Concept of Super Critcal

CONCEPT OF
SUPER CRITICAL
CYCLE
26 October 2017 PMI Revision 00 1

Presentation Outline
What is importance
History of this technology
Super Critical cycle details

PERCAPITA ELECTRIC POWER CONSUMPTION
COUNTRY PERCAPITA ELECTRICPOWER CONSUMPTION KWH
INDIA 513
CHINA 773
CANADA 16413
USA 13040
MEXICO 1439
NORWAY 24033
SWITZERLAND 7346
FRANCE 7069
UNITED KINGDOM 5968
SPAIN 4072
RUSSIA 5108
ITALY 4610
SWEDEN 15244
GERMANY 6406
TURKEY 1259
JAPAN 7749
These are collected from Ststistics Organisation for Economic Cooperation and Development of I.E.A.

Emerging Market Requirements For Utility
Units
High Reliability & Availability
Highest economically achievable plant
efficiency and heat rate
Suitable for differing modes of operation
Suitable for different quality of fuel
Ability to operate under adverse grid conditions
/ fluctuations
Minimum emission of Pollutants
Lowest life cycle cost

Thermal Power Generation
Higher cycle efficiency for :
Conservation of fuel resources
Reduction of Atmospheric Pollutants - SOX
& NOX
Reduction in CO2 emission (linked to
global warming)
Better economy in power generation where
fuel costs are high and pollution control
requirements are stringent

GROWTH OF UNIT SIZES IN INDIA
RATING YEAR OF INTRODUCTION
60/70MW 1965
110/120MW 1966
200/210MW 1972
250MW 1991
500MW 1979
660MW Commg
800 MW PROPOSAL STAGE

AS THE UNIT SIZES GREW, BOILER SIZES SUPPLYING
STEAM TO SUCH TURBINES HAVE ALSO INCREASED
UNIT STEAM SHO SHO/RHO

SIZE FLOW PRESSURE TEMPERATURE
(T/H.) (KG/CM2) (DEG. C)
30MW 150 63 490

60/70MW 260 96 540
110/120MW 375 139 540/540
200/210MW 690 137/156 540/540
250MW 805 156 540/540
500MW 1670 179 540/540
600MW 2100 255 540/568
800 MW 2565 255 568/596
Major Sulzer/Combustion Engineering
Innovations for Fossil Utility Boilers
Year of Introduction
1841
First Sulzer Boiler
1912
First Pulverized Coal Fired Utility Boiler
1927
Tangential Firing
First Commercial Monotube Steam

Generator 1931
Controlled Circulation 1942
First Commercial Supercritical Monotube

Steam Generator 1954

Major Sulzer/Combustion Engineering
Innovations for Fossil Utility Boilers
Year of Introduction
MHI Adopted as Monotube Technology Licensee
1957
Highest Temperature and Pressure Supercritical
Boiler
1960
Combined Circulation - Supercritical
1964
Largest Oil/Gas Fired Supercritical Steam
Generator
1970
Controlled Circulation Plus
1978
Sliding Pressure Supercritical
1980

Fuels for Steam Power Plants
Coal & Lignite:
Abundant availability
Lower cost
Will continue as the main fuels in many
countries

Cycle Efficiency
Higher efficiency can be realised with
Higher live steam parameters

Adoption of double reheat cycle
Reduction in condenser absolute pressure

Measures to improve Plant Efficiency and / or
Heat Rate
Boiler side measures :
Minimum RH spray
Minimum SH spray (if tapped off before feed heaters)
Minimum flue gas temperature at AH outlet
Minimum excess air at AH outlet
Minimum unburnt Carbon loss
Reduced auxiliary power consumption

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
Approximate improvement in Cycle Efficiency
Pressure increase : 0.005 % per bar

Temp increase : 0.011 % per deg K

500 MW Steam Generator
Coal Consumption and Emissions
Subcritical Supercritical
Unit Unit
Coal Saving t/year Base 68800
CO2 Reduction t/year Base 88270
SO2 Reduction t/year Base 385
Basis:
Cycle Efficiency % Base +1.0
No. of operating Hrs./year 8000 8000
hrs.
Steam generation details

Supercritical Cycles
Initially adopted in the late fifties and sixties
Higher Steam temperature employed on some units
Unit sizes also witnessed an increasing trend

Sliding Pressure Supercritical Design
Enthalpy Variations vs Pressure and Boiler Load

Operating Experience
The first generation

supercritical units
Experienced increased
forced outages
Witnessed reduced plant
reliability and availability

Comparison of Subcritical and
Supercritical
Cycle Availability (NERC)
14
12
10
EFOR %
0
1982-1984 1985-1987 1988-1990 1991-1993 1994-1996 1997
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

Increased outages were caused
by
Inadequate experience while extrapolating
to the new designs and the increased unit
sizes.
Inadequate knowledge of high

temperature materials.

The increased outages led to :
Reversal of steam pressures to subcritical

range
Lowering of steam temperatures to 540
Deg C

Current Trends in Steam Parameters
1980s : Pressure increased from 175-180

bar to 225 bar; temp mostly
around 540 Deg C
1990 : Pressures raised to 285 bar;temp
raised to 565-580-600 Deg C
300 bar & 620 Deg C not unusual today
255 bar 568/568 Deg C commonly used presently

Implications of higher steam parameters on
boiler design
Boiler type
Materials
Reliability and Availability

Types of boilers
Drum type
Once-through type

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

Drum type boiler
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
Once Through Boiler-Concept

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

COTROLLED CIRCULATION
(Vs) ONCE THRU
CC OT
Once Through Boiler-Concept

Once Through Boiler
Once -through flow through all sections of
boiler (economiser, water walls &
superheater)
Feed pump provides the driving head
Suitable for sub critical & super critical
pressures

Once-thru Boiler
Major differences from Drum type boiler :
Evaporator system
Low load circulation system
Separator

Once -thru Boiler
Evaporator system :
Formed by a number of parallel tubes
Tubes spirally wound around the furnace to
reduce number of tubes and to increase the mass
flow rate thru the tubes
Small tube diameter
Arrangement ensures high mass velocity thru the
tubes

Once -thru Boiler - Furnace Wall

Furnace Arrangement
SPIRAL TYPE
VERTICAL TYPE
ONCE - THROUGH OPERATING RANGE

Once -thru Boiler
Low load circulation system :
At part loads once -thru flow not adequate to cool the tubes
To maintain required mass velocities boiler operates on
circulating mode at low loads
Excess flow supplied by feed pump or a dedicated circulating
pump

LOW LOAD SYSTEM WITH CIRC.
PUMP

LOW LOAD SYSTEM WITH HEAT
EXCHANGER

Once - thru Boiler
Low load circulation system :
The excess flow over the once-thru flow
separated in separator and
Returned to the condenser thru a heat
exchanger
or
Recirculated back to the boiler directly
by the dedicated circulating pump

Once -thru Boiler
Separator :
Separates steam and water during the
circulating mode operation
Runs dry during once-thru flow mode
Smaller in size compared to drum in a
drum type boiler

Typical Separator sizes
Number of separators 2 4
Inside diameter approx mm 850 600
Thickness mm 95 70

Once -thru Boiler
Advantages:
Better suited for sliding pressure operation
Steam temperature can be maintained over wider load range
under sliding pressure
Quick response to load changes
Shorter start up time
Higher tolerance to varying coal quality
Suitable for sub critical & super critical pressures

Sliding Pressure Operation

Advantages of sliding pressure operation:
Lower thermal stresses in the turbine during load changes.
Control range of RH temp is extended.
Reduced pressure level at lower loads prolongs the life
span of the components.
Overall reduction in power consumption and improved heat
rate.

Once -thru Boiler
Requirements :
Stringent water quality
Sophisticated control system
Low load circulation system
Special design to support the spiral furnace wall weight
High pressure drop in pressure parts
Higher design pressure for components from feed pump
to separator

Advanced Cycles
Effect on Boiler Components
Evaporator (Furnace) walls

Superheaters
Thickwalled boiler components
Steam piping

Furnace walls
Increased operating pressure increases
the medium temperatures.
Increased regenerative feed heating
increases the fluid temp entering.
Larger furnaces required for NOX
reduction, increase SH steam temperature
at furnace wall outlet.

Superheaters
Tube metal temperatures in final sections

increase with outlet steam temperature.
Susceptibility for high temperature
corrosion.
Susceptibility to steam side oxidation

Thick walled components
Higher pressure & temperature lead to
increased thickness of :
Shells of separator, start-up system
components, SHO header..
Main steam piping.
Higher thickness results in larger temperature
gradients across walls.

Changed heat release in the furnace
by varying coal qualities
Varying combustion and fouling behaviour of

different coals within a wide range of coals
cause varying heat release and heat
absorption in the furnace
Benson boiler principle compensates these

effects by shifting of the final evaporation
point without diminishing efficiency

Definition of Supercritical Design
Evaporator pressure (MCR) 222 bar e Supercritical
Design
Source: Siemens
Changed heat absorption in
furnace due to changes in coal
quality
Varying combustion and fouling behaviour of

different coals within a wide range of coals cause
varying heat release and heat absorption in the
furnace
Benson boiler principle compensates these

effects by shifting of the final evaporation point.

Fixed evaporation end point
For a drum type boiler the flue gases at the combustion

chamber outlet can not be cooled below a certain value.
Dimensioning of the heating surfaces of boilers having
fixed evaporation end point must be done precisely.
Generation of steam and spraying quantity in the SH
change substantially if the operating point deviates from
the design point.

Faster Start-up Time with Supercritical Design
Once - Thru First Fire to Turbine Synch, First Fire to Turbine Synch,
Minute without Bypass System Minute with Bypass System
Hot Start Up, after 2 hr shutdown 40 30
Warm Start Up, after 8 hr shutdown 65 45
Cold Start Up, after 36 hr shutdown 130 90
Drum
First Fire to Turbine Synch, First Fire to Turbine Synch,
Warm Start Up, after 8 hr shutdown 65 - 90 45 - 70
Cold Start Up, after 36 hr shutdown 180 - 260 140 - 220

Present Trend in India
Unit Size SHO SHO pr. SHOT RHOT
MW flow(t/hr) (Kg/Sq.cm) (C) (C)
660 2100 255 568 596
800 2565 255 568 596

Faster Start-up Time with
Supercritical Design
Once - Thru
Warm Start Up, after 8 hr shutdown 65 45
Cold Start Up, after 36 hr shutdown 130 90
Drum
Warm Start Up, after 8 hr shutdown 65 - 90 45 - 70
Cold Start Up, after 36 hr shutdown 180 - 260 140 - 220

Tighter Control of Steam Temperatures
Typical Parameters
SH Outlet RH Outlet
Steam Temp., Steam Temp.
F F
Drum Type
3% per minute (30%-100% load) +/- 10 +/- 15
5% per minute (50% - 100% load) +/- 35 +/- 40
Once-Through
3% per minute (30% - 100% load) +/-10 +/-10
5% per minute (50% - 100% load) +/-10 +/-12
Note:Above values are based on sliding pressure mode and a 5 minute load ramp.

THANK YOU

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CONCEPT OF

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COUNTRY PERCAPITA ELECTRICPOWER CONSUMPTION KWH

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RATING YEAR OF INTRODUCTION

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UNIT STEAM SHO SHO/RHO

30MW 150 63 490

First Commercial Monotube Steam

Controlled Circulation 1942

First Commercial Supercritical Monotube

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Higher live steam parameters

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Pressure increase : 0.005 % per bar

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CO2 Reduction t/year Base 88270

SO2 Reduction t/year Base 385

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Enthalpy Variations vs Pressure and Boiler Load

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The first generation

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Inadequate knowledge of high

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Reversal of steam pressures to subcritical

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1980s : Pressure increased from 175-180

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Reliability and Availability

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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

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