Advanced technologies of power generation

Halina Pawlak-Kruczek
Advanced Thermal power
stations
and Idea of CHP
Halina Pawlak-Kruczek
 Power cycles
VAPOR AND COMBINED POWER CYCLES

In this part we consider vapor power cycles in which the working fluid is
alternatively vaporized and condensed.
The continued quest for higher thermal efficiencies has resulted in some
innovative modifications to the basic vapor power cycle. Among these, we
discussed the reheat and regenerative cycles.
Other possibilities consist of two separate cycles known as combined cycles where
the heat rejected by one fluid is used as the heat input to another fluid operating
at a lower temperature.- Combined cycle .
Steam is the most common working fluid used in vapor power cycles because of its
many desirable characteristics such as low cost, availability, and high enthalpy of
vaporization. Therefore, this part is mostly devoted to the discussion of steam
power plants. Steam power plants are commonly referred to as coal plants,
nuclear plants, or natural gas plants, depending on the type of fuel used to supply
heat to the steam. However, the steam goes through the same basic cycle in all of
them. Therefore, all can be analyzed in the same manner.
 In thermal power stations, mechanical power is produced by a heat engine,
which transforms thermal energy, often from combustion of a fuel, into
rotational energy.
Most thermal power stations produce steam, and these are sometimes called
steam power stations. About 86% of all electric power is generated by use of
steam turbines.
Not all thermal energy can be transformed to mechanical power, according to
the second law of thermodynamics. Therefore, there is always heat lost to the
environment. If this loss is employed as useful heat, for industrial processes
or district heating, the power plant is referred to as a cogeneration power
plant or CHP (combined heat-and-power) plant. In countries where district
heating is common, there are dedicated heat plants called heat-only boiler
stations. An important class of power stations in the Middle East uses
byproduct heat for desalination of water.
Thermal power plants are classified by the type of fuel and the
type of prime mover installed.
By fuel:

Nuclear power plants use a nuclear reactor's heat to operate a steam

turbine generator.
Fossil fuelled power plants may also use a steam turbine generator or in
the case of natural gas fired plants may use a combustion turbine.
Geothermal power plants use steam extracted from hot underground rocks.
Renewable energy plants may be fuelled by waste from sugar cane,
municipal solid waste, landfill methane, or other forms of biomass.
Waste heat from industrial processes is occasionally concentrated enough
to use for power generation, usually in a steam boiler and turbine.
 classification
By prime mover
Steam turbine plants use the dynamic pressure generated by expanding steam to turn the
blades of a turbine. Almost all large non-hydro plants use this system.
Gas turbine plants use the dynamic pressure from flowing gases to directly operate the
turbine. Natural-gas fuelled turbine plants can start rapidly and so are used to supply "peak"
energy during periods of high demand, though at higher cost than base-loaded plants. These
may be comparatively small units, and sometimes completely unmanned, being remotely
operated. This type was pioneered by the UK, Princetown being the world's first,
commissioned in 1959.
Combined cycle plants have both a gas turbine fired by natural gas, and a steam boiler and
steam turbine which use the exhaust gas from the gas turbine to produce electricity. This
greatly increases the overall efficiency of the plant, and many new base load power plants
are combined cycle plants fired by natural gas.
Internal combustion Reciprocating engines are used to provide power for isolated
communities and are frequently used for small cogeneration plants. Hospitals, office
buildings, industrial plants, and other critical facilities also use them to provide backup power
in case of a power outage. These are usually fuelled by diesel oil, heavy oil, natural gas and
landfill gas.
Microturbines, Stirling engine and internal combustion reciprocating engines are low cost
solutions for using opportunity fuels, such as landfill gas, digester gas from water treatment
plants and waste gas from oil production.
 COAL FIRED UNIT
Coal-fired units produce electricity by burning
coal in a boiler to heat water to produce
steam. The steam, at tremendous pressure,
flows into a turbine, which spins a generator
to produce electricity. The steam is cooled,
condensed back into water, and returned to
the boiler to start the process over.
1. Cooling tower 10. Steam governor valve 19. Superheater
2. Cooling water pump 11. High pressure turbine 20. Forced draught fan
3. Three-phase transmission line 12. Deaerator 21. Reheater
4. Unit transformer 13. Feed heater 22. Air intake
5. Three-phase electric generator 14. Coal conveyor 23. Economiser
6. Low pressure turbine 15. Coal hopper 24. Air preheater
7. Boiler feed pump 16. Pulverised fuel mill 25. Precipitator
8. Condensor 17. Boiler drum 26. Induced draught fan
9. Intermediate pressure turbine 18. Ash hopper 27.stack chimney
Flow Scheme chart
Of thermal power
unit
 Boilers types fired with coal

cfb pc
 Supercritical boilers
for Advanced Power Production Technology
Sub-critical v. Supercritical

Not a great deal of difference

 Notice the major difference between a modern Supercritical
Boiler and a traditional National Circulation Boiler.
(Supercritical boilers are higher pressure and higher
temperature, just as safe, just as easy to operate and the type
of boiler normally used in Germany, Scandanavia and Japan.
Two of the best supercritical plants in Europe are Doosan
Babcoc design Hemweg in Holland and Meri Pori in Finland.
The Chinese are very conservative and have been reluctant to
move to the Supercritical type but they will now change over.
Development of Thermal Efficiency in Coal Fired
55
Power Plants
Cycle Thermal Efficiency (%NCV)

THERMIE 700 TARGET

COST 522 TARGET

50 SKAERBECK/NORDJYLL
MBEL BAT
HEMWEG
LUBECK
MERI PORI
45

40
RECENT
CASTLE PEAK
DRAX CHINESE PLANTS
35 RATCLIFFE
FERRYBRIDGE

30
1960 1970 1980 1990 2000 2010 2020
Year
Natural Circulation
Supercritical

Note BAT= Best Available Technology , 2002

Reduced CO2 from Advanced Supercritical Coal Fired Power Stations
0%
Traditional Natural
% Reduction in CO2 emissions

Circulation Boiler

-10%
HEMWEG
Advanced
MBEL Supercritical
BAT
-20% Boilers

COST
522
TARGET
-30%
THERMIE 700
TARGET

1990 2000 2010 2015

 Comparison of measures to improve efficiency
Nett Efficiency
Improvements in boiler efficiency by reducing back end gas temperature,
% lower unburned carbon losses, lower excess air levels and improved
46 airheater sealing are necessary for optimum plant operation but when
compared to the gains offered by improvements to the overall cycle in 0.03 bar
terms of temperature pressure of steam and pressure of condenser they
45 are small. +1.5%
double
44
300 bar 0.065 bar
+1.5%
600/600 C
43
single
250 bar
42
540/560 C
250 bar
41 540/560 C
1.15 120
40 170 bar
1.25 130
535/535 C
39
Excess air Exit gas temp Steam conditions Reheat Condenser
pressure
DEVELOPMENT TARGETS
STEAM TEMPERATURE & PRESSURE 700C
375-400bar
50-55%
620-640C
320bar
48-50%
585-602C
305bar
42-46%

585C
180bar
37-42%

Conventional Modern Medium term Longer term

Plant Supercritical

low alloy 9-12% Cr new steels nickel based

steels steels needed alloys needed
 Spiral Furnace Features
Evaporation complete
Vertical tubes where in furnace tubes
heat flux is lower
Dry out zone
Transition mixing
Header
Welded strap to
support tubes
Spiral furnace tubes
Zone of highest
Burner region heat flux

Spiral hopper tubes

Optimised Ribbed Tubing for Vertical Tube
Furnace

Low fluid mass flux requires enhanced heat

transfer and special optimised ribbed tubing
 Current Supercritical Boiler Products
New Build :
Two-Pass Spiral Wound Furnace :
260 bar / 540 C / 540 C
300 bar / 600 C / 620C
Two-Pass Vertical Internally Ribbed Tube Furnace :
260 bar / 540C / 540 C
300 bar / 600C / 620C
Retrofit Options :
Two-Pass Vertical Internally Ribbed Tube Furnace :
300 bar / 600C / 620C
Mitsui Babcock Supercritical Boilers
Meri Pori, Finland Coal Fired Plant.
 Mitsui Babcock Supercritical Boilers
G
+7 0 .7 5 0

MeriPori 630 MW Unit

SEPERA TO R
V ESSEL

G
+5 9 .5 0 0 Evaporation 1814 t/hr
O U TLET REH EA TER

S/htr Outlet Press 239bar(g)

FIN A L SU PERH EA TER

PLA TEN SU PERH EA TER PRIMA RY

SU PERH EA TER
S/htr Outlet Temp. 540C
G
+4 7 .0 0 0

PRIMA RY
REH EA TER
R/htr Outlet Temp. 560C
ECO N O MISER Generating Efficiency 43.5%

G
CIRCU LA TI N G
PU MP 1 4 5 9 7 FU RN A CE D EPTH
O V ER A IR
PO RTS
Availability (1998) 100%
+3 2 .5 0 0

O V ER A IR
Commissioned 1993
PO RTS H
07.3 IDT
208 CE W
A LO W N O X
RN
FU CO A L BU RN ERS

Load following yes

Benson load 35%
G
+1 3 .5 0 0
Turndown 30%
Rate of load change 5% /min
Ignition-rated load (cold) 3.5 hrs
A SH
CO N V EY O R G A S RECIRCU LA TIO N
D U CT

25000 21000
 Nordjylland 3, Dania
USC, tower boiler, tangential corner firing,
int. bituminous coals, cold sea water

Most efficient coal-fired plant

Operating net efficiency 47% LHV, power only mode/44.9% HHV (not
annual)
High steam conditions 29 MPa/582C/580C/580C at boiler by early use
of new materials (P91)
Large number of feedwater heating stages
Double reheat has prevented LP blade erosion
Very low emissions and full waste utilisation
NOx abatement Combustion measures and SCR
Particulates removal ESP
Desulphurisation Wet FGD
IEA Clean Coal Centre www.iea-coal.org.uk
 Niederaussem K,
USC, tower boiler, tangential wall firing, lignite of 50-
60% moisture, inland

Most efficient lignite-fired plant

Operating net efficiency 43.2% LHV/37% HHV
High steam conditions 27.5 MPa/580C/600C at turbine; initial difficulties solved
using 27% Cr materials in critical areas
Unique heat recovery arrangements with heat extraction to low temperatures
complex feedwater circuit
Low backpressure: 200 m cooling tower, 14.7C condenser inlet
Lignite drying demonstration plant being installed to process 25% of fuel feed to
enable even higher efficiency
NOx abatement Combustion measures
Particulates removal ESP
Desulphurisation Wet FGD

IEA Clean Coal Centre www.iea-coal.org.uk

Types of CFB Boiler
 CFB Status
CFB has established of leading position in small and mid-size
industrial and utility plants
Fuel flexibility is a special advantage
Wide range for design coals
Opportunity fuels (biomass etc)
Hard-to-Burn fuels (petcoke etc)
Excellent emission performance
No DeSOx / DeNOx plants required
CFB has reached utility scale
Sizes up to 300 MWe in operation
460 MWe under design
 Sub critical CFB
lower solid loading and
superficial velocity
cyclone
In furnace superheat panel and
water panel
Partition of second pass for
superheater and reheater
Tubular air heater
Auxiliary power decreases >1%.
Less erosion in furnace
Simplified structure
 Scale-Up and Key References
UNIT CAPACITY MW
( e)
600
SECOND
550 GENERATION
DESIGN
500
Lagisza
450

400

350
FIRST GENERATION
JEA
300 DESIGN

250 Turow Turow 5

1
200
Nova Scotia
150 Vaskiluodon Voima NPS
Kajaani
100
Tri-State
50 Leykam Kokkola
Kauttua Kuhmo Thai Kraft
Pilot plant Pihlava Pilot plant
0
1970 1975 1980 1985 1990 1995 2000 2005 2010
YEAR OF INITIAL OPERATION
 Once-Through CFB Key Design Features
Proven and Efficient CFB Process
High Plant Efficiency
Supercritical Steam Pressure
Sliding Pressure Operation
BENSON Vertical Tube Technology
Vertical Tube Furnace Walls
Low Pressure Drop
Integrated Steam Cooled Solids Separators
Minimum amount of refractories
INTREX Fluidized Bed Heat Exchanger
High Heat Transfer Rates Minimize Surface Area
Regenerative Air Heater
Maximum Boiler Efficiency
 CFB More Economical than PC Alternative
CFB alternative had:
20 % lower investment cost than PC with SCR + FGD
Better net plant efficiency by 0.3 %-unit better than with
PC
Potential for savings in fuels costs due to multi-fuel
capability
 Steam Cycle
Hanger tubes SH I

To turbine

Furnace 2nd pass SH IV HP- bypass

SH II SH III
roof walls Solids INTREX
separators
From turbine
RH I
Water/Steam
separators RH II
INTREX To turbine
Furnace

To flash tank
INTREX-
chambers

Economizer

HP-heaters
From feed tank
Feed water pump
 Furnace Design
BENSON low mass flux technology
Water/Steam
Separator Furnace circuit:
Vertical tubing
To SH I
SH III SH SH III Membrane walls, smooth tubes 38 x 8.0
II Benson
Bottle mm, mass flux ~ 600 kg/m2s
Evaporation panels, rifled tubes 51 x 8.8
mm, mass flow flux ~ 600 kg/m2s
INTREX casing and support in an economizer
circuit
To Furnace inlet
Furnace roof in an primary superheater circuit
Furnace inlet
Solid separators in an tertiary superheater
INTREX-SH IV INTREX-RH II circuit
INTREX-heat exchanger in an final superheater
From Economizer
/ reheater circuit
 Furnace Heat Transfer
Low and Uniform Heat Flux
Calculated with 3D Furnace
Model
50 kW/m2
45
40
Furnace Height [m]

35
30
CFB furnace
25
20
PC furnace
15
10
5
0
0 100 200 300 400
Heat flux (average) [kW/m]
 agisza 460 MWe CFB

Furnace:
Depth: 10.6 m
Width: 27.6 m
Height: 48 m
 Boiler Materials

HEADERS, PIPING:
HEAT SURFACES:
Economizer:
Economizer:
15NiCuMoNb5
15Mo3
Furnace:
Furnace panels:
15NiCuMoNb5
13CrMo44
13CrMo44
Superheaters:
Superheaters:
13CrMo44
13CrMo44
7CrMoVTiB1010
X10CrMoVNb91
X20CrMoV121
X11CrMoWVNb911
TP347HFG
Main Steam Lines
X11CrMoWVNb911
 Flue Gas Heat Recovery LP-
M
Preheaters

LP-Bypass
Economize FW Tank
Rotary Air r
Preheater
M
ID-Fan
M Flue gas temperature 85 C
ESP
Heat Recovery
Air Aux. Steam Cooler
Preheaters Heater

M Improvement of 0.8 %-
M M
units in total plant
SA-Fan PA-Fan efficiency
 Conclusions

Supercritical Once-Through
Technology
High Plant Efficiency
Modern CFB Design
Excellent Fuel Flexibility
Competitive Cost
New CFB Designs up to 800
MWe Under Development