LAYOUT ARRANGEMENT OF SUPER CRITICAL BOILER

May 24, 2012

thermodynamic diagram for supercritical plant

May 24, 2012

The Water and Steam Flow Diagram

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Supercritical Boiler Flow Chart

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Cycle of Supercritical Power Plant

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ZR : Aux. Relief VV, WR : Water Relief VV LL : Level Control VV, UG : Recirculation VV

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General Arrangement of Boiler Component

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Sliding Pressure Supercritical Design

Straight Tube Wall vs. Spiral Tube Wall

Spiral Wall Furnace - Impact on Tube Numbers vs. Straight Wall Basic Principle of Spiral Wall furnace

Unit Size 500 MW, Conventional Vertical Furnace Wall Designs Unit Size 500 MW, Spiral-Wound Furnace may be Necessary (Fuel will be Final Determinant)
Vertical Tube Pitch Vertical Tube Pitch

Spiral Angle Spiral Tube Pitch Spiral Tube Pitch

Spiral Angle

May 24, 2012

Spiral Angle

Spiral Angle

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Design Types

NATURAL
STEAM DRUM

CONTROLLED
TO SUPERHEATER

ECON.

FURNACE WALLS

CIRC. PUMP

ONCE THROUGH
SEPARATOR

ECON.

CIRC. PUMP

May 24, 2012

DISTRIB. HEADER

Natural circulation - well suited for < 145 bar cycles Controlled circulation - optimum solution for reliable high-pressure subcritical operation Once-through technology Suitable for sub and supercritical cycles Both spiral-wall and vertical-wall arrangements available depending upon capacity and fuel
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Sliding Pressure Supercritical Design

Advanced Sliding Pressure Supercritical Design

PRESSURE VS LOAD

WATERWALL INLET PRESSURE

Subcritical Pressure Regime

Supercritical Pressure Regime

Waterwall Pressure Turbine Throttle Pressure

20

40

60

80

100

May 24, 2012

BOILER LOAD, % MCR

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Sliding Pressure Supercritical Design

Circulation and Start Up Systems
Spiral Wall Boiler Design Vertical Wall Boiler Design

Details Design Principles Test Data

Start up Systems

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Pumped and Drain Systems Components Performance and Advantages of Pumped Start up System

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Vertical Wall SPSC Boiler

Determination of Furnace Wall Tube Metal Temperature

Evaluation of Heat Evaluation of Heat Transfer at Tube Transfer at Tube Inside Wall is Key to Inside Wall is Key to Design of SPSC Design of SPSC Boilers Boilers

Factors Greatly Factors Greatly Affecting Heat Affecting Heat Transfer at Tube Transfer at Tube Inside Wall: Inside Wall: Rifled Tubing Rifled Tubing Mass Velocity Mass May 24, 2012 Velocity

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Controlled Circulation Boiler

N
S
uality

o r m

a l

C
R

o n d i t i o n s
i f l e d T u b i n g

o o t h

T u b i n g

Generated Q

Q ua lit y

Al lo w ab le

Elevation

Elevation

lity le Qua llowab A

1 % 1

Gen er

ated

Qua lity

1 % 1

D R

D R

B e g i o n

B e g i o n

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Q u a l i t y i n i m u m S ~1 1 %

f e

t y

r g

i n M

Q u a l i t y i n i m u m S ~1 1 %

a f e

t y

M
17

r g

Circulation and DNB Analysis

Normal Conditions in a Once Through Boiler Normal Conditions in Subcritical Boiler
FURNACE WALL OUTLET

100%
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SUPERHEAT
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Vertical Wall SPSC Boiler

Safety Margin Of Subcritical Boiler
X= Steam Quality Fraction X= 00 .

Top of Boiler

Critical Q/A (Kw/m1 ) Subcritical Boiler

X= 00 .

Boiler Height

Q/A Critical Q/A Boiler

11 Margin . 1
X= 00 .

>

1.25

Boiler Q/A (Kw/m1 )

X= 11 .

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Q/A (Kw/m1 )

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Vertical Wall SPSC Boiler

Conditions of Supercritical Once Through Boiler
X= 00 .

Critical Q/A (Kw/m1 ) Subcritical Boiler

Superheat

X= 11 .

X= 00 .

Boiler Height

X= 00 .

X= 11 .

Boiler Q/A (Kw/m1 ) Once Through Boiler

X= 11 .

X= 11 . May 24, 2012

Q/A (Kw/m1 )

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Spiral Boiler Technology

Mass Velocity study
Midwall Temperature vs. Mass Velocity Smooth Tube o Tfluid 111 C P= 00 Mpa .0
11 1 11 1 00 0 11 1 11 1 00 0

41 mm O.D. x x 6.4 mwt SA 213 T22

Midwall Temperature ( oC)

11 1 11 1 11 1 11 1 11 1 Q/A (Kw/m1 ) 11 1 11 1 00 0 11 11 00 0 00 0

00 0

00 0 00 0 11 1 11 1 11 1 11 1

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11 11

11 11

11 11

11 11

11 11

11 11
1

11 11

11 11

11 11

11 11

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Mass Velocity (Kg/m -sec)

Spiral Boiler Technology

Mass Velocity study
Midwall Temperature vs. Mass Velocity Rifled Tube Tfluid 1 1C 1 P= 0 0 Mpa .0
11 1 11 1 00 0 00 0
Midwall Temperature 00 0 11 1 00 0

41 mm O.D. x x 6.4 mwt SA 213 T22

Q/A (kw/m^ ) 1 11 1 11 1 11 1

00 0 11 1 00 0 00 0 00 0 00 0 11 1
11 1 00 0 11 1 11 1

11 1 00 0

1 12012 1 1 1 11 May 24, 1

11 11

11 11

11 11

11 11

11 11

11 11

11 11

11 11

11 11

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M ass Velocity (kg/m -sec) 1

Spiral Boiler Technology Number of Turns Study

Hear Absorption in %
140 120

100 % Load Spiral Waterwall

100 80 60

Central Fireball

Left Side Wall

Right Side Wall

May 24, 2012 Front Wall

Right Side Wall

Rear Wall

Left Side Wall

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Rear Wall

Front Wall

Spiral Boiler Technology Number of Turns Study

Hear Absorption in %
140 120 100 80 60

100 % Load Spiral Waterwall Fireball Shift to Corner

FW

RSW

RW

LSW

Left Side Wall

Right Side Wall

May 24, 2012 Front Wall

Right Side Wall

Rear Wall

Left Side Wall

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Rear Wall

Front Wall

Start-up System with Recirculation

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Start-up System with Recirculation

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Simplified Drain Discharge System

SH flash tank

WW ECO HWL

to condenser deaerator HPH WL BFP

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Supercritical Technology
Supercritical Cycle Advantages
0 -1 -2 -3 -4 -5 -6 -7 -8 -9 -10
1000/1000F Single Reheat 1000/1000/1000F Double Reheat 1100/1100/1100F

Better Plant Efficiencies Lower Plant Operating Costs Lower Emission Levels with Lower Coal Consumption

Relative Net Heat Rate, %

Double Reheat

1800

2400

3500

4500

Throttle Steam Pressure, psig

Effect of Steam Conditions on Heat Rate

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Supercritical Technology Designs to meet every application World leader ~ 100 supercritical units
Two-pass design Tower design

Spiral wound

Straight Wall

Design options to meet fuel specification Design options to meet fuel specificatio and customer preferences and customer preferences

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Steam Power Plant Technology Trends

Recent Contracts
CO- 2004 CO- 2002 CO-2002 CO-2001 CO- 2000 China Waigaoqiao 2x900 MW, 4078/1006/1056 Germany Niederaussem 1000MW, 3976/1076/1112 Korea Yunghung 2x800 MW,.3627/1056/1056 Greece Florina 330 MW, 3572/1009/1008 Taiwan Mai Liao 2x600MW, 3844/1006/1056

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5450/1290/1325/1325

Heat Rate

Heat Rate [%]

10 8 6 4 2
Technology maturity
2400/1005/1005 3500/1005/1050 (psi/F/F) 3600/1050/1085

4050/1160/1200 4050/1100/1150 4050/1075/1100

Subcritical Mature Technology

Supercritical Mature Technology

Advanced Steam Conditions -higher Temperatures/Pressures

May 24, 2012

50s

60s

70s

80s

90s

00s

30

10s

Advanced Sliding Pressure Supercritical Design

PRESSURE VS LOAD

WATERWALL INLET PRESSURE

Subcritical Pressure Regime Supercritical Pressure Regime Waterwall Pressure

Turbine Throttle Pressure

20

40

60

80

100

BOILER LOAD, % MCR May 24, 2012 31

Spiral Waterwall Tubing

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Lateral Heat Flux Profile

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Spiral Wall Sliding Pressure Supercritical Design

Spiral Furnace Windbox Panel

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THANK YOU

May 24, 2012

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