WELCOME

TO PRESENTATION ON

SUPERCRITICAL By BOILER
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OPERATION TEAM

APML,TIRODA

Introduction to Supercritical Technology

What is Supercritical Pressure ? Critical point in water vapour cycle is a thermodynamic state where there is no clear distinction between liquid and gaseous state of water. Water reaches to this state at a critical pressure above 22.1 MPa and 374 oC.

Rankine Cycle Subcritical Unit

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1 - 2 > CEP work 2 - 3 > LP Heating 3 - 4 > BFP work 4 - 5 > HP Heating 5 6 > Eco, WW 6 7 > Superheating 7 8 > HPT Work 8 9 > Reheating 9 10 > IPT Work 1011 > LPT Work 11 1 > Condensing

Rankine Cycle Supercritical Unit

1 - 2 > CEP work 2 2s > Regeneration 2s - 3 > Boiler Superheating 3 4 > HPT expansion 4 5 > Reheating 5 6 > IPT & LPT Expansion 6 1 > Condenser Heat

rejection
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VARIATION OF LATENT HEAT WITH PRESSURE

Absolute Pressure (Bar) Saturation Temperature (oC) 264 342 366 374 Latent Heat (K J/Kg.)

50 150 200 221

1640 1004 592 0

Departure from Nucleate Nucleate boiling is a type of boiling that takes place when the surface temp is hotter than the saturated fluid temp by a certain amount but where Boiling
heat flux is below the critical heat flux. Nucleate boiling occurs when the surface temperature is higher than the saturation temperature by between 40C to 300C.

WATER

DENSITY

STEAM

175 224 PRESSURE(ksc)

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Supercritical Boiler Water Wall Rifle Tube And Smooth Tube

Natural Circulation Vs. Once Through System

5710C To HP Turbine Mixer Header 4230C Separator 4620C

To IP Turbine 5690C

5340C 5260C
FRH

FSH Platen Heater From CRH Line 3240C LTRH

4730C

LTSH 4430C

3260C

From FRS Line 2800C

NRV

2830C Economizer Phase 1 Economizer Phase 2

Boiler Recirculation Pump

Bottom Ring Header

Feed water control

In Drum type Boiler Feed water flow control by

Three element controller

1.Drum level 2.Ms flow 3.Feed water flow.

Drum less Boiler Feed water control by 1.Load demand 2.Water/Fuel ratio(7:1) 3.OHD(Over heat degree)

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Difference of Subcritical(500MW) and Supercritical(660MW)

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COMPARISION OF SUPER CRITICAL & SUB CRITICAL

DESCRIPTION Circulation Ratio
SUPERCRITICAL (660MW) SUB-CRITICAL (500MW)
Once-thru=1 Assisted Circulation=3-4 Natural circulation= 7-8 Three Element Control -Feed Water Flow -MS Flow -Drum Level

Feed Water Flow Control

-Water to Fuel Ratio (7:1) -OHDR(22-35 OC) -Load Demand Nil Low Low Low

Latent Heat Addition Sp. Enthalpy Sp. Coal consumption Air flow, Dry flu gas loss

Heat addition more More High High

Continue..
DESCRIPTION SUPERCRITICAL (660MW) SUB-CRITICAL (500MW)

Coal & Ash handling Pollution Aux. Power Consumption Overall Efficiency

Low Low Low High (40-42%)

High High More Low (36-37%)

Total heating surface area Reqd

Tube diameter

Low (84439m2)
Low

High (71582m2)
High
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Continue..
DESCRIPTION SUPERCRITICAL SUB-CRITICAL (660MW) (500MW)

Material / Infrastructure (Tonnage)

Start up Time Blow down loss Water Consumption

Low 7502 MT
Less Nil Less

High 9200 MT
More More More

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Water Wall Design

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WATER WALL ARRANGEMENT

Bottom spiral & top vertical tube furnace arrangement Once through design feature is used for boiler water wall

design
The supercritical water wall is exposed to the higher heat

flux
Spiral tube wall design (wrapped around the unit) with

high mass flow & velocity of steam/water mixture through each spiral
Higher mass flow improves heat transfer between the
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WW tube and the fluid at high heat flux.

SPIRAL VS VERTICAL WALL

VERTICAL WALL
Less ash deposition on

SPIRAL WALL
More ash deposition More fluid mass flow Less number of tubes

wall Less mass flow More number of tubes More boiler height for same capacity No uniform heating of tubes and heat transfer in all tubes of WW

Less boiler height

Uniform heat transfer and

uniform heating of WW tubes

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Furnace Arrangement

SPIRAL TYPE

VERTICAL TYPE
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Supercritical Sliding Pressure Boiler Water Wall Design Comparison of Vertical Wall and Spiral Wall

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Ash accumulation on walls

Vertical water walls Spiral water walls

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Super Critical Boiler Materials

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Advanced Supercritical Tube Materials (300 bar/6000c/6200c)

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Material Comparison
Description Structural Steel Water wall 660 MW Alloy Steel T22 500 MW Carbon Steel Carbon Steel

SH Coil
RH Coil LTSH Economizer Welding Joints (Pressure Parts)

T23, T91
T91,Super 304 H T12 SA106-C 42,000 Nos

T11, T22
T22, T91,T11 T11 Carbon Steel 24,000 Nos

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Steam Water Cycle Chemistry Controls

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S. Parameter No.
1 Type of Boiler water treatment Silica pH 3

Sub Critical
LP and HP dosing. Or All Volatile Treatment (Hydrazine + Ammonia)

Super Critical
No HP dosing Combined water treatment (CWT).

< 20 ppb in feed water and steam, Standard value <15 ppb in the cycle < 250 ppb in boiler drum Expected value <10 ppb in the cycle 9.0 - 9.5 for feed, steam & condensate, 9.0 10.0 for Boiler drum < 7 ppb for feed. <0.20 S/cm in the feed & steam cycle 9.0 9.6 for AVT(All volatile treatment) 8.0 9.0 for CWT(Combine water treatment) < 7 ppb for feed in case of AVT 30 150 ppb for feed in case of CWT Standard value <0.15 S /cm in the cycle Expected value- <0.10 S /cm in the cycle

Dissolved Oxygen (DO)

Cation (H+) Conductivity

6 7 26

(CPU)

CPU is optional

CPU is essential for 100% flow.

Silica and TDS By maintaining feed water quality Blow down possible till separators are control and functioning (upto 30% load). By operating CBD

Advantages of SC Technology
I ) Higher cycle efficiency means Primarily less fuel consumption less per MW infrastructure investments less emission less auxiliary power consumption less water consumption II ) Operational flexibility Better temp. control and load change flexibility Shorter start-up time More suitable for widely variable pressure operation
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ECONOMY
Higher Efficiency (%)
Less fuel input. Low capacity fuel handling system. Low capacity ash handling system. Less Emissions.
Approximate improvement in Cycle Efficiency Pressure increase : 0.005 % per bar Temp increase : 0.011 % per deg K
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Increase of Cycle Efficiency due to Steam Parameters

Increase of efficiency [%] 10 9 8 7 6 5 4 3 2 1 0 300
Pressure [bar]

6,77 5,74 4,81 4,26 3,37 2,64 2,42 1,78 0

241 175 538 / 538

5,79 3,74 2,76

3,44 1,47

600 / 620

0,75
566 / 566 538 / 566

580 / 600

HP / RH outlet temperature [deg. C]

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Sub. vs. Supercritical Cycle

Impact on Emissions
Plant Efficiency, %* Plant Efficiency, Btu / kw-hr Subcritical 34 - 37 10,000 - 9,200 Supercritical 37 - 41 9,200 - 8,300

Plant Efficiency, % Fuel Consumption/Total Emissions including CO2

34% Base

37% Base-8%

41% Base-17%

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* HHV Basis

Challenges of supercritical technology

Water chemistry is more stringent in super critical

once through boiler. Metallurgical Challenges More complex in erection due to spiral water wall. More feed pump power is required due to more friction losses in spiral water wall. Maintenance of tube leakage is difficult due to complex design of water wall. Ash sticking tendency is more in spiral water wall in comparison of vertical wall.

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THANK YOU