Session Theme：Clean Coal saving the Earth and Economy

High Performance Coal Fired

Thermal Power Plant
Plant,
Achievement and R&D for Future
8th September, 2010
Toshiba Corporation

Copyright 2007, Toshiba Corporation.

 Contents

1. Introduction of Steam Turbine & Generator Achievements

2. Efficiency Improvement by Innovative Thermal Cycle
3. Development
p of Advanced-
Advanced-USC & CCS technologiesg

© TOSHIBA CORPORATION 2010, All rights reserved. 2

 Contents

1. Introduction of Steam Turbine & Generator Achievements

2. Efficiency Improvement by Innovative Thermal Cycle
3. Development
p of Advanced-
Advanced-USC & CCS technologiesg

© TOSHIBA CORPORATION 2010, All rights reserved. 3

 Turbine Power Plants supplied by Toshiba
Iran Pakistan As of March 2010
As of March 2010
4 Units USA
3 Units
255 MW 137 MW 96 Units
India Canada 29,370 MW
Kuwait
10 Units
22 Units 2,458 MW 10 Units
4,470 MW Thailand 1,427 MW
Bulgaria 8 Units China
348 MW (incl.
(i l TTaiwan
i R
Region)
i )
3 Units
532 MW 49 Units
12,037 MW

Iceland
1 Unit
34 MW
Korea
UK 28 Units
1 Unit 2,138 MW
210 MW Italy Japan Puerto Rico
4 Units Mexico 1 Unit
1,447 Units 214 MW
Cyprus 994 MW 30 Units Antigua
g
81,134
81 134 MW
2 Units 2,512 MW 2 Units
120 MW Philippines 18 MW
Egypt 27 Units Venezuela
1,114 MW Nauru
6 Units UAE 7 Units
1,764 MW 1 Unit 1,418 MW
4 Units 0.1 MW
Nigeria 968 MW
Papua New Guinea Brazil
4 Units Sri Lanka Costa Rica
Lebanon 3 Units 3 Units
56 MW 135 MW 1 Unit
4 Units 1 Unit 155 MW
6 MW Indonesia 55 MW
130 MW
15 Units
Bangladesh 2,328 MW Argentina
Bahrain 5 Units
Botswana
B 41 MW 3 Units
1 Unit Malaysia
1 Unit 14 MW
33 MW South Africa 65 MW 22 Units
Myanmar Australia
2 Units 2 Units 4556 MW 55 Units
118 MW 0.9 MW 11,672MW

T t l 1
Total: 1,890
890 U
Units,
it 160GW iin 37
37countries
t i since
i 1927
© TOSHIBA CORPORATION 2010, All rights reserved. 4
Recent EPC Thermal Power Projects in the World
Bulgaria – Maritsa East 2
#1,3,4 3x177MW Coal Fired
Plant Rehabilitation
(COD:#1 Sep.2007, #3
Nov.2008,, #4 Feb.2009))
China - Taizhou #1,#2 Japan – Maizuru
J M i #2 USA - Iatan
I t
2x1000MW Coal Fired 900MW Coal Fired 2x1000MW Coal Fired
USC 24.5MPa595/595℃ USC 25.5MPa582/582℃
USC 25MPa600/600℃
(COD:#1 Dec.2007/#2 Mar.2008)
(COD: Aug. 2010) (Under Construction)

Indonesia - Tanjung
Jati B Extension
2x660MW Coal Fired
(Under Construction)
Rumania – Paroseni #4
1x150MW Coal Fired
Plant Rehabilitation
(COD: Aug.2007) India - Mundra Malaysia - Tanjung Bin Malaysia - Jimah
5x800MW Coal Fired 3x700MW Coal Fired 2x700MW Coal Fired
USC 24.2MPa565/593℃ (COD:#1 Oct.2006/ (COD:#1 Jan./#2 Jul.2009)
((Under Construction)) #2 Feb./#3 Aug.2007)

© TOSHIBA CORPORATION 2010, All rights reserved. 5

 Profile of the Project (1)
KEPCO Maizuru
M i #2 Power
P Pl
Plant (COD A
August, 2010)
Customer: Kansai Electric Power Co., Japan
Turbine: Cross Compound
Compound, Four Flow( CC4F
CC4F-43
43”))
Generator: Pri./Sec.：670MVA/370MVA
Output: 900 MW
M i St
Main Steam: 25 MPag、595℃
MP 595℃
Reheat Steam: 595℃
Rotation Speed: Pri./Sec.：3,600rpm/1,800rpm
Features
Top Level Plant Performance
V i
Various Coals
C l Available
A il bl
High-efficiency on Various Coals
Sustainability and Landscape-Reserve, considering
the Location adjacent to the quasi-national park

C l Fi
Coal Fired
d Pl
Plantt with
ith th
the L
Latest
t tT Technologies
h l i
© TOSHIBA CORPORATION 2010, All rights reserved. 6
 Profile of the Project (2)

Eraring 660MW Thermal Power Station, Australia

The record of continuous operation in the World (at 2003)

Eraring Unit 4 & 10 (Australia): manufactured by Toshiba
The continuous operation : 673 days (from Feb 26, 1995 to Dec31,1996)
Availability : 99.63%
The most reliable turbine & generator in the world
© TOSHIBA CORPORATION 2010, All rights reserved. 7
 Profile of the Project (3)
Anpara #4,#5 Power Station, India
8 years continuous commercial
operation without major overhaul
Customer:
Custo e Uttar
Utta Pradesh
ades State
Electricity Board, India
Taking over: Unit # 4: Feb 1994
Unit # 5: Oct 1994
Turbine: Tandem Compound,
Double Flow,
Reheat Type (TCDF-42”)
(TCDF 42”)
Output: 500 MW
Main Steam: 166 barg, 538 ℃
R h t St
Reheat Steam: 538 ℃
Rotation Speed: 3000 rpm

R b tD i
Robust-Designed
d Turbine
T bi forf Breakdown
B kd Maintenance
M i t
© TOSHIBA CORPORATION 2010, All rights reserved. 8
 Contents

1. Introduction of Steam Turbine & Generator Achievements

2.
2 Efficiency Improvement by Innovative Thermal Cycle
3. Development of Advanced-
Advanced-USC & CCS technologies

© TOSHIBA CORPORATION 2010, All rights reserved. 9

 Growth of Thermal Power Plant （2007→2015）

【Europe】
 Shift to Low Emission Power Plants 【China】
 Mega Market more than 50% in the World
 Local Manufactures Supplied Equipment
42GW
371GW
35GW
76GW 15GW
【Japan】 【America】
【Middle East】 C
Construction of
 Shift from Oil Fired to 80GW Combined Cycle
 Shift from Coal to CC in North America
Natural Gas Fired Plant  Large Scale Thermal Plant
71GW in South America
【India】
 Large Scale Coal 【Asia & Oceania】
39GW Fired Thermal Plant  Large Scale Thermal Power Plant
 Geo Thermal
【Africa】
 Coal Firing Unit
& Combined Cycle
Plant
Source: IEA World Energy Outlook 2009

© TOSHIBA CORPORATION 2010, All rights reserved. 10

 Towards Clean Coal Thermal Power Plants

40 Gt Methods TOSHIBA activities

Advanced
• Hi
High-efficiency
h ffi i Countries
Performance
Baseline Improvement
Equipment supply Emerging
Countries
Temperature
Increase (57%) • Rehabilitation Advanced
6 deg C
of decrepit plants Countries

Advanced
Renewable • Hydro
Hydro, CSP,
CSP Countries
Energy Geothermal Emerging
(23%) Countries
450ppm Stabilization Scenario Neucler(10%)
2 0 – 2.4
temperature Increase 2.0 2 4 deg C
CCS(10%) • Thermal Plant Advanced
Countries
with CCS
26 Gt
(Source: World Energy Outlook 2009) @2030

Efficiency Improvement for CO2 Reduction

© TOSHIBA CORPORATION 2010, All rights reserved. 11
 Coal-Fired Plant Efficiency in the World

45 %
The Latest Plant Efficiency Level
43 %

41 % Japan
fficiency （ＬＨＶ）

39 % UK&Ireland

37 % German
35 % USA
33 %
Australia
Gross Eff

31 %
China
29 %
India
G

27 %

25 %
1990 1992 1994 1996 1998 2000 2002 2004 2006

Source: Ecofys International Comparison of Fossil

Power Efficiency and CO2 Intensity 2009

T Level
Top L l Efficiency
Effi i as Coal
C l Fired
Fi d Thermal
Th l Plant
Pl t
© TOSHIBA CORPORATION 2010, All rights reserved. 12
 CO2 Reduction by Efficiency Improvement
World
W ld T
Total
t l coal-fired
l fi d th
thermall plant
l t
capacity: 1,440GW
Efficiency and CO2 emissions of
(1/3 of entire power plants capacity) C l Fi d Th
Coal-Fired Thermall Pl
Plants
t
The Latest Plant Efficiency Level
Coal-Fired Thermal Plants
in the World （％）
40
China Base +760kｔ +1690kｔ

CO2 emissions
Others +1760kｔ
37% 35%

Effiiciency*
e
41 6%
41.6%
1,440GW 35
India 36.7%
5% USA
23% * 32.1% 31.8%
30
Japan USA China India
Source: ＩＥＡ Wｏｒｌｄ Ｅｎｅｒｇｙ Ｏｕｔｌｏｏｋ 2009
・ECOFYS INTERNATIONAL COMPARISON
・ECOFYS, *Gross
G efficiencyy (
(LHV)
)
OF FOSSIL POWER EFFICIENCY(2008) *CO2 emissions from a 1,000MW plant

Efficiency Improvement Technology

Contributes to Reduction of CO2 emissions
© TOSHIBA CORPORATION 2010, All rights reserved. 13
 Steam Cycles and Efficiency Gains

elative)
7
600/610℃
ent (% re 6
593/593℃
5 566/593℃

4 566/566℃
proveme

538/566℃
3
538/538℃
ency Imp

2
MST/RST Temperature
1
Efficie

0
15 20 25 30 35
Main Steam Pressure (MPa)

Higher the Pressure, Higher the Temperature

More Gains on Efficiency and Subsequent CO2 Reduction

© TOSHIBA CORPORATION 2010, All rights reserved. 14

 Super Critical Turbine Experience
Over 81 units
O it off Toshiba’s
T hib ’ Super
S Critical
C iti l STG have
h been
b
operating since 1969. (except China)
World Share of Supercritical Steam Turbine
(Among Major Manufactures, Past 20 Years)

Company E TOSHIBA
Company D 9%
14%
27%

16%
Company C 18%
Company B Company A
16%
as of 2009

Top Level efficiency Steam Turbines Supplied to the Markets

© TOSHIBA CORPORATION 2010, All rights reserved. 15

 Transition of Steam Conditions

MST/RST
J Power TACHIBANA BAY #1
J-Power
1050MW (CC) TAIZOH #1&2
(25MPag 600/610℃) 1000MW (TC)
(25MPag 600/600℃)
600/610℃ MAIZURU #2
KAWAGOE #1,#2 NANAO OTA #2 900MW (CC)
700MW (TC) 700MW (TC) (24 5MP 595/595℃)
(24.5MPag
(31MPag 566/566/566℃) (24.1MPag 593/593℃)

593/593℃ HEKINAN #4,#5 IATAN 914MW (TC)

NOSHIRO #2 1000MW (TC) (24.6MPag 582/582℃)
600MW (TC) (24.1MPag 566/593℃)
(24 1MP 566/593℃)
(24.1MPag
566/593℃ WESTON #4 5834MW (TC)
HARAMACHI #1 TACHIBANA BAY
TSURUGA #1 (24.7MPag 582/582℃)
500MW (TC) 1000MW (CC) 700MW (TC)
g 566/566℃)
((24.1MPag (24.5MPag 566/593 ℃ ) (24.1MPag 566/593℃)
TC : TANDEM COMPOUND
566/566℃ CC : CROSS COMPOUND
HEKINAN #1 CALLIDE #3,#4 : 60Hz
700MW (TC) 420MW(TC)
(24.1MPag 538/566℃) (25MPag 566/566℃) : 50Hz
538/566℃
1990 1995 2000 2005 2010

Towards to Top Level Steam Conditions

© TOSHIBA CORPORATION 2010, All rights reserved. 16
 Steam Turbine Development based on CFD
HP Turbine 1st Stage Nozzle Cross-Over Piping
HP Steam Valve

Nozzle
Box LP Inlet
IP Exhaust
Lead Piping

IP Inlet
Abradable Seal

RH Steam Valve LP Exhaust Casing

© TOSHIBA CORPORATION 2010, All rights reserved. 17

 Efficiency Improvement of Generator
High-efficiency,
High efficiency large-capacity
large capacity
indirectly hydrogen-cooled turbine generator
Reduce losses compared to water-cooled
water cooled generators

Award from
The Japan Machinery
Federation
as
Excellent Energy-saving
Equipment
in 2009

Generators: Primary 670MVA(600MW) Secondary 370MVA(300MW)

Achieved the largest capacity and highest-efficiency
in the world by indirectly hydrogen-cooled method
© TOSHIBA CORPORATION 2010, All rights reserved. 18
 Steam Turbine Efficiency Improvement
■ Steam
St Turbine
T bi Test
T t Facility
F ilit
Mikawa Power Station
Unit2 Turbine Test Facility
（ i
（since JJune 2008）
LP Turbine

HP Turbine Generator

MSV/CV
Condenser
Bypass valve

Condenser

Generator

HP Turbine Boiler LP Turbine

Speed: 3,600rpm
Speed: 6,000rpm Stages: 6
Stages: 16 LSB: up to 50 in.

Full-scaled Turbine Test Facility for R&D to Boost Up

© TOSHIBA CORPORATION 2010, All rights reserved. 19
 Performance Improvement R&D Process
New Technology R&D Planning Verification Phase
Analysis & Simulation
① Blade loss reduction
Rotational direction
O
・Optimized Reaction Stage
S Design Bucket
・Surface friction loss reduction
・Longitudinal flow distribution control
nozzle

② Pressure drop loss reduction

・Inlet/Exhaust scroll
・Steam valve Performance Practical
・piping connection part
・Section joint piping, duct Improvement Operation
p
③ Leakage loss reduction C l
Cycle
・Seal fin profile improvement
・Clearance reduction
Mikawa P/S Unit #2
Actual size test facility
④ Last stage blade development
・High efficiency LSB series
Increased annulus area
=> Exhaust steam speed reduction
=> Loss reduction
・High mach number blades
・Smaller radical clearance

Utilization of the test results for Analysis & Simulation

© TOSHIBA CORPORATION 2010, All rights reserved. 20
Latest Development – Steam Turbine Technology
O
Optimal Reaction Blade
Verified High Efficiency Direct Lubricated
Bearings 35in LSB
Drum-type Rotor Confirm 30% Loss Measure Moisture
Confirm Rotor Dynamics Reduction Coefficient

Abradable Coating Seal

Confirm Low Leakage Welded Rotor Corrosion-Resistant
Loss and good Shaved G
Good Inspection Result Coating
Surface after Long Operation Confirm Coating Effect

V i
Various Technical
T h i l Improvements
I t for
f Both
B th Performance
P f & Reliability
R li bilit

© TOSHIBA CORPORATION 2010, All rights reserved. 21

 Steam Turbine World Market Share
Worldwide US Market
（Yr03-09 Except China, >100MW） 100%
％

Others
Others
B F
日立
50% D
三菱

C B
Alstom
E 64% 61% C
Siemens
D 46%
37% 36% 32% 40% E
GE
TOSHIBA Toshiba
８%
0%

Total：362,393MW 03 04 05 06 07 08 09

No 4 Share worldwide
No. No 1 Share in US for 7 years
No.1

© TOSHIBA CORPORATION 2010, All rights reserved. 22

Advanced Technology for Plant Rehabilitation
■ 450MW 169atg - 538/538degC TC4F
TC4F-26”
26”
HIP Section Replace = Increased Heat Rate 0.8%
1% efficiency
improvement on
1,000MW rating coal-
fired plant means
about 46,000t CO2
reduction per year.

■ 780MW 246atg - 538/538degC TC4F-30”

LP Section Replace = Increased Power Output 18.6MW

L t t Technology
Latest T h l for
f High-efficiency
Hi h ffi i & Life
Lif Extension
E t i
© TOSHIBA CORPORATION 2010, All rights reserved. 23
 Profile of the latest Project (4)
Bulgaria – Maritsa East 2 #1-#6 6x177MW Plant Rehabilitation

Custo e
Customer Maritsa
a tsa East
ast II TPP
Taking Over #1 Sep.2007, #2 Jan.2007
#3 Nov.2008, #4 Feb.2009
#5 (Mar.2011),
( ) #6 (Aug.2010)
( )
(under construction) (under construction)

#1-4：4x150
#1 4：4x150 MW STG Replacement
Turbine：LMZ Make → Toshiba Latest Turbine
Generator：LMZ Make →
T hib Air
Toshiba Ai Cooling
C li Generator
G t for
f unit2
it2
→40 Years old Machine to Latest
#3,4： 2x210 MW LMZ Make Turbine Rehabilitation
HP IP LP Blade Nozzle, LP Rotor Replacement
→24 Years old Machine to renewal

R h bilit ti off decrepit

Rehabilitation d it Units
U it to
t Improve
I Efficiency
Effi i
© TOSHIBA CORPORATION 2010, All rights reserved. 24
 Contents

1. Introduction of Steam Turbine & Generator Achievements

2. Efficiency Improvement by Innovative Thermal Cycle
3. Development
p of Advanced-
Advanced-USC & CCS technologiesg

© TOSHIBA CORPORATION 2010, All rights reserved. 25

Turbine material for High Temperature Parts
Further material development is underway
to meet 700℃ condition
750
725 A-USC
700 New
700MW M t i l
Material
675 for A-USC
24.1MPa
650 375MW 593/593℃
16.7MPa
625 566/538℃ Advanced USC
12Cr
600
575 12Cr alloy Modified 12Cr

550 500MW
CrMoV alloy
24.1MPa
525 566/566℃
Sub / Super Critical
500
1950 1960 1970 1980 1990 2000 2010 2020（year）
Material Development as National Project
© TOSHIBA CORPORATION 2010, All rights reserved. 26
 A-USC (Advanced Ultra Super Critical) Turbines
Main steam
(35MPa 700C）
Steam turbine

η/η （％)
Generator 16 700/720/720℃ A-USC

Efficiency ⊿η
D bl Reheat
Double R h t
Reheat steam VHP HP IP LP LP 14
(750C）
12

10

ovement of E
Boiler 8
FWH Condenser 600/700C A-USC
6

elative Impro
4 600/610C
Overall system Steam Valve Steam Turbine USC 566/566/566C USC
●Steam condition ●High temperature ●High temperature material 2 Dual Reheat
●Heat balance material ●Turbine Structure / Flowpath
0 538/566C

Re
USC

20 30 40
Main Steam Pressure (MPa)

Reheat Valves VHP Rotor TP VHP Cross Section

（φ400mm, 3.9ton） （φ850mm, 7.7ton）

Drive towards Advanced USC technology for future low CO2 emissions

© TOSHIBA CORPORATION 2010, All rights reserved. 27

 CCS Pilot Plant

Plant Overview
- Location: Sigma Power Mikawa,
Omuta, Fukuoka, Japan
- Post Combustion Method
- Capacity:2,100Nm3/hr (Feed)
(10t CO2/day)
(10t-CO /d )
- Exhaust Flow: 2,100 Nm3/h
- Commenced: September, 2009

Objectives
- Testing using the actual flue gas of
live thermal power plant
- Verification of performance,
operability, maintainability, etc.
i view
in i off scaled
l d up plant
l t design.
d i

D
Development
l t iin Progress
P for
f Full-Scaled
F ll S l d Plant
Pl t
© TOSHIBA CORPORATION 2010, All rights reserved. 28
 Thermal Power Plant with CCS
Steam Turbine Boiler
Carbon Capture System Stack

Generator

DeNOx FGD

Absorber

Stripper
Condenser
EP Compressor
Reboiler
CO2

Steam Extractions Exhaust

e (t / MWh)
O2 Discharge
CO

Comparison of CO2 Discharge

R&D ffor Hi
High
hPPerformance
f S
Solvent
l t
© TOSHIBA CORPORATION 2010, All rights reserved. 29
 Towards Clean Coal Thermal Power Plant
grams / kWh) 1400

1200

1000 Sub Critical

USC
ssions (g

800 A USC
A-USC

600
USC+CCS
USC CCS
CO2 Emis

( 50% CO2 Capture ) A-USC+CCS

400 ( 50% CO2 Capture )
C

200
USC+CCS A-USC+CCS
( 90% CO2 Capture ) ( 90% CO2 Capture )
0
30 35 40 45 50 55 60
Plant Net Efficiency (LHV)

Clean Coal Thermal Power Plant is realized by Integration and

Optimization of both High efficiency Turbine Cycles and CCS technology

© TOSHIBA CORPORATION 2010, All rights reserved. 30

 Toshiba Steam Turbine for Solar Power Plant
Axial Flow Turbine
(Below 100-150MW)

Double Flow Turbine

(Over 100-150MW)

 Moisture Extraction Blade (MEB)

MEB from Geothermal Technology
Drain Catcher
Drain Removal
Four Flow Turbine G
Grooves
(Over 400MW)

St
Steam turbine
t bi line-up
li f R
for Renewable
bl Energy
E Plant
Pl t
© TOSHIBA CORPORATION 2010, All rights reserved. 31
© TOSHIBA CORPORATION 2010, All rights reserved. 32