100 % load

100 C
150 C
200 C
250 C
300 C
350 C
375 C
400 C
4
5
0
C
500 C
550 C
600 C
650 C
700 C
750 C





e
n
t
h
a
l
p
y
4 000
3 600
3 200
2 800
2 400
2 000
1 600
1 200
800
400
kJ/ kg
pressure
0 50 100 150 200 250 300 bar 400
.
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Schwarze Pumpe Heilbronn
Bergkamen Bexbach I
Scholven F GKM, K 18
.
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H/P-Diagram
Different Plants
008 131p
Steam Generator Circulation
Systems
008 406p
Feedwater Control
Natural circulation boiler Once-through boiler
Feedwater
control
Level
Feedwater
Steam flow
m

Eva Eco
T
T
Enthalpy
Feedwater
control
Feedwater
T P
Eco
Eva
Supercritical
Simplified flow diagram of
Combined Circulation unit
Constant Pressure Programme for
Combined Circulation steam generators
Sliding Pressure Programme for
Combined Circulation steam generators
002 065p quer
Evaporator Tubing (1)
a
t
t
1
a
a Furnace side length mm
d Tube diameter m
F Mass flow density kg/ m
2
s
k Constant mm/ m
m Mass flow kg/ s
n No. of tubes

t Tube pitch mm
t
1
Horizontal pitch mm
a Angle of inclination
The relation of the tube
system to the tube
diameter is constant for
approx. the same fin head
temperature
d k t =
d
t
k =
o t
=
t
=
sin d a
m k
4
d n
m
F
2

o = = sin
t
a 4
t
a 4
n
1
Spiral Wall Design
- Reduced number of
tubes with pitch.
- Increased mass
flow.
- Mass flow rate can
be chosen by
number of parallel
tubes.
Features
Evaporator Wall Design
011 104p
Wall Furnace Supporting Structure
Horizontal
Buckstay
Vertical
Buckstay
Tension
Strap
Transition
Zone
Spiral
Tubes
Finger
Straps
Corner
Assembl
y
008 435p
Start-Up and Low-Load
System
Separator Separator
Leveling
vessel
Leveling
vessel
Flash
tank
Flash
tank
Eco Eco
Circulation
pump
Feedwatern
pump
Start-up
heat exchanger
HP feedwater
heater
Deaerator
Evaporator Temperatures
at Spiral Outlet
at 40 % and 100 % Load
002 502p
0
100
200
300
400
500
T
e
m
p
e
r
a
t
u
r
e

a
t

s
p
i
r
a
l
e

o
u
t
l
e
t
100 % Load
C
left
side wall
front wall
right
side wall
rear wall
40 % Load
Rifled Tube
Predicted Lateral Water Wall Heat
Accumulation
Percent of Wall Dimension, Corner to Corner
Furnace Waterside Arrangement
Water / Steam Diagram
Separators
Surrounding
walls
Leveling vessel
SH 1
Evaporator
Economizer
SH 2
SH 3
I 1
I 2
RH 1
RH 2
I RH
I RH
Modified Tower Arrangement
Steam-water Separator System and Water
Storage Tank
Drain Discharge with Indirect Heat
Recovery System
Drain Water return system with low load
circulation pump
Drain Water Return System with a
start-up Heat Exchanger system
o
F
54
36
18
0
Once-Through Boilers Reference List -
Typical Units
sioning
[MW]
[KPPH/tonnes/hr [psig/bar)
[F]
Patnow 2004 Brown Coal 460
3012/1345 4205/290
Wai Gao Qiao 2003
Bituminous
Coal
2 x 900 (980)
6247/2789 4045/279 1008/1055
Yonghung 2003
Bituminous
Coal
2 x 800
5410/2415 3930/271 1056/1056
Niederauem K 2002 Brown Coal 1,012
5860/2662 4205/290 1075/1112
Florina 2002 Lignite 330
2278/1017 3800/262 1010/1008
Mai Liao 2000
Bituminous
Coal
2 x 600
4368/1950 3841/265 1005/1055
Schwarze Pumpe 1997 Brown Coal 2 x 800
5420/2420 4135/285 1017/1050
Poryong 3 & 4 1993 ..
Bituminous
Coal
2x 500
3852/1720 3840/265 1005/1005
Vestkraft Unit 3 1992
Bituminous
Coal
400
2420/1080 4000/276 1040/1040
Shidongkou II 1992
Bituminous
Coal
2 x 600
4250/1897
3885/268
4
1005/1055
GKM Mannheim
Boiler 18
1982
Bituminous
Coal
475
3068/1370 3990/275
986/1004/986
Scholven, Unit F 1979 ..
Bituminous
Coal
4 x 750
4928/2200 3335/230
995/995
Temperature
Design Pressure Steam Capacity Electrical Output Fuel Type Plant Commis-
Year of
SH/Reheat
[C]
544/568
542/568
569/569
580/600
543/542
540/569
541/569
541/541
547/565
1010/1055
560/560
530/540/530
535/535
First Supercritical Monotube
Boiler for China




M
HP
527 kg/s
P
HP
254 bar
T
HP
541
O
C
M
MP
448 kg/s
P
MP
45.8 bar
T
MP
569
O
C
Coal-Fired, Pendant
Two-Pass Design
Main Steam
Conditions
Reheat Steam
Conditions
First Supercritical Monotube
Boiler for South Korea


M
HP
478 kg/s
P
HP
251 bar
T
HP
541
O
C
M
MP
382 kg/s
P
MP
40.8 bar
T
MP
541
O
C
Coal-Fired, Horizontal
Single-Pass Design
Main Steam
Conditions
Reheat Steam
Conditions
011 351p quer
NTPC Super Thermal PS
Talcher, Unit I + II
Steam output: 1100 t/h
Design pressure: 190 bar
SH steam temperature: 540 C
RH steam temperature: 540 C
Utility Boilers
Major Recent References
011 350p
Power Station Schwarze Pumpe
2 x 800 MW
The Largest Supercritical Boilers
World-Wide with Brown Coal Firing

Technology - Once
Through
Fuel - Brown
Coal
Capacity t/h 2 x 2,420
Design Pressure bar 285
Temperature C 547/565
Country - Germany
Customer - VEAG
Berlin
Utility Boilers
Major Recent References
011 341p
Power Station Niederauem
1,000 MW
World-Wide Largest Supercritical
Boiler

Technology - Once
Through
Fuel - Brown Coal
Capacity t/h 2,662
Design Pressure bar 290
Temperature C 580/600
Commissioning - 2002
Country - Germany
Customer - RWE
Energie
Wai Gao Qiao, 2 x 900 MW
011 414px
Live Steam
279 bar (design pressure)
542 C
774.4 kg/s (2,788 t/h)
Reheater Steam
69 bar (design pressure)
568 C
687.6 kg/s (2,475 t/h)
Feedwater
273 C
Fuel
Bituminous coal
Mai Liao - Taiwan
2 x 600 MW
011 456px
Live Steam
279 bar (degin pressure)
540 C
1,950 t/h
Reheater Steam
569 C
Fuel
Bituminous Coal
001 394p
Year of Commissioning, Hours
of Operation & No. of Start-ups
Commissioning Status Hours of operation No. of start-ups
Scholven F 1979 12/ 2000 137,200 1,830
Bergkamen A 1981 12/ 2000 147,096 311
GKM K 18 1982 12/ 2000 140,950 350
Bexbach I 1983 02/ 2001 106,156 2,007
Heilbronn Unit 7 1985 12/ 2000 83,230 1,108
Vestkraft 1992 06/ 2000 58,300 200
Shidongkou 1 & 2
1)
1992 12/ 2000 63,842/ 60,474 162/ 112
Poryong 3 & 4
1)
1993 12/ 2000 60,685/ 61,025 73/ 71
Poryong 5 & 6
1)
1993 12/ 2000 57,378/ 56,818 113/ 74
Schwarze Pumpe A/ B 1997 06/ 2002 40,457/ 35,050 120/ 124
Hadong 1 & 2
1)
1997 12/ 2000 27,631/ 25,418 19/ 14
Note:
1)
Above data includes only startups after commercial operation, i.e., no commissioning phase startups
Load Increase
004 252p
0
363
725
1088
1450
1813
2175
2538
2900
3263
3625
psig
32
122
212
302
392
482
572
662
752
842
932
1022
1112
F
0
10
20
30
40
50
60
70
80
90
100
110
120
10:00 10:05 10:10 10:15 10:20 10:25 10:30
%
Total firing rate [%] SH Steam temperature [F]
RH Steam temperature [F] SH Steam flow [%]
SH Steam pressure [ psig ] Auxiliary line
64.8 %/10:10:19
6.7 %/min.
95.28 %/10:14:52
Load Runback
004 251p
8:3
8:30:20
80:24
8:30:28
8:30:32
8:30:36
8:30:36
8:30:40
8:30:44
8:30:48
8:30:52
8:30:56
8:31:00
8:31:04
8:31:08
8:31:08
8:31:12
8:31:16
8:31:21
8:31:24
8:31:28
8:31:32
8:31:36
8:31:36
8:31:40
8:31:44
8:31:48
8:31:52
8:31:56
0
10
20
30
40
50
60
70
80
90
100
8:30 8:45 9:00
Total firing rate [%] SH Steam pressure [psig] SH Steam flow [%]
RH Steam temperature [F] SH Steam temperature [F]
%
0
363
725
1088
1450
1813
2175
2538
2900
3263
3625
psig
932
968
1004
1040
1076
1112
1148
1184
1220
1256
1292
F
001 381p
Statistics of Forced Outage
(Extract)
ca. 750 MW
el
ca. 475 MW
el
ca. 750 MW
el
Year
[h] [%] [h] [%] [h] [%]
1983 128 1.5
1984 682 7.7 93 1.1
1985 215 2.5 146 1.7
1986 19 0.2 95 1.1
1987 73 0.8 147 1.7
1988 252 2.8 89 1.0
1989 60 0.6 21 0.2
1990 244 2.8 28 0.3
1991 276 3.2 0 0 24 0.3
1992 124 1.4 55 0.6 14 0.2
1993 421 4.8 120 1.3 24 0.3
1994 188 2.1 43 0.4 11 0.1
1995 158 1.8 63 0.7 15 0.2
121 078p quer
Wall Thickness
HP-Outlet Headers
Materials: Tungsten
alloyed 9 - 12 %
Chromium Steels
540 560 580 600 620
SH temperature
20
40
60
80
100
120
140
H
e
a
d
e
r

w
a
l
l

t
h
i
c
k
n
e
s
s

HP-pressure
260 bar/300 bar
E 911/300 bar
NF 616/300 bar
E 911/260 bar
mm
C
i.d.= 200 mm
HCM 12 A/300 bar
HCM 12 A/260 bar
NF 616/260 bar
Steam Parameter Limits
(Superheater Tubes)
Allowable Stresses for Ferritic Alloys
ALLOWABLE STRESS T91, T22 vs. T23
0
20
40
60
80
100
120
140
370.0 420.0 470.0 520.0 570.0 620.0
Temperature, deg. C
A
l
l
o
w
a
b
l
e

S
t
r
e
s
s
,

M
P
A
T91
T23
T22
Part of the manufactured
Test Superheaters
021 147p
5
180 240 300 360
25 C = 1.25 %
improvement
10
Relative heat rate (Semi-net) Single reheat
%
bar
Advanced Steam Power Plants
Relative Efficiency Improvement
002 510p
Efficiencies of
Steam Power Stations in Europe
002 636p
30
35
40
45
50
55
1950 1960 1970 1980 1990 2000 2010 2020
Time
q ||
I
n
t
r
o
d
u
c
t
i
o
n

o
f
O
n
c
e
-
T
h
r
o
u
g
h

T
e
c
h
n
o
l
o
g
y
1
7
5

/

5
4
0

/

5
4
0
1
s
t

S
u
p
e
r
c
r
i
t
i
c
a
l

P
l
a
n
t
s
(
2
4
0

-

2
8
0

b
a
r
E
v
a
p
o
r
a
t
o
r

P
r
e
s
s
u
r
e
)
2
5
0

/

5
5
0

/

5
7
0
3
5
0

/

7
0
0

/

7
2
0
2
6
0

/

5
8
0

/

6
0
0
2
8
0

/

6
0
0

/

6
2
0
Net Efficiency vs. Design Data
35
36
37
38
39
40
N
e
t

E
f
f
i
c
i
e
n
c
y

(
H
H
V
)



[

%

]
Live Steam Press. 2407 3625 3915 [ psig ]
Live Steam Temp. 998 1005 1050 998 1005 1050 998 1005 1050 1050 1050 1085 [ F ]
Reheat Temp. 1000 1040 1112 1000 1040 1112 1000 1040 1112 1112 1112 1148 [ F ]
Feedwater Temp. 500 525 555 [ F ]
Numb. of Heaters 7 8 7 8
Design Data
(500) - 600 - [700] MW Class
Cond. Pressure : 1.23 psi
Net Efficiency (HHV) vs.
Steam Cycle Design
Supercritical Boilers
Typical Emission Advantages
India Coal
Subcritical Supercritical
Plant Efficiency, % 34-37 37-41

Emissions, @ 6%O
2
d.v. Total Emissions Rate (g/KWhe)
Plant Efficiency, % 34% 37% 41%
Fuel Consumption Base Base-9% Base-21%
NOx (650 mg/Nm
3
) 2.41 2.22 2.00
SOx (2000 mg/Nm
3
) 7.43 6.82 6.16
Particulates (50 mg/Nm
3
) 0.19 0.17 0.15
CO
2
(272,000 mg/NM
3
) 1008 926 835
0
2
4
6
8
10
12
14
EFOR %
Plant (Super) 13.347 12.077 9.668 7.685 7.534 7.482
Plant (Sub) 10.405 9.439 8.16 6.793 7.103 7.013
Blr (Super) 8.441 7.285 5.823 4.872 4.434 4.023
Blr (Sub) 5.928 5.464 4.344 3.811 3.926 4.018
1982-1984 1985-1987 1988-1990 1991-1993 1994-1996 1997
Comparison of Supercritical and
Supercritical Cycle Availability
Once-through Benefits
Summary
Once-through is the most flexible boiler system
since it offers
optimum adaptation to various fouling conditions
(fuel flexibility)
best efficiencies due to high steam parameters at full
load and due to low losses at part load (sliding pressure)
max. operational flexibility
either base load
or two-shift or cycling operation mode would be possible
001 699p
Conclusion Supercritical
Coal is and will stay a fuel with an important contribution to
power generation
Worldwide development in steam power plant technology promises
further improvements in economic and environmental performance
Technology trend worldwide is to go for increased steam parameters,
new projects are evaluated / tendered for supercritical technology
The introduction of supercritical technology (once-through boilers)
shows highest potential for customers as the most important step
to keep pace with SPP development
Supercritical power plants are state-of-the-art in many countries
- as reliable as subcritical
- highly efficient with a potential for further improvements
- cost-effective in terms of investment and lifetime costs
- reducing emissions in regard to worldwide CO
2
discussions
- well designed for shift and cycling operation
001 812p
www.alstom.com