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General
The critical pressure point of water and steam is 22.1 MPa abs, below
this pressure it is called sub-critical pressure and above this pressure it
is called as supercritical pressure. In the supercritical region, co-
existence of water and steam is not present, therefore in the absence of
steam/water mixture, the recirculating boiler technology adopted for
subcritical pressure could not be used. This was the key to the
advancement of cycle efficiency through the adoption of economic and
reliable once-through supercritical boilers.
In the 1950s when the USA showed interest in using advanced steam
conditions, the two major holders of the “supercritical” boiler technology
were Sulzer of Switzerland and Siemens in Germany. Sulzer boilers were
known as ‘monotube’ boilers whereas Siemens the licensor of the Benson
once-through boiler technology. The USA boiler manufacturers therefore
turned to Europe and signed technology licenses with the Europeans. It
was this USA push that spawned the majority of the supercritical boilers
that operate in the world today. By comparison the number of
supercritical plants of direct European origin is modest, although the
numbers have grown in recent years. Combustion Engineering signed
with Sulzer and Babcock and Wilcox and Foster Wheeler had an
agreement with Siemens. Riley Stoker also built supercritical pressure
units.
Between 1957 and 1960 six supercritical plants were commissioned in
the USA using the European knowledge but with USA additions. Some
ambitious steam conditions, up to 5000 psi, (34.5 MPa) and 1200°F
(650°C) most with double reheat, were adopted. A number of these plants
should be put in the category of ‘pioneering plants’ as they were not a
commercial success.
Design developments were undertaken in USA and in the mid sixties the
second generation of supercritical units was being commissioned. Through their Japanese
licensees supercritical units of the USA design were constructed in Japan. Babcock &
Wilcox’s once-though boiler was called the ‘Universal Pressure’ (UP) boiler, suitable for
both sub and supercritical pressures.
In USA from 1963 to 1970 about half of the sales of utility fossil fuel fired
plant were designed for supercritical pressure. From 1971 to 1974 it had
fallen to around 25%. The reasons for the reduction were:
The number of supercritical plants sold in the USA in the decade starting
1965 amounted to 125 units. In total there are now some 150 units in service in the USA,
the reduction in the rate of their installation being in part a result slowdown in the growth
of demand and the trend towards gas fired combined cycle plants.
As can be seen from the above the countries which have the most
experience with supercritical pressure cycles are USA, (although most of the units
installed are of an out-dated technology) Japan, Germany and Denmark. There are
also a number of units in Korea, China and a lesser number elsewhere.
Thus Germany, Japan and Denmark have a number of modern plants
which could be described as ‘world’s best practice’ in terms of efficiency
and operational flexibility. It is natural that the major advancement in
the technology has occurred in those countries where the high cost of
fossil fuels is a major driver. In the case of Germany and Japan they also
have the necessary industrial base and the major boiler and turbine
designers who have the resources to develop advanced designs. In the
European scene the major players are Alstom and Siemens on both
boilers and turbines, and Deutsche Babcock on boiler design. In the case
of Japan all the usual heavy industry manufacturers are involved, MHI
and Hitachi with both boiler and turbines, and Toshiba on turbines, IHI
on boilers. The major USA manufacturers also offer supercritical boilers
of a similar design to those offered by the German and Japanese
manufactures.
Supercritical Boilers
With supercritical pressure boiler there is not only a need to increase the
wall thickness of the pressure components and also use advanced
materials but there is also a need to adopt a type of boiler which is
different to the type normally used for sub-critical pressures. This need
is related to the type of technology that can be used in the evaporation
circuit of the boiler. It is this need for a different boiler technology which
is the critical requirement in the adoption of supercritical pressure.
As stated earlier, at supercritical pressures, unlike at sub-critical
pressures, there is no co-existence of the two phases, water and steam.
Therefore the standard circulation system, which relies on the density
difference between steam and water to drive the circulation for cooling
the furnace wall tubes, and to separate the steam from the water to
enable superheating to take place in the superheater tubes, is no longer
suitable. Instead a once-through type of system must be used.
Unlike the boiler plant the design of the turbine plant is little affected by
the use of supercritical pressure. Of course the high pressure cylinder
must be designed to withstand the higher pressure and temperature and
also the reheater pressure and temperature will be higher, generally in
proportion to the increase in the main steam pressure.
With improved cycle efficiency, i.e. a lower heat rate, there will be a
reduction in heat rejected to the condenser. There is a multiplying effect for a given
improvement in heat rate. For example, if the heat rate is reduced by say 3.5% due to the
use of supercritical pressure and higher steam temperatures, the heat rejected to the
condenser is reduced by about 6.4%.
Efficiency Gains
Environmental Benefits
Comparative Costs
However the total heating surface area in the boiler may not change
significantly as the heat is transferred at a higher average fluid
temperature, thereby reducing the temperature differences between flue
gas and the working fluid.
Overall the cost of the boiler plant is higher mainly as a result of the
thicker walls for pressure containment and the more complicated
furnace wall system required for the once-through design. The cost of the
turbine is expected to be marginally higher due to the thicker walled
components or the higher grade material required because of the higher
emperatures. There is no significant extra equipment required to meet
the requirements of the supercritical plant, for e.g. supercritical pressure
plants would require 100% condensate polishing where as recirculation
sub-critical plants does not require this. But of late, condensing
polishing plants are widely used in recirculation sub-critical plants also.
Because of the reduction in size of much of the ancillary plant, coal and
ash handling plant, CW system, etc, which will partly off-set the
increased cost of the boiler and turbine, the overall cost of a supercritical
plant compared with a recirculation sub-critical plant should not be
more than 5% above a sub-critical pressure plant. This assumes that
moderate temperatures for steam conditions are used such as 570°C for
main steam and 580-600°C of hot reheat.
Higher temperatures and any higher pressure more than 25MPa may
push the price increase above the 5% increase.
Size Considerations/Selection
Therefore the problem of covering the furnace wall with tubes whilst
simultaneously maintaining an adequate cooling water velocity becomes
more difficult for smaller unit sizes. Also as indicated earlier small
turbine blade heights lead to higher losses. For these reasons
supercritical pressures are more suited to large unit sizes rather than
smaller sizes.
With the recirculation boiler most of the impurities in the feed water are
retained within the recirculation system as only pure steam passes onto
the superheater. Periodically the boiler water is ‘blown down’ to limit the
concentration of impurities in the boiler water. With a once- through
boiler there is no means of removing impurities from the system, any
impurities therefore will either deposit on the furnace walls or be carried
forward, either in particulate matter or in the vapour phase, to the
superheater and turbine. During the late 1950s and early 1960s with the
growth in the number of once-through boilers advances were made in the
cycle chemistry and water treatment technology to match the demand.
These days the feed water quality standards used for recirculation boilers
and once-through boilers are very similar. There is virtually no
distinction in the standard as to whether the boiler operates at sub or
supercritical pressure. Because of late 100% condensate polishing plant
are provided for sub-critical plants also.
With respect to level of the thermal inertia, i.e., the metal and fluid mass, which af-
fects the degree of overfiring (and underfiring) required on load changing, the
once-through boiler has a lower inertia. The furnace wall tubes are smaller
in diameter, the separator is smaller than the drum and no array of down-
comers exist. Higher loading rates are therefore possible on a once-though
boiler compared to a recirculation boiler.
The load change rate of the supercritical plant will be in the range of 3 to
5% per min. which is faster than the sub-critical plant load change rate
of 1 to 2% per min. As a result start-up time will be less in the
supercritical plants.
(iv) Availability/Reliability