT - 34.2 TO 36.6 %
• WITH SUPER CRITICAL PARAMETERS- 36.0 TO 39.15 %
 Critical Point

• A Boiler operating at a pressure above critical point is called

‘SUPERCRITICAL BOILER’
• A point where boiling water and dry saturated lines meet so
that associated latent heat is zero, this point is called Critical
Point and occurs at 225 kg/cm2 (abs) 374.15º C temperature.

It is a thermodynamic expression describing the state of a

substance (in our case water/steam) where there is no
clear distinction between the liquid and the gaseous phase.

Critical Conditions Ultra super critical conditions

•Temperature 374.150C •Temperature above 5600C

•Pressure 225.56kg/cm2 •Pressure above 306kg/cm2

Representation of steam/ water
parameters on T-S diagram
1. Sub critical parameter
3 2. Critical parameter,
Temperature
(225.65 ksc/ 374.16oC)
374.16oC 2 1 3. Supercritical parameter

Entropy
 OPERATION OF BOILER PAGE- 17
Basics of Supercritical Plant
(2) What is supercritical pressure ?
1000
900
800
700
Bulk Density [kg/m3]

600
779.3 kg/m3
500
400 No fixed
steam and
300 waterline
24.8 kg/m3
200 Quick
Steam
100 Generation
0
0 4.9 9.8 14.7 19.6 24.5 29.4

Pressure [MPa] Critical Pressure:

22.12MPa
 SUPERCRITICAL BOILER

• Supercritical pressure boiler has no drum and heat

absorbing surface being, in effect, one continuous tube,
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.
Increase of Cycle Efficiency due to Steam Parameters
Increase of efficiency [%]

10
6,77
9
5,79
8 5,74
7 4,81
3,74
6 4,26
5 3,44 2,76
3,37
4
2,64
3
2,42 1,47
2 600 / 620
1,78 0,75
1 580 / 600

0 566 / 566
0 538 / 566
300
241 HP / RH outlet temperature [deg. C]
Pressure [bar] 175 538 / 538
 Drum type boiler

 Steam generation takes place in furnace water walls

 Fixed evaporation end point - the drum
 Steam -water separation takes place in the drum
 Separated water mixed with incoming feed water

 Natural Circulation Boiler

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

To Superheater To Superheater

Drum Drum
Risers

Furnace
or Furnace
Combustor Econ
Econ

Downcomers (Orifices)
Downcomers BWCPs
 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

 OPERATION OF BOILER PAGE- 30
Operation Mode and Range
(1) Operating Characteristic of Supercritical Plant

Wet Operation
Same as drum type boiler operation
BCP: Maintain minimum inlet water flow for
SH furnace protection (25% flow)
Water WDC Valve: Water Separator Drain Tank
Separator level control
100
Wet Dry Operation
WSDT Operation
Feed Water Flow (%)
75
WDC Valve
Furnace
50

BCP
BFP 25

Eco
0
0 25 50 75 100
Load (%)
 OPERATION OF BOILER PAGE- 31
Operation Mode and Range
(1) Operating Characteristic of Supercritical Plant

Dry Operation • Boiler operation is transferred from wet

mode to dry mode at approx. 25% load
• BCP is out of service during dry operation
SH • Once-through operation from ECO to SH
Water
• Approx. 70% load : Reaches to supercritical
Separator
pressure
100
WSDT Wet Dry Operation
Operation
Feed Water Flow (%)
WDC Valve 75
Furnace

50
BCP
BFP 25
Eco
0
0 25 50 75 100
Load (%)
LOW LOAD SYSTEM WITH HEAT EXCHANGER
 OPERATION OF BOILER PAGE- 33

Basics of Supercritical Plant

(6) Basic philosophy of the controllability of the once-through type

(f) Summary of comparison for main process control

between supercritical type and drum type

Main parameters for main steam pressure / temperature control

Supercritical
Drum
Once-throgh

Main steam Wet SH Spray

MS Temp
temperature
SH Spray
Dry
Dry Water Fuel Ratio

Main steam
Main Wet Fuel Flow
pressure Fuel Flow
pressure Dry
Dry Feed Water Flow
 Steam

Partial Steam Generation

Complete or Once-through
Steam Generation

Heat Input
Water

Heat Input

Water
Water
Boiling process in Tubular Geometries
Types of Supercritical Boilers
Make : Mitshubishi Heavy Industries Ltd, Nagasaki, Japan

Type : Super Critical Once thru boiler, single furnace,

single reheat, balance draft, top suspended, double gas
passes, dry ash Water Impounded, Vertical wall
evaporator, Sliding pressure operation, Two fire wall.
 OPERATION OF BOILER PAGE- 54

Basics of Supercritical Plant

(7) Characteristics of sliding pressure operation

Main steam pressure setting (MPa)

Turbine governor opening (%)

25.12
100

8.43
Sliding pressure range

35% 100%
For Reference Generator load
 OPERATION OF BOILER PAGE- 55

Basics of Supercritical Plant

(7) Characteristics of sliding pressure operation

Merit of the sliding pressure operation

Thermal efficiency of the plant is elevated for the
following reasons.
1) Throttle pressure loss of the steam turbine
governor can be reduced. Accordingly, internal
efficiency of the turbine is elevated.
2) Shaft power of the boiler feed water pump can
be reduced.
3) Steam temperature is easy to rise by means of
reducing pressure. (Specific heat of the steam
is reduced in the vicinity of the low pressure
range.)
Supercritical Boilers

SPIRAL WALLS

• Can be used in boilers of any capacity.

• As the tubes pass through all the furnace walls more

uniform heat absorption .

• Evaporator outlet steam temperatures more uniform

Supercritical Boilers

SPIRAL WALLS

• Furnace walls are not self supporting because the tubes are
inclined.
• External support strap system is needed
• Fabrication and installation are more difficult.
• Above apspects tend to increase the cost.
 Water & steam Flow Diagram
Roof Inlet Manifold Pry SH De-SH
2 ry SH De-SH
ry
Pry RH De-SH
ry
Front Outlet HDR 2ry SH Inlet HDR 3 SH Inlet 3 SH Outlet Pry SH Outlet HDR nd
ry HDR HDR 2ry RH Outlet Pry RH Outlet HDR 2 Pass Rear Outlet
2 SH Outlet HDR HDR
HDR Eco Outlet HDR
Side Outlet HDR 2ry RH Inlet HDR Roof Outlet HDR Water Separator
Roof Inlet HDR nd
2 Pass Outlet HDR
3ry SH Tube 2ry RH Tube
2ry SH Tube
Pry SH Terminal
Bank Water Separator
Pry RH Terminal
Drain Tank
Bank
Rear Outlet HDR
Main Steam Pipe Pry RH Bank Pry SH Bank
Passage Inlet
Hanger Inlet HDR Hanger & Pry RH Bank Pry SH Bank
HDR Passage 2nd Pass
Manifold Pry RH Bank Pry SH Bank Inlet Pipe
Furnace Intermediate Furnace Intermediate
Pry SH Inlet HDR
Eco Int. HDR
Pry RH Bank
Eco Bank
Eco Int. HDR
Pry RH Inlet HDR
Eco Bank Eco Bank 2nd Pass Inlet
2nd Pass Inlet Ring HDR Manifold
Feed Water Economizer Inlet HDR

To High Pressure
Turbine
To Intermediate Pressure
Turbine
Boiler Circulating
Pump
From High Pressure Turbine Furnace Inlet Furnace Inlet
Manifold Manifold
Furnace Inlet HDR
Prepared By: Anup Kumar Singh
 Design Feature of Mitsubishi Coal Fired
Supercritical Sliding Pressure Boiler

4. Reliable high-temp.
material

1. Vertical 5. Double fire-vortexes

Waterwall design
Design for SC
Once-through
Boiler
2. Low NOx Firing
System 6. Split Pass
with Damper Control
3. Vertical Mill with System
dynamic
separator
Corner- 8 Corner- 7 Corner- 6 Corner- 5

Corner- 1 Corner- 2 Corner- 3 Corner- 4

 Boiler Circulation Pump

Pump Technical data

- Type Vertical Glandless Circulating Pump
- Fluid pumped Boiler water
- Operating temperature 287.3deg. C
- Capacity 890 m3/h
- Total head 110 m
Motor
- Type Wet motor
- Rating 400 kW
- Voltage 3,300 V
- Nominal Current 96.6 A
- Starting Current 628.6 A

- Motor alarm temp. 60 deg. C (at upper motor cavity)

- Motor trip temp. 65 deg. C (at upper motor cavity)

14/43
 STANDARD MODEL
Separator
Assembly

MVM32R
Hydraulic
Assembly Housing
Assembly
Roller
( UH, MH,
Assembly
LH)
Grinding
Table
Assembly

MVM32R : MITSUBISHI
VERTICAL MILL (3.2 Mtr Dia)
Gear Box
with Rotary Separator Assembly
Fan Designation
ID FAN
AN N - 3700 / 2000 B; 740
Rotational Speed in rpm
Hub Type
Hub diameter in mm
Impeller Diameter in mm
N = Single-stage ; T = Two-stage
AN = Axial, Enlarged Inlet Box

FD FAN – ANN 2520 / 1400 C; 990

PA FAN – ANT 1710 / 900 C; 1490

NGK | Customer Class room Training | October 09,2012 4/35

 Heaters
 Tri-Sector heater

33 VAT - 1620

Total rotor depth in mm

Heater with Vertical shaft
Adjustable hot end sector plate
Tri sector model

Rotor tire diameter (~16000 mm)

NGK | Customer Class room Training | October 09,2012 22/34
 Coal Feeder Technical Specification

Sl.No Description

1 Make Stock redler India PVt ltd

2 Type of Feeder Gravimetric Feeder

3 Type of Speed control VFD

4 Feeder Capacity 120 TPH

5 Control range of drive Unit 5:1

6 Max Size of coal handled 50 mm

89
7 No of feeder per boiler 6
Fundamentals of boiler water treatment PAGE 97

5. All Volatile Treatment (AVT)

pH 9.3-9.6

O2 7ppb
RH
Cation 0.025
Conductivity mS/cm

Turbine
SH Condenser

Dearater
WW
+ CP
N 2H 4
Eco LP-HTR
CPP
BFP
HP-HTR

N2H4 NH3
L&T MHI
CONFIDENTIAL
Fundamentals of boiler water treatment PAGE 98

6. Combined Water Treatment (CWT)

pH 8.5-9.3
O2 20 - 200ppb
RH

Cation 0.2
Conductivity mS/cm
Turbine
SH Condenser

Dearater
WW
+ CP
O2
Eco LP-HTR
CPP
BFP
HP-HTR

O2 NH3
L&T MHI
CONFIDENTIAL
 OPERATION OF BOILER PAGE- 99
Basics of Supercritical Plant
(6) Strict control of water quality
Clean-up Operation
Required Water Quality
Drum Once-through
Item
PT AVT CWT

pH - 9.3 – 9.6 9.3 – 9.6 8.5 – 9.3

CC mS/m < 0.05 < 0.025 < 0.02

Economizer
DO m g/l <7 <7 < 20 20 - 200
Inlet
< 200
Hydrazine m g/l > 10 > 10 N/A

Silica m g/l N/A < 20

< 20 < 20
Silica m g/l < 200
Boiler Drum Nonsignificant
Fundamentals of boiler water treatment PAGE 100

8. Advantages of CWT
Comparison of Scale between CWT & AVT
AVT CWT

(Magnetite Scale : Fe3O4) Hematite Scale: Fe2O3

High Low
Pressure loss pressure loss
L&T MHI
CONFIDENTIAL
 PAGE 101

Boiler Trip Condition :

Boiler trip (MFT) conditions are:

(a) Boiler Trip PB operated

(b) All BFP Stop

(c) All Flame Loss

(d) All Fuel Loss

(e) Unstable Combustion

(f) Reheater Protection

(g) Both FDF Stop

(h) Both IDF Stop

(i) Feed Water Flow Low Low ( <376t/h)

 PAGE 102

(j) Boiler Outlet Main Steam Pressure High High (>285Kg/Cm2)

(k) Furnace Draft High High (>400mmH2O)

(l) Furnace Draft Low Low (<-400mmH2O)

(m) W/W Outlet Temperature Very High

(n) 1RY SH Outlet Temperature Very High

(o) Air Flow Low Low (<25.4% BMCR)

(p) WSDT Level High High (>14.4m)

(q) Turbine Trip With Condenser Vacuum Low Low or All CWP Stop

(r) Boiler Closed Loop Control System (Station DCS) Failure

(s) Burner Management System (BMS) Failure

 Start-up schedule

Description Cold Warm Hot Very Hot

Turbine mode:

HPT metal Temperature ⁰C < 150⁰C 150 – 375 ⁰C 375 – 450 ⁰C ≤ 2 hours
shut down

Boiler mode:

Water separator inlet fluid ≤ 120⁰C >120 ⁰C > 260 ⁰C > 340 ⁰C
temperature ≤ 260 ⁰C ≤ 340 ⁰C
 Sequence of Clean up
Pre Boiler clean up
1 .Condensate clean up (Blow Out)
2 .Condensate clean up (Circulation)
3 .LP System clean up (Blow Out)
4 .LP System clean up (Circulation)
5 .HP System clean up (Blow Out)
6 .HP System clean up (Circulation)

Boiler clean up
7 .Boiler Cold clean up (Blow Out)
8 .Boiler Cold clean up (Circulation)
9 .Boiler Hot clean up (Circulation)
 Sequence of Clean up
Clean-up schedule
Start-up mode
Clean-up Process
Very Hot/ Hot Warm Cold
1 Condensate clean up (Blow Out) X O* O
2 Condensate clean up (Circulation) X O* O
3 LP System clean up (Blow Out) X O* O
4 LP System clean up (Circulation) O* O* O
5 HP System clean up (Blow Out) X O* O
6 HP System clean up (Circulation) X O* O
7 Boiler Cold clean up clean up (Blow Out) X X O
8 Boiler Cold clean up (Circulation) X X O
9 Boiler Hot clean up (Circulation) X X O
* If water quality comply with the required quality, this process may be passed through.