Spiral OTSC boilers – An Overview

Date 17th Nov 2008

Department P & P
Relevant References

Steam conditions
Fuel Conditions
Tube materials

Page 2
Hemweg

Page 3
Hemweg
Holland

650MW

Evaporation 550 kg/s

S/htr Outlet Press. 250 bar
S/htr Outlet Temp. 540 °C
R/htr Outlet Temp. 568 °C
Generating Efficiency 43.2 %
Availability (1998) 98.0 %
Commissioned 1992
Load following yes
Benson load 35%
Turndown 30%
Rate of load change 5% /min
Ignition - rated load (cold) 3.75 hrs
World traded coals

Page 4
Meri Pori
Meri-Pori
Finland
G
+70.750

SEPERATOR
VESSEL

560 MW
G
+59.500

OUTLET REHEATER

FINAL SUPERHEATER

Evaporation 440 Kg/s PLATEN SUPERHEATER PRIMARY

SUPERHEATER

S/htr Outlet Press 239 bar G

+47.000

S/htr Outlet Temp. 540 °C PRIMARY

REHEATER

R/htr Outlet Temp. 560 °C ECONOMISER

Generating Efficiency 43.5% CIRCULATING

14597 FURNACE DEPTH

Availability (1998) 100%

PUMP
OVER AIR
PORTS
G
+32.500

Commissioned 1993
Load following yes OVER AIR
PORTS

FU
07.3 IDT
208 CE W
RN
A
H
LOW NOX
COAL BURNERS

Benson load 35%

Turndown 30%
Rate of load change 5% /min
Ignition-rated load (cold) 3.5 hrs G
+13.500

World traded coals

ASH
CONVEYOR GAS RECIRCULATION
DUCT

Page 6
Changshu
China

Page 7
Changshu
China

MAIN STEAM REHEATER

OUTLET OUTLET

+72425

+70695
PENTHOUSE ROOF

3 x 600 MWe
+69815
+69415
+68815

SEPERATOR
VESSEL
+66345

+63844
ROOF TUBES +63975

REHEATER

BMCR Evaporation : 541 kg/s FINAL

SUPERHEATER
6555 6555

REHEATER

S/Htr outlet press : 254 bar PLATEN

SUPERHEATER
TO STORAGE
VESSEL

S/Htr outlet temp : 543 °C

PRIMARY
SUPERHEATER
+47844

5300

+43859 +43720

R/htr outlet press : 667 psi +42720

ECONOMISER

+38280

R/htr outlet temp : 569 °C

+37840

AFTER AIR

+35750

ECONOMISER
+34560

+33388

Benson Load : 35% BMCR +29880

Load Following : Yes

15632

+26037

Max Load Change Rate : 5%BMCR/min

+22194

22187 FURNACE WIDTH

+20250

+18351

AIRHEATER
LOW NOX
COAL BURNER

+13500

+9400

+5200

+0.0m (GRADE)

-1000

ASH REMOVAL SYSTEM

4800 (BY OTHERS)

9500 11700 12771 13309

Page 8
Wangqu
China

Page 9
Wangqu Boiler For Low Volatile Coal

MAIN STEAM REHEATER

OUTLET OUTLET

Pr ep are d b y T er ry Ev an s, Jan ua ry 20 04 fo r Wan gqu

SEPARATOR
VESSEL
Once Through Supercritical Boiler.
(Operation 2006)
REHEATER

REHEATER

Benson boiler featuring

TO STORAGE
FINAL VESSEL
SUPERHEATER

PLATEN
SUPERHEATER

spiral furnace construction.

PRIMARY
SUPERHEATER

ECONOMISER Maximum output 671 MWe

Superheater outlet pressure 24.2 MPa
ECONOMISER
Superheater outlet temperature 566°C
Reheat outlet steam temperature 566°C
Design Coal

Moisture % 7.96
Ash % 22.3
HOPPER KNUCKLE

Volatiles % daf 14.42

FURNACE ACCESS DOOR

% dmmf 12.15
Sulphur % 0.35
W ATER
IMPOUNDED
HOPPER
Nitrogen % daf 0.93
HHV kJ/kg 24600

Page 10
Wangqu Boiler -- A comparison of relative heights

+79280

240 ft
+67000

+65000

+52800

WANGQU LIAOCHENG HEZE STATUE of

600MW 600MW 300MW LIBERTY
O.T.S.C.

Page 11
Spiral Furnace Arrangement

The most widely used furnace tube

layout today is the Spiral Membrane.

It uses a small number of plain bore

tubes with a high water velocity.

The long tubes wind through all the

different heat zones of the furnace and
to pick up the same amount of heat.

Because the tubes are nearly horizontal,

a secondary support structure is needed
to bring bending stresses in the tubes
within limits.

Page 12
Doosan Babcock Supercritical Boilers

Doosan Babcock Spiral Tube Furnace Design Features:

Layout of spiral tubes

in opposed fired
AA Ports
boiler with low NOx
combustion system
Burners
and ash removal
hopper for coal
firing.

Hopper end wall Hopper end wall

Hopper slope Hopper slope
Page 13
Spiral Furnace Features

Evaporation complete
Vertical tubes where in furnace tubes
heat flux is lower

Welded strap to
support tubes
Transition mixing
header

Pressure balancing
ring
Spiral furnace tubes

Zone of highest
Burner region heat flux

Spiral hopper tubes

Page 14
Pressure Balancing Ring

Flexible Corner Pipes

Flexible Corner Pipes

Individual Connections
to each spiral tube

Pressure Balancing Headers

Page 15
 Doosan Babcock Supercritical Boilers

Doosan Babcock Spiral Tube Furnace Design Features

Twin welded straps provide

auxiliary supports for inclined
furnace tubes

Buckstay
and Link
System
Inclined blocks attached
to the tube membrane
provide attachment
points and a thermal
path between fluid and
each pair of straps
ensuring acceptable
temperature differentials

Page 16
Horizontal Wall Firing

COMBUSTION AIR

PRIMARY AIR + FUEL

Burnout
Zone

Low NOx Burner Design

Burner & OFA

NOx
levels Reduction Zone

Low NOx Burners

in operation

Furnace Configuration
Page 17
Spiral or Vertical Furnace ?

Vertical Tube Boiler Type

Property Spiral Furnace Design Universal Pressure Japanese Style High True low Mass Flux
High Mass Flux Design Mass Flux Design Design

Mass Flux lb/ft2/hr 1,600,000 1,300,000 1,300,000 800,000

Flow Characteristic Negative Negative Negative Positive

Adjustable flow orifices no yes yes no

Feed Pump Power high high medium low

Temperature diff in moderate wide Narrow (separate narrow

furnace wall exit tubes evaporator)
Min Unit Size 250 MW 300 MW 600 MW 250 MW

Load Following good bad poor Very good

Min. Load in once- 30-35% 30% 35% 20-25%

through mode
Circulating Pumps 1 - 1 1

Page 18
Features of Doosan Babcock Spiral Furnace Boilers

Page 19
Doosan Babcock Supercritical Boilers

Some Typical Features are:

•Two pass layout

•Opposed wall firing
•Combustion system
•Pendant surfaces
•Stub headers systems
•Modular design
•Many others

Supercritical 600 MWe

Page 20
Doosan Babcock Supercritical Boilers

Typical view of Pressure part fabrication shop

Supercritical Fabrication

Page 21
Once Through Boiler Technology

Once-through boiler flow circuit

Economiser Platen Fin Rehtr

Furnace Primar

Upper furnace
Reheate
Separator **
Roof and rear cage Reheate

Reheate
Horizontal S/H
Eco
Platen S/H
Final S/H

**Optimum position in
circuit varies

Page 22
Recirculation Start-Up System

• Furnace tubes require a minimum

flow
• At loads where the evaporation is Pla te n Fin Re htr

less than this minimum flow then Prim a r

recirculation is required Re he a te

• The load at which the minimum flow Re he a te

equals evaporation is known as the Re he a te

Benson load Eco

• Benson load is typically 35 % MCR

Page 23
Recirculation Start-Up System

• During start-up and up to Benson load the

recirculating pump is in service
Pla te n Fin Re htr
• Separator vessel acts as steam drum
• Evaporation is made up by feedwater to Prim a r

economizer Re he a te

Re he a te
• Above Benson load the recirculating pump is Re he a te

stopped and the separator vessel becomes Eco

dry

Page 24
Typical Circulation Pump

Start-up and low load operation mostly uses Circulation pumps:

• Type of high pressure low head pump needed for spiral furnace
Section of circulating pump circulation.
• Pump is suspended directly from the suction piping.
• The pump requires cooling water supply to protect the motor
windings.

Page 25
Typical Separator Vessel

• Steam/water enters tangentially for

cyclonic separation
• Vortex eliminator in water outlet
• Low pressure loss
• High efficiency
• Small diameter thin walled vessel for
resistance to fatigue

Page 26
Comparison of Damper Positions

Vertical
Spindle

Horizontal
Spindle

Other OEM
Page 27
Damper Arrangement View

REHEATER PASS SUPERHEATER PASS R/HTR S/HTR R/HTR S/HTR R/HTR

HOPPER

SECTION 'A-A'
SECTION 'A-A'

DIVISION PLATE

B
ECONOMISER
CASING

SUPERHEATER PASS

A A REHEATER PASS

REHEATER
OUTLET

BIASING SUPERHEATER
DAMPER OUTLET

REHEATER
OUTLET
ISOMETRIC VIEW

HOPPERS SUPERHEATER
B OUTLET

PLAN
REHEATER
OUTLET

Page 28
 Typical Arrangement of Stub Pipes & Headers

Steam Manifolds

Stub Pipes Front Elevation

Plan

Stub Headers

Heating Surface
Page 29
Followed Arrangement of Stub Pipes & Headers

DB Other
Manufacturer

High Temperature Tube Connections Page 30

Finite Element Analysis of Components under Two Shift Operation

Page 31
Spiral Furnace Construction

Page 32
Spiral transition to vertical

Page 33
Control Aspects

Page 34
Typical Modified Sliding Pressure Line

3500

3000

2500
Press psig

2000

1500

1000

500

0
0 10 20 30 40 50 60 70 80 90 100

Load %

Page 35
Control and Steam Temperature Matching:

• Position of separator
in system is selected
to bring enthalpy at
minimum Benson
load close to
saturation.
• This enables a close
match of
superheater steam
temperature to
turbine parts for
starting and on shut
down.
• For cold starting
cooler warming
steam is available.

Page 36
Start-up System Description

To Superheaters

Furnace wall Separator Vessels

Storage vessel

Economizer

To drains vessel

Circulation pump

Feed Pump
Page 37
Start-up System Instrumentation

PT

LT

Circulation Drain valve

FT Control
valve

FT

Start up feed control valve

Page 38
Storage Vessel Levels

7610
Large overflow
Small 7160 6960 valve
overflow valve
6285
6000
Circulation valve
control range

2350 2500
Pump permissive

Pump trip 1200

Page 39
Typical Spiral Furnace OTSC Boiler Design

Page 40
Boiler Design Solution -1
MAIN STEAM REHEATER
MANIFOLD MANIFOLD

• Incorporates Doosan Babcock features to

prevent slagging and fouling, and to protect
SEPERATOR
VESSEL
from erosion
REHEATER
OUTLET LOOP

FINAL
18'-10 3/8" 21'-10 5/8"

REHEATER
• Ease of construction
SUPERHEATER

PRIMARY
SUPERHEATER

PLATEN
SUPERHEATER
• Minimize interfaces to provide manageable
schedule
THERMO-PROBE

56'-1/2" FURNACE DEPTH 18'-9/16"

ECONOMIZER
• Intergraph Drawing system to aid Designer,
Constructor, and Operator

ECONOMIZER
• Engineering phase includes electronic
transfer of drawings / documents
E W IDT H
" FU RN AC
86'-4 1/2
27'-4 1/4"

S.C.C.

Page 41
 Boiler Design Solution -2
MAIN STEAM REHEATER
MANIFOLD MANIFOLD

• Doosan Babcock 2 pass design

• Spiral Tube Furnace
SEPERATOR

• Platen surface in high temperature zone

VESSEL

REHEATER
OUTLET LOOP

FINAL
SUPERHEATER
18'-10 3/8" 21'-10 5/8"

REHEATER • Stub pipe arrangements for high flexibility

• Divided back pass for reheat temperature
PRIMARY
SUPERHEATER

PLATEN
SUPERHEATER

control
THERMO-PROBE

56'-1/2" FURNACE DEPTH 18'-9/16"

• Austenitic materials for high temperature
ECONOMIZER
zones
• Wall burners grouped in horizontal rows for
ECONOMIZER fuel and air supplies.
86'-4 1/2
" FU RN AC
E W IDT H
• SCR plant to meet the specified NOx
levels
27'-4 1/4"

S.C.C.

Page 42
Boiler Design Solution - 3

+277'-6" TOS

SEPERATOR
VESSEL

+230'-0" RO OF TUBES
AM M ONIA Nox REDUCTION
INJECTION G RID (SCR UNIT)

M AIN SERVICE PIPEW ORK

TO STORAGE
IS INDICATIVE ONLY
VESSEL

M OBILE TRIPPER
LO CATION

PA FAN
SUCTION
DUCT

RAW COAL
SILO

RO TARY
TRI-SECTOR
G AS AIRHEATER
CO AL FEEDER

+55'-0" TOF

ACCESS AND
HANDLING ZONE
FO R CO AL MILLS

C OA L M ILL PRIM ARY AIR

FAN (PA)
TEM PERING AIR
DUCTING TO
S CRAPE R CHAIN CO AL M ILLS
CO NVEYO R (SCC)
+0'-0" LVL (GRADE)

HO T PRIM ARY
AIR DUCTIM G FO RCE D DRAUGHT
TO CO AL M ILLS FAN (FD)

Sectional Side Elevation

Page 43
Boiler Design Solution - 4

HOT PRIMARY FD FAN FORCED

AIR DUCTIMG DISCHARGE DRAUGHT
TO COAL MILLS DUCT FAN (FD)

STAIR &
HOIST WELL

12'
33'-4"

32'
46'
33'-4"

PA FAN
DISCHARGE
DUCT

60'
TEMPERING AIR
CROSS-OVER
DUCT
33'-4"

8'
200'

C.L. BOILER

8'
FD FAN
COAL MILL
CROSS-OVER
(6 OFF)
DUCT
33'-4"

PRIMARY AIR
FAN (PA)

TEMPERING AIR
DUCTING TO STEAM
COAL MILLS AIRHEATER

60'
C.L. FURNACE
33'-4"

GAS AIRHEATER
OUTLET DUCT
46'
33'-4"

32'
SCC OUTLET
CHUTE TO
CRUSHER
12'

STAIR &
FREIGHT
ELEVATOR

24' 12' 16'-0 1/4"

48' 20' 36' 41' 40' 38' 38' 30' 30'

321'

Plan View – Ground Level

Page 44
Boiler Design Solution - 5
HOT SECONDARY AIR HOT PRIMARY HOT SECONDARY
AIR DUCTING FD FAN
DUCTING CONNECTIONS AIR DUCTING SUCTION DUCT
TO BURNER W INDBOXES TO COAL MILLS

STAIR &
HOIST W ELL

12'
33'-4"

32'
46'

BURNER
W INDBOX
(6 OFF)

ROTARY
TRI-SECTOR
GAS AIRHEATER
33'-4"

60'
33'-4"

RAW COAL

C.L. FURNACE
FEEDERS
(6 OFF)

8'
C.L. BOILER
200'

8'
33'-4"

PA FAN
16'-0 1/4" SUCTION DUCT

HOT SECONDARY AIR

60'
CRO SS-OVER DUCT
33'-4"

G AS AIRHEATER
INLET DUCT
46'
33'-4"

32'
12'

STAIR &
FREIGHT
ELEVATOR

24' 12'

48' 20' 36' 41' 40' 38' 38' 30' 30'

321'

Plan View – Feeder Floor Level

Page 45
Development of Thermal Efficiency in
Coal Fired Power Plants

55
Cycle Thermal Efficiency (%NCV)

THERMIE 700 TARGET

COST 522 TARGET

50 SKAERBECK/NORDJYLL
MBEL BAT
HEMWEG
LUBECK
MERI PORI
45

40
RECENT
CASTLE PEAK
DRAX CHINESE PLANTS
35 RATCLIFFE
FERRYBRIDGE

30
1960 1970 1980 1990 2000 2010 2020
Year
Natural Circulation
Supercritical

Note BAT= Best Available Technology , 2002

Page 46
Reduced CO2 from Advanced Supercritical Coal Fired Power Stations

0%
Traditional Natural
% Reduction in CO2 emissions

Circulation Boiler

-10%
HEMWEG
Advanced
MBEL Supercritical
BAT
-20% Boilers

COST
522
TARGET
-30%
THERMIE 700
TARGET

1990 2000 2010 2015

Page 47
Doosan Babcock
Advanced Supercritical Benefits

Efficiency
% LHV, net
45 • Best available supercritical technology is 300 bar,
600/620oC (4350psi,1110oF,1150 oF)
44
• Comparing new plant efficiencies (with FGD)
43 • 10% fuel saving
– 10% emissions saving
42
• Vertical Tube Furnace offers optimum solution
41
40
39
38
Sub-crit 600 C
Single reheat Supercrit
Inland site
Bituminous coal Page 48
Tube materials
FINAL SUPERHEATER
OUTLET MANIFOLD
REHEATER OUTLET
MANIFOLD
Final RH outlet Leg & Stub
+76325 TOS
Header Austenitic
Final RH Centre Loop T91
+72015 PENTHOUSE ROOF

+68500 STEAM DRUM

Plain Tubes T23 +64855 ROOF TUBES

+64600 TOS
Final RH Inlet Leg
Platen & Final SH
PLATEN SUPERHEATER

FINAL SUPERHEATER
Primary SH Outlet Leg & Manifold T91
REHEATER

Inlet Header & Leg

Austenitic
REHEATER
OUTLET BANK
PRIMARY
SUPERHEATER
Plain Tubes T23
+50250 TOS
+49855

Primary RH Bank2 & Outlet Leg T12

Platen & Final SH THERMOPROBE
REHEATER
INLET MANIFOLD
ECONOMISER Primary RH Bank 1 A210C
Outlet Header & Leg
Austenitic +38425 W /C

Primary SH Banks 1,2 & 3 T23

+35355 AFTER AIR

+34200 TOS

+31855 BURNERS FEEDW ATER

INLET TO
ECONOMISER

Economiser A210C
Ribbed Tubes T23 +25855 BURNERS

All tube materials proposed for

+19855 BURNERS +19855

Trimble County 2 have

W ATER CANNON (W /C)

+15350 TOS
extensive references at similar
temperatures and conditions
Plain Tubes T12 +5457

SCRAPER CHAIN
CONVEYOR (SCC)

+0.0m GRADE LEVEL (925'-0")

Page 49
Furnace Cleanliness

• 4 water cannon or hydro-jets are provided

• 16 heat flux sensors
• Good coverage of the furnace including underside of nose arch
• Software determines order and frequency of cleaning zones
• Thermal stress analyzer module measures thermal impact
• Adaptive software can balance cleaning success with thermal impact

Page 50