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By Steve Voss, P.E., and In a typical coal-fired steam cycle 2 shows a similar single reheat cycle,
power plant the operating pressure is but operating at 3500 psi, or in the
Greg Gould, P.E. 2400 psi. Steam temperature is typical- supercritical range. Increased efficien-
ly 1000 or 1050 degrees F. Steam tem- cy is represented by the increase in
The steam cycle in a power plant is perature is limited by available mate- area under the curve, approximately
characterized by the maximum oper- rials that can survive at elevated tem- as shown in Figure 3.
ating pressure of the cycle. The typical peratures. Most larger units have a
steam turbine power plant operates reheat cycle (shown as line from point Increasing the steam pressure
on the Rankine cycle, the workhorse 2 to 3 in figure 1), where the steam is improves cycle efficiency. It also pro-
of the coal-fired utility industry. produced in the boiler, passes through vides the opportunity to go to a "dou-
a portion of the turbine, is "reheated" ble reheat" cycle, which allows even
Subcritical Rankine Cycle in the boiler and then goes through more improvement in overall efficien-
The main feature of the Rankine cycle the remainder of the turbine. This cy. The overall net efficiency for a typ-
is the compression or pumping that increases the efficiency of the cycle ical subcritical coal-fired unit is about
occurs when the working fluid, water, without increasing the maximum 10,000 Btu/kWh. Increasing the initial
is in the liquid phase. The amount of steam temperatures. steam pressure to 3500 psi from 2400
energy available for extraction by the psi improves the heat rate by about
working fluid is dependent on the The operating pressure of convention- 1.5%. The efficiency of a unit with
operating temperature and pressure of al coal-fired power plants can be clas- 3500 psi initial steam pressure and
the fluid. Raising the steam pressure sified as subcritical or supercritical. double reheat is about 4% better than
or steam temperature improves effi- The critical point is where the temper- a typical subcritical unit. For a 600
ciency. ature and pressure are such that the MW unit burning $1.20 per million
fluid is no longer classified exclusive- Btu fuel with an 80% annual capacity
Why is it desirable to raise pressures ly as liquid or gas. It is thought of as a factor, this represents an annual cost
and temperatures? Figure 1 represents fluid above the critical point. The criti- savings of about $2 million.
the Rankine cycle. The upper line rep- cal point for water is slightly above
resents the steam temperature and 3200 psi. Figure 1 shows a typical 2400 Existing subcritical units in the United
pressure generated by the boiler. The psi subcritical Rankine cycle with sin- States typically have a steam drum
lower line represents the condensing gle reheat. The critical point is shown where the working fluid circulates
portion of the steam cycle. The differ- slightly above the cycle shown. Figure through the water walls either by heat
ence between the upper and lower transfer and gravity in the case of nat-
lines determines how much energy
can be extracted by the steam turbine,
and thus the efficiency of the cycle.
The condenser operates at a tempera-
ture and pressure dictated by external
conditions such as the temperature of Rankine Cycle Legend
Critical Point
the atmosphere or the cooling water 1-2 HP Turbine Expansion
2-3 Reheat
temperature. It is not feasible to sub- 3-4 IP/LP Turbine Expansion
stantially lower this line. The only 4-5 Condenser
way to improve the cycle efficiency is 5-6 Feedwater
Heating/Pumping
by pushing the upper line higher. 6-1 Boiler
Figure 1
Temperature Entropy Diagram
Subcritical Rankine Cycle
TechBriefs 5
because it required the use of redun- taken place overseas, where the mar-
dant mainframe computers, which did ket for coal-fired boilers has been bet-
not provide the reliable control ter. Since 1997, over 22,000 MW of
required for power plants. coal-fired generation has been built in
Europe. In that same time, less than
Lastly, there is the higher capital cost. 10% of that number has been built in
The added capital cost of a supercriti- the United States. An interesting trend
cal unit over a drum-type unit ranges to note is that over 80% of the over-
from no change to 3-5% depending on seas units are supercritical. There are
the source of the information. approximately 360 supercritical units
worldwide.
Steve Voss is manager of the
Where Is All This Headed? plant services group in Burns &
The last big hurdle is overcoming a What About Unit Availability? McDonnell’s Energy Group. He has
technology that is decades old. The The availability of supercritical units a bachelor’s degree in mechanical
latest developments are aimed at even built since 1990 is every bit as high as engineering from the University of
higher thermal efficiencies: 4500 psi the subcritical units. The early super- Missouri-Rolla. He has worked for
with temperatures of 1500° F results in critical unit population in the U.S. has Burns & McDonnell since 1990.
as much as 20% better thermal effi- a dark cloud that followed it around
ciency than conventional drum-type due to availability problems. Some of
units. The limiting factors are the the problems can be attributed to the
materials of construction that can supercritical cycle, but just as many
withstand extreme conditions and can be attributed to the fact that the
what advances in metallurgy and supercritical units are on the average
ceramics can solve the problems. newer units that were built to tighter
emission control standards and have
The construction of coal-fired base- had more control equipment. As any
load power has been all but non-exis- statistician or maintenance person can
tent in the United States for the last 20 confirm, a system with more moving
years. A few projects have been com- parts has a higher potential for failure
pleted here and there, but the majority than a simple system.
of the technological advances have
Figure 3
Temperature Entropy Diagram
Super vs. Subcritical Rankine Cycle