Advanced Supercritical Boiler Technologies

Official Opening of the OxyCoalTM Clean Combustion

Test Facility
Technical Seminar

Dr David Smith
Date: 24 July 2009

AGENDA

• Why Advanced Supercritical?

• Advanced Supercritical : State of the Art

• Next step: Ultra Supercritical

Page 1

1
WHY ADVANCED SUPERCRITICAL?

TRACK 2: Carbon Capture

and Storage (CCS)

- 95%

CO2
Reduction

TRACK 1: Increased Efficiency

Baseline

Time

• Both tracks are required to mitigate CO2 emissions from coal fired generation
• Primary means to increase efficiency is to increase the steam conditions we use in our power plant cycle

Page 2

WHY ADVANCED SUPERCRITICAL?

• Efficiency of the Rankine Cycle

increases with increasing Turbine inlet
Temperature and Pressure

• Cycle efficiency of typical sub-critical

plant is 38% whereas today’s
supercritical technology increases this
to around 45-47%

Advanced Ultra
Sub-Critical Super-Critical Super-Critical Super-Critical
• Supercritical means above the “critical”
point for water / steam (220.89 bar) after
which there is no phase change between
220.89 250 290 water and steam
Main Steam Pressure (bar)
• Other terms “Advanced Supercritical” and
“Ultra Supercritical” are loose definitions to
540 570 610 indicate steps in technology as opposed to
Main Steam Temperature (°C) any distinction in thermodynamic
properties Page 3

2
 DEVELOPMENT IN THERMAL EFFICIENCY

Meaningful CO2 reductions can be achieved by replacing old units with modern advanced supercritical
plant

Increasing
Efficiency
Best Available Advanced 50 – 55%
55 Supercritical Technology
Target (-29%) Lower CO2
being offered now – eg
Kingsnorth, Greifswald AD700
emissions
50
Doosan Babcock 46%
Supercritical
ASC (-23%) Boilers
45
Plant Meri Pori New Chinese 42%
efficiency Hemweg Orders
40
% NCV UK Chinese fleet 38%
38%
fleet
35
32% Sub Critical
Older Boilers
30
Plants
Year
1960 1980 2000 2020 Page 4

STEAM CYCLE AND PLANT EFFICIENCY GAINS

Efficiency gains have mostly been achieved by pushing the steam cycle, lower excess air and lower
gas exit temperature have also contributed

55
Target
375-700/700 AD700
50
305-585/602
Efficiency (%NCV)

285-580/580
275-585/602
45
274-580/600
Sub-Critical
260-540/560 Supercritical
239-540/560
40

169-541/539
166-568/568
35
159-566/566
166-568/568
Main Steam Pressure (barg) – Steam Temperature Main / Reheat (°C)
30
1960 1970 1980 1990 2000 2010 2020
Year Page 5

3
 AGENDA

• Why Advanced Supercritical?

• Advanced Supercritical : State of the Art

• Next step: Ultra Supercritical

Page 6

WANGQU, SHANXI PROVINCE, CHINA

MAIN STEAM REHEATER
OUTLET OUTLET

Pr ep ar ed by Te r y E van s, J anu ar y 200 4 f or W ang qu

SEPARATO R
VES SEL

REHEAT ER

REHEATER
TO S TORAGE
FINAL VESSEL
SUPERHEAT ER

PLA TEN
SUPERHEAT ER

PRIMARY
SUPERHEATER

ECONO MISE R

ECONO MISE R

2 x 600MWe Units

Evaporation 540 kg/s

HOPPER KNUCKLE

S/htr Outlet Press 248 bar FURNACE ACCES S DOOR

S/htr Outlet Temperature 571°C

R/htr Outlet Temperature 569°C W ATER
IMPO UNDED
HOPPER

Contract Effective 09/03

Operational 36 months later
Page 7

4
 DEPLOYMENT OF SUPERCRITICAL TECHNOLOGY

China’s deployment of supercritical technology far outstrips other countries and regions – UK deployment is
zero

Page 8

GREIFSWALD, GERMANY

2 x 800MWe Units

Evaporation 588 kg/s

S/htr Outlet Press 277 bar
S/htr Outlet Temperature 600°C
R/htr Outlet Temperature 605°C
PosiflowTM vertical tube furnace
Page 9

5
DEVELOPMENTS IN SUPERCRITICAL BOILERS

• PosiflowTM Best Available Technology for

Once-Through boiler furnace
• Lower pressure drop means lower feed-pump
power and lower through-life energy
consumption
• Other advantages include better turn-down,
simpler construction and improved availability

• With a PosiflowTM furnace the supercritical

down-shot boiler can be realised: combines the
economic and environmental benefits of
supercritical steam conditions with anthracite
combustion for the first time
• Doosan Babcock 2 x 600MW supercritical
down-shot units for Zhenxiong, Yunnan
Province, China.
Page 10

DEVELOPMENTS IN SUPERCRITICAL BOILERS: PLANT UPGRADE

• Supercritical Retrofit - existing plant can be

upgraded to supercritical steam conditions with
lower capital cost and more rapid timescale
than new plant
• New boiler within existing structure
• POSIFLOWTM vertical tube low mass flux
furnace
• Re-use of other equipment (eg fans,
airheaters, coal mills)
• New HP and IP turbine

• Doosan Babcock Upgrade of Yaomeng Power

Plant in China 2002
• Owner chose not to upgrade to supercritical
steam conditions…..
• However, application of PosiflowTM furnace and
combustion system modifications gave 10%
lower coal consumption and availability of 96%

Page 11

6
AGENDA

• Why Advanced Supercritical?

• Advanced Supercritical : State of the Art

• Next step: Ultra Supercritical

Page 12

ULTRA SUPERCRITICAL

Boiler concept for > 700°C

Generation 550MW
Overall cycle efficiency >50%

Main Steam Pressure 365 bar-a

Main Steam Temperature 705°C
Reheat Steam Temperature 720°C

Reduction in CO2 emission relative to sub-critical ~30%

Page 13

7
 MATERIALS FOR ADVANCED STEAM CYCLES - TUBING

Steam cycle based efficiency gains are constrained by the availability of suitable alloys
Average Stress Rupture (MPa) (100000 Hours)

300
Ferritic Alloys
All available now Austenitic Alloys
250 Super 304H, 347HFG available now Nickel Alloys
Sanicro 25 available – not yet codified Validation ongoing
T24

200
P92
Super 304H Alloy 617
T23
150 Alloy 740
Sanicro 25
Alloy 263
100
347 HFG

50
Steam Temperature ~550°C ~600°C ~650°C ~700°C

0
500 550 600 650 700 750
Metal Temperature (°C)

Page 14
Note – maximum allowable temperatures are also limited by steam-side oxidation

MATERIALS FOR ADVANCED STEAM CYCLES - TUBING

To put that in context consider a 48mm tube operating at 700°C with a design pressure of 380 bar:

HR3C Alloy 617mod Alloy 740

Austenitic Nickel Alloy Nickel Alloy

Allowable Stress @ 750°C 44.5 56.0 96.0

(MPa)

Calculated thickness 20.5 16.2 9.5

t = P.D / 2.σ (mm)

Page 15

8
MATERIALS FOR ADVANCED STEAM CYCLES – HEADERS AND PIPEWORK

Austenitic alloys suffer from thermal fatigue, making them less suitable for thicker wall section
components
Average Stress Rupture (MPa) (100000 Hours)

300
Ferritic Alloys
All available now
250 Nickel Alloys
Validation ongoing
T24

200
P92
Alloy 617
T23
150 Alloy 740

Alloy 263
100

50
Steam Temperature ~600°C ~650°C ~700°C

0
500 550 600 650 700 750
Metal Temperature (°C)

Page 16
Note – maximum allowable temperatures are also limited by steam-side oxidation

MATERIALS FOR ADVANCED STEAM CYCLES – MANUFACTURING

Manufacturing processes for components from new materials require extensive validation

Bend tests in Sanicro 25

Test bending furnace wall panels in T23 material

Alloy 263 pipe production Alloy 263 weld qualification

Page 17

9
ULTRA SUPERCRITICAL – CYCLE OPTIMISATION

• In addition to improvements in Rankine Cycle efficiency from increasing steam temperatures we can make
better use of low grade heat in our power plant cycle

• Feedwater heating can be optimised to reduce the quantity of high grade bled steam taken from the turbine
and better utilise the low grade heat in the flue gas leaving the boiler

Page 18

SUMMARY

• Increasing plant efficiency is fundamental to reducing all emissions including CO2

• Primary means to increase efficiency is to increase the steam pressure and temperature at the turbine
inlet

• This means using steam at supercritical pressures – we use terms such as “Advanced Supercritical” and
“Ultra Supercritical” to indicate higher ranges of temperatures and pressures

• We can make improvements to the basic once-through boiler concept like the PosiflowTM furnace to
further increase efficiency and operating flexibility

• Supercritical technology can be readily retrofitted to life-expired existing plant

• Today’s Advanced Supercritical plant will achieve around 46-47% cycle efficiency (LHV basis) and about
20% reduction in CO2 for the same MWe output as existing sub-critical plant

• Ultra Supercritical plant operating at steam temperatures above 700°C is the next step. Together with
improved cycles this will achieve a plant efficiency over 50% and about a 30% reduction in CO2
compared to existing sub-critical plant

• Attainment of 700°C is constrained by the availability of suitable materials for the highest temperature
components and development programmes are underway
Page 19

10
Commercial Contact Details

Doosan Babcock is committed to delivering unique and advanced supercritical

boiler technologies.

Steve Whyley
Global Sales Director

Doosan Babcock Energy

11 The Boulevard
CRAWLEY
West Sussex
RH10 1UX

T +44 (0) 1293 612888

D +44 (0) 1293 584908
E swhyley2@doosanbabcock.com

Page 20

11