Advanced (700 C) PF Power Plant: A Clean Coal European

Technology
CESI Auditorium, Milano, Italy
Thursday, 27th of October 2005

Advanced Materials for AD700 Boilers

R.U. Husemann, Babcock Hitachi Europe

Membrane Wall Materials

Header and Piping Materials
Superheater and Reheater Materials

Babcock-Hitachi Europe GmbH

700 C- Plant Future Potential

400 MW
High pressure part
Steam rating

275 kg/s
990 t/h

Allowable working
pressure (gauge)

393 bar

SH-Outlet temperature

700 C

Reheater
Steam rating

S304H (SB) up to
610C
HR3C up to 630 C
Sanicro 25
up to 650 C steam

Alloy 740
Alloy 617
Thick wall Alloy
263/Alloy 617

215 kg/s
774 t/h

Allowable working
pressure (gauge)

83 bar

RH-Outlet temperature

720 C

13CrMo44
7CrMoVTiB10-10
X10CrMoVNb9-1
Alloy 617

Babcock-Hitachi Europe GmbH

Materials for Membrane Walls

Si Mn P

Al Cr Ni

Mo V

Nb

0,19- max. 0,40- max. max. max. 0,70- max. 0,40- ------- ------13CrMo4-5 0,17 0,35 0,70 0,025 0,020 0,040 1,15 0,30 0,60 ------- -------

Ti

B Co

------- ------- ------- ------- ------------- ------- ------- ------- -------

7CrMoVTiB
0,050- 0,15- 0,30- max. max. max. 2,20- ------- 0,90- 0,20- ------- 0,05- ------- max. 0,0015- ------10 -10
0,095 0,45 0,70 0,020 0,010 0,020 2,60 ------- 1,10 0,30 ------- 0,10 ------- 0,010 0,0070 ------T 24

VM12

0,08
0,18

0,20
0,60

0,10 max. max.

0,80 0,020 0,010

max. 10,0
0,040 13,0

max. max. 0,18

0,60 0,80 0,30

0,030 ------0,060 -------

1,00 0,030 0,001 0,50

1,80 0,090 0,010 2,00

X10CrMoV
0,08- 0,20- 0,30- max. max. max. 8,00- max. 0,85- 0,18- 0,06- ------- ------- 0,030- ------- ------Nb9-1
0,12 0,50 0,60 0,020 0,010 0,040 9,50 0,40 1,05 0,25 0,10 ------- ------- 0,070 ------- ------T 91
Alloy 617

0,05- max. max. max. max. 0,60

0,10 0,70 0,70 0,012 0,008 1,50

20,0- Rest
23,0

8,0- Fe m. ------- 0,20- ------- As m. Pb m.

10-13
10,0 2,0
0,50
0,010 0,007

Babcock-Hitachi Europe GmbH

Materials for Membrane Walls

Materials:
13CrMo4-5
7CrMoVTiB10-10
X10CrMoVNb9-1
105 h Average Creep Strength in MPa
300
250

VM 12 / T92

Alloy 617 A130

200
150
100
50

13CrMo4-5

0
480

500

520

540

T 91
7CrMoVTiB10-10
560

580

Temperatur in C
Babcock-Hitachi Europe GmbH

600

620

640

660

Materials for Membrane Walls

Design temperatures according EN 12952

630 C

580 C

590 C
Alloy 617

550 C
T 91

500 C
7CrMoVTiB10-10

VM 12

Considering the material properties :

Oxidation in Steam
Creep Strength

13CrMo4-5
Babcock-Hitachi Europe GmbH

Codes for Membrane Walls Materials

13CrMo4-5

DIN EN 10216-2 07.2004

T91

DIN EN 10216-2 07.2004

7CrMoVTiB10-10

VdTV 533 12.2003,

prEN10216-2 3.2004,

T24

ASTM A213

Babcock-Hitachi Europe GmbH

Superheater/ Reheater Tubes

Outer
Oxide layer

Inner
Oxide layer
corrosion

tube wall

corrosion layer

am
e
st

s = f (allowable stress)

steam oxydation

flue gas
Babcock-Hitachi Europe GmbH

Austenitic and Nickel Base Alloys

C Si Mn
TP 347H FG

S Fe Cr

0,04- max. max. max. max. res.

0,10 0.75 2,00 0,040 0,030

Super 304H 0,070,13

0,04HR3C
0,10
0,05DMV310N
0,07
Sanicro 25

max.
0.30
max.
0.75
0,30
0.50

max.
0,08 yes

Alloy617 0,05- max.

NiCr23Co12
0,10 0.70
Mo 2.4663

max.
1,00
max.
2,00
1,00
1,40
yes

max.
0,040
max.
0,030
max.
0,030

max. res.
0,010
max.
res.
0,030
max. res.
0,010

max. max.
0,030 0,010

max. max. max.

0.70 0,012 0,008

res.

0,04- max. max. max. max. max.

0,08 0.40 0.60 0,007 0,007 0,7

Alloy 740

0,03 max.
0.50

max. max. max.

0,007 0,007 0,7

9,0- -----13,0 ------

17,07,5- -----19,0 10,5 -----24,0- 17,0- -----26,0 23,0 -----24,4- 20,8- -----25,0 21,5 -----22,0- 23,0 -----24,0
25,0 ------

Ti

----------8xC
----------2,50- 0,30- -----3,50 0,60 --------------------------

0,200,60
0,400,50

---------------------

yes

yes

-----------

used as
Tube

N 0,05 - 0,12

Tube

N 0,15 - 0,35

Tube

N 0,18 - 0,24

Tube

N yes

Tube

Co 10,00 - 13,00

res.

res.

5,66,1

max.
0.70

-----------

1,9
2,4

Co 19,00 - 21,00
Al max.0,60
B max. 0,005

Pipe/Tube

22,0res.
25,0

0,50

max.
0.70

2,0

1,8

Co 20,0
Al 0,90

Tube

19,021,0

Babcock-Hitachi Europe GmbH

Bi m 0,200,010 0,60

Others

8,0- As m
10,0 0,010

max. 20,02,00 23,0

Alloy 263

0.30

17,020,0

Ni Mo Cu Nb

Al 0,60 -1,50
Pb max. 0,007

Pipe/Tube

Materials for Reheater and Superheater

Materials:
TP 347H FG
HR3C/DMV 310N
Super304H/DMV 304H Cu
N/mm
200

105h Average creep strength

Sanicro 25 expected
150
Alloy 617 A 130
Super 304H

100

HR3C/DMV 310N

TP 347H FG
50
600

620

640

660

680

Temperature in C
Babcock-Hitachi Europe GmbH

700

720

740

Measures Improving Oxidation Behaviour in Steam

1. High Cr Content > 24% e.g. HR3C, DMV 310N, Sanicro 25
Fe3O4

2. Shot
Peening e.g.
Super 304H

Thin Cr2O3
layer

Cr2O3

Schematic

Cold worked
layer

Metal

50m

(Fe,Cr)3O4

The layer where the

crystal grains were collapsed.

Diffusion
of Cr

Metal

Shot peened
Grain
boundary

3. Fine Grain e.g.

TP347H FG

Babcock-Hitachi Europe GmbH

Increase of Temperature on Superheater Tubes Caused by Inner Layer

K

300
280
260
240
220
200
180
160
140
120
100
80
60
40
20
0

125 KW/m
Example:
0,4 mm Inner layer thickness
50 KW/m Heat flux

100 KW/m

60 K Increase of temperature
75 KW/m

50 KW/m

Porosity max. 10 %

0,1

0,2

0,3

0,4

0,5

0,6

0,7

Inner layer thickness in mm

Babcock-Hitachi Europe GmbH

0,8

Materials for Reheater and Superheater Tubes

X3CrNiMoN17-13

HR3C ( 24% 26% Cr)

TP 347H Fine Grain

TP 347H Shot Peened

Originally 500 : 1
Babcock-Hitachi Europe GmbH

Materials for Reheater and Superheater Tubes

Design temperatures according EN 12952

770 C

770 C

700 C
645 C*

670 C
Alloy 617

615 C

Alloy 263

Sanicro25 under investigation

e.g. S 304 H e.g. HR3C

(SB)

600 C
for example:

X3CrNiMoN17-13
(SB)

Considering the material properties :

Oxidation in Steam
High-Temperature Corrosion in Flue Gas
Creep Strength

X20CrMoVNi11-1

* Bituminous coal firing systems with contents of sulphur until approx. 1 %

Babcock-Hitachi Europe GmbH

Codes for Superheater Materials

Materials

DIN EN

VdTV

ASME

Others

X20CrMoV11-1

10216-2

DIN17175

X3CrNiMoN17-13

pr10216-5

DIN17459

TP347H FG (SB)

547 6.2003

Code2159

SA213

Super 304H (SB)

550 9.2003

Code2328

SA213

Code2113

SA213

DMV310N

Single appraisal
TV Kln
HR3C

546 9.2003

Code2125

SA213

NiCr23Co12Mo

485 9.2001

Code1982

Single appraisal

Code1956

TV Kln

Babcock-Hitachi Europe GmbH

Martensitic Cr Steels for Headers and Piping

C
X20CrMo
V12-1

Si

Mn

Al

Cr

Ni

Mo

Nb

Ti

Co

0,17- max. max. max. max. max. 10,00- 0,30- 0,80- 0,25- ------- ------- ------- ------- ------- ------0,23 0,50 1,00 0,030 0,030 0,040 12,50 0,80 1,20 0,35 ------- ------- ------- ------- ------- -------

X10CrMoV 0,08- 0,20- 0,30- max. max. max. 8,00- max. 0,85- 0,18- 0,06- ------- ------- 0,030- ------- ------Nb9-1
0,12 0,50 0,60 0,020 0,010 0,040 9,50 0,40 1,05 0,25 0,10 ------- ------- 0,070 ------- ------P 91
X11CrMoW
0,09- 0,10- 0,30- max. max. max. 8,50- 0,10- 0,90- 0,18- 0,06- ------- 0,90- 0,050- 0,001- ------VNb9-1-1
0,13 0,50 0,60 0,020 0,010 0,040 9,50 0,40 1,10 0,25 0,10 ------- 1,10 0,090 0,006 ------E 911
X10CrWMo
0,07- max. 0,30- max. max. max. 8,50- max. 0,30- 0,15- 0,04- ------- 1,50- 0,030- 0,001 ------Nb9-2
0,13 0,50 0,60 0,020 0,010 0,040 9,50 0,40 0,60 0,25 0,09 ------- 2,00 0,070 0,006 ------P 92

VM12

0,08
0,18

0,20
0,60

0,10 max. max.

0,80 0,020 0,010

max. 10,0
0,040 13,0

max. max. 0,18

0,60 0,80 0,30

Babcock-Hitachi Europe GmbH

0,030 ------- 1,00

0,060 ------- 1,80

0,030 0,001 0,50

0,090 0,010 2,00

Materials for Headers and Piping

Materials:
X20CrMoV12-1
P91
E911, P92
2

N/mm

300

105h Average creep strength

105h Average creep strength

P 91

250
200
150

Alloy 617 A130

100
50

X20CrMoV12-1

VM12

P 92

0
480

500

520

540

560

580

600

620

640

Temperature in C
Babcock-Hitachi Europe GmbH

660

680

700

720

740

Materials for Headers and Piping

Design temperatures according EN 12952

625 C*

735 C

735 C

Alloy 617

Alloy 263

625 C

600 C
E 911, P 92

580 C
P 91

VM 12 under investigation
Considering the material properties :
Oxidation in Steam
Creep Strength

X20CrMoVNi11-1

* 635 C reheater systems

Babcock-Hitachi Europe GmbH

Codes for Headers and Piping Materials

Others
X20CrMoV12-1

17175 5.79

P 91

------------

E 911

ECCC

P 92
VM 12
Alloy 617
Alloy 263

VdTV

DIN EN

ASME / ASTM

110 12.95

10 216 - 2
07.04

------------

10 216 - 2
07.04

ASME SA 335
ASTM A 335

prEN10216-2
Mrz 2004

ASME Code Case 2327

May 2000

prEN10216-2
Mrz 2004

ASME Code Case 2179

ASTM A 335

511/2 06.01
511/3 09.01

Evaluation Sept.2005
ECCC
Evaluation Sept.2005

522/2 09.01
522/3 12.99

------------

------------

------------

------------

Single appraisal
1.2004 TV
Rheinland

485 9.01

------------

------------

------------

------------

(ECCC) European Creep Collaborative Committee

Babcock-Hitachi Europe GmbH

-----------ASME B 167
ASME Code Case 1982
ASME Code Case 1956

------------

Status of Investigations

Babcock-Hitachi Europe GmbH

CESI Auditorium, Milano, Italy

Thursday, 27th of October 2005

Thank you
for your attention
Grazie per la
vostra attenzione

Babcock-Hitachi Europe GmbH