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Benson Boiler

Benson Boiler

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Published by: jigsprajapati on Oct 22, 2009
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The World’s First Supercritical FW-BENSONVertical PC Boiler – The 750 MWeLongview Power Project
Stephen J. GoidichRichard J. DochertyKenneth P. Melzer
 Foster Wheeler North America Corp.Clinton, NJ 08809
Presented at
 PowerGen EuropeCologne, GermanyMay 26 – 28, 2009
When the 750 MW
Longview Power Project begins commercial operation in March of 2011, it will be the world's first supercritical FW-BENSON Vertical pulverized coal (PC)boiler and will demonstrate the innovative features of its low mass flux evaporator designthat utilizes optimized rifled tubing. Structural steel is in place, pressure part erection isunderway, and mechanical completion is scheduled for October 2010.The project is located on a greenfield site in a mine mouth location at Maidsville, WestVirginia, 70 miles south of Pittsburgh. The project is owned by Longview Power, LLC,which is 100% owned by GenPower Holdings, LP. The Project is being constructed by aconsortium of Siemens Energy, Inc. and Aker Construction, Inc., with the boiler supplied byFoster Wheeler directly to Longview.Foster Wheeler (FW) designed and is supplying the boiler, Siemens is providing the steamturbine generator, air quality control equipment, cooling tower and stack. Aker is responsiblefor construction/installation of equipment and materials.The boiler will generate supercritical steam at 1056
F (569
C), 3840 psia (265 bar) to drive asingle reheat turbine to deliver 769 MW
gross (695 MW
net) firing an Eastern USAbituminous coal. Pollution control equipment includes a wet scrubber and baghouse for SO
 and particulate control. A selective catalytic reduction (SCR) system is provided for NO
 control.Other unique aspects of the project include that it is the first US supercritical coal plantdeveloped by an independent power producer (IPP), the first greenfield coal plant in thenortheastern USA in over 20 years, the first major private equity participation in a new UScoal plant project, and the first Siemens steam reference plant in the US.Described in this paper are the project participants, structure, and status, the main boilerdesign features, and the innovative FW/BENSON low mass flux boiler technology.
Since supercritical once-through boiler technology was introduced to the power industry inthe early 1960's, there have been many innovative boiler design configurations and featuresintroduced to reduce capital and operating costs, simplify operation and maintenance, andincrease reliability. A notable example is the introduction of in-line steam/water separatorswhich eliminated complicated valve manipulations that made every start-up an adventure.Another milestone was use of a spiral furnace tube configuration which, by having a singleupflow configuration, permitted both furnace and superheater variable pressure operation.This allowed for cycling operation with the benefits of reduced low load auxiliary power andoptimum matching of steam and turbine metal temperatures to maximize turbine life. In the1980's, the spiral configuration became the state-of-the-art for new supercritical powerprojects. However, the inclined tube configuration requires high (power consuming) massflow rates to maintain good tube cooling, and a special (complex) support system.In the 1990's, vertical tube configurations with standard rifled tubes were introduced tosimplify fabrication, construction, and maintenance while permitting full variable pressurecycling operation with reduced pressure loss. However, with standard rifled tubes there is aminimum fluid mass flow that must be maintained when passing near the critical pressure.As will be described in more detail later, this minimum mass flow for standard rifled tubesresults in a negative flow characteristic which means that tubes that receive more heat getless flow. To prevent tube overheating, the tubes must be properly orificed to push moreflow to the tubes receiving the most heat.In the mid 1990's, after extensive laboratory testing of many rifled tube rib geometries,Siemens developed and began licensing the BENSON Vertical evaporator configuration foronce-through boilers. The BENSON Vertical evaporator includes optimized rifled tubes thatprovide enhanced tube cooling with very low mass flow rates. With low mass flow rates apositive flow characteristic, similar to a drum type boiler, is achieved. Tubes that receivemore heat receive more flow. This self-compensating, low mass flux feature eliminates theneed for customized orificing which must be engineered for each project, and minimizespressure loss which reduces auxiliary power consumption.

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