Ultra Super Critical Power Plants: An Efficient Coal Technology

Bharat Heavy Electricals Limited
International conference
Thermal Power India ‐3
“Ultra Supercritical power plants”
ULTRA SUPER CRITICAL POWER PLANTS

Introduction
•Energy, in general, and electricity in particular, plays a vital role

in improving the standard of life
•World has abundant proven reserves of coal and thus coal‐
based thermal power plants dominate
• The development of coal fired supercritical power plant
technology can be described as an evolutionary advancement
towards
d greater power output per unit i andd higher
hi h efficiency
ffi i
•Energy conversion efficiency of steam turbine cycle can be
improved by increasing the main steam pressure and
temperature

Introduction
Worldwide energy and electricity consumption is projected to
grow att an average annuall rate
t off 2‐2.5%
2 2 5% between
b t now and d 2025
caused by increase of population (up to 7.5 billion) and increase
of consumption (mainly of China and India).
Coal offers an abundant, widely spread energy resource at quite

stable
bl price,
i from
f many international
i i l suppliers.
li I will
It ill continue
i to
play a significant role in new generating capacity

Coal Technologies
Coal Technologies
Integrated gasification combined‐cycle generation technology

(IGCC)
Circulating fluidized bed combustion generation technology
(CFBC and pressurized circulating fluidized bed combustion
combined‐cycle generation technology (PFBC‐CC）
Supercritical and ultra supercritical generation technology
(SC/USC)

Advantages of Supercritical units

Advantages of Supercritical units
•Reduced fuel costs due to improved plant efficiency
•Significant improvement of environment by reduction in CO2

emissions
•Plant costs less than other clean coal technologies
Much reduced NOx, SOx and particulate emissions

•Much

Efficiency gain due to Supercritical parameters

•Supercritical units have higher plant efficiency than that of
subcritical units because of higher steam parameters.
• The Gross plant efficiency is around 40‐41% for supercritical units
24 7MPa/565Ԩ /593 Ԩ,
with steam parameters of 24.7MPa/565Ԩ Ԩ which is about
2%‐3% higher than that (38%) of sub‐critical unit with steam
parameters of 16.7MPa/537/537Ԩ
•The Gross plant efficiency is around 41‐42% for ultra‐supercritical
units with steam parameters of 28MPa/593 Ԩ/593 Ԩ,which is
about 3‐4% higher than that of the above supercritical units.
units
•The advanced ultra supercritical units have reached an overall
plant efficiency of 47% to 49% in the world.

National mission on enhanced energy efficiency

National mission on enhanced energy efficiency
•Increasing efficiency of existing power plants, using clean

technologies and switching to fuels other than coal
•Adoption of super critical boiler, wherever cost effective and
otherwise suitable
•Adoption of ultra‐super critical boiler when their commercial
viabilityy under Indian conditions is established
Source : CEA

What is supercritical parameters
p p
As the fluid pressure increases, Latent Heat
((Enthalpy
py of Steam –Enthalpy py of Water))
reduces.
At Critical point it becomes zero.
In physical terms at this pressure water
transforms to steam spontaneously.
4.3
%
SUPER CRITICAL STEAM PARAMETERS:
mprovement
45
40
35
PARAMETERS MORE THAN CRITICAL STATE 30

25
20
15
• STEAM PRESSURE > 221.2 BAR 10
Im
5
0
• STEAM TEMPERATURE > 374.15 Deg C 500 MW 800 MW
Super Critical
Subcritical
247 ata / 565 °C / 593 °C
170 ata / 537 °C / 537 °C
INCREASE IN PRESSURE & MAIN AND REHEAT TEMP. > 537 Deg C
RESULTS IN SIGNIFICANT IMPROVEMENT IN HEATRATE
Parameters for Ultra supercritical Plants

Parameters for Ultra supercritical Plants
There is no clear definition of ‘ultra‐supercritical’
•There ultra supercritical
conditions, However Plants operating above 275 kg/cm2
pressure and MS/RH temperatures of 593°C and above are
generally called ultra super critical.
critical
•World over, many Ultra super critical power plants ranging
350MW to 1000MW are under operation/construction.
p /

Development of SC/USC Technology

Development of SC/USC Technology
• Supercritical steam cycle technology has been used for decades and is
becoming the system of choice for new commercial coal‐fired plants in many
countries.
• Recent plant built in Europe and Asia use supercritical boiler‐turbine
technology and China has made this standard on all new plant 600MWe and
upwards.
• Research and development is under way for ultra‐supercritical units operating
at even higher efficiencies,
efficiencies potentially up to around 50%.
50%
• The introduction of ultra‐supercritical technology has been driven over recent
years in countries such as Denmark, Germany and Japan, in order to achieve
improved plant efficiencies and reduce fuel costs.
costs
• Research is focusing on the development of new steels for boiler tubes and on
high alloy steels that minimise corrosion.
• These developments are expected to result in a dramatic increase in the
number of SC plants and USC units installed over coming years.
Present status of SC/USC Coal fired Units

Present status of SC/USC Coal‐fired Units
• Supercritical
p and ultra‐supercritical
p units have been developed
p
into proven mature and commercialized advanced technologies
in the world
• Over
O 600 supercritical
iti l coal‐fired
l fi d units
it have
h b
been successfully
f ll
into commercial operation for decades worldwide
• About 60 ultra‐supercritical
p units in operation
p worldwide
• The 1000MW class ultra‐supercritical units with steam
parameters of 31MPa/600 Ԩ/600 Ԩ are being developed in
i d
industrial
i l economies
i

Parameters of Some SC/USC Plants
/
Country Power Plant Unit Rating Steam Main Reheat RH1 Reheat RH2 Efficiency
Mwe net Pressure Steam Steam Steam (% net
(Gross) (Bar) Temp. (oC) Temp. (oC) Temp. (oC) LHV)
Denmark Avedorevaerket 2 390 300 580 600 ‐‐‐‐‐ 48.3
Denmark Nordjylland 3 411 285 580 580 580 47
Denmark Skaerbeaek 3 411 290 582 580 580 49
Holland Hemweg 8 630 260 540 568 ‐‐‐‐‐ 42
Finland Meri Pori 550 244 540 560 ‐‐‐‐‐ 45
Germany Staudinger 509 262 545 562 ‐‐‐‐‐ 43
Germany Niederaussem K 965 275 580 600 ‐‐‐‐‐ 45.2
Japan Tachibanawan 1050 250 600 610 ‐‐‐‐‐ 43.5
Japan Isogo 600 266 600 610 ‐‐‐‐‐ Not Available
China Changshu 600 259 569 569 ‐‐‐‐‐ 42
China Wangqu 600 247 571 569 ‐‐‐‐‐ 43
USA Tanners Creek 580 241 538 552 566 39.8
USA Duke Power 1120 241 538 538 ‐‐‐‐‐ Not Available

Comparison of some state of the art steam plants

Comparison of some state‐of‐the‐art steam plants
Plant Steam Condition Net Thermal efficiency, %

Mpa/ oC/oC
HHV LHV
TTachibanawan
hib 24 1/600/610
24.1/600/610 42 1
42.1 44
(Japan)
Tanners Creek 24.1/538/552/566 39.8 42
(USA)
Nordjylland 3 29.0/582/580/580 45 47.0
(Denmark)
Niederaussem K 27.5/580/600 42.5 45.2
(Germany)

Efficiency vs. Emissions

Efficiency vs. Emissions

Typical efficiencies
Typical efficiencies
Pulverized coal option Steam Conditions Typical Efficiency
(% HHV)
Sub critical
Sub critical <22.1 M Pa
<22 1 M Pa 35 0 38 0
35.0 ‐38.0
538oC/538oC
Supercritical (SC)
Supercritical (SC) 24.7 M Pa
24 7 M Pa 38 0 ‐40
38.0 40.0
0
538‐565oC/565oC
Ultra‐supercritical (USC)
p ( ) 27 M Pa 40.0 ‐42.5
565‐625oC
Advanced USC 27 M Pa 42.5 ‐46.0

(not commercial yet) above 625oC

Levelised cost of electricity (CoE) for nominal
cost of electricity (CoE) for nominal
600MWe (A European comparison)

Relative efficiency improvement with
parameters

Evolution of Steam Power Stations
Efficiency Worldwide

Supercritical Technology Indian scenario

Supercritical Technology – Indian scenario
• Supercritical technology being adopted to enhance
efficiency, reduce coal consumption and GHG emission
• 660/ 800 MW units planned in big way.
• Parameters adopted 247 ata / 537/565 OC & 247 ata / 565/ 593
OC
• Eight
g units of 660 MW under execution at Sipat
p and Barh
• Two units of 800MW under execution at Krishnapattnam
• Ultra Mega Projects, 4000 MW each, envisaged with
supercritical units.
• 4 projects already awarded to IPPs through tariff based
competitive bidding.
bidding
• Many more supercritical units in pipeline.
Supercritical Technology – Indian
scenario (Cont..)
• Wid
Widely
l prevalent
l t cycle
l parameters
t (At turbine
t bi end):
d)
– Pressure: 246 ‐250 kg/cm2
– Temperature: 537/566 deg C (In 660MW Sipat & Barh –I TPS)
565/593 deg C (In 660 MW Barh‐II and
2 X 800MW Krishnapattnam)
• Parameters adopted for 800MW are 247kg/cm2 /565/593 deg C.

Ultra Mega Power Projects

Ultra Mega Power Projects
Ministry of Power,
Power Central Electricity Authority and PFC are
working together to facilitate development of Ultra Mega Power
Projects with super critical parameters and capacity of about
4000 MW each under Tariff based competitive bidding route.
Being large in size,

size these projects will meet the power needs of
number of states through transmission of power on regional and
national grids.

Identified Ultra Mega Projects
State Project Location Status
g
Chattisgarh Akaltara Pithead ‐
Gujarat Mundra coastal Awarded to Tata

Karnataka Tadri coastal ‐
Madhya Pradesh Sasan Pithead Awarded to Reliance
Maharashtra Giriye coastal ‐
Andhra Pradesh
Andhra Pradesh Krishnapatnam coastal Awarded to Reliance
Awarded to Reliance
Orissa Bhedabahal Pithead ‐

((Sundergarh
g district)
)
Tamil Nadu Cheyyur coastal ‐

Jharkhand Tilaiyya Pithead LOI issued to Reliance

Typical Comparison of Parameters
S b iti l
Subcritical vs. Supercritical
S iti l
Parameter Unit 500MW 660MW 800MW

Main Steam Pressure ATA 170 247 247
M i S
Main Steam Temp.
T 0C 537 565 565
Main Steam Flow T/Hr 1515 1960 2340
Reheat Pressure ATA 40.5 50.4 56.6
Reheat Temperature 0C 537 593 593
Reheat Flow T/Hr 1335 1625 1940
CRH Pressure
CRH Pressure ATA 45 56 0
56.0 61 5
61.5
Cold Reheat Temp. 0C 336 336 348
Final FW Temp. oC0C 253 290 290
BMCR Flow T/hr 1625 2120 2600

Power Cycle Equipment

Power Cycle Equipment
EQUIPMENT 500 MW SUB CRITICAL 800 MW SUPER CRITICAL
BOILER Drum Type Once Through Type

TURBINE 1HP + 1IP + 1LP 1HP + 1IP+ 2LP
CONDENSER One Two
GENERATOR 588 MVA 950 MVA
LP HEATERS 3 Nos 4 Nos
HP HEATERS TWO ( 2X50% EACH)) THREE ( 2X50% EACH))

DEAERATOR ONE ONE
CONDENSATE EXTN.
3 x 50% 3 x 50%
PUMPS
BOILER FEED PUMPS 2 x 50%(TD) / 1 x 50% (MD) 2 x 50 % (TD) / 1 x 35 %MD
2 x 100%
VACUUM PUMPS 2x100%
(For Each Condenser)
CONDENSATE POLISHING
2 x 50% 4 x 25%
UNIT

Typical 800 MW Cycle

Typical 800 MW Cycle

Reference HBD for 800MW


Improvement in Gross plant efficiency

Improvement in Gross plant efficiency
41.5
41.0
%)
40 5
40.5
Gross Plant efficiency (%
40.0
39.5
39.0
38.5
38.0
37.5
37.0
36.5
500 MW/ 170ATA/
500 MW/ 170ATA/
600 MW/ 170ATA/
600 MW/ 170ATA/
660 MW/ 247ATA/
800 MW/ 247ATA/
800 MW/ 280ATA/
537/537 537/565 537/537 537/565 565/593 565/593 593/593
Parameters

Coal Consumption
Coal Consumption
0.660
0.650
0.640
nsumption kg//KW‐hr
0.630
0.620
0.610
0.600
Coal Con
0.590
0.580
0 570
0.570
0.560
500 MW/ 170ATA/
500 MW/ 170ATA/
600 MW/ 170ATA/
600 MW/ 170ATA/
660 MW/ 247ATA/
800 MW/ 247ATA/
800 MW/ 280ATA/
537/537 537/565 537/537 537/565 565/593 565/593 593/593
Parameters

Supercritical Boilers
Supercritical Boilers
• Supercritical pressure boiler has no drum and heat absorbing
surface being, in effect, one continuous tube, in which the water
& steam generated in the furnace water walls passes through
only once hence called ‘OnceOnce through Supercritical pressure
boilers’
• The water in boiler is pressurized by Boiler Feed Pump, sensible
heat is added in feed heaters, economizer and furnace
tubes, until water attains saturation temperature and flashes
instantaneously to dry saturated steam and super heating
commences.

Supercritical
Separators Steam Generators
Collecting
vessel

Once ‐through
Once through Operating Range
Operating Range

Low Load System with Circulating Pump

Boiler Parameters
Boiler Parameters
500
Description Unit 800 MW 660 MW
MW
Boiler
B il
- BMCR BMCR BMCR
Parameters
SH steam flow t/h

/ 2585 2100 1625
SHO pressure kg/cm2(a) 256 256 179
SHO/RHO temp. oC 568/596 568/596 540/540

Feed water oC 294 291 254
temp
temp.

SIEMENS References
SIEMENS References
For Super Critical Steam Turbine
Plant Name Country MW First M.S. Pr.(bar) / MS Temp.
operation (°C) / HRH Temp. (°C)
Kw Schwarze Pumpe1,2 Germany 823 1997 253.08 544 562
Boxberg Q Germany 910 2000 252.58 541 578
Isogo Japan 600 2001 251.00 600 610
NiederauBem K Germany 1027 2002 251.00 576 599
Wai Gao Qiao 1,2 China 900 2003 249.60 538 566
Wai Gao Qiao 3,4 China 1000 2007 270 600 600
Kogan Creek Australia 750 2007 250.00 540 560
Yuhuan
h 11,2,3,4
234 Chi
China 1000 2006 262 50
262.50 600 600

Large capacity Supercritical Sets
g p y p
660MW Steam turbine: With Supercritical parameters
Module Combination
• HP : H30-100
• IP : M30-63
• LP : N30-2x12.5
Salient Feature:
247 ata
t MMain
i St
Steam PPressure
• New series of HP & IP modules for 565 0C Main Steam Temperature
supercritical parameters 593 0C Hot reheat Temperature
• Higher size LP module
Order received for NTPC 2x660 MW Barh Extn.
800MW Steam turbine: With Supercritical parameters
Module Combination
• HP : H30-100 (H70-V4)
• IP : M30-100 (I60-V2)
• LP : N30-4x8 (L4x8)
Salient features:
•New series of HP, IP modules for super 246 ata Main Steam Pressure
critical parameters 565 0C Main Steam Temperature
593 0C Hot reheat Temperature
• 4 cylinder turbine (2 LP’s)
LP s)


Rating - 800 MW Generator Module - THDF 125/67
Parameters -
Voltage - 27 KV
Insulation - Micalastic
Gas Pressure - 5 Bar
Excitation - Brushless
Transport wt. - 443 Tons
Stator Cooling - DM water
Rotor Cooling - Hydrogen
Transportation - By Road


STEAM SURFACE CONDENSER
FOR 660 MW TG SET
• ONE CONDENSER PER SET
• SINGLE / DOUBLE PASS CONDENSER
SINGLE / DOUBLE PASS CONDENSER
• CONDENSER IS SOLID SUPPORTED
• LP HEATER NO.1 IS LOCATED INSIDE
• CONDENSER NECK

DESIGN FEATURES OF CONDENSER FOR 800 MW TG SET
• TWO CONDENSERS CONNECTED TO TWO
LP TURBINES
• SINGLE PASS
•SOLID SUPPORTED WITHOUT ANY EXPN.

EXPN
JOINT BETWEEN TURBINE & COND.
•CONDENSERS IN SERIES WITH DIFFERENT

BACK PRESSURES (

Pumps for Supercritical Power Plants

Pumps for Supercritical Power Plants
• BHEL entered into collaboration with M/S/ Mitsubishi Heavyy
Industries, Japan for
‐BFPs
‐ Booster Pumps
‐ CEPs &
‐ CWPs for Super Critical power plants.
plants
• Range from 660MW to 1000MW.

Pump Models for 660MW

PUMP MODEL Q(m3/hr) H (mlc)
H (mlc) N (rpm)
N (rpm)
BFP MDG 405 1385 3315 5730
BP MLC 400 1385 160 1475
CEP 145 RND 1015 345 1470
CWP 72 MN 30000 27 370


PUMP MODEL Q(m3/hr) H (mlc)
H (mlc) N (rpm)
N (rpm)
BFP MDG 455 1605 3310 5100
BP MLC 450 1605 240 1475
CEP 145 RND 1210 350 1470
CWP 78 MN 35000 29 329

Development of Materials for SC/USC
parameters
• For adopting
p g SC/USC/ parameters,, superior
p p material are
required
• Some of the critical materials are Boiler quality plates and
P91 Critical
C iti l piping
i i
• These material are not indigenously available and have to be
essentiallyy imported
p
• There is a need to join hands with the countries which have
already developed these materials

Concluding Remarks
Concluding Remarks
• Electric power generation in India will continue to be
dominated by coalcoal‐fired
fired power generation for at least next
30‐40 years
• Development and application of clean, high efficiency, large
capacity, coal‐fired power generation technology is a long‐
term strategic task for India
• In order to meet our increasing demand for electric power,
power as
well as to improve coal utilization efficiency and reduce
pollutant emissions from coal‐fired power plants, we have to
d l domestic
develop d ti supercritical
iti l / Ultra
Ult supercritical
iti l units
it


Ultra Super Critical Power Plants: An Efficient Coal Technology

Uploaded by

Document Information

Original Description:

Original Title

Copyright

Available Formats

Share this document

Share or Embed Document

Sharing Options

Did you find this document useful?

Is this content inappropriate?

Copyright:

Available Formats

Ultra Super Critical Power Plants: An Efficient Coal Technology

Uploaded by

Copyright:

Available Formats

Bharat Heavy Electricals Limited

ULTRA SUPER CRITICAL POWER PLANTS

•Energy, in general, and electricity in particular, plays a vital role

ULTRA SUPER CRITICAL POWER PLANTS

Coal offers an abundant, widely spread energy resource at quite

ULTRA SUPER CRITICAL POWER PLANTS

Integrated gasification combined‐cycle generation technology

ULTRA SUPER CRITICAL POWER PLANTS

Advantages of Supercritical units

•Significant improvement of environment by reduction in CO2

•Plant costs less than other clean coal technologies

Much reduced NOx, SOx and particulate emissions

ULTRA SUPER CRITICAL POWER PLANTS

Efficiency gain due to Supercritical parameters

ULTRA SUPER CRITICAL POWER PLANTS

National mission on enhanced energy efficiency

•Increasing efficiency of existing power plants, using clean

ULTRA SUPER CRITICAL POWER PLANTS

PARAMETERS MORE THAN CRITICAL STATE 30

• STEAM PRESSURE > 221.2 BAR 10

• STEAM TEMPERATURE > 374.15 Deg C 500 MW 800 MW

Parameters for Ultra supercritical Plants

ULTRA SUPER CRITICAL POWER PLANTS

Development of SC/USC Technology

Present status of SC/USC Coal fired Units

ULTRA SUPER CRITICAL POWER PLANTS

Denmark Nordjylland 3 411 285 580 580 580 47

Denmark Skaerbeaek 3 411 290 582 580 580 49

Holland Hemweg 8 630 260 540 568 ‐‐‐‐‐ 42

Finland Meri Pori 550 244 540 560 ‐‐‐‐‐ 45

Germany Staudinger 509 262 545 562 ‐‐‐‐‐ 43

Germany Niederaussem K 965 275 580 600 ‐‐‐‐‐ 45.2

Japan Tachibanawan 1050 250 600 610 ‐‐‐‐‐ 43.5

Japan Isogo 600 266 600 610 ‐‐‐‐‐ Not Available

China Changshu 600 259 569 569 ‐‐‐‐‐ 42

China Wangqu 600 247 571 569 ‐‐‐‐‐ 43

USA Tanners Creek 580 241 538 552 566 39.8

USA Duke Power 1120 241 538 538 ‐‐‐‐‐ Not Available

ULTRA SUPER CRITICAL POWER PLANTS

Comparison of some state of the art steam plants

Plant Steam Condition Net Thermal efficiency, %

ULTRA SUPER CRITICAL POWER PLANTS

Efficiency vs. Emissions

ULTRA SUPER CRITICAL POWER PLANTS

Advanced USC 27 M Pa 42.5 ‐46.0

ULTRA SUPER CRITICAL POWER PLANTS

ULTRA SUPER CRITICAL POWER PLANTS

ULTRA SUPER CRITICAL POWER PLANTS

ULTRA SUPER CRITICAL POWER PLANTS

Supercritical Technology Indian scenario

• Parameters adopted for 800MW are 247kg/cm2 /565/593 deg C.

ULTRA SUPER CRITICAL POWER PLANTS

Ultra Mega Power Projects

Being large in size,

ULTRA SUPER CRITICAL POWER PLANTS

Gujarat Mundra coastal Awarded to Tata

Orissa Bhedabahal Pithead ‐

Tamil Nadu Cheyyur coastal ‐

ULTRA SUPER CRITICAL POWER PLANTS

Parameter Unit 500MW 660MW 800MW

ULTRA SUPER CRITICAL POWER PLANTS

Power Cycle Equipment