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Electricity

Indian Scenario
Per Capita Electric Power Consumption
Country Per Capita Electric Power Consumption kWh
1995 2005 2011
India 367 461 684
Mexico 1364 1853 2092
Turkey 1227 2019 2709
China 770 1784 3298
Malaysia 1982 2857 4246
Italy 4598 5669 5393
United Kingdom 5576 6272 5472
Spain 3951 6111 5530
Russia 5110 5785 6486
Germany 6328 7113 7081
France 6619 7665 7289
Japan 7365 8213 7848
Switzerland 7283 8305 7928
South Korea 3881 7804 10162
USA 12660 13705 13246
Sweden 15475 15431 14030
Canada 16503 17319 16473
Norway 24528 25083 23174
International Energy Agency (IEA Statistics OECD/IEA, http://www.iea.org/stats/index.asp),
Energy Statistics and Balances of Non-OECD Countries and Energy Statistics of OECD Countries.
Catalog Sources World Development Indicators
 BHEL - Boiler

Technology & Capability

 Technology Development over the Years
1960s
Boiler design as per Czechoslovakian Technology : 30 MW, 60 MW

1970s
Technology from Combustion Engineering, USA;
Unit capacities 110 MW, 210 MW Low Pressure Steam cycle
1980s
Pressure ratings increased to achieve higher plant efficiency; Unit capacity
increased to 500 MW; Controlled circulation introduced for very high pressures
Firing system design for Low NOx emission
Deteriorating coal properties led to increased tube erosion and performance
deviations; units redesigned for inferior coals.
Tower type boilers introduced for highly erosive coals
 Technology Development over the Years

1990s
250 MW units developed
130 MW unit firing Steel plant by- product gas (Corex gas)
Boiler efficiency improvement by designing for low exit gas temperatures

2000s
Technology tied up for Super critical steam generators with Alstom.
IT based Soot Blowing Optimisation System developed.
Designs for firing Washed Coals developed.
 Technology through Collaborations
Products (HPBP) Collaborators
Steam Generators Skoda, Czech; Combustion Engg., USA(now GE)

Gravimetric Feeders Stock Equipment Co., USA (now part of SPX Corporation)

Safety, Safety Relief, Y Type Valves Dresser Industries Inc. USA (now part of Halliburton Group)

High Pressure Valves Toa Valve Co. Ltd, Japan

Soot Blowers Copes Vulcan, USA (now part of Clyde Bergmann)

HPLP Bypass System Sulzer Brothers Ltd (now part of CCI, USA)
Christmas Trees & Wellhead Assemblies, Kvaerner Oilfield Products, Singapore (now AKER KVAERNER,
Subsea Well Head, Casing support & Mudline Norway)
Suspension Systems & Block Valves

HRSG Vogt-NeM Inc.(now Vogt Power International, USA)

Circulating Fluidised Bed Combustion (CFBC) LLA, Germany (earlier LLB, Germany)
Boilers
 Technology

Pulverised Coal Combustion (PCC)

Fluidised Bed Combustion (FBC)

Circulating Fluidised Bed Combustion (CFBC)

Combined Cycle Gas Turbine / Co-generation Plants

Integrated Gasification Combined Cycle (IGCC)

 Pulverised Coal Combustion

PCC is the most commonly used method in coal-fired power

plants and is based on many decades of experience.
The technology is well developed and understood and there are
thousands of units around the world.
Boiler design - two broadly different arrangements are used for
pcc boilers - conventional two-pass or single-pass tower type.
 Boiler Systems Engineered

Tangential / Wall Firing

Direct / Indirect Firing System
Bowl / Ball-Tube / Ball & Race / Beater Wheel Type Pulverizers
Hot / Cold Primary Air / Suction Mill System
Axial / Radial Type Fans
Tubular / Regenerative Airheaters
 Power Plant

Efficiency & Heat Rate

Improvement & Growth Trends
Major Components : Coal based Power Plant
Steam Generation Cycle
 Requirements of Power Plants

Highest Plant Efficiency and Lowest Heat Rate

High Reliability & Availability
Suitable for differing modes of Operation
Suitable for different quality of Fuel
(Especially High Ash, Low grade Indian Coals)
Ability to operate under adverse grid conditions /
fluctuations
Minimum Emission of Pollutants
Lowest Life Cycle Cost
 Thermal Power Generation

Higher cycle efficiency for :

Conservation of fuel resources
Reduction of Atmospheric Pollutants - SOx & NOx
Reduction in CO2 emission (linked to global warming)
Better economy in power generation where fuel costs
are high and pollution control requirements are
stringent
Energy Conversion Process
 Measures to improve Plant Efficiency

Boiler side measures :

Minimum RH spray
Minimum SH spray (if tapped off before feed heaters)
Minimum flue gas temperature at AH outlet
Minimum excess air at AH outlet
Minimum unburnt Carbon loss
Reduced auxiliary power consumption
 Measures to improve Plant Efficiency

Turbine side measures :

Higher Steam parameters (MS Pressure & SHO / RHO
Steam Temp).
Adoption of double Reheat Cycle
Increasing feed water temperature with Enhanced
Regenerative Feed Heating
Increase in condenser vacuum
Increase of Cycle Efficiency due to Steam Parameters
Increase of efficiency [%]

10
6,77
9
5,79
8 5,74
7 4,81
3,74
6 4,26
5 3,44 2,76
3,37
4
2,64
3
2,42 1,47
2 600 / 620
1,78
1
0,75 580 / 600

0 566 / 566
0 538 / 566
300
241 HP / RH outlet temperature [deg. C]
Pressure [bar] 175 538 / 538
Heat Rate Improvement vs Steam Conditions
(Single Reheat)
 Unit Size Growth
Size Flow Pressure Temperature
(T/H) (Kg/Cm2) (Deg.C)
30MW 150 63 490
60/70MW 260 96 540
110/120MW 375 139 540/540
200/210MW 690 137/156 540/540
250MW 805 156 540/540
500MW 1670 179 540/540
600MW 1950 179 540/540
660 MW 2120 255 568/596
700 MW 2310 255 568/596
800MW 2590 255 568/596
800 MW 2485 280 603/603
 Utility Boiler Technology Growth
30 SUBCRITICAL SUPERCRITICAL

NATURAL CONTROLLED ONCE 800 MW & above

CIRCULATION CIRCULATION THROUGH 300 ata,
25 700C/700C
25 660 / 800MW
Heat Rate Improvement %

250 ata,
568C/598C
500 MW 20.5
210/250 MW 500 MW 170 ata,
20 540C/568C
150 ata, 170 ata,
540C/540C 540C/540C 17.2
110/200 MW
130 ata, 15.7
14.6
15 540C/540C
12.5
60/100 MW
96 ata,
10 540C

0
1960 1970 1980 1990 2000 2010 2020
Year
 Rankine Cycle
The Carnot Cycle is theoretically most efficient, but it is having
practical difficulties.
For steam power plant, practical thermal cycle was suggested by
Rankine, called Ideal cycle or Rankine cycle.
3-3 : BFP raises pressure from p2 to p1
T
4 1 3-4 : Heating In feed heaters & economizer
T1 P1
4 -1 : Heating In boiler
3
1-2 : Work done in Turbine from p1 to p2
T2 3 2
P2 2-3 : Heat reduction in condenser

S
 Rankine Cycle Subcritical & Supercritical
Critical Point : 221
bar, 374C
 Supercritical condition
Pressure range

Sub critical : Below 221 bar

Super critical : 221 and above

3
 What is Supercritical Parameters

As the Fluid Pressure increases, Latent Heat

(Enthalpy of Steam Enthalpy of Water) reduces.

The point where Boiling Water and Dry Saturated

Lines meet so that associated Latent Heat is Zero,
this point is called Critical Point

CRITICAL is a thermodynamic expression

describing the state of a substance beyond which
45
there is no clear distinction between the liquid and 40
gaseous phase. 4.3 %
35
30

Improvement
In physical terms at this Pressure Water transforms
25
to Steam spontaneously. 20
15
Super critical Steam Parameters :
10

Parameters more than Critical State 5

0
500 MW 800 MW
Steam Pressure > 221.2 bar (225.5 kg/cm2(g))
Sub critical Super critical
170ata / 247ata /
Steam Temperature > 374.15C
537C / 537C 565C / 593C
 Why Supercritical Pressure

A Boiler Operating at a Pressure above Critical Point is called

Supercritical Boiler

Increase in Steam Parameters including Pressure and Main & Reheat

Temperature > 537C

Results in improvement in Cycle Efficiency

Results in significant improvement in Heat Rate
Boiler Types
 Types of Boilers

Application

Utility
(Power Generation)

Industrial
(Process Steam
Requirements)
 Types of Boilers

Steam
Application
Parameters

Subcritical
Utility
(Power Generation)

Supercritical

Industrial
(Process Steam Subcritical
Requirements)
 Types of Boilers

Steam
Application
Parameters

Subcritical
Utility
(Power Generation)

Supercritical

Industrial
(Process Steam Subcritical
Requirements)
 Types of Boilers

Steam
Application Circulation
Parameters

Natural Circulation

Subcritical Controlled Circulation

Utility
(Power Generation)
Once through

Supercritical Once through

Industrial
(Process Steam Subcritical Natural Circulation
Requirements)
Basic Data for Design

Boiler Parameters

Fuel Data

Site Data
Boiler Parameters
 Boiler Parameters

Boiler Parameters define heat duty of the boiler

Heat Fired = (SH + RH Heat duty) Efficiency

Coal Fired = Heat Fired HHV of Coal

Air Quantity = (kg. of Air per kg. of fuel) x (Qty. of Coal

Fired

Gas quantity = Fuel + Air - Ash

 Fuels Handled

Coal / Oil / Natural Gas in any combination

Lignite
Blast Furnace Gas / Coke Oven Gas / Corex Gas
Carbon Monoxide / Tail Gas
Asphalt
Black Liquor
Bagasse
Rice Husk
Washery Rejects
Wheat / Rice straw
Fuel Analysis - Coal
 Coal Properties Affecting Boiler Design

Type of Coal (Anthracite, Bituminous, Lignite)

Higher Heating Value
Volatile Matter
Moisture Content
Ash Content
Ash Characteristics
Hard Grove Index ( HGI )
 Characteristics of Typical Indian Coal

High Ash (35 50%)

Highly Abrasive (55 65%)

Medium Moisture (10 15%)

Medium Volatile Matter (18 24%)

Low Heating Value (HHV Kcal/Kg) (3000 3500)

Low Sulphur (0.2 0.5%)

 Problems Associated with Indian Coals

Inconsistent Coal Properties

Presence of Extraneous Matters in Coal
High Quantum of Ash with High % of Quartz
Highly Abrasive Nature of Coal Ash
Due to Low Sulphur Content - Extremly High Electrical
Resistivity of Ash
Low Heating Value of the Coal
Site Conditions
 Design Criteria

Control Range : 60% TMCR 100% BMCR

Flue Gas Velocity : 10 m/s

(SH / RH / ECO Sections)

Excess Air : 20% @ 100% BMCR

 Furnace Design

Furnace for Burning Pulverised Coal are Designed

To allow complete combustion by providing adequate retention
time.
To prevent formation of slag deposits
Temperature at entry to closely spaced SH/ RH sections is brought
down well below the lowest of the ash softening temperatures.
Adequate mass flow through water wall tubes so that tube metal
temperatures are well within allowable limits.
Ensuring the above in design stage will lead to high boiler
availability
 Furnace Design

Furnace for Burning Pulverised Coal are Designed

The possibility of slagging and fouling of heat transfer surfaces

is minimised even while firing worst type of fuels.
The furnaces of BHEL boilers are conservatively sized with low
heat release rates to ensure maximum output all the times.
Furnace design accommodates wider range of coals normally
experienced by Indian utilities
 Furnace Selection Criteria

NHI / PA
NHI/ EPRS
Q Fired / Volume
Burner Zone Heat Release Rate
Furnace Residence Time
Distance between Furnace Bottom-hopper & Lower Most
Fuel Nozzle
Distance between Upper Most Fuel - Nozzle & Bottom of SH
Furnace Outlet Temperature
Aspect Ratio
 Furnace Design

Furnace design is influenced by the following

factors
Fuel
Allowable heat loading
Surface (EPRS)
Plan area
Volumetric
Burner clearance
Burner zone Heat Release Rate
Burner loading
 Furnace Heat Loadings

EPRS Loading
Plan Area Loading
Volumetric Loading
Burner Zone Heat Release Rate
 Definition in Furnace Design

Furnace Width : Distance b/w centerlines of opposing Side Wall Tubes

Furnace Depth : Distance b/w centerlines of Front & Rear Wall Tubes
Plan Area : Furnace Width * Furnace Depth
Furnace Volume : cubage of Furnace within the Walls & Planes defined
under EPRS
Gross Heat Input : m * HHV + Sensible Heat (fuel,PA,GR,SA)
Net Heat Input : Gross Heat Input Losses
Net Heat Release Rate : NHI / EPRS
 Furnace Heat Loadings
Standard Supercritical Advanced USC
Description Unit
800 MW 800 MW

Heat Duty MkCal/h 1621.1 1512.3

Heat fired MkCal/h 1818.0 1699.9

NHI MkCal/h 1893.5 1785.0

NHI/PA loading MkCal/h/m2 4.52 4.26

EPRS loading 105Kcal/h/m2 1.80 1.48

Volumetric loading Kcal/h/m3 70479 65806

Advanced USC Boiler is designed for the conservative furnace loadings

 Effective Projected Radiant Surface (EPRS)

It includes total Projected Area of followings

Planes which passes through the centres of all Walls Tubes

Plane which passes through perpendicular to the Gas Flow

Surfaces of both sides of the Superheater and Reheater

 EPRS Heat Loading

Effects on Furnace Outlet Gas Temperature

EPRS Heat Loding = NHI / EPRS area
EPRS Values for
Coal fired Boiler = 0.2 0.325 mKCal/hr/m2.
Oil & Gas fired Boiler = 0.55 mKCal/hr/m2 (max.)
 Plan Area Heat Loading

PA Heat Loading = NHI/PA

Effects on
Maximum localised heat absorption rate
Maximum temperature of products of combustion

High PA heat loading Results

increase slag in coal fired Boilers
increase furnace wall temperature in oil and gas fired Boilers

PA Heat Loading value for

Coal fired Boiler = 3 4 mKCal/hr/m2
Oil & Gas fired Boiler = 5 mKCal/hr/m2 (max.)
 Plan Area Loading

Description Unit 67.5MW 120MW 210MW 500MW

Net Heat Input mKcal/h 189 319 542 1270

Furnace Plan Area m2 62.4 78 147 276

Firing Zone Surface m2 86.8 126.9 254.4 621.8

NHI / PA mKcal/m2h 3.03 4.09 3.69 4.61

NHI / FZS mKcal/m2h 2.18 2.51 2.13 2.04

 Volumetric Heat Loading

Volumetric Heat Loading = NHI/ Volume

Especially for fuel criteria about stabilisation for

combustion and low heating value gases.

Low value indicates an increase residence time for

combustion
Values for Normal fuels : 0.13 - 0.3 mKCal/hr/m3
 SH, RH, Eco - Arrangement

No. of SH Stages : 3 (Div. Panel + SH Platen + Finish SH)

No. of RH Stages : 2 (LTRH + Finishing RH)

No. of ECO stages : 1 (Economiser)

 SH, RH, & Economiser

Design criteria
Adequate heating surface to get rated SHO / RHO temperature
over control load for the range of coals.
Low gas velocity to minimise pressure part erosion
Proper tube spacing to prevent plugging and fouling of heat
transfer surfaces
Proper pressure part support and alignments
Pressure Part Arrangement 500 MW
SH Platen RH Front RH Rear LTSH Term
Assy = 27 Assy = 80 Assy = 80 Assy = 134
Ele = 513 Ele = 960 Ele = 960 Ele = 804
ST = 762 ST = 254 ST = 254 ST = 304.8
SL = 60.3 SL = 73 SL = 100 SL = 101
OD = 51.0 OD = 63.5 OD = 54.0 OD = 51.0

75731

SH Panellete LTSH
Assy = 48 Assy = 134

12211
Ele = 432 Ele = 804
ST = 3048 ST = 152.4
SL = 60.5 SL = 101
OD = 51.0 OD = 51.0

30
55

22276
Future Provision
Economiser
Assy = 228
Ele = 684
ST = 90
FD 18146.7 x FW 20701 6451.6
SL = 76.2
OD = 38.1

13258.8
Pressure Part Arrangement 210 MW
RH Front RH Rear SH Final LTSH
Assy = 65 Assy = 65 Assy = 131 Assy = 132
Ele = 6 Ele = 6 Ele = 3 Ele = 114.3
ST = 228.6 ST = 228.6 ST = 114.3 ST = 4
SL = 100 SL = 100 SL = 114.3 SL = 101/102
OD = 54 OD = 54 OD = 47.63 OD = 47.63

458.1 650
55863 55920
658.8 1100 1100 1254 763

LTSH Terminal
SH Platen

SH Finish
Platen SH
Assy = 32

RH Front

9750
RH Rear
Ele
12325

= 7+1
ST = 457.2
SL = 57

20
OD = 47.63

30

770
1518
LTSH

1923
LTSH
50

Economiser

1650
7593 1653 1829 Assy = 177

2080
Ele = 1 Economiser

770
ST = 85
SL = 130

2080
Economiser

885
OD = 44.5

34494

FD 11506.2 5791.2 8763

FW 15240
 Pressure Part Arrangement (Typical)

Main Steam
Some amount of Superheating
in WW itself
Higher SH Temperature after
SCW
Gas Temperature at the 2nd
Pass not adequate to heat the
SH Steam
Platen SH and Final SH are
provided
Reheat Steam
Hence RH is arranged in the 2nd
Pass as LTRH
Final RH is above the arch
 Challenges in Boiler Design

Fuel Flexibility

High Ash Indian Coals

Blending of Coals

Materials for High Temperature applications

Fabrication techniques for new Materials

Pollution Control
 Boiler Design

Coal Properties influence

The sizing of the Boiler Heat Transfer Surfaces

The Flue Gas Velocities

The size of Boiler Auxiliaries

 Effect of Fuel on Boiler Design

Coals vary widely in their properties - mine to mine

and seam to seam

Coal firing therefore presents a varying set of demands

before the boiler designer
 Effect of Fuel on Boiler Design

Specifying wide range of coal properties have the

following implications:
If pulverising/firing equipment is oversized, turn down is
limited and auxiliary power consumption will go up.
If furnace is oversized, attaining rated SH, RH outlet temperature
becomes difficult.
If pulverisers and airheaters are oversized to handle occasionally
high moisture coals, there will be excessive tempering air and
higher gas outlet temperature when handling normal moisture
coals.

.
 India Coal vs Foreign Coals
INDIA GERMANY USA CANADA AUSTRLIA

Coal A B C RUHR WESTERN ALBERTA NSW

Moisture % 15.0 12.0 12.0 8.5 16.0 4.0 8.0

Vol. Matter % 20.0 18.0 30.0 20.5 33.0 18.0 29.0

Ash % 40.0 40.0 30.0 8.0 8.0 8.5 15.7

Sulphur % 0.5 0.3 0.2 1.5 0.5 0.5 0.69

HHV Kcal/kg 3200 3500 4500 6700 5730 7600 6200

Coal Ash Kg/mKal 125 114 67 12 14 11 25

 Normally specified Coal Properties

Proximate Analysis
Ultimate Analysis
Calorific Value
Ash Constituents
Ash Fusion Temperatures
Hard Grove Index
YGP Index
Coal Analysis (Proximate) - Typical Indian Coals

Unit Design Worst Best

Coal Coal Coal
Fixed carbon % 22.0 20.0 25.0
Volatile matter % 21.0 19.5 23.0
Moisture % 15.0 16.5 14.0
Ash % 42.0 44.0 38.0
Total % 100.0 100.0 100.0
HHV Kcal/kg 3300 3000 3600
 Coal Analysis (Ultimate) -Typical Indian Coals

Unit Design Coal Worst Coal Best Coal

Carbon % 33.73 30.90 38.26

Hydrogen % 2.35 2.09 2.49
Oxygen(difference) % 5.48 5.00 5.96
sulphur % 0.37 0.36 0.38
Nitrogen % 0.75 0.85 0.57
Moisture % 15.00 16.50 14.00
Ash % 42.00 44.00 38.00
Hard Grove Index 55 54 56
 Ash Characteristics -Typical Indian Coals
Design Worst Best

Initial Deformation Temp. Deg.C 1150 1100 1200

Hemispherical Temp. Deg.C 1400 1400 1400
Fusion Temp. Deg.C 1400 1400 1400
Ash Analysis:
A SiO2 % 60.08 61.40 60.30
A Al2O3 % 29.50 28.50 29.80
B Fe2O3 % 4.10 3.90 4.70
B CaO % 1.70 1.93 1.57
B MgO % 0.75 0.92 0.59
B Na2O + K2O % 0.65 0.85 0.53
A TiO2 % 1.70 1.60 1.80
- P2O5 % 0.80 1.10 0.13
- SO3 % 0.27 0.31 0.25
 Ash Analysis

Provides indicators to

Slagging / fouling / deposition potential

Erosion potential

Corrosion potential
 Design Considerations for Indian Coals

Boilers
Conservative Furnace Heat Loadings
Lower Flue Gas Velocity Over Tube Banks
Plain Tube InLine Arrangement of Heat Transfer Surface
Optimum End Gaps to avoid Preferential Gas Flow
Erosion Shields / Cassette Baffles
Erosion Allowance for Leading Tubes
Cast Steel PF Bends & Ceramic Lined PF Bends
 Design Considerations for Indian Coals

Auxiliaries
Improved Sealing Arrangement in Airheaters
Extended Tube - Tubular APH
Low Speed Radial ID Fans
Lined Impellers of Radial Fans
 Boiler Water Circulating Systems

Choice of Circulating system depends on Operating Pressure

The density difference between water and steam-water mixture provides the
driving force for the Circulating fluid to overcome the frictional drop in the Furnace
Water Walls.
At Lower Pressures the density difference is adequate to ensure circulation.
Natural Circulation.
Higher pressures units warrant pumps to ensure circulation. Natural
circulation not adequate.
Controlled Circulation.
At Supercritical Pressures, 100% steam at Water Wall outlet, and no Water is
there to be separated and circulated.
Once through.
If Water circulation is not envisaged in Subcritical Pressures Once through.
 Circulation Boiler Natural Circulation
Natural Circulation Operating Pressure

Circulation through WW by Thermo-Siphon Effect The Density difference between Water & Steam
provides the driving Force for the Circulating Fluid
 Natural Circulation

Density difference between Water & Steam driving Force

Net Hydro Head to overcome the System Resistance

Mostly Constant Flow through WW Tubes

Plain WW tubes to reduce Pressure Drop

CR = 4 to 8

210 MW, 250 MW, 270 MW, and Industrial Boilers

 Circulation Boiler Controlled Circulation
Operating Pressure Controlled Circulation

Higher Pressures units warrant Pumps to ensure Circulation through WW by Thermo-Siphon Effect
Circulation (Natural Circulation not adequate) supplemented by Pumps
 Controlled Circulation

Higher Pressures (>150 kg/cm2) reduced Density Difference

3/4 Circulation Pumps to assist in developing Head to

overcome System Resistance

Flow thro WW tubes varied by Orifices according to Heat

Absorption Rates

Ribbed / Rifled Tubes used

CR = 2 to 4
 Circulation Boiler
Natural Circulation Controlled Circulation

Circulation through WW by Thermo-Siphon Effect Circulation through WW by Thermo-Siphon Effect

supplemented by Pumps
 Advantages of Controlled
Circulation

Presentation title - P 80
 Advantages of
Controlled Circulation vs Natural Circulation

Positive Circulation Before Applying Heat

Positive Flow in Low Heat Absorbing Tubes

Uniform Drum Shell Temperatures During Start-up and Load Change

Rapid Start-up Time

Quick Access to Furnace

Rapid and Uniform Circulation for Chemical Cleaning

Smaller Diameter Tubes Yield Lower Metal Temperatures

Uniform Expansion Minimizes Stress and Prolongs Unit Life

Presentation title - P 81
 Advantages of Controlled
Circulation

Presentation title - P 82
 Advantages of Controlled
Circulation

Presentation title - P 83
 Start-Up and Shut Down

Maximum Drum Shell Temperature

Change
Controlled Circulation Natural Circulation
(shrouded drum)

400F per hour (222 C) 200 F per hour (111C)

Controlled Circulation Drum Designs

Allow Fast Start-Up and Shutdowns to Minimize Downtime

Presentation title - P 84
 Circulation Boiler Drum Type

Steam (Wet) Generation takes place in Furnace Water Walls

Drum is the fixed Evaporation end point, and hence no Superheating
happens in Furnace Water Walls
Steam-Water mixture separation to Dry Steam takes place in the
Drum
Separated Water mixes with incoming Feed Water, and goes to
Circulation System via the Downcomer
 Once Through Type Boiler
Operating Pressure Once Through Type

Mass Flow Rate thru all Heat Transfer Circuits from Eco Inlet
Super Critical Once Through
to SH Outlet is kept same (no circulation in Water Walls),
and
except at Low Loads wherein Recirculation is resorted to
Sub Critical Once Through
protect the Water Wall system
 Once Through Boiler Separator Type

The Water in Boiler is Pressurized by Boiler Feed Pump

Heat absorbing surface is one continuous Tube
hence called once through boilers.
Sensible Heat & Latent Heat is added in Feed heaters, Economizer, and Furnace
Tubes, and Steam Generation takes place in Furnace Water Walls
Evaporation end point happens within the Water Wall itself, leading to some amount
of Superheating in the Water Walls

Recirculation Mode in the Lower Loads

Steam - Water separation takes place in the Separator during the Recirculation mode
Once through Boiler has Separator.
There is no Drum.
 Once through Boiler Flow Diagram
Live steam
No fixed Evaporator End Point

No Thick Wall Components Superheater

Increased Mass Flow through Water separator

Spiral Water Wall Tubing, Economizer

or

Improved Heat Transfer

through Rifled Vertical Wall
Tubing. FW-
Pump

Evaporator
Feedwater
 Once through Boiler - Supercritical

All Supercritical Boilers are once through

No Wet Steam at the Supercritical Pressures.

At Supercritical Pressures the Sensible Heat is added in Feed

heaters, Economizer, and Furnace,
until Water attains Saturation Temperature and flashes
instantaneously to Dry Saturated Steam

And then Super heating commences

 Once through Boiler

Advantages:
Better suited for sliding pressure operation
Steam temperature can be maintained over wider load range
under sliding pressure

Quick response to load changes

Shorter start up time
Higher tolerance to varying coal quality
Suitable for sub critical & super critical pressures
Heat Absorption by various types of Boilers
Supercritical Once Through
 Sliding Pressure Supercritical Design
Pressure and Enthalpy Variations vs. Type of Circulation Design
Economiz SUPERCRITICAL FLUID
er
Waterwall
s Superheater
SuSUPERCRITICAL
percritica FLUID
l Boiler
CRITICALPRESSURE
CRITICAL PRESSURE
PRESSURE K g /cm 2 (ps ia )

226
(3208)

Economiz
er
201 Eco omizer Waterwalls
(2865) Wa Superheater
A TER Controlleterwalls
d Circulati Superheat e

SAT U
on r
T ED W

STEAM &

RATE
WATER WATER
STEAM & STEAM

D STE AM
SATURA

WATER
MIXTURE
127 MIXTURE
Waterwalls
(1800)
Economiz Examples of Steam by Weight
er
Thermal C
25%
irculati on Superheater
100%
0%

Increasing Enthalpy ( h )
Enthalpy Kj/Kg (BTU/lb)
Presentation title - P 96
 Sliding Pressure Supercritical Design
Enthalpy Variations vs Pressure and Boiler Load
SUPERCRITICAL FLUID
Full Load
Operation
Economiz
er SUPERCRITICAL FLUID
Waterwalls
Superheater
CRITICALPRESSURE
CRITICAL PRESSURE
PRESSURE K g /cm 2 (ps ia )

226
(3208)

Economiz
er
201 Eco omizer Waterwalls
(2865) Waterwalls Superheater
A TER
Middle Lo Superheat e

SAT U
ad r
Operation
T ED W

STEAM &

RATE
WATER WATER
STEAM & STEAM

D STE AM
SATURA

WATER
MIXTURE
127 MIXTURE
(1800) Waterwalls
Economiz Examples of Steam by Weight
er
Low Load
25% Operatio n
Superheater
100%
0%

Increasing Enthalpy ( h )

Enthalpy Kj/Kg (BTU/lb)

Presentation title - P 97
Features Once through Boilers
 Features of Once through Boiler

To ensure adequate Mass Flow rates through Water Wall,

Spirally Wound Water Wall Tubes are used.

Start-up and Low Load system up to 30-40% BMCR

required.

Feed Water Quality requirements are very stringent.

Ideally suited for Sliding Pressure operation due to the

absence of Thick Walled components
 Features of Once through Boiler

Once through Flow through all sections of Boiler

Economiser, Water Walls & Superheater

Boiler Feed Pump provides the driving Head

Suitable for Sub critical & Super critical pressures

 Requirements of Once through Boiler

Stringent water quality

Sophisticated control system

Low load circulation system

Special design to support the spiral furnace wall weight

High pressure drop in pressure parts

Higher design pressure for components from feed pump to

separator
 Once Through Boiler

Major differences from Drum type Boiler :

RH Low Temperature Section

Separator

Evaporator system

Low Load Circulation system

Low Temperature Reheater
 Pressure Part Arrangement (Typical)
Main Steam
Some amount of
Superheating in WW itself
Higher SH Temperature after
SCW
Gas Temperature at the 2nd
Pass not adequate to heat
the SH Steam
Platen SH and Final SH are
provided
Reheat Steam
Hence RH is arranged in the
2nd Pass as LTRH
Final RH is above the arch
Separator
 Separator
Separates steam and
water during the
circulating mode
operation
Runs dry during once-
thru flow mode
Smaller in size
compared to drum in
a drum type boiler
Sliding Pressure Supercritical Design
INTEGRAL SEPARATOR and STORAGE TANK

AXIAL STEAM OUTLET

A A STEAM
OUT
TANGENTIAL OUTLETS
(In Lieu of Axial Outlets)
View A - A
IMMERSION TUBE

BAFFLE

B B
MIXTURE
IN

TANGENTIAL INLETS
View B - B
C ROOF TUBES
5 - 70 TYP.

WATER
OUT
D
VORTEX
BREAKERS View C - C
2 OR 4
UPPER LEVEL TAP

Water
Level
Range
C C
LOWER LEVEL TAP

LOWER LEVEL TAP

ALTERNATE:
TANGENTIAL WATER
AXIAL WATER OUTLET OUTLET
Arrangement of Separator & Collecting Vessel
Evaporator (Water Wall) System
 Evaporator (Water Wall) system
Spiral Water Wall Vertical Water Wall

Lateral Heat Flux Lateral Heat Flux

Profile Profile
Spiral Furnace Arrangement

Reduced number of Tubes,

with higher Pitch for the
same perimeter of Furnace,
when compared to Vertical
Wall
Due to lesser no of Tubes,
Increased Mass Flow
through Tubes
Each Tube through each
Wall, through all Heating
Zones
 Evaporator (Water Wall) system
Spiral Water Wall
Tubes spirally wound around the furnace
Each tube forms a part of each furnace wall, and
goes through is each heating zone
Water in each tube gets the same amount of
(uniform) heating, leading to almost uniform
flow through each tube
Fluid Temperature variation at the outlet of
different Tubes is minimum
Performance wise inherently better, without
requiring any additional provisions to obtain
uniform flow and temperature between tubes
Furnace walls are not self supporting as the
tubes are inclined
External support strap system is needed to
transfer the loads
Fabrication and installation is difficult
Vertical Water Wall
Tubes laid vertically along the furnace height
Each tube forms part of the particular zone of
the particular furnace wall
Water in Each tube gets a different heating,
leading to different flows through each tube
Fluid Temperature variation at the outlet of
different Tubes is large
Performance wise inferior, and requires
additional provisions to obtain uniform flow
and temperature between tubes
Furnace Walls are self supporting with
traditional furnace wall support system
No external supports are required to transfer
the loads.
Fabrication and installation is easy
 Evaporator (Water Wall) system
Spiral Water Wall
Less Number of Tubes required to cover the
perimeter of the Furnace, hence the mass flow
rate through the tubes high. (Higher OD Tubes).
Plain Tubes used as Mass Flow per tube is High
Requires intermediate furnace wall transition
from spiral to vertical. (spiral wall cannot be
continued into the arch zone and horizontal
pass)
Water Wall Pressure Drop due to plain tubes
which are longer due to the Spiralling.
Very complex Windbox
Welding required in the Four Corners also.
Not easy to identify the Tube Leaks
Suitable for any capacity.
Vertical Water Wall
Higher number of Tubes required to cover the
perimeter of the Furnace, hence the mass flow
rate through the tubes low. (Lower OD Tubes)
Rifled Tube used as the Mass Flow per tube is
less
Elimination of intermediate furnace wall
transition header
Water Wall Pressure Drop due to Orifices and
Rifled Tubes
Simple Windbox Openings
Less welding in the Lower Furnace Wall
Easier to identify and repair tubes leaks
Limited to larger capacity units (>700 MW
depending on fuel)
Low Load Circulation System
 Low Load Recirculation System

At Lower Loads, Water Flow corresponding

to the Load is not enough to adequately cool
the Tubes, as the Combustion Zone
Temperature does not decrease proportional
to the decreasing Load.
So to ensure adequate cooling of the tubes,
a particular minimum Water Flow should be
always ensured in the Water Walls - and at
no point the Water in WW shall be less than
this minimum Water Flow.
This Load corresponding to the minimum
Water requirement is called minimum OT
Load.
Start Up Systems
 Once Through Boiler

Low Load Circulation system

The excess Flow over the once-thru Flow separated in

Separator and

Returned to the Condenser thru a Heat Exchanger

or

Recirculated back to the Boiler directly by the dedicated

Circulating Pump
 Start Up system

To maintain Minimum once thru flow in Evaporator Tubes

To load the Boiler and provide Steam to Turbine
Smooth & Controlled Pressurizing and Warming-up of the
Boiler vital components
Quick and Smooth Start up
Low Load operation
Wet-Dry Transfer
 Types of Start Up System

Simplified Drain Discharge System

Base Load units

Low capital cost

Startup Heat Loss

Startup System with Recirculation Pump

Minimum startup Heat Loss

Less startup time

Recirculation Pump

Startup System with Heat Exchanger

Start Up System with simplified Drain Discharge
SH

Separator
C

Flash

Tank
W
W
HWL
ECO

To Condenser

Deaerator
C
HPH
WL
BFP
Start Up System with Heat Exchanger
 Low Load StartUp system with Circulating Pump

Below min OT Load

Steam Water mixture is obtained at
the end of Water Wall
Steam is separated in the Separator
and sent to SH
Water separated is recirculated using
Recirculation Pump along with the
Feed Water
Thereby the heat absorbed by the
Water in the Water Wall is used
effectively
Above min OT Load
Superheat Steam is obtained at the
end of Water Wall
Separator runs dry, acting as a link
Below OT Load pipe to SH Above OT Load
Operation - Recirculation
Operation - OT Mode
Mode
Start Up system with Recirculation Pump
in Recirculation Line
Start Up system with Recirculation Pump
in Main Line Bypass
SH

Separator
WW
C

Flash

Tank
ECO
HWL

To Condenser
C

Deaerator

HPH
C

BFP
Start Up Drain System
 Warm up System

Separator

Storage Tank

To Desuperheater
#1
Warm up Control Valve

Bypass around Valve

Orifices (3-4 Locations)

Flash Tank

Economizer Outlet
Flow
Feedwater Flow
Dp
Once through Supercritical Boilers

Major Components
Once through Supercritical Spiral Wall Boiler
Vertical Separator
Spiral to Vertical Transition Intermediate Header
Vertical Wall Tubes

Vertical Tube Forgings

Spiral Wall Tubes

Spiral Tube Forgings

Spiral to Vertical Transition Intermediate Header
Spiral Furnace Transition Area Load Transfer

Support
Fingers

Spiral Wall Support

Spiral Wall Furnace Burner Panel
Once Through Supercritical Vertical Wall Boiler

Unit Mwe : 750

Max. Continuous Rating : 5,560,000

lb/hr (2522 t/hr)

SH Outlet Press : 3800 psig (262 bar)

SH Outlet Temp : 1054F (568C)

RH Outlet Temp : 1105F (596 C)

Fuel : Sub-bituminous (PRB)

 Vertical Wall Furnace
Front Wall Side Wall
Rifled Tubing Rifled Tubing Screen Tubes
Smooth Tubing
Hanger Tubes
Smooth Tubing
Arch
Rifled Tubing 1 1/4 (31.8 Mm) OD Tubing

1 1/8 (28.5 Mm) OD Tubing

Side Wall
Rifled Tubing

Rear Wall
Rifled Tubing
Front Wall
Rifled Tubing

Smooth Tubing
from this Elevation
All Walls
Vertical Wall Furnace Windbox

Only a few Bends at the Top

& Bottom

Straight Tubes
 SubCritical Vs SuperCrtical
Particulars Sub critical Super critical
Type Drum type Once through Once through
Operating pressure Below 221.1 bar Below 221.1 bar Above 221.1 bar
No boiling process.
Steam generation Boiling (Two phase Boiling (Two phase
Phase change is
process heat transfer) heat transfer)
gradual.
Thick walled Thick walled drum is
Smaller vertical separators provided
component provided
Start up and load
Base Better start up and load change rates
change rates
Water wall Generally spiral wall.
Vertical
construction Vertical wall for higher capacity
Higher loads: Once through
Circulation Circulation at all loads
Lower loads : Circulation
Water quality Base More stringent requirements
 Comparison of Parameters
Parameter Unit 500 MW 800 MW
Main Steam Pressure ATA 170.0 247.0
O
Main Steam Temp C 537.0 565.0
Main Steam Flow T/Hr 1515.0 2340.0
Reheat Pressure ATA 40.5 56.6
O
Reheat Temperature C 537.0 593.0
Reheat Flow T/Hr 1335.0 1940.0
Cold Reheat Pressure ATA 45.0 61.5
O
Cold Reheat Temp C 336.0 348.0
O
Final FW Temp C 253.0 290.0
BMCR T/Hr 1625.0 2600.0
Thank You