Escolar Documentos
Profissional Documentos
Cultura Documentos
A
SEMINAR REPORT
ON
SUPER CRITICAL STEAM GENERATORS
By
SREENATH K R
(REGISTER NO.: 15020560)
(AICTE APPROVED)
01
DEPT. OF MECHANICAL ENGINEERINGG.P.T.C. ,PALAKKAD
Seminar report on super critical steam generator
CERTIFICATE
02
DEPT. OF MECHANICAL ENGINEERINGG.P.T.C. ,PALAKKAD
Seminar report on super critical steam generator
ACKNOWLEDGEMENT
I express my sincere grateful to MR A V PRAVEEN KUMAR, Head Of
Department of Mechanical Engineering for all his help for presenting this seminar.
03
DEPT. OF MECHANICAL ENGINEERINGG.P.T.C. ,PALAKKAD
Seminar report on super critical steam generator
INDEX PAGE
CHAPTER 01 ABSTRACT
2-1 HISTORY
CHAPTER 03 BOILERS
3-1 INTRODUCTION
4-5 ADVANTAGES
4-6 DISADVANTAGES
04
DEPT. OF MECHANICAL ENGINEERINGG.P.T.C. ,PALAKKAD
Seminar report on super critical steam generator
4-9 APPLICATIONS
CHAPTER 05 CONCLUSION
CHAPTER 06 REFERENCES
INDEX OF TABLES
TABLE NO.: 2.1 DESIGN EFFICIENCY AND STEAM
TABLE NO.: 2.3 INDIAS PERSPECTIVE PLAN FOR POWER FOR ZERO
DEFICITPOWER BY 2011/12 (SOURCE TENTH AND
ELEVENTH FIVE-YEAR PLAN PROJECTIONS)
05
DEPT. OF MECHANICAL ENGINEERINGG.P.T.C. ,PALAKKAD
Seminar report on super critical steam generator
INDEX OF FIGURES
FIGURE NO.: 3-1 CHAIN GRATE STOKER
FIGURE NO.: 4-8 STEAM SIDE OXIDATION, EROSION AND FIRE SIDE
CORROSION
06
DEPT. OF MECHANICAL ENGINEERINGG.P.T.C. ,PALAKKAD
Seminar report on super critical steam generator
01 ABSTRACT
The report is the outgrowth of notes of seminar on super-critical steam generators.
Steam generators or boilers are used in industries for various applications such as
heating, power generation, farm machineries, locomotive propulsion, marine
propulsion, etc. There are two essential concepts of modern utility steam generators
for electric-power generating plants. They are (1) subcritical water tube drum type
and (2) supercritical once-through type. Here we are focusing on the super critical
once through type.
Generally boilers are using fossil fuels, but coal fired boilers are most favourable
because of their characteristics. The paper highlights and traces the development of
the super critical steam generators with their special aspects which make it reliable
for the purpose.
The first plant with super critical technology was commissioned on 1957s. The
research and development of these types of units resulted in the improved efficiency
for power plants. The hazardous emissions from boilers are also decreased to a lower
level. At present we can adopt SC units of large capacity up to 800 MW. Reduction
in specific fuel consumption reduces the cost of electricity produced. However the
super critical technology had developed to ultra- supercritical and advanced ultra-
supercritical which replaces the low efficient sub-critical units.
07
DEPT. OF MECHANICAL ENGINEERINGG.P.T.C. ,PALAKKAD
Seminar report on super critical steam generator
02 POWER SECTOR
2.1 HISTORY
The history of power development in India started since Independence when
installed capacity of power generation was only 1367 MW, consisting of mainly the
Hydroelectric Units of small capacity and few very small capacity coal fired units and
diesel sets as well. The demand of electricity continuously increased and installed
capacity also grew with installation of the thermal units in ratings of 30, 60, 82.5,
100, 110, 120, 140, 200/210 MW units. The units in ratings of 82.5, 110,120, 140 and
200 MW were reheat units. The rest were non-reheat units. This scenario continued
till the mid-seventies. The demand of electricity was still growing and the planners
attention was drawn to setting up of large capacity units commensurate with the
increase of grid size 500 MW units were then conceived. The first 500 MW units
were commissioned at Trombay Thermal Power Plant(TPP) of TATA Electric Co in
the year 1984.
The increase in unit size was associated with corresponding increase in steam
parameters(temperature and pressure) as well as efficiency of generation. Enhanced
efficiency implies lesser green- house gas (GHG) emissions. The design efficiency
and steam parametersassociated with various unit sizes starting from 30MW till
500MWare indicated in table 1.1. It is pertinent to mention that most of super-critical
units which are in operation in various countries are operating either with natural gas
as the fuel or better quality of coal (Higher calorific value is the order of 6000/7000
kCal/kg).very few numbers are in operation with coal of heating value or calorific
valueof around 3500kCal/kgas available India. The super-critical technology have
been adopted world-wide. These are in operation since 1950s especially in countries
like USSR, USA, Japan and others. The development of super-critical technology
leads to better efficiency as well as consequential higher unit sizes of800/1000
MWdue to techno economic considerations.
08
DEPT. OF MECHANICAL ENGINEERINGG.P.T.C. ,PALAKKAD
Seminar report on super critical steam generator
Four 800 MW units with imported coal have also been commissioned by M/s
TATA Electric Company at Mundra. 800 MW unit size are the largest sizeoperating
today in the country.
09
DEPT. OF MECHANICAL ENGINEERINGG.P.T.C. ,PALAKKAD
Seminar report on super critical steam generator
India currently has apeak demand shortageof around 14% and anenergy
deficit of 8.4%.Keeping this in viewand to maintain a GDP(gross domestic
product)growth of 8% to10%, the Governmentof India has very prudentlyset a target
of215,804 MW power generation capacity byMarch 2012 from thelevel of 100,010
MW ason March 2001, that is a capacity addition of 115,794 MW in the next 11
years (Table 1.3).In the area of nuclear power the objective is to achieve 20,000 MW
of nuclear generation capacityby the year 2020.
The Indian government have a programme called the the AUSC (Advanced
Ultra Super Critical) project under the ninth National Mission on Clean Coal
Technologies in keeping with the National Action Plan for Climate Change.
The Indian Material Research Programme was initiated in 2008 and was
estimated to cost at least RS 600010000 CRORE. The programme is being funded
and undertaken by a joint venture between the research institute Indira Gandhi Centre
for Atomic Research (IGCAR), the equipment manufacturer Bharat Heavy Electrical
(BHEL) and the power generating company National Thermal Power Corporation
(NTPC). IGCAR will develop the materials, Misra Dhatu Nigam and BHEL will
design, manufacture, and commission the equipment and NTPC will construct the test
loop and demonstration unit.
010
DEPT. OF MECHANICAL ENGINEERINGG.P.T.C. ,PALAKKAD
Seminar report on super critical steam generator
TABLE 2.3 INDIAS PERSPECTIVE PLAN FOR POWER FOR ZERO DEFICIT
POWER BY 2011/12 (SOURCE TENTH AND ELEVENTH FIVE-
YEAR PLAN PROJECTIONS)
Thermal Gas/LNG/ Nuclear Hydro Total
(Coal) Diesel(MW) (MW) (MW) (MW)
(MW)
Installed capacity as Gas:10153
on March 2001 61157 Diesel:864 2720 2516 100010
Additional capacity 53333 20408 9380 32673 115794
(2001-2012)
Total capacity as on 114490 31425 12100 57789 215804
March 2012 (53.0%) (14.6%) (5.6%) (26.8%)
011
DEPT. OF MECHANICAL ENGINEERINGG.P.T.C. ,PALAKKAD
Seminar report on super critical steam generator
03 BOILERS
3.1 INTRODUCTION
Boilers are devices which imparts or transfers heat energy to the working
substance (water) on the system until it become heated water or steam by the
combustion of fuels inside the combustion chamber or furnace. Since the mass and
energy crosses the boundary of the system, they are open systems in thermodynamic
point of view. The steam at pressure is then usable for transferring the heat to a
process. When the water is boiled at atmospheric pressure (1.01325 bar at 100C) the
volume increases about 1600 times, producing a force that is almost as explosive as
gun power. This causes the boiler to be extremely dangerous equipment that must be
treated with utmost care.The process of heating a liquid until it reaches its gaseous
state is called evaporation.
012
DEPT. OF MECHANICAL ENGINEERINGG.P.T.C. ,PALAKKAD
Seminar report on super critical steam generator
ENTHALPY
Enthalpy is the total heat content in a substance. Heat is a form of energy that
transferred across the boundary of a system due to temperature difference. The sum
of internal energy and product of pressure and volume is the enthalpy. Its SI unit is kJ
or kCal.Enthalpy per unit mass of substance is known as specific enthalpy whose unit
is kJ/kg.
LIQUID ENTHALPY
It is the enthalpy of water / fluid when it has been raised to its boiling point
(saturation liquid point) to produce steam. It is the total heat content at the saturation
liquid point.
Liquid enthalpy, hf = s
SENSIBLE HEAT
The heat required to change to change the temperature of the substance is called
sensible heat. It is the enthalpy change during the pre-heating of water in economiser
units of a boiler.
Sensible heat, SH =
= t1 - t2
013
DEPT. OF MECHANICAL ENGINEERINGG.P.T.C. ,PALAKKAD
Seminar report on super critical steam generator
hidden heat energy absorption during the steam formation. The entire heat addition
takes place under iso-thermal and iso-bar conditions. The LH is utilised for the phase
change of saturated water to saturated steam. The latent heat may depend on the
pressure at which the water boiling. It is denoted by hfg. The LH absorption with
respect to the operating pressure of a boiler is given in the table 3-1.
Result: The latent heat absorption during the steam formation is get reduced
as the operating pressure of boiler increases. At certain point that will be 0 kJ /kg and
that point is known as Critical Point.
Latent heat addition gives the energy storing capacity of a substance during its
phase change occurs. As the enthalpy of evaporation or condensation increases, more
heat energy can be imparted to the working fluid during steam formationwhich can be
utilised for various processes in industries. Since LH dissipation from steam is high
in low pressure steam systems the industries are adopting LP boilers for their
operations such as tea leaf drying, sugar industries, district heating, etc. The power
plant working with high pressure steam system because they are not utilising the LH
of condensation or evaporation for producing the work. The turbines are mainly
utilising the het of super heat of super-heated steam.
014
DEPT. OF MECHANICAL ENGINEERINGG.P.T.C. ,PALAKKAD
Seminar report on super critical steam generator
DRYNESS FRACTION
Steam containing wet particles are known as wet steam. The dryness fraction is the
fraction of steam contain in a steam-water mixture to represent how much portion of
water is turned into steam. . It has no unit
ENTROPY
Entropy is the property of a substance which is the function of temperature. It is the
disturbance produced in a system due to heat adding. Its unit is kJ/K. The specific
entropy is the entropy of unit mass of substance (kJ/kgK). The entropy change
during the steam formation can be taken from stem tables or by using the mathematic
equation:
Change in entropy, ds = S2 S1
S2 = enthalpy at state 2.
TEMPERATURE
Temperature is the degree of coldness or hotness of a body. Its unit is C (decree
centigrade) or F or K. In the phase diagram of steam formation, each state points
have a particular value depending up on the condition of fluid. Temperature indicates
the quality of steam the increased temperature refers to the more heat content in the
working substance. The Carnot efficiency of steam power plant will increases with
015
DEPT. OF MECHANICAL ENGINEERINGG.P.T.C. ,PALAKKAD
Seminar report on super critical steam generator
difference between the main steam temperature and the temperature of steam at outlet
of turbine. The temperature at which the fluid absorbs heat without changing its
temperature is known as the saturation temperature or boiling point.
PRESSURE
The pressure is the normal force exerted by system against the bounding area or
surface. Unit of pressure is Pascal. The atmospheric pressure is 1.01325 bar
(absolute).
DENSITY
Density is defined as the mass of substance distributed in unit volume of substance.
The unit is g/cc or kg/m3. It is also a rough measure of the mass of the substance. \
SPECIFIC VOLUME
The inverse of mass density is known as the specific volume. Or it is the volume of
substance per unit mass. Its unit is m3/kg or cc/kg. The specific volume line has more
slope than the constant pressure lines in Mollier diagram. It may be noticed that the
specific volume increases as the pressure of compressible fluid (steam) decreases.
RELATIVE DENSITY
The density of substance can also be represented relative to the density of standard
fluid (water). It is also known as the specific gravity. The ratio of density of
substance to the density of water is called specific gravity. Since it is a fraction, it has
no unit.
STEAM TABLES
Steam are the tabular representation of the properties of steam from which the state of
steam can be directly found out. It is the reference to be taken for plotting the Mollier
diagrams.
MOLLIER CHARTS
Mollier diagrams are the graphical representation of properties of steam by taking
specific enthalpy on y-axis and specific entropy on x-axis. They are also termed as h-
s diagram.
016
DEPT. OF MECHANICAL ENGINEERINGG.P.T.C. ,PALAKKAD
Seminar report on super critical steam generator
1. Fire-tube boilers
2. Water tube boilers
3. Natural-circulation boilers
4. Controlled-circulation boilers
5. Once-through flow
The hot flue gases flow through tubes surrounded by water in a shell is called fire
tube boilers. Water-tube boilers water from a drum flows through the tubes and hot
flue gases flow over them.
SUB-CRITICAL BOILERS
They are water drum type and they usually operate at between 130 -180 bar
steam pressure (1900 to 2600 psig). They are purchased most widely during the
1970s in power plants.
017
DEPT. OF MECHANICAL ENGINEERINGG.P.T.C. ,PALAKKAD
Seminar report on super critical steam generator
These include water tube pulverized coal units similar to those used by utilities, but
they also may burn stoker (lump) col, oil or natural gas, often in combination, as well
as municipal refuse and process wastes or by-products. Some are heat recovery types
that use waste heat from industrial processes. They usually dont produce super-
heated steam. The operating pressure is around 105 bar.
018
DEPT. OF MECHANICAL ENGINEERINGG.P.T.C. ,PALAKKAD
Seminar report on super critical steam generator
SPREADER STOKER
Spreader stokers utilize a combination of suspension burning and grate burning. The
coal is continually fed into the furnace above a burning bed of coal. The fine coal
particles are burned in suspension and the larger particles fall to the grate, where they
are burned in a thin, fast burning coal bed. This method of firing provides good
flexibility to meet load fluctuations, since ignition is almost instantaneous when
firing rate (more fuel can be supplied for combustion per unit time) is increased.
Hence, the spreader stoker is favoured over other types of stokers in many industrial
applications. The arrangement is shown in figure 3-2.
019
DEPT. OF MECHANICAL ENGINEERINGG.P.T.C. ,PALAKKAD
Seminar report on super critical steam generator
The mean solid velocity increases at a slower rate than does the gas velocity. The
difference in mean solid velocity and mean gas velocity is called as slip velocity.
Maximum slip velocity is desirable for good heat transfer and intimate contact.
020
DEPT. OF MECHANICAL ENGINEERINGG.P.T.C. ,PALAKKAD
Seminar report on super critical steam generator
021
DEPT. OF MECHANICAL ENGINEERINGG.P.T.C. ,PALAKKAD
Seminar report on super critical steam generator
ADVANTAGGES
I. Suitable for large to medium capacity boilers
II. Sulphur emission and NOxcontrol is strictly reduced.
III. The boiler is required to fire low-grade fuel or fuel with highly fluctuating
fuel quality can be used in this type of firing system.
IV. It has a high processing capacity because of the high gas velocity through
the system.
V. The temperature of about 870 C is reasonably constant throughout the
process because of the high turbulence and circulation of solids. The low
combustion temperature also results in minimal NOx formation..
VI. It has high combustion efficiency.
VII. Erosion of the heat transfer surface in the combustion chamber is reduced,
since the surface is parallel to the flow. In a bubbling bed system, the
surface generally is perpendicular to the flow.
PFBC
Pressurised Fluidised Bed Combustion (PFBC) is a variation of fluid bed technology
that is\ meant for large-scale coal burning applications. In PFBC, the bed vessel is
operated at pressure up to 16 ata (16 kg/cm2).
The off-gas from the fluidised bed combustor drives the gas turbine. The steam
turbine is driven by steam raised in tubes immersed in the fluidised bed. The
condensate from the steam turbine is pre-heated using waste heat from gas turbine
exhaust and is then taken as feed water for steam generation.
The PFBC system can be used for cogeneration or combined cycle power
generation.
PULVERIZED COAL FIRED
Most coal-fired power station boilers use pulverized coal, and many of the larger
industrial water-tube boilers also use this pulverized fuel. This technology is well
developed, and there are thousands of units around the world, accounting for well
over 90% of coal-fired capacity. The coal is ground (pulverised) to a fine powder, so
that less than 2% is +300 micro metre (m) and 70-75% is below 75 microns, for a
bituminous coal. It should be noted that too fine a powder is wasteful of grinding mill
power. On the other hand, too coarse a powder does not burn completely in the
022
DEPT. OF MECHANICAL ENGINEERINGG.P.T.C. ,PALAKKAD
Seminar report on super critical steam generator
combustion chamber and results in higher unburnt losses. The pulverised coal is
blown with part of the combustion air into the boiler plant through a series of burner
nozzles. Secondary and tertiary air may also be added. Combustion takes place at
temperatures from 1300-1700C, depending largely on coal grade. Particle residence
time in the boiler is typically 2 to 5 seconds, and the particles must be small enough
for complete combustion to have taken place during this time.
This system has many advantages such as ability to fire varying quality of coal, quick
responses to changes inload, use of high pre-heat air temperaturesetc. One of the most
popular systems for firing pulverized coal is the tangential firing using four burners
corner to corner to create a fireball at the centre of the furnace (refer Figure 3-3).
023
DEPT. OF MECHANICAL ENGINEERINGG.P.T.C. ,PALAKKAD
Seminar report on super critical steam generator
type of fuel is simultaneously burned to meet the total heat requirement, the boiler is
said to have combination firing.
024
DEPT. OF MECHANICAL ENGINEERINGG.P.T.C. ,PALAKKAD
Seminar report on super critical steam generator
Line 1-2 :- The adiabatic compression of boiler feed water in a multi-stage pump
(centrifugal or turbine type having 35-40 stages)which imparts a pressure head about
3500 psi (241 bar) to the sub-cooled water. The pressurised fluid is then passed to the
header (large cross-sectional pipes) of economiser in the boilers.
Line 2-3 :- It is the constant pressure (iso-baric)heat additionto the boiler feed water
in a once-through circulated boiler. The boiler provides super heated steam for
spinning the turbines. The heat addition can be sub-divided into water pre-heating in
economiser, heating in water walls, (LH addition) super-heating in super-heaters.
Line 6-1 :- it is the constant pressure heat rejection from the working substance (two-
phase mixture or wet steam) to the heat sink (coolant) which has large capacity to
absorb heat from the substance without changing the temperature of sump. The
process called Condensing in carried out iso-thermally. The sink may be a sea or lake
which supplies large quantity of cooling water to condense the steam. Then the water
is fed to the cycle by a re-circulating pump. Then the cycle is being repeated.
025
DEPT. OF MECHANICAL ENGINEERINGG.P.T.C. ,PALAKKAD
Seminar report on super critical steam generator
026
DEPT. OF MECHANICAL ENGINEERINGG.P.T.C. ,PALAKKAD
Seminar report on super critical steam generator
027
DEPT. OF MECHANICAL ENGINEERINGG.P.T.C. ,PALAKKAD
Seminar report on super critical steam generator
The super critical boilers are once through type boilers. In once-
through boilers, the feed water goes through the economiser, furnace walls, and super
heater sections, changing sequentialy to saturated water, saturated steam and
superheated steam in one continuous pass. No steam drum is required to separate
saturated steam from boiling waterand no water recirculation takes place (but in
actual cases steam separators are provided at the inlet of super-heater headers and
collected moisture will fed into the boiler economiser). Reheating of steam after iot is
expanded in the High Pressure is performed in a re-heater in ausual manner.
The once- through boiler is only one type which is suited to super-
critical operation because there is no Latent Heat addition involved, and water on
being heated at constant (assumed) super-critical pressure suddenly flashes into
vapour, there being no saturation temperature as such, and the vapour is further
heated to desired temperature in the super-heaters. Water enters the boiler at one end
of a number of parallel paths and emerges at the outlet as super-heated steam.
Movement of water is created by a feed pump. Usually the pump (figure 4-6)may
centrifugal type with several stages of impeller (about 30 to 40 stages) for making a
mass flow through the water tubes. The block diagram of a once-through system is
given in the figure 4-4. The different boiler circulation method is shown in figure 4-5.
028
DEPT. OF MECHANICAL ENGINEERINGG.P.T.C. ,PALAKKAD
Seminar report on super critical steam generator
029
DEPT. OF MECHANICAL ENGINEERINGG.P.T.C. ,PALAKKAD
Seminar report on super critical steam generator
convection pass. The height of the furnace is adjusted to meet the required furnace
gas exit temperature and ensuring that the residence time (time for completing the
combustion) for complete combustion will be sufficient.
A general problem for the once through boiler is to ensure an effective
cooling of the membrane walls in the burner zone where the radiation level is high.
Several solutions for this have been seen over time. Traditional solution has been the
spiralled membrane wall designed to provide satisfactory cooling by means of
water/steam velocity and an evenly distributed heat flux. Spiral water wall is arranged
at the bottom of combustion chamber and the top portion are of vertical water walls.
From an engineering point of view this design is a complication compared to
solutions with vertical tubes. However, the experience is that the spiralled membrane
wall contributes to form a uniform steam exit temperature profile of the membrane
wall tubes.
The spiral water walls are arranged at a helix angle of 30 with the
horizontal axis (figure 4-6). So the bottom portion of water walls are similar to that of
a cross-flow heat exchangers in the radiator section in the automotive cooling system.
The flow of flue gas crosses the water tubes. The schematic arrangement of a water
wall is shown in figure 4-6. The comparison between vertical and spiral water walls
are given in the table 4-1.
Since the vertical wall is parallel to flow More ash deposition due to the wall
less ash deposition on water walls. made obstructions to the flue gas flow.
Erection of tubes is less Erection is more
Head loss is less Head loss is high
Boiler height is high for the same Boiler height can be reduced
capacity
More number of tubes are required Less number of tubes are required
Less maintenance Periodic maintenance is strict
Non uniform heating of water walls Uniform heating of water walls
030
DEPT. OF MECHANICAL ENGINEERINGG.P.T.C. ,PALAKKAD
Seminar report on super critical steam generator
031
DEPT. OF MECHANICAL ENGINEERINGG.P.T.C. ,PALAKKAD
Seminar report on super critical steam generator
032
DEPT. OF MECHANICAL ENGINEERINGG.P.T.C. ,PALAKKAD
Seminar report on super critical steam generator
ELECTRO-STATIC PRECIPITATOR
It is a traditional and effective attachment for a boiler to remove particulate matters
and fly ash from the flue gases. They are arranged at the flue gas exit line. The flue
gas flows through asets of electrodes whose potential difference is 20 to 100kV. The
electrodes are being charged by an external DC source. Since high voltage is passed
through the electrodes there will be a blue luminous glow called corona will form
and it will ionises the gases and the ions will be get discharged. Then they are
collected in collecting plates and it is periodically removed. The collected fly ash
particles are used as an additive for making mortar in combination with cement for
better binding and to provide finish to the object.
A fabric filter system contains a large number of fabric filter elements arranged in
parallel rows. It is called a bag-house. The gas is passed through the bag-filters. It
will remove the contaminants in the flue gases and stored at the conical shaped cup
provided at the bottom of the arrangement.
DESULFERIZATION UNIT
The oxides of sulphur are removed by this units. They may be dry wet flue gas type
and dry flue gas type. In wet system the lime stone (CaCO3)is crushed and mixed
with water to produce a aqueous slurry. This slurry is brought into contact with the
flue gas by various techniques, absorbs the SO2 in it. The produced gypsum is used
for cement manufacturing for controlling the setting time of concrete
033
DEPT. OF MECHANICAL ENGINEERINGG.P.T.C. ,PALAKKAD
Seminar report on super critical steam generator
4-5 ADVANTAGES
i. Cycle efficiency is primarily (40-42%).
ii. Fuel consumed per unit electricity generated (kg/kWh) is less.
iii. Less water consumption.
iv. Auxiliary power consumption (needed for effective working) is less.
v. Better temperature control and load change flexibility can obtained.
vi. Reduced green-housegas emissions as compared to sub-critical boilers
vii. Great plant efficiencies over wider range of part loads than sub-critical
boilers with drum.
viii. Quicker start up
ix. There is no water drum is used and hence the accumulation of water
for a shorter or temporary period is not.
x. Due to high temperature difference working substance at inlet and
outlet of the steam turbine, the Carnot efficiency is high.
xi. The emissions from the stack is very less.
xii. Since the FBC or Pulverized Coal Technology is adopted, the
combustion bed temperature maintained at a range of 750 to 900C
there is no slagging occurs in the furnace and easy ash removal is
possible.
xiii. Once-through circulated boilers will increases the mass flow rate and
velocity of fluid through tubes which will increase the heat transfer
rate.
xiv. The most of waste heat from the flue gasses can be recovered by the
effective waste heat recovery section on the boiler.
xv. The overall efficiency of the Super Critical Plant is 40-42% and it is
around 44-47% for Ultra-Super Critical Plants and it is near 50% for
the Advanced Ultra Super Critical Units.
xvi. The sliding or variable pressure operation is suitable in this type of
units
xvii. Operating cost of super critical plants are less as compared to sub-
critical units.
034
DEPT. OF MECHANICAL ENGINEERINGG.P.T.C. ,PALAKKAD
Seminar report on super critical steam generator
xviii. Since the major part of water walls are arranged in spiral water walls,
the height of the boiler will get reduced as that of the same capacity of
a sub-critical boiler.
xix. Adoption of re-heat stages will prevent the condensation of steam at
turbines which will reduce blade damages due to pitting of water
particles, cavitation, etc.
4-6 DISADVANTAGES
a. Since they are operating at high temperature and pressure, the safety measures
and precautions to prevent the disaster to be followed strictly. Also it
enhances maintenance cost.
b. The water is directly passed through the narrow tubes and hence scaling or
fouling should be prevented by water treatment.
c. Since the water tube crosses the flow of flue gases the fly ash deposition and
erection of metallic parts are considerably high.
d. Since there is no latent heat absorption during evaporation, they arent used
for heating processesin industries (such as street heating /district heating,
sugarmills, tea leaf drying, etc.)
e. Water chemistry is more stringent in this types of boilers (Ph value, salinity,
etc.)
f. The metallurgical challenges limits the efficiency of such plants.
g. Since the water walls are complex in shape they are costlier.
035
DEPT. OF MECHANICAL ENGINEERINGG.P.T.C. ,PALAKKAD
Seminar report on super critical steam generator
STEAM SIDE OXIDATION is the oxidation of metal surfaces exposed to the steam
in the steam loop; this will be most prevalent in higher temperature locations, such as
pipes, tubes, valves and steam turbines. Steam side oxidation consists of three stages.
Firstly, oxide scale builds up causing materials to overheat, which decreases material
strength. Secondly, the oxide scale eventually exfoliates, gradually reducing the
materials cross-sectional area, which again decreases material strength. Finally, the
oxide scale fragments and erodes the entire steam loop, further decreasing strength.
In short, steam side oxidation will lower steam turbine efficiency and decrease
material strength and may lead to pipe blockages, see left picture and middle picture
in Figure 4-7.
036
DEPT. OF MECHANICAL ENGINEERINGG.P.T.C. ,PALAKKAD
Seminar report on super critical steam generator
FATIGUE is caused by cyclic stresses and can result in internal cracking. Generally,
cyclic stresses have increased with more vigorous cyclic operation in super critical
plant over the last two decades (due to market forces and the use of renewable
energy).
037
DEPT. OF MECHANICAL ENGINEERINGG.P.T.C. ,PALAKKAD
Seminar report on super critical steam generator
4-8MODERN DEVOLOPMENTS
In pulverised coal combustion (PCC) power plant, increasing the maximum
temperature of the steam cycle increases the electrical efficiency, which in turn
lowers both coal consumption and flue gas emissions. However, the maximum steam
temperature is limited by materials that can operate at these conditions for practical
service lifetimes without failure. The EU, USA, Japan, India and China all have
material research programmes aiming for the next generation of increased steam
temperatures and efficiency, known as Advanced Ultra-Super Critical (AUSC) or
700C technology.
IGCAR (Indira Gandhi Centre For Atomic Research) will design and develop
new 70% nickel alloys capable of 710C and 35 MPa super-heater steam
parameters, raising net efficiency from 3840% to 46% (LHV) and reducing carbon
dioxide emissions by 1520%. IGCAR have experience with new nickel alloys
through its prototype fast breeder nuclear reactor project. Materials include Super
304H, Inconel 617, Haynes 230, T92 and T91.However the research and
developments of new technologies are needs several years.
038
DEPT. OF MECHANICAL ENGINEERINGG.P.T.C. ,PALAKKAD
Seminar report on super critical steam generator
4-9 APPLICATIONS
039
DEPT. OF MECHANICAL ENGINEERINGG.P.T.C. ,PALAKKAD
Seminar report on super critical steam generator
05 CONCLUSION
The generation of electricity will in India continue at least for 40 to
50 years by coal fired steam power plants because of their cheapness, availability and
deposits of fuel. About 12% of coal fired power plants in India are working with
super-critical technology. Theybecomes favourable because of their high cycle
efficiency and large capacity generation.
In order to adopt the technology, there are many challenges towards these
technology to adopt it effectively such as material consideration as mentioned above.
However the technology replaces old thermal power plants in the world.
040
DEPT. OF MECHANICAL ENGINEERINGG.P.T.C. ,PALAKKAD
Seminar report on super critical steam generator
06 REFERENCES
[1] M. M. EI-Wakil, Power Plant Technology, McGraw-Hill Book Company, First
Edition of 1984.
[2] D.S. Kumar, Heat and Mass Transfer, S.K.Kataria & Sons publishers, Sixth
Edition.
[3] P.K. Nag, Power Plant Engineering: Steam and Nuclear, Tata McGraw-Hill
[4] R.S. Khurmi and N. Khurmi, Steam Tables with Mollier Diagram, S. Chand
[6]INDIAN Power Sector to India July 2011 International Seminar-Base paper for
Edition.
041
DEPT. OF MECHANICAL ENGINEERINGG.P.T.C. ,PALAKKAD
Seminar report on super critical steam generator
042
DEPT. OF MECHANICAL ENGINEERINGG.P.T.C. ,PALAKKAD
Seminar report on super critical steam generator
043
DEPT. OF MECHANICAL ENGINEERINGG.P.T.C. ,PALAKKAD
Seminar report on super critical steam generator
044
DEPT. OF MECHANICAL ENGINEERINGG.P.T.C. ,PALAKKAD
Seminar report on super critical steam generator
045
DEPT. OF MECHANICAL ENGINEERINGG.P.T.C. ,PALAKKAD
Seminar report on super critical steam generator
046
DEPT. OF MECHANICAL ENGINEERINGG.P.T.C. ,PALAKKAD
Seminar report on super critical steam generator
047
DEPT. OF MECHANICAL ENGINEERINGG.P.T.C. ,PALAKKAD
Seminar report on super critical steam generator
048
DEPT. OF MECHANICAL ENGINEERINGG.P.T.C. ,PALAKKAD