Hitachi Power Materials

Boiler Design of innovative 600 C- and 700 C- Power Plants
Power Plants Technology in Dialogue 22th April 2008, Power Plant Technology, Hannover
Liisa Menp, Hitachi Power Europe GmbH l_maeenpaeae@hitachi-power.com
Introduction 600 C - and 700 C - Technology
Design Aspects
Material selection
Conclusion Z
Liisa Menp / HPE Power Plants Technology in Dialogue, Hannover, 22th April 2008
CO2 Emissions of Power Plants with different Fuels

1600 1400
Average China Russia 2003
CO2 Emissions [g/kWh]
1200 1000 800 600 400 200 0 0.25 Average worldwide
Current Average EU15-countries
lignite (rhenish) BAT 600/620 C 700/720 C 1 RH

Bituminous coal (Average)
Gas
Source: Marheineke T., Krewitt W., Neubarth J., Friedrich R., Vo A. IER-Bd. 74, IER, University of Stuttgart, Germany, 2000
0.3
0.35
0.4
0.45
0.5
0.55
0.6
Net efficiency [-]
Liisa Menp / HPE
Power Plants Technology in Dialogue, Hannover, 22th April 2008
Further CO2 Reduction: Carbon Capture
CO2 Emissions
with current Technology Trend with improved Efficiency Plants
with CCS
2000
2020
2050
Efficiency is the fast track CCS achieves near Zero-Emission

CO2 Emissions Increase of Power Plants with Bituminous coal by applying CCS
1600 1400
CO2 Emissions [g/kWh]
1200
+ 44 %
1000 800 600 400 200 0 0.25
Current Average EU15-countries BAT 600/620 C

+ 30 % Bituminous coal 700/720 C (Average) 1 RH
Source: Marheineke T., Krewitt W., Neubarth J., Friedrich R., Vo A. IER-Bd. 74, IER, University of Stuttgart, Germany, 2000
0.3
0.35
0.4
0.45
0.5
0.55
0.6
Net efficiency [-] Loss of efficiency is derived by Power demand for ASU and compression of CO2 for Oxyfuel
Design Aspects
Material selection
Conclusion
Liisa Menp / HPE
600 C - Technology: NRW Power Plant Study

Tower type RKW Vorzugsvariante 600 MW Turmkessel boiler Preferred Boiler Design 600 MW
Plant power outputAnlage 500 - 600 MW Bruttoleistung der (gross) 500 - 600 MW Efficiency (target) 45 47 % Zielwirkungsgrad 45 47 % (el, net) Steam conditions Dampfzustnde HP Turbineneintritt 285 bar / FD Turbine inlet 285 bar / 600 C600 C IP Turbine inlet 60 bar C Z Turbineneintritt 60 bar / 620 / 620 C
PS Moorburg A/B
2 x 820 MWel / 2 x 2088 t/h HP: 600 C / 276 bar a RH: 610 C / 51 bar a Time of commissioning: 2011/2012
PS Datteln
1100 MWel / 2939 t/h HP: 600 C / 285 bar RH : 620 C / 58 bar Time of commissioning : 2011
Walsum K. 10
1 x 790 MWel / 1 x 2143 t/h HP : 603 C / 290 bar a RH : 621 C / 75 bar a Time of commissioning : 2009
Liisa Menp / HPE
600 C - Technology: PS Datteln (1100 MW)

+ 121.5 m + 115.5 m
1100 MWel / 2939 t/h Benson steam generator

+ 80.0 m
Bituminous coal Design parameters: HP: 600 C / 285 bar RH: 620 C / 58 bar Time of commissioning: 2011 Efficiency: > 45.5 % (el, net)
+ 0.0 m
16946
Liisa Menp / HPE
600 C - Technology: Boiler materials Existing PP Today

= 45 47 % 285 bar / 600 C / 620 C
= 43 % 262 bar / 545 C / 562 C
1 21 oV1 MoV12 rM Cr C X20 X20
itic sten als Au eri P92 mat
44 rMo 13C
0 10 B1 VTi rMo 7C
Liisa Menp / HPE
700 C - Technology: Power Plant Study NRWPP700
Power Plant Study NRWPP700 500 MWel Efficiency (target) 50 % (el, net)
Preferred boiler design:

365 bar / 705 C / 720 C single reheat
Three different versions for boiler design: 365 bar / 705 C / 720 C, single reheat 260 bar / 705 C / 720 C, single reheat 365 bar / 702 C / 720 C / 720 C, double reheat
Base for current design of first 700 C boiler.
Source: NRW Power Plant 700C (NRWPP700)

10
700 C - Technology: steam generator for 500 MWel
HP-Part: Life steam pressure Life steam temperature
365 bar 705 C
RH-Part: Inlet pressure Outlet temperature
74 bar 720 C
Bituminous coal Benson steam generator First 700 C - Power Plant scheduled for: 2014 (E.ON)
Liisa Menp / HPE
11
700 C - Technology: Boiler materials Existing PP Today

= 45 47 % 285 bar / 600 C / 620 C
= 43 % 262 bar / 545 C / 562 C
2014
= 50 % 365 bar / 705 C / 720 C
1 21 oV1 MoV12 rM Cr C X20 X20
itic sten als Au eri P92 mat
se-ba ls Ni ia e- mater s a Ni-b rials e mat als, teri s ma itic aterial ns arte ase-m M Ni-b
44 rMo 13C
0 10 B1 VTi rMo 7C
Liisa Menp / HPE
12
Design Aspects
Material selection
Conclusion Z
13
Component design in the creep regime Tools / Methods

Design based on formula which are being defined by empirical knowledge
Current-State
Demand for 700 C - Technology cannot be satisfied using the existing design methods.
serf
p di 2 zul p
Perspectives
New methods for the design of high temperature components: European Pressure Equipment Directive (PED) allows the use of Design by Analysis (DBA)-Methods. For components operating in the creep regime the inelastic Finite Element Analyses have to be applied. Appropriate inelastic constitutive equations are necessary. Required research projects concerning inelastic constitutive equations have started.
14
HPE FEM Calculation of thick walled components

Example HP-Outlet header
Membranecreep 0,6 % 200.000 h
Wall thickness: Calculation acc. EN 12952-3: s=100 mm FEM: s= 77 mm

local creep max. 3,9 % at 200.000 h
s = 77 mm
Liisa Menp / HPE
15
Life time expectancy of superheater tubes
Reduction of life time of superheater tubes by: - creep - fire side corrosion - steam side oxidation
Each of the three mechanisms affects the others. Isolated consideration is not possible.
Calculation program to estimate the life time of superheater tubes considering all three influencing factors.
Liisa Menp / HPE
16
Examples Different materials
100 90
expended life time [%]
80 70 60 50 40 30 20 10 0 0
TP347H FG
Super304H not shot peened
200000
400000 time [h]
600000
800000
1000000
Liisa Menp / HPE
17
Examples Different materials
100 90
80 70 60 50 40 30 20 10 0 0
TP347H FG
Super304H not shot peened
HR3C
Super304H shot peened

200000 400000 time [h] 600000 800000 1000000
Liisa Menp / HPE
18
Examples Variations for design of superheater tubes
100 90
Flue gas temperature imbalances Steam temperature imbalances
80 70 60 50 40 30 20 10 0 0
Manufacturing tolerances
Design parameters
200000
400000
600000 time [h]
800000
1000000
Liisa Menp / HPE
19
Design Aspects
Material selection
Conclusion Z
20
Material selection superheater and reheater tubes

105 h creep strength (mean values) in MPa 300
250
er Pl an ts
200
Sanicro 25 Alloy 617 expected modified Super 304H
150
100
50
ferritic materials
Ex is tin
Po w
7CrMoVTiB10-10 16Mo3 13CrMo4-5
austenitic materials
DMV 310N HR3C
0 460 480 500 520 540 560
580
600
620
640
660
680
700
720
740
temperature C
21

250
er Pl an ts
ferritic materials
200
Sanicro 25 Alloy 617 expected modified
150
60 0
100
Po w
Super 304H
50
DMV 310N HR3C
0 460 480 500 520 540 560
580
600
620
640
660
680
700
720
740
temperature C
22

250
Sanicro 25 Alloy 617 expected modified Super 304H
200
150
50
ferritic materials
70 0
100
C
Po w
er Pl an ts
DMV 310N HR3C
0 460 480 500 520 540 560
580
600
620
640
660
680
700
720
740
temperature C
23
Material selection fire side corrosion

0.8
corrosion rate [mm/10.000 h]
0.7 0.6 600 C Technology 0.5 0.4 0.3 0.2 0.1 0 580 590 600 610 620 630 material temperature [C] 640
a eg flu em st p tu era re
00 14
00 12
C 00 10 C 800
650
660
Corrosion rate of austenitic materials with 18 % chromium

Source: Cutler, A.J.B., Flatley, T and Hay, K.A.: Fire-side corrosion in power-station boilers. Combustion (Dez. 1980) S. 17-25
Liisa Menp / HPE
24
Material selection fire side corrosion

0.8
corrosion rate [mm/10.000 h]
0.7 0.6 700 C Technology 0.5 0.4 0.3 0.2 0.1 0 580 590 600 610 620 630 material temperature [C] 640
a eg flu em st p tu era re
00 14
00 12
C 00 10 C 800
650
660
Corrosion rate of austenitic materials with 18 % chromium

Source: Cutler, A.J.B., Flatley, T and Hay, K.A.: Fire-side corrosion in power-station boilers. Combustion (Dez. 1980) S. 17-25
Liisa Menp / HPE
25
Material selection - membrane walls

Materials for 600C - Power Plant: 13CrMo4-5 (T1) 10CrMo9-10 (T11) 7CrMoVTiB10-10 (T24)
Ferritic
Possible additional materials for 700C - Power Plant: VM12-SHC X10CrWMoVNb9-2 (T92) Alloy 617 (modified)
Martensitic Nickel base alloy

26
Material selection superheater and reheater

Materials for 600C - Power Plant: Ferritic materials like 7CrMoVTiB10-10 (T24) X20CrMoV12-1, VM12-SHC TP 347H FG SP Super 304 H SP HR3C
Martensitic
Austenitic
Possible additional materials for 700C Power Plant: Sanicro 25 HR6W Alloy 617 (modified) Alloy 740, Alloy 263
Austenitic Nickel base alloys

27
Material selection - headers and pipes

Materials for 600C - Power Plant: X20CrMoV12-1 X10CrMoVNb9-1 (P91) X11CrMoWVNb9-1-1 (E911) X10CrWMoVNb9-2 (P92)
Martensitic
Possible additional materials for 700C Power Plant: Alloy 617 (modified) Alloy 263 HR6W
Nickel base alloys Austenitic

28
Design Aspects
Material selection
Conclusion
Liisa Menp / HPE
29
Conclusion
600 C - boiler 700 C - boiler Biggest innovation of 700 C boiler lies in the materials ! New materials with higher strength and corrosion/ oxidation resistance needed. Highest grade for materials are the nickel base alloys.
Common for both boilers: FEM-Calculations for thick walled components Calculation program for life time expectancy of superheater tubes
Liisa Menp / HPE
30
Liisa Menp / HPE
31

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Boiler Design of innovative 600 C- and 700 C- Power Plants

Liisa Menp, Hitachi Power Europe GmbH l_maeenpaeae@hitachi-power.com

Boiler Design of innovative 600 C- and 700 C- Power Plants

Introduction 600 C - and 700 C - Technology

CO2 Emissions of Power Plants with different Fuels

CO2 Emissions [g/kWh]

1200 1000 800 600 400 200 0 0.25 Average worldwide

Current Average EU15-countries

lignite (rhenish) BAT 600/620 C 700/720 C 1 RH

Net efficiency [-]

Liisa Menp / HPE

Power Plants Technology in Dialogue, Hannover, 22th April 2008

Further CO2 Reduction: Carbon Capture

with current Technology Trend with improved Efficiency Plants

Efficiency is the fast track CCS achieves near Zero-Emission

CO2 Emissions [g/kWh]

1000 800 600 400 200 0 0.25

Current Average EU15-countries BAT 600/620 C

Boiler Design of innovative 600 C- and 700 C- Power Plants

Introduction 600 C - and 700 C - Technology

Liisa Menp / HPE

Power Plants Technology in Dialogue, Hannover, 22th April 2008

600 C - Technology: NRW Power Plant Study

Liisa Menp / HPE

Power Plants Technology in Dialogue, Hannover, 22th April 2008

600 C - Technology: PS Datteln (1100 MW)

1100 MWel / 2939 t/h Benson steam generator

Liisa Menp / HPE

Power Plants Technology in Dialogue, Hannover, 22th April 2008

600 C - Technology: Boiler materials Existing PP Today

= 43 % 262 bar / 545 C / 562 C

1 21 oV1 MoV12 rM Cr C X20 X20

itic sten als Au eri P92 mat

Liisa Menp / HPE

Power Plants Technology in Dialogue, Hannover, 22th April 2008

700 C - Technology: Power Plant Study NRWPP700

Preferred boiler design:

Base for current design of first 700 C boiler.

Source: NRW Power Plant 700C (NRWPP700)

700 C - Technology: steam generator for 500 MWel

HP-Part: Life steam pressure Life steam temperature

365 bar 705 C

RH-Part: Inlet pressure Outlet temperature

Liisa Menp / HPE

Power Plants Technology in Dialogue, Hannover, 22th April 2008

700 C - Technology: Boiler materials Existing PP Today

= 43 % 262 bar / 545 C / 562 C

1 21 oV1 MoV12 rM Cr C X20 X20

itic sten als Au eri P92 mat

Liisa Menp / HPE

Power Plants Technology in Dialogue, Hannover, 22th April 2008

Boiler Design of innovative 600 C- and 700 C- Power Plants

Introduction 600 C - and 700 C - Technology

Component design in the creep regime Tools / Methods

HPE FEM Calculation of thick walled components

Membranecreep 0,6 % 200.000 h

Wall thickness: Calculation acc. EN 12952-3: s=100 mm FEM: s= 77 mm

Liisa Menp / HPE

Power Plants Technology in Dialogue, Hannover, 22th April 2008

Life time expectancy of superheater tubes

Liisa Menp / HPE

Power Plants Technology in Dialogue, Hannover, 22th April 2008

Examples Different materials