INTERNATIONAL

International Journal of JOURNAL OF MECHANICAL

Mechanical Engineering ENGINEERING
and Technology AND
(IJMET), ISSN 0976 –
6340(Print), ISSN 0976 – 6359(Online) Volume 3,
TECHNOLOGY (IJMET)Issue 2, May-August (2012), © IAEME

ISSN 0976 – 6340 (Print)

ISSN 0976 – 6359 (Online) IJMET
Volume 3, Issue 2, May-August (2012), pp. 422-430
© IAEME: www.iaeme.com/ijmet.html
Journal Impact Factor (2012): 3.8071 (Calculated by GISI) ©IAEME
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PERFORMANCE ANALYSIS OF SUPERCRITICAL BOILER

Sanjay Kumar Patel1 Dr. A.C. Tiwari2

University institute of technology University institute of technology
Rajiv Gandhi Proudyogiki Vishwavidyalya Rajiv Gandhi Proudyogiki Vishwavidyalya
Bhopal, India Bhopal, India
Email- sanjay.ermech@gmail.com Email- aseemctiwari@yahoo.com

Abstract

Coal fired power generation is switching over to supercritical (SC) and ultra supercritical (USC) plants which
operate with steam on higher temperature and above critical pressure to produce power output at higher thermal
efficiency. Due to involvement of high heat resistant material, manufacturing cost of the components of
supercritical plants are increases, but due to higher efficiency its operating cost is low as compare to subcritical
plants. An analysis has been made in the study to explore the possibilities of operating power plants with steam
at higher temperature and pressure. Due to high efficiency of this plant 15 % lower co2 emission is achieved by
high steam parameters as compare to subcritical plants. Analysis shows that for different operating condition of
boilers and turbine, if there is an increment in the load of boiler and drop in the load of turbine higher efficiency
is obtained. There are two parameters boiler maximum continuous rating (BMCR) and turbine maximum
continuous rating (TMCR) are varied by increasing the value of steam flow rate of superheaters and reheaters.
By increasing or decreasing these values we can find out which condition is best for power generation. A
comparative study between subcritical and supercritical boilers and analysing the performance of boilers, Factor
affecting efficiency of boilers has carried out with identification and analysis for improved working of
supercritical plants.

Keywords:
Supercritical-Boilers, steam-turbine, BMCR, TMCR, rankine cycle, superheaters

Introduction:
Supercritical is a thermodynamic phase that describes the state of a substance where there is no clear distinction
between liquid phase and gaseous phase. (i.e. they are a homogeneous fluid). Water reaches this state at a
pressure above 22.1 MPa (221 bar), also known as ‘supercritical pressure’ of water. Beyond this pressure, it is a
homogeneous mixture of water and steam, as shown in Fig-1. Up to an operating pressure of around 19 MPa in
the evaporator part of the boiler, there is a non-homogeneous mixture of water and steam in the evaporator. Up
to an operating pressure of around 19 MPa in the evaporator part of the boiler, there is a non-homogeneous
mixture of water and steam in the evaporator.

Up to an operating pressure of around 19 MPa in the evaporator part of the boiler, there is a non-homogeneous
mixture of water and steam in the evaporator. In this case, a drum-type boiler is used because the steam needs to
be separated from water in the drum of the boiler before it is superheated and led into the turbine. Above an
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International Journal of Mechanical Engineering and Technology (IJMET), ISSN 0976 –
6340(Print), ISSN 0976 – 6359(Online) Volume 3, Issue 2, May-August
May August (2012), © IAEME

operating pressure of 22.1 MPa in the evaporator part of the boiler, the cycle medium is a single
single-phase fluid
with homogeneous properties and there is no need to separate steam ffrom water in a drum.

Fig-1. Water Phase Diagram

Once-through
through boilers are therefore used in supercritical cycles. A critical point can be illustrated on a Rankine
cycle, on which a typical steam turbine power plant operates. At working pressures in excess excess of this critical
pressure, the Rankine cycle becomes supercritical cycle. The region below critical point is the subcritical region
having a non-homogeneous
homogeneous mixture of water and steam. Figure-2
Figure 2 shows the supercritical Rankine cycle. Point
‘A’ on the T-SS diagram represents the critical point. Based on the operating pressures, there are two basic boiler
technologies employed in the modern coal-fired
coal power plants. These are Subcritical and Supercritical
Subcritical boilers operate below 220 bars, the supercritical pressure of water. This means that there is a non non-
homogeneous mixture of water and steam in the evaporator part of the boiler. In this case a drumdrum-type boiler is
used because the steam needs to be separated from water before it is superheated and led into the turbine. The
remaining water in the drum re-enters
enters the boiler for further conversion to steam. The water circulation system
can be a natural circulation or a forced (assisted) circulation
circulation.

Steam Conditions
Today’s supercritical coal fired power plants permits efficiencies that exceed 45%, depending on cooling
conditions. Options to increase the efficiency above 50 % in ultra-supercritical
supercritical power plants rely on elevated
steam conditions as welll as on improved process and component quality. Steam conditions up to 30
MPa/600°C/620°C are achieved using steels with 12 % chromium content. Up to 31.5 MPa/620°C/620°C is
achieved using Austenite, which is a proven, but expensive material. Nickel-based
Nickel based alloys, e.g. Inconel, would
permit 35 MPa/700°C/720°C,
720°C, yielding efficiencies up to 48%.

1-2: HP Turbine Expansion 4-5: Condenser

2-3: Reheat 5-6: Feedwater heating and pumping

3-4: IP + LP Turbine Expansion 6-1: Boiler

Fig-2. Supercritical Rankine Cycle

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BOILER LOAD CONDITIONS

Boiler Maximum Continuous Rating (BMCR): Boiler Maximum Continuous Rating (BMCR)
is the maximum rating specified for the boiler. This corresponds to 109.94% of Turbine maximum
continuous rating.
Turbine Maximum Continuous Rating (TMCR): Turbine Maximum Continuous Rating
(TMCR) is the basis of steam generator output and is equal to the turbine generator maximum
guaranteed rating.
Constant Pressure Operation
Above 90% TMCR, the main steam pressure remains constant at the rated value, condition, while the
load is controlled by throttling main steam flow with the designated partial arc control valve. Below
30% TMCR, the main steam pressure remains constant at the minimum. The minimum constant pr. is
92 bar. The start-up and re-circulation system is designed to provide the necessary mass flow for
adequate cooling of the evaporator during start-up and low load operation. A minimum of 30% of
TMCR flow is maintained up to a boiler load of 30% TMCR. In this re-circulation system, the
feedwater flows through the boiler feedwater line to the economizer, to the evaporator and then to the
water separator. From the separator the recirculated water returns through the Boiler Recirculation
Pump to the boiler feedwater line, where it is mixed with feedwater.

BFP Economizer Water Wall Separator Superheater

BCP

Fig- 4 Once through operation of supercritical boiler

Division Platen Final HP

Superheater Superheater Superheater TBN

Reheater
Water separator HP BPV

IP LP
t

Evaporator Condenser
BCP

Economizer Deaerator

COP
LP BPV
HP HTR BFP
LP HTR

Fig-3 Cycle of supercritical power plant

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6340(Print), ISSN 0976 – 6359(Online) Volume 3, Issue 2, May-August (2012), © IAEME

Performance of supercritical boiler:

1. Efficiency calculation of boiler:
There are two methods to calculate the efficiency of boiler. That is, Heat loss method and heat input-
output method. To calculate the efficiency of boiler correctly we use heat loss method.

ηb = (1 - L ) X 100 [%] .......................................1

H f + Ba

Where, H f : Higher heating value of fuel [J/kg]

Ba : Total heat credit [J/kg]

Heat Loss Items of Boiler

(a) Dry Gas Loss
(b) Heat Loss of Water Contents Caused by Hydrogen Combustion in Fuel
(c) Heat Loss of Unburned Carbon
(d) Water Loss in Fuel
(e) Water Loss in Combustion Air
(f) Radiation Loss
(g) Unaccounted Losses
Heat Distribution of Boiler
(a) Economizer
The heat absorption rate in economizer of subcritical boiler is twice more than that of supercritical boiler.

Heat Absorption Rate in Economiser

12000
10000
8000
6000
4000
2000
0
0 20 40 60 Load 80 100 120
subcritical supercritical

(b) Furnace (Radiation)

The radiation heat absorption of subcritical boiler in furnace is less than that of supercritical boiler at every load.

Radiation Absorption Rate in Furnace

14000
12000
10000
8000
6000
4000
2000
0
0 20 40 60 Load 80 100 120
subcritical supercritical

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International Journal of Mechanical Engineering and Technology (IJMET), ISSN 0976 –
6340(Print), ISSN 0976 – 6359(Online) Volume 3, Issue 2, May-August (2012), © IAEME

(c) Furnace (Convection)

The convection heat absorption of supercritical boiler in furnace is twice more than that of subcritical boiler.

Convective Heat Absorption Rate in Furnace

12000
10000
8000
6000
4000
2000
0
0 20 40 60 Load 80 100 120
subcritical supercritical

(d) Primary Superheater

The heat absorption rate in primary superheater of supercritical boiler is twice more than that of subcritical
boiler.

Heat Absorption Rate in primary superheater

30000
25000
20000
15000
10000
5000
0
0 20 40 60 Load 80 100 120
subcritical supercritical

(e) Secondary superheater

The heat absorption rate in secondary superheater of subcritical boiler is 3 times more than that of supercritical
boiler.

Heat Absorption Rate in secondary superheater

140,000
120,000
100,000
80,000
60,000
40,000
20,000
0
0 20 40 60 Load 80 100 120
subcritical supercritical

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International Journal of Mechanical Engineering and Technology (IJMET), ISSN 0976 –
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(f) Final Superheater

The heat absorption rate in final superheater of subcritical boiler is approximately the same that of supercritical
boiler.

Heat Absorption Rate in Final superheater

15000

10000

5000

0
0 20 40 60 Load 80 100 120
subcritical supercritical

(g) Primary Reheater

The heat absorption rate in primary reheater of subcritical boiler is 10 times more than that of supercritical
boiler.

Heat Absorption Rate in Primary Reheater

120,000
100,000
80,000
60,000
40,000
20,000
0
0 20 40 60 Load 80 100 120
subcritical supercritical

(h) Final Reheater

The heat absorption rate in final reheater of subcritical boiler is much more than that of supercritical boiler.

Heat Absorption Rate in Final Reheater

30,000
25,000
20,000
15,000
10,000
5,000
0
0 20 40 60 Load 80 100 120
subcritical supercritical

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International Journal of Mechanical Engineering and Technology (IJMET), ISSN 0976 –
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(i) Air Preheater

The heat absorption rate in air preheater of subcritical boiler is much more than that of supercritical boiler.

Heat Absorption in Air preheater

2,000
1,500
1,000
500
0
0 20 40 60 Load 80 100 120
subcritical supercritical
(j) Heat Absorption Rate of Each Part in Boiler
The heat absorption rate in water wall of supercritical boiler is approximately twice more than that of subcritical
boiler. The heat absorption rate in economizer of subcritical boiler is approximately 4 times more than that of
supercritical boiler.

Boiler Heat Absorption Rate (%)

60

40

20

0
Economiser Waterwall Superheater Reheater
subcritical supercritical

Efficiency of Boiler
The boiler efficiency of supercritical boiler is a little lower than that of subcritical boiler.

Boiler Efficiency (%)

100
80
60
40
20
0
Subcritical Supercritical
Boiler Efficiency Total Loss

CONCLUSIONS

Analysis shows that higher output can be obtained with high temperature steam at supercritical
pressure comparing with the output of subcritical units operating with same steam flow rates. Thermal
efficiency of supercritical plant is high as well as emission is also reduced due to higher efficiency.
Performance of supercritical boiler is calculated by different graphical representation and it is
compared to subcritical boilers curves. The increased pressure also increases cycle efficiency and,
although this effect is a second-order effect compared with the effect of temperature, it can still make

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an important contribution to increasing overall plant efficiency. However Supercritical boilers operate
in a higher pressure and temperature zone as compared to subcritical boilers leading to increased
thermal efficiencies.

REFERENCES

1. Bejan A., Tsatsaronis, G., and Moran A., 1996, Thermal Design and Optimization, Wiley,
New York.
2. Kotas T.J., 1985, The Exergy method of Thermal Power analysis, Butterworth.
3. Nag P.K., Power plant engineering, 2nd Ed., Tata Mc Graw – Hill, New York, 1995.
4. Dr. gupta A.V.S., second low analysis of super critical cycle.
5. Viswanathan, R., 2001, Boiler materials for ultra supercritical coal power plants, USC
Materials quarterly report, EPRI Inc., Oct-Dec 2001.
6. Kiameh, P. (2002), Power Generation Handbook, McGraw-Hill Handbooks.
7. Rajput, R.K. (2001), Thermal Engineering, Laxmi, New Delhi.
8. Babcock & Wilcox power generation groups technical papers.

Appendix: select data

Table 1
Operating condition
BMCR SH control point 50%
TMCR
Steam flow superheater kg/hr 2225,000 963,760
Steam flow reheaters kg/hr 1741,820 836,410
0
Steam temp. superheater c 540 540
0
Steam temp. reheaters c 568 568
0
Reheat entering temp. c 299 289
Reheat entering pressure bar 45.39 22.15
0
Feed water temperature c 289.64 244.34
Boiler efficiency % 86.28 86.85

Table 2
performance
load BMCR TMCR 80%TMCR 60%TMCR
Steam flow superheater kg/hr 2225,000 2,023,750 1,572,470 1,158,410
Steam flow reheaters kg/hr 1,741,820 1,678,370 1,328,960 996,950
0
Superheater outlet temp. c 540 540 540 540
Superheater outlet press. bar 250 248.48 232.35 174.92
0
Reheat inlet temp. c 299 296 281 286
0
Reheat otlet temp. c 568 568 568 568
Reheat inlet pressure bar 46.37 44.80 35.49 26.56
Reheat oulet pressure bar 44.71 43.21 34.21 25.56
Reheat pressure drop. bar 1.65 1.58 1.27 1.0
0
Feed water temperature c 289.64 286.23 270.35 254.09
Fuel fired kg/hr 471800 438100 354900 272400
Efficiency % 86.28 86.29 86.69 86.88

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International Journal of Mechanical Engineering and Technology (IJMET), ISSN 0976 –
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Table 3
performance
load 50% TMCR 30% TMCR Both HPH out
Steam flow superheater kg/hr 963,760 596,100 1,839,500
Steam flow reheaters kg/hr 836410 517200 1,784,200
0
Superheater outlet temp. c 540 540 540
Superheater outlet press. bar 147.30 91.0 246.98
0
Reheat inlet temp. c 289 294 309
0
Reheat otlet temp. c 568 540 568
Reheat inlet pressure bar 22.15 13.33 48.52
Reheat oulet pressure bar 21.29 12.77 46.86
Reheat pressure drop. bar .86 .55 1.66
0
Feed water temperature c 244.34 219 196.15
Fuel fired kg/hr 231100 147300 463100
Efficiency % 86.85 86.24 87.31

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