SUPERCRITICAL

BOILER
ASHVANI SHUKLA
C&I
BGR ENERGY
 POINTS OF DISCUSSION
 SUB CRITICAL & SUPER CRITICAL BOILER

 SIPAT BOILER DESIGN

 BOILER DESIGN PARAMETERS

 CHEMICAL TREATMENT SYSTEM

 OPERATION
 FEED WATER SYSTEM

 BOILER CONTROL

 BOILER LIGHT UP

 START UP CURVES
 WHY SUPER CRITICAL TECHNOLOGY

 To Reduce emission for each Kwh of electricity generated : Superior Environmental

1% rise in efficiency reduce the CO2 emission by 2-3%

 The Most Economical way to enhance efficiency

 To Achieve Fuel cost saving : Economical

 Operating Flexibility

 Reduces the Boiler size / MW

 To Reduce Start-Up Time

 UNDERSTANDING SUB CRITICAL TECHNOLOGY

 Water when heated to sub critical pressure, Temperature increases until it

starts boiling

 This temperature remain constant till all the water converted to steam

 When all liquid converted to steam than again temperature starts rising.

 Sub critical boiler typically have a mean ( Boiler Drum) to separate Steam And
Water

 The mass of this boiler drum, which limits the rate at which the sub critical
boiler responds to the load changes

 Too great a firing rate will result in high thermal stresses in the boiler drum
Role of SG in Rankine Cycle

Perform Using Natural resources of energy …….

 UNDERSTANDING SUPER CRITICAL TECHNOLOGY

 When Water is heated at constant pressure above the critical pressure, its
temperature will never be constant

 No distinction between the Liquid and Gas, the mass density of the two
phases remain same

 No Stage where the water exist as two phases and require separation : No
Drum

 The actual location of the transition from liquid to steam in a once through
super critical boiler is free to move with different condition : Sliding Pressure
Operation

 For changing boiler loads and pressure, the process is able to optimize the
amount of liquid and gas regions for effective heat transfer.
Circulation Vs Once Through
No Religious Attitude
 540°C, 255 Ksc

568°C, 47
Ksc 492°C, 260 Ksc

FUR ROOF
457°C, 49 Ksc
I/L HDR ECO HGR O/L
HDR
HRH LINE
MS LINE

411°C, 411°C,
277Ksc 275 Ksc

SEPARATOR

S
T FINAL SH
FINAL
O RH LTRH
R
DIV PANELS SH PLATEN
A SH
G
E

T VERTICAL WW
A
G ECO

305°C, 49 Ksc
N JUNCTION
K HDR
LPT LPT IPT
C
O HPT
N ECONOMISER
D
E
N
S
E
R
ECO I/L
lls
r wa
ate
lw
ira
Sp

FEED WATER
BWRP
290°C, 302 KSC

FUR LOWER HDR

FRS
 Steam

Partial Steam Generation

Complete or Once-through
Steam Generation

Heat Input
Water

Heat Input

Water
Water
Boiling process in Tubular Geometries
SEPARATOR TANK
 PENTHOUSE Eco. O/L hdr (E7)

LTRH O/L hdr (R8)

2nd pass top hdrs (S11)

Back pass Roof o/l hdr (S5)

SH final I/L hdr (S34) SH final O/L hdr (S36)

F19
1 pass top hdrs
st
RH O/L hdr (R12)
RH I/L hdr (R10)

F28 Platen O/L hdr (S30)

Platen I/L hdr (S28) F28

Div. Pan. I/L hdrs Div. Pan. O/L hdrs (S24)

(S20)
F8 1st pass top hdrs
Back pass Roof i/l hdr
S2
Separator (F31) Storage Tank (F33)
 SIPAT SUPER CRITICAL BOILER

 BOILER DESIGN PARAMETER

 DRUM LESS BOILER : START-UP SYSTEM

 TYPE OF TUBE
 Vertical
 Spiral

 SPIRAL WATER WALL TUBING

 Advantage
 Disadvantage over Vertical water wall
Vertical Tube Furnace

 To provide sufficient flow per tube, constant pressure furnaces employ

vertically oriented tubes.

 Tubes are appropriately sized and arranged in multiple passes in the lower
furnace where the burners are located and the heat input is high.

 By passing the flow twice through the lower furnace periphery (two passes),
the mass flow per tube can be kept high enough to ensure sufficient cooling.

 In addition, the fluid is mixed between passes to reduce the upset fluid
temperature.
Spiral Tube Furnace

 The spiral design, on the other hand, utilizes fewer tubes to obtain the
desired flow per tube by wrapping them around the furnace to create the
enclosure.

 This also has the benefit of passing all tubes through all heat zones to
maintain a nearly even fluid temperature at the outlet of the lower portion
of the furnace.

 Because the tubes are “wrapped” around the furnace to form the
enclosure, fabrication and erection are considerably more complicated
and costly.
 SPIRAL WATER WALL

ADVANTAGE

 Benefits from averaging of heat absorption variation : Less tube leakages

 Simplified inlet header arrangement
 Use of smooth bore tubing
 No individual tube orifice
 Reduced Number of evaporator wall tubes & Ensures minimum water flow
 Minimizes Peak Tube Metal Temperature
 Minimizes Tube to Tube Metal Temperature difference

DISADVANTAGE

 Complex wind-box opening

 Complex water wall support system
 tube leakage identification : a tough task
 More the water wall pressure drop : increases Boiler Feed Pump Power
 Adherence of Ash on the shelf of tube fin
 BOILER OPERATING PARAMETER
FD FAN 2 No’S ( AXIAL ) 11 kv / 1950 KW 228 mmwc

1732 T / Hr

PA FAN 2 No’s ( AXIAL) 11 KV / 3920 KW 884 mmwc

947 T / Hr

ID FAN 2 No’s ( AXIAL) 11 KV / 5820 KW 3020 T / Hr

TOTAL AIR 2535 T / Hr
SH OUT LET PRESSURE / TEMPERATURE / 256 Ksc / 540 C
FLOW 2225 T / Hr
RH OUTLET PRESSURE/ TEMPERATURE / 46 Ksc / 568 C
FLOW 1742 T / Hr
SEPARATOR OUT LET PRESSURE/ 277 Ksc / 412 C
TEMPERATURE
ECONOMISER INLET 304 Ksc / 270 C
MILL OPERATION 7 / 10

COAL REQUIREMENT 471 T / Hr

SH / RH SPRAY 89 / 0.0 T / Hr
BOILER EFFICIENCY 87 %
 Coal Analysis

Unit
Design Worst Best Young Hung Tangjin 1. High erosion
Parameter Coal Coal Coal #1,2(800MW) #5,6(500MW) potential for
High Heating Value kcal/kg 3,300 3,000 3,750 6,020 6,080 pulverizer and
backpass tube is
Total Moisture % 12.0 15.0 11.0 10.0 10.0 expected due to
Proximate Volatile Matter % 21.0 20.0 24.0 23.20 26.53 high ash content.
Analysis Fixed Carbon % 24.0 20.0 29.0 52.89 49.26
Ash % 43.0 45.0 36.0 13.92 14.21 2. Combustibility
Fuel Ratio (FC/VM) - 1.14 1.00 1.21 2.28 1.86 Index is relatively
low but
Combustibility Index - 2,067 2,353 2,476 2,781 3,492
combustion
Carbon % 39.53 31.35 40.24 63.03 62.15 characteristic is
Hydrogen % 2.43 2.30 2.68 3.60 3.87 good owing to
high volatile
Nitrogen % 0.69 0.60 0.83 1.53 1.29 content.
Ultimate
Oxygen % 6.64 5.35 8.65 7.20 7.80
Analysis
Sulfur % 0.45 0.40 0.60 0.72 0.68
Ash % 43.00 45.00 36.00 13.92 14.21
Moisture % 12.00 15.00 11.00 10.00 10.00
Grindability HGI 50 47 52 45 48
Hi–Vol. ‘C’ Hi–Vol. ‘C’ Hi–Vol. ‘C’ Midium Vol. Hi–Vol. ‘C’
ASTM Coal Classification -
Bituminous Bituminous Bituminous Bituminous Bituminous
 Ash Analysis

Design Worst Best Young Hung Tangjin

Parameter Unit
Coal Coal Coal #1,2(800MW) #5,6(500MW)
SiO2 % 61.85 62.40 61.20 57.40 57.40 1. Lower
Al2O3 % 27.36 27.31 27.32 29.20 29.20 slagging
potential is
Fe2O3 % 5.18 4.96 5.40 4.40 4.40
expected due
CaO % 1.47 1.42 1.52 2.70 2.70 to low ash
Ash MgO % 1.00 1.03 0.97 0.90 0.90 fusion temp.
Analysis Na2O % 0.08 0.08 0.08 0.30 0.30 and low
K2O % 0.63 0.32 1.22 0.70 0.70 basic / acid
ratio.
TiO2 % 1.84 1.88 1.80 1.30 1.30
P2O5 % 0.54 0.55 0.44 - - 2. Lower fouling
SO3 % 0.05 0.05 0.05 - - potential is
expected due
Others % - - - 3.10 3.10
o
to low Na2O
Ash Fusion Initial Deformation C 1150 1100 1250 1200 1200
and CaO
Temp. (oC) Softening o
C - - - content.
o
(Reducing Hemispheric C 1400 1280 1400
Atmos.) Flow o
C 1400 1280 1400
Ash Content kg/Gcal 130.3 150.0 96.0 23.12 23.37
Basic / Acid B/A 0.09 0.09 0.10 1.63 1.63
 AIR AND FLUE GAS SYSTEM
AIR PATH : Similar as 500 MW Unit

FLUE GAS PATH:

No Of ESP Passes : 6 Pass

No Of Fields / Pass : 18 1-7 fields  70 KV.

8&9 field  90 KV

No Of Hopper / Pass : 36

Flue Gas Flow / Pass: 1058 T/ Hr

COMMISSIONING DEPARTMENT, NTPC-SIPAT

 M M M
M TO PULVERISER SYSTEM

HOT PRIMARY AIR DUCT

PAPH # A
M M
PA FAN # A
M AIR MOTOR

M
M M M
M M AIR MOTOR

M
SAPH # A
M M
FD FAN # A
M

M M
M SAPH # B

M AIR MOTOR
M M M
FD FAN # B

M
M AIR MOTOR

M M
M PAPH # B
HOT PRIMARY AIR DUCT

TO PULVERISER SYSTEM
M M
M
PA FAN # B

LHS WIND BOX

FURNACE
FINAL SUPERHEATER

BACK PASS
DIVISIONAL PANEL

FINAL REHEATER

ECONOMISER
PLATEN COILS

LTRH

RHS WIND BOX

AIR PATH
 FUEL OIL SYSTEM
Type Of Oil : LDO / HFO

Boiler Load Attainable With All Oil Burner In Service : 30 %

Oil Consumption / Burner : 2123 Kg / Hr

Capacity Of HFO / Coal : 42.1 %

Capacity Of LDO / Coal : 52.5 %

HFO Temperature : 192 C

All Data Are At 30 % BMCR

 DESIGN BASIS FOR SAFETY VALVES :
1. Minimum Discharge Capacities.

Safety valves on Separator and SH Combined capacity 105%BMCR

(excluding power operated impulse safety valve)

Safety valves on RH system Combined capacity 105% of Reheat

flow at BMCR
(excluding power operated impulse safety valve)

Power operated impulse safety valve 40%BMCR at super-heater outlet

60% of Reheat flow at BMCR at RH outlet

2. Blow down 4% (max.)b

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