Accepted Manuscript

300 MW Boiler Design Study for Coal-fired Supercritical CO2 Brayton Cycle

Wengang Bai, Yifan Zhang, Yu Yang, Hongzhi Li, Mingyu Yao

PII: S1359-4311(17)36220-8
DOI: https://doi.org/10.1016/j.applthermaleng.2018.01.110
Reference: ATE 11764

To appear in: Applied Thermal Engineering

Received Date: 26 September 2017

Revised Date: 29 January 2018
Accepted Date: 29 January 2018

Please cite this article as: W. Bai, Y. Zhang, Y. Yang, H. Li, M. Yao, 300 MW Boiler Design Study for Coal-fired
Supercritical CO2 Brayton Cycle, Applied Thermal Engineering (2018), doi: https://doi.org/10.1016/
j.applthermaleng.2018.01.110

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 300 MW Boiler Design Study for Coal-fired Supercritical CO2

Brayton Cycle
Wengang Bai, Yifan Zhang, Yu Yang, Hongzhi Li*, Mingyu Yao
National Energy R&D Center of Clean and High-efficiency Fossil-fired Power Generation

Technology, Xi'an Thermal Power Research Institute Co. Ltd , Xi'an, 710054, People’s Republic

of China
Abstract: Supercritical CO2 (S-CO2) Brayton power cycle has been considered as a promising
alternative choice of conventional steam cycle for coal-fired power plants. A conceptual design of
the boiler is conducted for a 300 MW single reheated recompression S-CO2 Brayton cycle for
coal-fired power plant with turbine inlet parameters of 32 MPa/600 oC/620 oC. The conventional
economizer (ECO) is replaced with the split heater (SH) to reduce the inlet temperature of cooling
wall of the furnace as well as to recover the flue gas heat The technology adaption of S-CO2
power cycle for coal-fired power plant has been evaluated in terms of specific design of the
300MW coal fired boiler as well as the whole thermodynamic cycle layout. The boiler design and
off-design thermal calculation results show that the S-CO2 boiler proposed in this paper can match
well with the entire coal-fired S-CO2 Brayton cycle power generation system and has a good
boiler variation performance.

Keywords: S-CO2 boiler; Brayton cycle; conceptual design; heat transfer

1. Introduction

Coal is expected to remain the main fuel source of power generation for a long time in the

world[1,2]. Unfortunately, air pollution and global warming problems caused by SO2, NOx, CO2

and dust emission from coal combustion should be seriously addressed [2-4]. Thus, it is of great

importance to increase energy conversion efficiency and in turn to reduce the fuel consumption

and air pollutants emission.

Up to now, steam Rankine cycle has dominated absolutely in coal power plants to convert

thermal energy to electricity. However, it is very difficult to improve the power conversion

efficiency further, as it is a great challenge to increase the turbine inlet steam temperature up to

*
Corresponding Author: Hongzhi Li, PhD.
Tel: +86-029-82001207; Fax: +86-029-82001204;
E-mail address: lihongzhi@tpri.com.cn
1
700 oC [5,6]. Although new nickel-based superalloys can be used in the steam parameters of 32-37

o
MPa and 700-720 C, it is not economic affordable considering the high components

manufacturing costs[7].

A great effort has been made to look for more effective alternative methods of convert

thermal energy to electricity [1,8-12]. Among various candidates, the supercritical CO2 (S-CO2)

Brayton closed-loop power cycle has been considered as a promising alternative choice

[1,10,11,13,14]. The advantages of the S-CO2 cycle are high efficiency and compact physical

devices such as small turbomachinery and heat exchangers. Compared to the steam Rankine cycle,

the S-CO2 Brayton cycle can achieve higher thermal power conversion efficiency at moderate

turbine inlet temperatures, while the turbomachinery is 10 times smaller than that of the steam

Rankine cycle[1,15]. Therefore, the S-CO2 Brayton cycle can improve the system efficiency and

the economic performance of power plants.

It was recommended that a recompression cycle was mandatory for the application of S-CO2

cycle, as shown in Figure 1 [1], because it can increase the efficiency by 4.5%pt up to a standard

S-CO2 cycle (without recompression). Besides, it can also mitigate the pinch-point problem in the

recuperators [1,8,9,14]. Although the concept of the S-CO2 power cycle is not new and has been

widely proved by previous studies in recent years, compared with a large amount of studies

focused on nuclear and concentrating solar power (CSP) applications, the studies on utilization of

S-CO2 power cycle for coal-fired power plants was relatively limited. More specific system layout

and key components design analysis is still imperative to demonstrate the technology feasibility

and commercial viability of large scale utility.

Furthermore, the coal-fired boiler is significantly different from nuclear and CSP heaters. The

2
S-CO2 power cycle must be tailored to deal with coal-fired system integration constraints. For

instance, the inlet temperature of the working fluid entering coal-fired boiler in S-CO2 cycle

(about 500 oC [16]) is much higher than that in steam cycle (about 283 oC, as shown in Figure 2),

as the working fluid is preheated sufficiently by the high temperature turbine exhaust CO 2 in

recuperators before entering the boiler. In this case, the exhaust heat of coal-fired boiler flue gas

cannot be fully utilized itself. The high boiler inlet temperature brings a big challenge to the

design of the S-CO2 boiler, such as the arrangement of the boiler heating surfaces, the security of

the furnace radiation heating surfaces, and the recovery and utilization of a great deal of flue gas

heat to increase the boiler thermal efficiency Thus, it is of great importance to study on how to

make good use of the exhaust heat of the flue gas from the perspective of cycle layout. That is the

most important contribution of the present work.

In the present study, a 300 MW single reheated recompression coal-fired S-CO2 Brayton

cycle power generation system is proposed and the research work is focused on the conceptual

design of the boiler, including thermodynamics analysis, heating surfaces arrangement and the

coordination between the boiler and the other components in the S-CO2 cycle system. The

technology adaption of S-CO2 power cycle for coal-fired power plant has been evaluated in terms

of specific design of a 300MW large scale coal fired boiler as well as the whole thermodynamic

cycle layout.

2. S-CO2 Brayton cycle for coal-fired power plants

3
 As for S-CO2 Brayton cycle for coal-fired power plant, a large amount of flue gas heat (＞550

o
C) could not be effectively used because of the high temperature of S-CO2 entering the boiler.

This is the primary problem for developing S-CO2 Brayton cycle for coal-fired power plant.

To solve this problem, a S-CO2 cycle with a new boiler layout scheme was proposed by

Electricite De France (EDF)[1]. Figure 3 shows the process flow diagram of the EDF’s S-CO2

Brayton cycle for coal-fired power plant. The flue gas (from 550 oC to 110 oC) in the boiler is

divided into two streams. One stream enters the air preheater (APH), and the other enters the

boiler bypass, where the heat of the flue gas is recovered by a fraction of CO 2 stream extracted

from the outlet of the main compressor (MC). In the APH, the primary air and the secondary air

are heated to about 110 oC and 510 oC, respectively, while the flue gas is cooled to about 110 oC.

In the bypass, the flue gas is cooled from ＞550 oC to about 110 oC by releasing heat to the split

CO2 flow from the MC outlet.

It is well known that selective catalytic reduction (SCR) NOx removal equipment is

indispensable in modern coal-fired power plants to realize ultra-low emission and its optimal

reaction temperature range is from 350 oC to 400 oC.[17,18] Considering the employ of SCR in

the coal-fired boiler, the authors put forward a new kind of S-CO2 Brayton cycle for coal-fired

power plant, as shown in Figure 4. The main characteristics of this cycle system are as follows: (1)

a fraction of CO2 stream is split after the merge point of the recompression compressor (RC) outlet

and the cold side outlet of the low temperature recuperator (LTR), which has little effect on the

LTR’s heat transfer effectiveness and can ensure a relatively low hot side exhaust temperature of

LTR; (2) the heating surfaces arrangement in the boiler are appropriate and there is suitable

temperature range for the optimal SCR reaction; (3) the ECO in the conventional steam boiler is

4
replaced with a S-CO2 split flow (~10%) heater, the S-CO2 main stream (~90%) flows into the

furnace radiation heating surface directly, thus the temperature level of the furnace radiation

heating surface can be significantly reduced so that the security problems can be alleviated to

some extent.

Figure 5 shows the specific process flow diagram of a 300 MW coal-fired S-CO2 Brayton

cycle power generation system with turbine inlet parameters of 32 MPa/600 oC/620 oC proposed

by the authors. The design parameters of the S-CO2 coal-fired power cycle are presented in Table

1. The system is made up of a main compressor (MC), a recompression compressor (RC), a high

pressure turbine (HT), a low pressure turbine (LT), a high temperature recuperator (HTR), a low

temperature recuperator (LTR), a pre-cooler (PC) and a coal-fired boiler. The CO2 stream out of

the LTR hot side is divided into two streams. The hot side herein refers to heat releasing side of

the working fluid. The main stream (~68.3%) enters the PC to be cooled to 31.5 oC, then enters the

MC to be compressed from 7.6 MPa to 34.1 MPa. The other stream (~31.7%) enters the RC and is

compressed from 7.65 MPa to 34.05 MPa. By adjusting the split-flow ratio to the MC loop, the

pinch point problems in the recuperators can be alleviated. Figure 6 shows the internal

temperature profiles of the working fluids both in the hot and cold sides of the LTR. It can be seen

that the temperature difference at the inlet or the outlet of the LTR is smaller than that in the

middle of the LTR. The temperature difference along the flow path is always larger than 5 oC. The

CO2 stream out of the MC is heated in the LTR and then mixes with the CO2 stream from the RC.

The mixed flow is then split into two streams, one steam is heated in the HTR, and the other is

heated in the split heater (SH). Finally, the two steams mix together before entering the boiler

radiation heating surface. After entering the boiler, the primary CO 2 flow is heated by the spiral

5
wall heater (SWH), the low temperature super heater (LSH), and the high temperature super heater

(HSH) in sequence. The design parameters of the CO2 stream out of the boiler is 32 MPa and 600

o
C and then the CO2 flow with high temperature and high pressure is introduced into the HT to

convert thermal energy to mechanical power. After expanding in the HT, the CO2 stream out of the

HT is introduced into the boiler again to be reheated in order to increase the cycle efficiency

further and this reheated CO2 stream is also referred to as the secondary CO2 stream. The

secondary CO2 stream is heated in the wall re-heater (WRH), low temperature re-heater (LRH)

and the high temperature re-heater (HRH) successively to 620 oC, and then the CO2 flow is

introduced into the LT to convert thermal energy to mechanical power. As discussed above, the

temperature of the CO2 stream out of the LT is relatively high. Therefore, two recuperators (HTR

and LTR) are adopted to recover the heat by cold CO2 stream.

From Figure 5, it can be observed that the boiler for S-CO2 cycle power generation system is

significantly different from the conventional steam boiler. The layout of the boiler proposed by the

authors can be used to the entire S-CO2 Brayton cycle system and can also address the waste heat

recovery problem of the flue gas (＞550 oC).

3. Design methodology

As we know, the fundamental principles of boiler thermal design are the First Law of

Thermodynamics and the basic rules of heat transfer[19,20]. The thermal calculation of a boiler is

composed of furnace radiation heat transfer and convection heat transfer of the convective heating

surfaces.

3.1 Calculation of furnace heat transfer and furnace exit gas temperature

6
 The determination of furnace heat transfer is identical to the determination of the furnace exit

gas temperature. The value of the furnace exit gas temperature governs the quantity of heat

distributed to the furnace.

The basic equations for furnace heat transfer are the heat balance equation, i.e. (1) and the

radiant heat transfer equation governed by the furnace emissivity, i.e. (2)[19]:

Qheatbalance   Bj (Ql  Il )   BVC

j pj (Tll  Tl ) (1)

Qradiation   0 al FT
l hy
4
(2)

where  is furnace thermal effectiveness factor, which is defined as follows:

qyx1  qyx 2
  (3)
qyx1

Radiative heat transfer in the furnace is predominant and the heat transfer proportion by

convection is very small (no more than 5%) and can be ignored. Therefore, according to the First

Law of Thermodynamics, Qheatbalance  Qradiation , then  BVC

j pj (Tll  Tl )   0 al FT
4
l hy . From this

equation, the furnace exit gas temperature can be obtained.

3.2 Heat transfer calculation of convective heating surfaces

Calculations steps of convection heat transfer are as follows[19]:

(1) Under the condition of the known flue gas inlet temperature and working fluid inlet

temperature (or outlet temperature), the outlet temperature of the heating surface is assumed and

then, the heating surface outlet gas enthalpy can be obtained.

(2) According to the heating surface outlet gas enthalpy, the convection heat transfer (Qc) of

the heating surface can be obtained by the following equation:

Qc   ( I   I    I ca 0 )  Qaddc (4)

7
 (3) According to the First Law of Thermodynamics, the heat release for the flue gas side is

D(i  i)
equal to the heat absorption for the working fluid side. Therefore, Qc   Qr , and then,
Bj

the working fluid outlet enthalpy and temperature can be obtained.

(4) Calculating the convection heat transfer coefficient 1 for the flue gas side. It is calculated

as follows:

1  （c + r） (5)

When the flow between the flue gas and heating surface is cross flow and the heating surface

is in-series tube bundle, the convection heat transfer coefficient  c is calculated as follows:


 c  0.2Cs Cz Re0.65 Pr 0.33 (6)
d

ay ags 0 (Ty4  Thb4 )

r  (7)
Ty  Thb

where ags is the tube bundle emissivity, which is calculated as follows:

1  ab
ags  (8)
2

(5) Calculating the convection heat transfer coefficient  2 for the working fluid side.

1
(6) Then calculating the heat transfer coefficient K, K  . In the thermal
1 h 1
 
1 h  2

calculation of a boiler, following practical equations are used to determine K. When solid fuel is

1
fired and tubes are in staggered arrangement, K  , where  is the fouling factor,
1 1
 
1 2

heat absorption by heating surface

 . When solid fuel is fired and tubes are in in-line
heat striking heating surface
1
arrangement, K   .
1 1

1 2

8
 (7) Calculating the heat transfer temperature difference t , which is calculated by

td  tx
logarithmic mean temperature difference, t  .
t
ln d
tx

KH t
(8) Calculating the convection heat transfer by the equation of Qc tr  . If the error
Bj

between Qc tr and Qc is in a reasonable range, such as less than 2%, the calculation process is over,

or repeat the above calculation process.

The S-CO2 boiler design process presented in this article is performed using the S-CO2 boiler

Thermal Calculation (TC) software, developed by Xi'an Thermal Power Research Institute Co. Ltd.

(TPRI) [20]. The software is a modified version of steam boiler, which has been widely used in

practical engineering applications and shows excellent agreement with the operational data. We

developed the S-CO2 boiler TC software by replacement of the steam physical properties with the

supercritical CO2 physical properties. The physical properties of supercritical CO2 were from

NIST REFPROP V9.0 [21].

The value of  2 is calculated based on the heat transfer correlations obtained by experiments,

and the selection of the heat transfer correlations is based on the Reynolds number (Re)[22].

According to the heat transfer correlations, when single phase fluid flows turbulently inside tube,

the inside surface heat transfer coefficient is obtained as follows:


 2  0.023 Re0.8 Pr 0.4Ct Cl , (9)
ddl

In the present paper, we assume the relevant correction factors (Ct and Cl) in the heat transfer

correlations for S-CO2 boiler convection heat surfaces are the same as those of steam boiler. This

assumption is reasonable since the thermal properties of working fluids have little effect on the

correction factors.
9
4. Results and discussion
4.1 Arrangement of the heating surfaces

As mentioned above, the S-CO2 boiler is significantly different from the conventional steam

boiler. Table 2 shows the proximate and ultimate analyses of the design coal as a base used in the

thermal design calculation. The design parameters of a 300 MW S-CO2 boiler are shown in Table

3. It can be seen that the boiler inlet temperature is as high as 493 oC. If the conventional ECO is

employed in the S-CO2 boiler to preheat the working fluid, the inlet temperature of furnace

radiation heating surface will be up to about 570 oC, assuming the ECO temperature-pinch value is

30 oC, which might result in serious furnace radiation heating surface security problems.

Therefore, the ECO is removed and the S-CO2 working fluid enters the furnace radiation heating

surface directly, which can reduce the temperature level and alleviate the furnace radiation heating

surface security problems Moreover, the split heater (SH) is employed in the design of the S-CO2

boiler to recover the flue gas heat and ensure suitable reaction conditions for SCR. The layout of

the 300 MW coal-fired S-CO2 boiler is illustrated in Figure 7 and the geometry sizes of the

furnace structure and the various heating surfaces are also shown in the figure.

The basic dimensions of the S-CO2 boiler are 12.5 m  12.5 m  52.2 m

(Depth  Width  Height). The furnace volume heat load, the furnace cross-section heat load and

the burner region cross-section heat load are 90 kW/m3, 4.00 MW/m2 and 1.03 MW/m2,

respectively. The ratio of include coal to working fluid and flue gas damper are combined to

control the flue gas temperature. As for the thermal design calculation of the S-CO2 boiler, the flue

gas proportion of the main flue gas (LRH side) is 59%.

4.2 Thermal performance analysis

10
 Figure 8 shows the flue gas outlet temperature of each heating surface of the designed S-CO2

boiler. It can be obtained that the furnace exit gas temperature (FEGT) of the S-CO2 boiler is

1025.0 oC, and the SH exit gas temperature is 361.4 oC, which is within the optimal reaction

temperature range of SCR (350 oC~400 oC). Moreover, it can also be observed that the boiler

exhaust temperature (the APH exit gas temperature) is as low as about 110 oC, which ensures a

relatively high boiler thermal efficiency.

The working fluid (S-CO2) temperature and the heat absorption of the S-CO2 boiler various

heating surfaces are presented in Table 4. It can be obtained that the primary S-CO2 temperature

and the secondary S-CO2 temperature can meet the design value.

Figure 9 shows the area of the S-CO2 boiler various heating surfaces. The heat absorption of

the S-CO2 boiler primary S-CO2 heating surfaces and secondary S-CO2 heating surfaces is shown

in Table 5.

4.3 Thermal calculation under off-design conditions

The proximate and ultimate analyses of the off-design coal is shown in Table 6. By adjusting

the ratio of coal to CO2 and the flue gas damper, the designed S-CO2 boiler presented in this paper

can meet the design parameters (primary S-CO2 temperature and secondary S-CO2 temperature)

when burning the off-design coal, and the flue gas proportion of the main flue (LRH flue) is 56%.

The boiler exhaust temperature is 112 oC, and the boiler thermal efficiency is 94.1%. The working

fluid (S-CO2) temperature and the heat absorption of various heating surfaces in the S-CO2 boiler

when burning the off-design coal are presented in Table 7.

4.4 Boiler part load performance

11
 Table 8 shows the calculation results of the S-CO2 boiler part load performance. Three kinds

of boiler loads are selected, which are 100%, 70% and 50%. The boiler part load performance

calculation is based on three assumptions: (1) the designed coal is employed; (2) the boiler inlet

temperature remains constant; (3) variable pressure operation mode is employed. It can be

obtained from the table that the boiler FEGT decreases with the boiler load. By adjusting the ratio

of coal to CO2 and the flue gas damper, the primary S-CO2 temperature and the secondary S-CO2

temperature are not higher than the design temperature and the overheating problem of boiler

tubes can be eliminated well under the off-design conditions.

5. Conclusions and perspectives

In the present study, the conceptual design study of the boiler is carried out for a novel 300

MW single reheated recompression S-CO2 Brayton cycle tailored for coal-fired power plant.

Arrangement of the boiler’s heating surfaces is conducted, which make the S-CO2 boiler suitable

with the whole coal-fired S-CO2 Brayton cycle power generation system. The main characteristics

of the S-CO2 boiler are as follows: (1) removing the conventional ECO to reduce the inlet

temperature of radiation heating surface; (2) employing the split heater in the boiler to recover the

flue gas heat and ensure suitable reaction conditions for SCR; (3) the total heat absorption of the

primary working fluid is close to that of the secondary working fluid. In addition, the calculation

results of boiler off-design and part load performance indicate that the boiler has a reasonable

good off-design performance.

Acknowledgements

The authors acknowledge the financial support provided by the National Natural Science

Foundation of China (Grant No. 51706181 and 51406166), Key Programs of China Huaneng

12
Group (Grant No. HNKJ15-H07) and Basic Research Plan of Shaanxi Natural Science (Grant No.

2017JQ5124).

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Nomenclature
S-CO2 supercritical CO2
CSP concentrating solar power
ECO economizer
SH split heater
SCR selective catalytic reduction
CCS CO2 capture and storage
PSH platen superheater
EDF Electricite De France
APH air preheater
MC main compressor
TPRI Xi'an Thermal Power Research Institute Co. Ltd.
LTR low temperature recuperator
RC recompression compressor
HT high pressure turbine
LT low pressure turbine
HTR high temperature recuperator
PC pre-cooler
SWH spiral wall heater
LSH low temperature superheater
HSH high temperature superheater
WRH wall re-heater
LRH low temperature reheater
HRH high temperature reheater
FEGT furnace exit gas temperature
 heat retention coefficient

Bj calculation fuel consumption rate

Qheat balance heat transfer in furnace

Ql available heat

Qraiation radiant heat transfer in furnace

Il  furnace exit gas enthalpy

15
Tll adiabatic flame temperature

Tl  furnace exit gas temperature

VCpj average specific heat capacity

0 blackbody radiation constant

al furnace emissivity
 furnace thermal effectiveness factor
qyx1 radiosity of flame to furnace wall
qyx2 radiosity of furnace to flame

Fl furnace wall area

Thy average flame temperature

Qc convection heat transfer

I heating surface inlet gas enthalpy
I heating surface outlet gas enthalpy

 I ca 0 air leakage enthalpy

Qadd c hypothetical convection heat transfer of the additional heating surface

D mass flow rate of the working fluid

Qr radiant heat transfer from the upper heating surface

1 convection heat transfer coefficient for the flue gas side

correction coefficient (a correction taking into account the reduction of


heat absorption due to imperfect sweeping of heating surface by flue gases)

c convection heat transfer coefficient

r radiation heat transfer coefficient

Re Reynolds number
Pr Prantle number
 heat conduction coefficient
Cs correction factor for tube bundle arrangement
Cz correction factor of tube rows in flue pass

ay flue gas emissivity

Ty average flue gas temperature

Thb ash layer outside surface temperature

16
 ags tube bundle emissivity

ab tube wall emissivity

2 convection heat transfer coefficient for the working fluid side

K heat transfer coefficient

h ash layer thickness

h ash layer heat conduction coefficient

fouling factor (the reduction of the heat absorption of tubes owing to the
 rise of outside surface temperature and the decrease of emissivity because
of the ash buildup on tube outside wall)
t heat transfer temperature difference
the larger one of the initial temperature difference and the final temperature
td
difference between the hot fluid and the cold fluid
the smaller one of the initial temperature difference and the final
tx
temperature difference between the hot fluid and the cold fluid

Qc tr heat transfer calculated by heat transfer equation

H area of heating surface

d dl characteristic dimension

correction factor taking into account the impact of the tube wall
Ct
temperature on the fluid properties
correction factor with respect to relative length, which takes into account
Cl
the impact of the inlet heat transfer effect on  2

Table captions

Table 1. Design parameters of TPRI’s 300 MW S-CO2 coal-fired power cycle

Table 2. Proximate and ultimate analyses of the design coal

Table 3 Design parameters of the 300 MW S-CO2 boiler

Table 4 Working fluid temperature and heat absorption of boiler various heating surfaces

Table 5 Heat absorption of primary S-CO2 heating surfaces and secondary S-CO2 heating surfaces

17
Table 6 Proximate and ultimate analyses of the off-design coal

Table 7 Working fluid temperature and heat absorption of boiler various heating surfaces when

burning off-design coal

Table 8 Calculation results of the S-CO2 boiler part load performance

Table 1. Design parameters of TPRI’s 300 MW S-CO2 coal-fired power cycle

Parameter Unit Value

o
Main compressor inlet temperature C 31.5

Main compressor inlet pressure MPa 7.6

Main compressor outlet pressure MPa 34.1

o
Re-compressor inlet temperature C 84.1

18
Re-compressor inlet pressure MPa 7.65
o
High pressure turbine inlet temperature C 600

High pressure turbine inlet pressure MPa 32

o
Low pressure turbine inlet temperature C 620

Low pressure turbine inlet pressure MPa 17.8

o
HTR pinch temperature C 5
o
LTR pinch temperature C 5
o
PC pinch temperature C 5

High pressure turbine isentropic efficiency % 92

Low pressure turbine isentropic efficiency % 92

Main compressor isentropic efficiency % 90

Re-compressor isentropic efficiency % 90

Number of reheat stages - 1

Number of recompression stages - 1

Cycle thermal efficiency % 50.03%

Table 2. Proximate and ultimate analyses of the design coal

Designed

Coal

Volatile
20.43
Proximate analysis (wt.%, air-dry) matters

Fixed carbon 54.33

19
 Ash 12.54

Carbon (C) 81

Hydrogen (H) 4.8

Ultimate analysis (%, dry and ash-free) Oxygen (O) 12.5

Nitrogen (N) 0.9

Surfer (S) 0.8

Net heating value (kJ/kg, as received) Heating value 22800

Table 3. Design parameters of the 300 MW S-CO2 boiler

Primary S-CO2 mass flow rate t/h 7150.2

Primary S-CO2 pressure MPa 32.0

o
Primary S-CO2 temperature C 602

Secondary S-CO2 mass flow rate t/h 7150.2

Secondary S-CO2 inlet pressure MPa 18.7

20
 Secondary S-CO2 outlet pressure MPa 17.8
o
Secondary S-CO2 inlet temperature C 527.4
o
Secondary S-CO2 outlet temperature C 622

Mass flow rate in the SH t/h 715.0

o
Boiler inlet temperature C 493
o
Ambient air temperature C 25
o
Hot air temperature C 338
o
Boiler exhaust temperature C 110

Boiler thermal efficiency % 94.3

Fuel mass consumption rate t/h 98.8

Table 4. Working fluid temperature and heat absorption of boiler various

heating surfaces

Heating Inlet temperature Outlet Temperature Heat absorption

surface (oC) temperature (oC) increment (oC) (MW)

SWH 493.0 565.8 72.8 184.7

21
WRH 527.4 566.1 38.7 95.0

HSH 572.6 602.0 27.4 74.2

HRH 576.3 622.0 43.7 113.9

LRH 566.1 576.3 10.2 25.5

LSH 565.8 572.6 6.8 17.6

SH 230.3 493.0 262.7 79.5

Table 5. Heat absorption of primary S-CO2 heating surfaces and secondary

S-CO2 heating surfaces

Primary S-CO2 heating surface MW 276.5

Secondary S-CO2 heating surface MW 234.3

22
 Table 6. Proximate and ultimate analyses of the off-design coal

Off-design Coal

Volatile matters 26.49

Proximate analysis (wt.%, air-dry) Fixed carbon 31.88

Ash 33.13

23
 Carbon (C) 83.9

Hydrogen (H) 4.8

Ultimate analysis (%, dry and ash-free) Oxygen (O) 9.0

Nitrogen (N) 1.2

Surfer (S) 1.1

Net heating value (kJ/kg, as received) Heating value 18640

Table 7. Working fluid temperature and heat absorption of boiler various

heating surfaces when burning off-design coal

Heating Inlet temperature Outlet Temperature Heat absorption

surface (oC) temperature (oC) increment (oC) (MW)

SWH 493.0 566.2 73.2 185.8

24
WRH 527.4 566.6 39.2 96.6

HSH 572.3 602.0 29.7 74.3

HRH 575.7 622.0 46.3 116.5

LRH 566.6 575.7 9.1 22.5

LSH 566.2 572.3 6.1 45.5

SH 230.3 493.0 262.7 78.9

Table 8. Calculation results of the S-CO2 boiler part load performance

Boiler load
Parameter
100% 70% 50%

Flue gas proportion of the main flue 59% 65% 73%

25
 Furnace exit gas temperature 1025.0 oC 976.6 oC 855.8 oC

Primary S-CO2 temperature 602.0 oC 602.3 oC 622.6 oC

Secondary S-CO2 temperature 622.0 oC 620.3 oC 614.5 oC

Boiler exhaust temperature 110 oC 103 oC 97 oC

Boiler thermal efficiency 94.30% 94.60% 94.93%

Figure captions
Figure 1. A simple S-CO2 recompression cycle layout for coal-fired power plant

Figure 2. The heating surface arrangement of a conventional 300MW supercritical steam boiler

26
Figure 3. EDF’s S-CO2 Brayton cycle for coal-fired power plants

Figure 4. TPRI’s double reheated single recompression S-CO2 cycle for coal-fired power plants

Figure 5. Layout of the 300 MW coal-fired S-CO2 Brayton cycle power generation system

Figure 6 Temperature profile of the working fluid in the LTR

Figure 7. Layout of the 300 MW coal-fired S-CO2 boiler

Figure 8. Flue gas outlet temperature of each heating surface

Figure 9. Area of boiler heating surface

27
 Precooler
Boiler

Recompresssing ~620℃
compressor ~500℃

Main Turbine
compressor

Low T recuperator High T recuperator

Figure 1. A simple S-CO2 recompression cycle layout for coal-fired power plant

28
Figure 2. The heating surface arrangement of a conventional 300MW supercritical steam boiler

29
Figure 3. EDF’s S-CO2 Brayton cycle for coal-fired power plants

30
 110~120℃

APH

SCR
350~400℃

PC

Flue gas
LT
RC

HT

Boiler
HTR LTR MC

Figure 4. TPRI’s double reheated single recompression S-CO2 cycle for coal-fired power plants

31
Figure 5. Layout of the 300 MW coal-fired S-CO2 Brayton cycle power generation system

32
Figure 6 Temperature profile of the working fluid in the LTR

33
Figure 7. Layout of the 300 MW coal-fired S-CO2 boiler

34
Figure 8. Flue gas outlet temperature of each heating surface

35
Figure 9. Area of boiler heating surface

36
Nomenclature

S-CO2 supercritical CO2

CSP concentrating solar power
ECO economizer
SH split heater
SCR selective catalytic reduction
CCS CO2 capture and storage
PSH platen superheater
EDF Electricite De France
APH air preheater
MC main compressor
TPRI Xi'an Thermal Power Research Institute Co. Ltd.
LTR low temperature recuperator
RC recompression compressor
HT high pressure turbine
LT low pressure turbine
HTR high temperature recuperator
PC pre-cooler
SWH spiral wall heater
LSH low temperature superheater
HSH high temperature superheater
WRH wall re-heater
LRH low temperature reheater
HRH high temperature reheater
FEGT furnace exit gas temperature
 heat retention coefficient

Bj calculation fuel consumption rate

Qheat balance heat transfer in furnace

Ql available heat
Qraiation radiant heat transfer in furnace
Il  furnace exit gas enthalpy
Tll adiabatic flame temperature
Tl  furnace exit gas temperature

VCpj average specific heat capacity

0 blackbody radiation constant

al furnace emissivity
 furnace thermal effectiveness factor
qyx1 radiosity of flame to furnace wall
qyx2 radiosity of furnace to flame
Fl furnace wall area

Thy average flame temperature

37
Qc convection heat transfer
I heating surface inlet gas enthalpy
I heating surface outlet gas enthalpy

 I ca 0 air leakage enthalpy

Qadd c hypothetical convection heat transfer of the additional heating surface

D mass flow rate of the working fluid

Qr radiant heat transfer from the upper heating surface
1 convection heat transfer coefficient for the flue gas side
 correction coefficient (a correction taking into account the reduction of heat
absorption due to imperfect sweeping of heating surface by flue gases)

c convection heat transfer coefficient

r radiation heat transfer coefficient

Re Reynolds number
Pr Prantle number
 heat conduction coefficient
Cs correction factor for tube bundle arrangement
Cz correction factor of tube rows in flue pass

ay flue gas emissivity

Ty average flue gas temperature

Thb ash layer outside surface temperature

ags tube bundle emissivity

ab tube wall emissivity

2 convection heat transfer coefficient for the working fluid side

K heat transfer coefficient

h ash layer thickness

h ash layer heat conduction coefficient

 fouling factor (the reduction of the heat absorption of tubes owing to the rise
of outside surface temperature and the decrease of emissivity because of the
ash buildup on tube outside wall)
t heat transfer temperature difference

td the larger one of the initial temperature difference and the final temperature

difference between the hot fluid and the cold fluid

tx the smaller one of the initial temperature difference and the final temperature

38
 difference between the hot fluid and the cold fluid

Qc tr heat transfer calculated by heat transfer equation

H area of heating surface

d dl characteristic dimension
Ct correction factor taking into account the impact of the tube wall temperature
on the fluid properties
Cl correction factor with respect to relative length, which takes into account the
impact of the inlet heat transfer effect on  2

39