LEADING THE INDUSTRY IN SUPERCRITICAL BOILER TECHNOLOGY

HIGH-EFFICIENCY SUPERCRITICAL TECHNOLOGY

Alstom is a global leader in the world of power generation, setting the benchmark for clean, innovative technologies to create customer value. We supply major equipment in 25% of the installed base worldwide. wide. In addition weve trained and licensed other companies to And weve developed an unmatched level of expertise in steam install an additional 72,000 MWe of Alstom supercritical boiler generation and fuel combustion technology, having supplied more technology. Globally, we have unmatched experience in tailoring than 400 GWe of boilers around the world. boiler designs to fuel properties. Our boilers convert fuel into steam for the generation of electricity cleanly, cost-effectively, reliably. As the No 1 supplier of boilers worldwide, we can meet your project requirements today and in the future with the design, manufacture and supply of state-of-the-art systems and equipment. Alstom pioneered supercritical steam generation and today leads the industry in supercritical boiler technology. We have directly supplied more than 80,000 MWe of supercritical boilers world-

FOR CLEAN POWER TODAY!

Why Alstom Advanced Supercritical? Leading Through Technology

Today, our advanced high-efficiency pulverized coal supercritical boilers offer plant owners many benefits. The technologys higher steam temperature and pressure parameters deliver the most economical way to improve plant efficiency and operating flexibility, achieve fuel cost savings, and reduce emissions for each kWh of electricity generated. Alstoms Advanced Supercritical technology reduces all emissions, including CO2. In fact, an efficiency improvement of 1 percentage point equals 2%-3% less CO2 emitted. Alstom is also driving the development and deployment of the next generation of clean coal combustion technologies. We are investing in the future of clean power across 22 development centers and 13 laboratories around the world with the express goal of minimizing environmental impact. One Alstom combustion technology currently in the pilot plant demonstration phase Superior environmental enables the capture performance of CO2 emissions Highest unit efficiency from fossil fuels, including pulverized Operating flexibility coal boilers. Known Design tailored to fuel choice as oxy-fuel firing, this technology is Fuel cost savings being tested in a 30 MWth pilot at the Schwarze Pumpe Power Station in Germany. Oxy-fuel firing is especially promising for CO2 -free supercritical generation in the near term. In addition to our own R&D activities, we participate in a number of public development projects and partnerships, including those sponsored by the European Union and the US Department of Energy, as well as nearly all joint boiler materials development programs.

THE SUPERCRITICAL DIFFERENCE

Once-through supercritical technology offers important benefits to plant owners, including: Increased efficiency Lower emissions levels Lower operating costs Greater operating flexibility These benefits are possible because of the higher steam pressures and temperatures which are a hallmark of the technology.

Increased Efficiency and Lower Emission Levels

Plants that employ todays generation of Alstom supercritical boilers can operate at cycle efficiencies in excess of 42-45% HHV (44-47% LHV). As efficiency is increased, less fuel is consumed per kilowatt-hour (kWh) with a corresponding decrease in emissions per kWh. Because these units do not have thick-walled steam drums, their start-up times are quicker, further enhancing efficiency and plant economics. We continue to develop increasingly efficient supercritical cycles for improved efficiency. Alstoms current technology development will lead to our prototype ultra-supercritical plant, operating at 1290 F (700 C) / 5075 psi (350 bar).

Understanding Supercritical Technology

Water/steam circulation systems are divided into two main classifications: once-through, in which the water and steam generated in the furnace waterwalls passes through only once; and drum-type boilers, in which water/steam separation occurs, and water is recycled back to the waterwalls. Supercritical conditions occur when the boiler pressure increases above the critical pressure of 3,208 psi / 221.2 bar. Above this point, two phase mixtures of water and steam cease to exist, and are replaced by a single supercritical fluid. This eliminates the need for water/steam separation in drums during operation, and allows a simpler separator to be employed during start-up conditions.

Lower Operating Costs

Lower fuel consumption is a direct consequence of higher efficiencies. Fuel costs are a power plants largest operating cost item. Because the capital cost of supercritical plants is close to those of subcritical plants, overall life cycle costs are often reduced.

Heat Rate Improvement vs. Steam Conditions (Single Reheat)

Faster Start-up Time with Once-Through Design

Efficiency Improvement with Increasing Steam Conditions

5075/1350/1400 5075/1290/1330 350/730/760 350/700/720 4050/1110/1150 280/600/620 psi/OF/OF (bar/OC/OC) Efficiency Increase 2400/1000/1000 167/540/540 3500/1000/1050 240/540/565 Mature technology R&D ongoing USA USC Materials Consortium & EC AD 700 project (Ni-base) R&D ongoing

3900/1075/1110 270/580/600 Market intro. by Japan and Europe

CONTINUED ADVANCEMENTS SUPERCRITICAL SUBCRITICAL DOE USC Matl. DOE Steam Turbine Matl. AD 700 project COMTES 700

1960
Steam Conditions

1980

2000
Today

2010

2020

Material Improvement Milestones

Greater Operational Flexibility

Todays market realities demand that units are not only designed for baseload operation, but are capable of cycling and/or two-shift operation. Units must be designed for rapid response times. Alstom once-through supercritical boilers have the ability to respond and adjust to changes in load demand while maintaining tight control of steam temperatures. Alstoms supercritical boilers operate in the sliding pressure mode, where pressure is reduced with load. This allows the maintenance of relatively constant first-stage turbine temperature, reducing the thermal stress on components as the unit is cycled. Less stress translates into less maintenance and higher availability. Todays generation of supercritical boilers boast high availabilities, comparable to those of subcritical units, as well as improved plant efficiency at lower loads.

Unlike drum boilers, onceSliding Pressure Operation through units do not have a for Once-Through Boilers fixed evaporative point: the final evaporation occurs in the furnace wall systems with steam that is leaving the furnace walls being superheated to a certain degree. Since the evaporation point is not fixed, heat duties can be shifted between the furnace and the superheaters, allowing for adjustment to changing 1. Constant pressure operation slagging and fouling 2. Modified sliding pressure operation conditions caused by 3. Pure sliding pressure operation changing fuel properties.

ADVANCED BOILER DESIGNS

Alstom technologies deliver realistic solutions for reliable clean coal generation now. Our advanced supercritical boiler designs are at the heart of todays state-of-the art plants, meeting the diverse requirements of projects all over the globe and firing the full range of international coals. With Alstoms supercritical boiler design advantages, coal is clean, economical and secure.

1 x 750 MWe, US

Furnace Wall Designs

In todays market, two designs dominate for once-through units: the spiral furnace tube arrangement and the vertical tube arrangement. Design choice is governed by furnace size and customer preference there are advantages to both, depending on project drivers. The furnace walls are exposed to the greatest heat flux of all heat-absorbing surfaces. This is because of the intense radiant heat from the fireball.

For any given furnace size, the spiral wall unit in which the tube is wrapped around the unit has fewer tubes than the vertical wall unit. The vertical waterwall design uses internal ribbing in the tubes to improve heat transfer. The vertical wall option is available for larger units where lower perimeter-to-furnace plan area ratios result in higher fluid flow per tube. The vertically oriented tubes are self-supporting within the wall, allowing a simpler support system. In fact, the relative simplicity of a vertical wall furnace can result in significant construction cost savings.

Spiral Configuration
Benefits from averaging of lateral heat absorption variation (each tube forms a part of each furnace wall) Simplified inlet header arrangement Large number of operating units Use of smooth bore tubing throughout entire furnace wall system No individual tube orifices

Vertical Configuration
Simpler windbox openings Simpler furnace water wall support system Elimination of intermediate furnace wall transition header Less costly to construct Easier to identify and repair tubes leaks Lower water wall system pressure drop thereby reducing required feed pump power

ADVANCED BOILER DESIGNS

2 x 800 MWe, South Korea

Tower and Two-Pass Designs

Alstom provides tower and two-pass boiler designs, both of which are widespread in power generation applications. In a tower design, all heating surfaces are horizontal and drainable, and generally in a single vertical configuration within the furnace bounding walls.

Two-pass is a shorter design which incorporates vertical heating surface in the radiant section of the furnace, and horizontal surface in a parallel backpass. The selection of boiler configuration is project specific, with consideration given to fuel ash characteristics, site restrictions, and customer preference.

Nominal 900 MWe Tower Boiler Arrangement Two-Pass, Pendant Arrangement

Niederaussem Unit K, Germany 1 x 1000 MWe Tower Design

Houshi Units 5-7, China 3 x 600 MWe Two-Pass Design

Waterwall

Tubes

SH Outlet Header

Advanced Materials
High temperature materials enable the steam conditions and corresponding thermal efficiency of advanced supercritical steam cycles. Ideally, materials used in steam generator pressure parts combine high temperature strength with reasonable resistance to oxidation. In addition, the workability of the materials and corrosion behavior are important attributes. The increase of steam conditions primarily affects the waterwalls, final superheater and reheater tubing, and the thick-walled components, mainly the high pressure outlet headers and piping to the turbine. Classes of materials include conventional and advanced ferritic steel, austenitic steel, and nickel alloys.

Several boiler materials with improved mechanical properties have been developed recently, and new materials still in the R&D stages will enable higher ultra-supercritical steam cycles than are today commercially available. Most materials development is being conducted under national or internationally coordinated programs. Alstom participates in nearly all cooperative materials development programs, including the AD 700 / COMTES 700 program funded by the European Commission, and the US Ultra-Supercritical Materials Consortium sponsored by the US Department of Energy.

Material Development Stages and Related Steam Parameter Limits

Membrane Wall Future Options

T92 Nickel Alloy

Tubes

SH Outlet Header

Nickel Alloy

Nickel Alloy

9-12% Cr-Steels

Austenitic NF 12, SAVE 12, VM12

Current
7 CrMo VTiB 10 10 HCM 2S Austenitic E 911, P 92, P 122

X 20 CrMoV 121

X 20 CrMoV 121

Past
13 CrMo 4 4 Bar SHO 0 C - SH Temp 0 C - RH Temp 260 550 570 270 580 600 290 600 620 300 630 650 350 700 720 Austenitic 260 550 570 270 580 600 290 600 620 300 630 650 350 700 720 P 91 260 550 570 270 580 600 290 600 620 300 630 650 350 700 720

A WORLD OF SUCCESS STORIES

Recent References Alstom Advanced Supercritical Boiler Technology
BELCHATOW POLAND
1 x 833 MWe Lignite Owner: BOT Elektrownia Belchatow SA Commercial operation: 2010 Highest efficiency level of any brown coal-fired plant in the country

BEIJIANG CHINA
2 x 1000 MWe Chinese Bituminous Owner: Tianjian Guotou Jinning Power Generation Ltd. Commercial operation: 2010 Most advanced steam conditions for China

IATAN 2 US
1 x 920 MWe Powder River Basin coal Owner: Kansas City Power & Light Commercial operation: 2010 Features advanced vertical wall construction

COMANCHE 3 US
1 x 814 MWe Powder River Basin coal Owner: Xcel Energy Commercial operation: 2009 Will achieve one of the lowest NOx levels in US

NEURATH F & G GERMANY

2 x 1100 MWe Lignite Owner: RWE Power AG Commercial operation: 2010 CO2, SO2, NOx and dust emissions reduced by 31% compared to existing lignite-fired plants

1954: Earliest Extant Supercritical Generating Unit in the World

Alstom laid the foundation for todays Advanced Supercritical fleet at Philadelphia Electric Companys Eddystone Unit 1 (US). Eddystone pushed the technology for steam generating electric plants, pioneering substantial increases in steam pressure, steam temperature and unit size. At the time of start up, the 394 MWe Eddystone 1 was the most efficient plant in the United States. It is still operating at advanced steam conditions. Initial steam cycle: 5293 psig, 1200/1050/1050 F 365 bar, 649/566/566 C 5200 psig, 1130/1030/1030 F 359 bar, 610/554/554 C

Current steam cycle:

NING HAI CHINA

2 x 1000 MWe Range of Chinese coals Owner: Zhejiang Guohua Zheneng Power Generation Co. Commercial operation: 2009 Another addition to Chinas highest-efficiency fleet

PEE DEE US
1 x 640 MWe Eastern Bituminous Owner: Santee Cooper Commercial operation: 2011 Designed to fire up to 30% petcoke

WAI GAO QIAO PHASE II CHINA

2 x 900 MWe Range of Chinese coals Owner: Shanghai Municipal Electric Company Commercial operation: 2003-2004 Design replicated in Wai Gao Qiao Phase III 2 x 1000 MWe, scheduled to enter commercial operation in 2008

YONGHUNG SOUTH KOREA

2 x 800 MWe International coal Owner: KEPCO Commercial operation: 2004 First units based on the new 800 MWe Korean Standard Thermal Power Plant

FIRING SYSTEMS
Alstom is a global leader in supplying firing systems for utility boilers. Our firing systems burn a wide range of fuels, reduce emissions levels and retain excellent levels of availability and reliability. Primary classes of utility-scale firing systems include suspension firing and fluidized bed combustion. In suspension firing, the fuel is either finely ground (for solid fuels), atomized (for liquid fuels), or fired as a gas that quickly burns as it mixes with combustion air and passes through the furnace. Fuel is not recirculated in suspension firing as it is in fluidized bed combustion.

State of the Art. Proven. Innovative.

Taean, one of the 20 x 500 MWe sliding pressure supercritical units using Alstom technology in Korea. Since 1995, this unit has operated in daily two-shift operation with high reliability.

2 x 800 MWe efficient and highly reliable supercritical steam generation since 1996 at the Schwarze Pumpe Station in Germany.

Alstom An Industry Leader

Alstom introduced tangential firing systems to the power generation industry. Today, Alstoms family of advanced low NOx tangential firing systems leads the industry in reduced emissions.

Tangential Firing

Supercritical CFB For Maximum Fuel Flexibility and Efficiency

Alstom has led the power industry in scaling-up utility-class CFB boilers from 50 MWe to 600 MWe. Now customers can benefit from our expertise in both supercritical and CFB technology with Alstoms commercial designs for 400-600 MWe supercritical CFB units. This premier technology application combines the improved efficiency of advanced supercritical steam cycles with the unparalleled fuel flexibility of CFBs. Based on rational design innovations in larger size boilers, including 6 cyclones and higher steam parameters, Alstoms supercritical CFB technology is another step in bringing our customers added value, improving the overall environmental performance of coal-fired plants, and reducing global CO2 emissions.

Alstoms preeminent suspension firing system is tangential (corner) firing, with a track record of reliable performance, efficient combustion, and very low nitrogen oxide emissions. With tangential firing, a stable fireball is formed in the center of the furnace over the entire operating range. Heat absorption profiles are more predictable. As boiler load changes, corresponding fuel elevations are deployed. Tangential firing has the additional advantage of a stable flame pattern with any combination of fuel elevations in service. Unbalances are minimized, and the predictable lateral heat absorption profiles allow a more conservative design of furnace wall circuits. Alstoms family of TFS 2000 firing systems employs both horizontal and vertical staging of combustion air to produce ultra-low NOx emissions. The latest addition to this product line is the TFS-XP system, delivering enhanced performance to owners of new pulverized coal units. Vortex control improvements to this design result in better gas mixing, lower combustible gaseous emissions, and uniform furnace outlet energy.

Supercritical CFB Boiler Design

Circulating Fluidized Bed

Alstoms most popular fluidized bed combustion system is the Circulating Fluid Bed (CFB). Used especially for more difficult to burn fuels, CFBs also reduce NOx emissions because of their lower combustion temperatures. Longer residence time of fuel in the boiler is key unburned fuel is captured and recirculated for further combustion. The addition of a sorbent (generally limestone) also allows SO2 capture within the boiler for reduced SO2 emissions without post-combustion capture.

MORE SOLUTIONS FOR CLEAN POWER

Alstom has the expertise and experience to make todays energy production as clean and efficient as it can be. We are a worldleading provider of integrated environmental solutions for power, petrochemical and industrial plants including ways to improve the performance and lifespan of your existing units. In addition to high-efficiency boilers, Alstom's supercritical plant offering includes supercritical turbines, mills, air heaters and postcombustion equipment. Alstoms in-furnace and post-combustion technologies can help meet todays strictest requirements for NOx, SOx, VOCs, mercury, CO and particulates. And our integrated boiler/backend designs will optimize your units sizing and performance criteria, all with the lowest installed and operating costs. Renewable targets? Alstoms experts in biomass co-firing can reduce your carbon footprint and help your bottom-line. Alstoms unparalleled breadth of product offering in Air Quality Control (AQS) systems and Energy Recovery systems means we can meet your toughest project requirements. With the largest installed base in the world for air preheaters and coal pulverizers, our customers benefit from superior performance, increased efficiencies, and reliable service. And with more than 70 years of experience in customizing AQS systems for new and existing plants, you can depend on Alstom to deliver sustainable, high-quality solutions at a competitive cost and performance ratio.

1 x 1000 MWe, Germany

For further information, please contact one of our Regional Offices or e-mail Boiler.Marketing@power.alstom.com

Western Europe/South America/ Africa/Middle East Sales Region Tel: +33 (0)1 46 29 16 32 Fax: +33 (0)1 46 29 16 70 Central and Eastern Europe/India Sales Region Tel: +49 711 917 1269 Fax: +49 711 917 1222 Tel: +91 124 4221 100 Fax: +91 124 4221 660 Asia Pacific Sales Region Tel: +33 (0)1 46 29 15 85 Fax: +33 (0)1 46 29 16 70 North America/Mexico/ Central America/Caribbean Sales Region Tel: +1 860 285 2348 Fax: +1 860 285 4172

Ref: PWER/BPROB/BOILERTECHNO/eng/BUBB/ 12.07/US/3329 ALSTOM 2007. Alstom, the Alstom logo and any alternative version thereof are trademarks and service marks of Alstom. The other names mentioned, registered or not, are the property of their respective companies. Please note: The information in this brochure is of a general nature, and may not be applicable for use in any specific application. Reprinted 2007.

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