Clean Coal Technology, Sardinia May 2005

Advantages of Ultra Super Critical Technology in Power Generation

by Hans H. Poulsen Burmeister & Wain Energy A/S
Group Burmeister & Wain Energy A/S Jgersborg All 164 DK-2820 Gentofte Denmark Tel/fax +45 39 45 20 00/+45 39 45 20 05 info@bwe.dk

Clean Coal Technology, Sardinia May 2005

Burmeister & Wain Energy A/S (I):

Company founded in 1843 First steam boiler supplied 1852. First Benson once-through boiler supplied in 1952 World record - above 47% in efficiency for a coal fired utility boiler 1999 Part of the Italian STF S.p.A. Group (2002)
Group Burmeister & Wain Energy A/S Jgersborg All 164 DK-2820 Gentofte Denmark Tel/fax +45 39 45 20 00/+45 39 45 20 05 info@bwe.dk

Clean Coal Technology, Sardinia May 2005

Burmeister & Wain Energy A/S (II):

Advanced Ultra Super Critical steam boilers FGD Flue Gas Desulphurization plants Low-NOx firing systems Regenerative Gas-Gas Heaters Upgrading of existing boilers to improved performance

Group Burmeister & Wain Energy A/S Jgersborg All 164 DK-2820 Gentofte Denmark Tel/fax +45 39 45 20 00/+45 39 45 20 05 info@bwe.dk

Clean Coal Technology, Sardinia May 2005

Clean Coal technology: IGCC processes PFBC processes USC power cycles

Group Burmeister & Wain Energy A/S Jgersborg All 164 DK-2820 Gentofte Denmark Tel/fax +45 39 45 20 00/+45 39 45 20 05 info@bwe.dk

Clean Coal Technology, Sardinia May 2005

Efficiency Increase in DK
Net Efficiency (LHV) % 60 58 56 54 52 50 48 46 44 42 40 38 36 34 32 30 1950 1960 1970 1980 1990 2000 2010 2020
Commissioning Year
Ensted 3 Avedre 2 Esbjerg 3 No rdjylla nds v rk et Line of Steel Line of Super Alloys

Fynsv. 7 Studstrup 3/4

250 M W

Group Burmeister & Wain Energy A/S Jgersborg All 164 DK-2820 Gentofte Denmark Tel/fax +45 39 45 20 00/+45 39 45 20 05 info@bwe.dk

Clean Coal Technology, Sardinia May 2005

BENSON once-through boiler system

Asnsvrket #2 Asnsvrket #3 150MWe, 1958 250MWe, 1962 Fynsvrket #7 350MWe, 1991 Nordjyllandsvrket #3 415MWe, 1998

IP1.1 IP2.1

ECO

IP2.2 HP2 HP1 IP1.2

Supplied on a licens from Siemens since 1952

Group Burmeister & Wain Energy A/S Jgersborg All 164 DK-2820 Gentofte Denmark Tel/fax +45 39 45 20 00/+45 39 45 20 05 info@bwe.dk

Clean Coal Technology, Sardinia May 2005

Conventional 2-pass design:

Fynvrket Unit 7 (FV-7): 350MWe 2-Pass Benson boiler, Single Reheat Tangential firing system Furnace dimensions Height of Boiler 66m

Problems related to this design: Flue gas changes flow direction through the boiler. Flue gas flow direction not perpendicular to the first heating surfaces Cracks can appear in the connections between the membrane walls of the first and second pass. Flue gas flow in the second pass are not uniform causing problems of erosion as well as thermal unbalance Uneven distribution of loads on the top frame Pressure part not fully drainable

Group

Burmeister & Wain Energy A/S Jgersborg All 164 DK-2820 Gentofte Denmark Tel/fax +45 39 45 20 00/+45 39 45 20 05 info@bwe.dk

Clean Coal Technology, Sardinia May 2005

Tower design (I):

Nordjyllandsvrket Unit 3 (NVV-3): 400MWe Tower type Benson boiler, Double Reheat Tangential firing system Furnace dimensions: 12.2512.25m Height of Boiler 80m

IP1.1 IP2.1

ECO

IP2.2 HP2 HP1 IP1.2

Problems solved by this design: The flue gas flows in one direction through the boiler. The main direction of the flue gas is perpendicular to the tubes in all heating surfaces The flue gas flow through the convention pass seems to be uniform. Problems of erosion are not reported. Heat pick-up are uniform Even distribution of loads on the top frame Pressure part fully drainable

Group Burmeister & Wain Energy A/S Jgersborg All 164 DK-2820 Gentofte Denmark Tel/fax +45 39 45 20 00/+45 39 45 20 05 info@bwe.dk

Clean Coal Technology, Sardinia May 2005

Tower design (II): Compared to 2-pass boilers 15-20% additional height App. 10% reduction of material consumption Penthouse not necessary Ideal for T-firing

Group Burmeister & Wain Energy A/S Jgersborg All 164 DK-2820 Gentofte Denmark Tel/fax +45 39 45 20 00/+45 39 45 20 05 info@bwe.dk

Clean Coal Technology, Sardinia May 2005

First tower type boiler supplied to STEAG in 1987

Walsum #9 400MWe
Group Burmeister & Wain Energy A/S Jgersborg All 164 DK-2820 Gentofte Denmark Tel/fax +45 39 45 20 00/+45 39 45 20 05 info@bwe.dk

Clean Coal Technology, Sardinia May 2005

Ultra Super Critical Installations of the World

Power station Matsuura 2 Skrbk 3 Haramachi 2 Nordjylland 3 Nanaoota 2 Misumi 1 Lippendorf Boxberg Tsuruga 2 Tachibanawan 2 Avedre 2 Niederaussen Isogo 1 Cap. Steam parameters MW 1000 255bar/598C/596C 400 Fuel Year of Eff. Boiler/steam Comm. % line materials PC 1997 1997 1998 1998 1998 1998 47 49 Super304HP91 TP347FG/P91 Super304H/P91 TP347FG/P91 P91 Super304H/P91 42.3 1.4910/P91 41.7 1.4910/P91 Super304H/P122 Super304H/P122/P92 49.7 TP347FG/P92 >43 1.4910/E911 Super304/P122 Turbine materials TMK1 COST 501 F HR1100 COST 501 F Toshiba 12Cr TMK2/TMK1 COST 501 E COST 501 E Toshiba 12Cr TMK2/TMK1 COST 501 E COST 501 E COST 501 E

290bar/580C/580C/580C NG PC

1000 259bar/604C/602C 400 700

290bar/580C/580C/580C PC 255bar/593C/593C PC PC

1000 259bar/604C/602C 934 915 700 267bar/554C/583C 267bar/555C/578C 255bar/597C/597C

Lignite 1999 Lignite 2000 PC PC NG 2000 2001 2001

1050 260bar/605C/613C 400 975 600 300bar/580C/600C 265bar/565C/600C 250bar/600C/610C

Lignite 2002 Coal 2002

Group Burmeister & Wain Energy A/S Jgersborg All 164 DK-2820 Gentofte Denmark Tel/fax +45 39 45 20 00/+45 39 45 20 05 info@bwe.dk

Clean Coal Technology, Sardinia May 2005

Ultra Super Critical ??

4000 750C 700C 3600 650C 600C 3200 550C 500C 2800 450C

Sub Critical Super Critical Ultra Super Critical

Enthalpy [kJ/kg]

2400

2000

400C

350C 1600 300C 1200 250C 200C 800 150C 100C 400 0 50 100 150 200 Pressure [bar] 250 300 350 400

Group Burmeister & Wain Energy A/S Jgersborg All 164 DK-2820 Gentofte Denmark Tel/fax +45 39 45 20 00/+45 39 45 20 05 info@bwe.dk

Clean Coal Technology, Sardinia May 2005

Sub-, Super- and Ultra Super Critical Boilers

4000 3500 3000 ENTHALPY, H [kJ/kg] 2500
400C IP2 IP1 HT 600C

2000 1500 1000 500 0 0 50 100 150

ASV 5

FV 7

NVV 3

200C 100C

200

250

300

350

Pressure [Bara]

Group Burmeister & Wain Energy A/S Jgersborg All 164 DK-2820 Gentofte Denmark Tel/fax +45 39 45 20 00/+45 39 45 20 05 info@bwe.dk

Clean Coal Technology, Sardinia May 2005

Increasing Plant Efficiency

Increasing live steam parameters (temperature and pressure) Reducing the condenser pressure by means of a cold and effective cooling media preferably sea water Using reheat and maybe double reheat Optimizing the feed water temperature Selecting the single train mono component solution for the air/flue gas path and thereby reduce aux. power Increasing boiler efficiency

Group Burmeister & Wain Energy A/S Jgersborg All 164 DK-2820 Gentofte Denmark Tel/fax +45 39 45 20 00/+45 39 45 20 05 info@bwe.dk

Clean Coal Technology, Sardinia May 2005

Increasing Boiler Efficiency

Reducing flue gas exit temperature by means of an effective air preheater reducing Unburned Carbon (UBC) in the fly ash by effective and improved combustion Reducing air excess and thereby a reduced flue gas loss Reducing leakage in the air prehaeter Reducing pressure loss of the water/steam cycle

Group Burmeister & Wain Energy A/S Jgersborg All 164 DK-2820 Gentofte Denmark Tel/fax +45 39 45 20 00/+45 39 45 20 05 info@bwe.dk

Clean Coal Technology, Sardinia May 2005

Nordjyllandsvrket (I):
3 Generations of Power Plants:
Ultra Super Critical

Super Critical

Sub Critical

Group Burmeister & Wain Energy A/S Jgersborg All 164 DK-2820 Gentofte Denmark Tel/fax +45 39 45 20 00/+45 39 45 20 05 info@bwe.dk

Clean Coal Technology, Sardinia May 2005

Nordjyllandsvrket (II):
Unit 3: State of the art Clean Coal Technology More than 50.000 h of operational hours has proven: Plant efficiency >47% Availability > 98%

Group Burmeister & Wain Energy A/S Jgersborg All 164 DK-2820 Gentofte Denmark Tel/fax +45 39 45 20 00/+45 39 45 20 05 info@bwe.dk

Clean Coal Technology, Sardinia May 2005

NVV B3 operationdata, Cond. mode

Nordjyllandsvrket (III):
Operational results: Power production only
Generator output Aux. Power consumption incl. DeNOx- and DeSOx plant Aux. Power consumption excl. DeNOx- and DeSOx plant 400 kV output to grid, incl. DeNOx- and DeSOx plants 400 kV output to grid, excl. DeNOx- and DeSOx plants Turbogenerator, heat rate, based on gen. output 6.736,6 Boiler efficiency Power plant, heat rate, based on gen. output 7.151,4 Gross calorific value of coal Specific coal consumption, based on gen. output Specific coal consumption, based on 400 kV output to grid Thermal efficiency, based on 400 kV output to grid 411 MW 26 MW 23 MW 385 MW 388 MW kJ/kWh 94,2 % kJ/kWh 26 MJ/kg 275 g/kWh 293 g/kwh 47,2 %

Operational data, power production only 100% load, condensing mode, 10 c cooling water.
Group Burmeister & Wain Energy A/S Jgersborg All 164 DK-2820 Gentofte Denmark Tel/fax +45 39 45 20 00/+45 39 45 20 05 info@bwe.dk

Clean Coal Technology, Sardinia May 2005

NVV B3 op CHP mode

Nordjyllandsvrket (IV):
Operational results: Combined Heat and Power production:
Generator output 339,5 MW Aux. Power consumption incl. DeNOx- and DeSOx plant 26,5 MW Aux. Power consumption excl. DeNOx- and DeSOx plant 23,5 MW 400 kV output to grid, incl. DeNOx- and DeSOx plants 313 MW 400 kV output to grid, excl. DeNOx- and DeSOx plants 316 MW District heating output 422 Mj/s Turbogenerator, heat rate, based on gen. output 8150,3 kJ/kWh Boiler efficiency 94,2 % Power plant, heat rate, based on gen. output 8652,1 kJ/kWh Gross calorific value of coal 26 MJ/kg Specific coal consumption, based on gen. output + DH output 148 g/kWh Specific coal consumption, 400 kV output to grid + DH output 154 g/kwh Thermal efficiency, 400 kV output to grid +DH output 90 %
Operational data, combined heat and power production 100% load, back pressure mode, 4 c cooling water. .

Group

Burmeister & Wain Energy A/S Jgersborg All 164 DK-2820 Gentofte Denmark Tel/fax +45 39 45 20 00/+45 39 45 20 05 info@bwe.dk

Clean Coal Technology, Sardinia May 2005

Materials for membrane walls:

300 250
Allowable stress [N/mm2]

200 13CrMo4-5 150 SA-213 T23 7CrMoVTiB10-10 HCM12 100

50

0 0 100 200 300 400 500 600 700 Temperature [C]

Group Burmeister & Wain Energy A/S Jgersborg All 164 DK-2820 Gentofte Denmark Tel/fax +45 39 45 20 00/+45 39 45 20 05 info@bwe.dk

Clean Coal Technology, Sardinia May 2005

Materials for super heaters:

250

200

Allowable stress [N/mm2]

150

HR3C Super304H TP347HFG

100

50

0 0 100 200 300 400 500 600 700 Temperature [C]

Group Burmeister & Wain Energy A/S Jgersborg All 164 DK-2820 Gentofte Denmark Tel/fax +45 39 45 20 00/+45 39 45 20 05 info@bwe.dk

Clean Coal Technology, Sardinia May 2005

Future efficiencies
Net Efficiency (LHV) % 60 58 56 54 52 50 48 46 44 42 40 38 36 34 32 30 1950 1960 1970 1980 1990 2000 2010 2020
Commissioning Year
Ensted 3 Avedre 2 Esbjerg 3 No rdjylla nds v rk et Line of Steel Line of Super Alloys

Fynsv. 7 Studstrup 3/4

250 M W

Group Burmeister & Wain Energy A/S Jgersborg All 164 DK-2820 Gentofte Denmark Tel/fax +45 39 45 20 00/+45 39 45 20 05 info@bwe.dk

Clean Coal Technology, Sardinia May 2005

NVV B3 op CHP mode

Conclusion:
The USC Power Cycle : is the current development edge of the conventional Rankine power cycle has proved to have high and satisfactory availability has demonstrated high efficiency and has a potential for further efficiency increase

Group Burmeister & Wain Energy A/S Jgersborg All 164 DK-2820 Gentofte Denmark Tel/fax +45 39 45 20 00/+45 39 45 20 05 info@bwe.dk

Clean Coal Technology, Sardinia May 2005

Visit us on the web www.bwe.dk

Group Burmeister & Wain Energy A/S Jgersborg All 164 DK-2820 Gentofte Denmark Tel/fax +45 39 45 20 00/+45 39 45 20 05 info@bwe.dk