oilers’ Advanced Constructive Solutions for the Ultra ... power plant arrangement with horizontal steam boiler has been developed. If the solutions under consideration are used,

International Journal of Applied Engineering Research ISSN 0973-4562 Volume 11, Number 18 (2016) pp 9297-9306

© Research India Publications. http://www.ripublication.com

9297

Steam Boilers’ Advanced Constructive Solutions for the Ultra-supercritical

Power Plants

Nikolay Rogalev, Vadim Prokhorov, Andrey Rogalev, Ivan Komarov and Vladimir Kindra

National Research University “Moscow Power Engineering Institute”

Krasnokazarmennaya str. 14, 111250, Moscow, Russian Federation.

Abstract This paper presents possible construction solutions to new

steam boilers for ultra-supercritical power plants. At the current

stage of development science and technology, one of the main

problems with the transition to ultra-supercritical steam

parameters is that a nickel-rich refractory and high temperature

resistant steels and alloys prevail on weighting structure of

materials for the ultra-supercritical power plants. Two

advanced versions of boiler units’ arrangement allowing to

reduce the length of main steam piping and reheat piping are

selected: horizontal and M-type.

Optimal gas path geometry, arrangement of heating surfaces,

slag removal system has been designed and the length of main

steam piping and reheat piping has been estimated for the

considered solutions. When passing to horizontal arrangement,

the flow structure in boiler unit circuit changes significantly.

Therefore, for the given version the extension study of furnace

chamber aerodynamics, based on 3D modeling, was conducted.

The burner units arrangement was developed as well as the ash

hopper design that affects greatly aerodynamics.

New power plant arrangement with horizontal steam boiler has

been developed. If the solutions under consideration are used,

the length of the main steam piping could be reduced from 150

m to 70 m compared to tower-type arrangement.

Keywords: arrangement, horizontal boiler, ultra-supercritical

steam parameters, 3D modelling, furnace chamber

INTRODUCTION

The thermal efficiency improvement of a power plant depends

on an increase in the energy price and an attempt to decrease

the power generation cost as well as on the global climate

change threat resulting from a rapid growth of greenhouse gas

and pollutants emission into the atmosphere in the last 50 years.

In the foreseeable future, the fossil fuel will remain crucial in

power generation. Combined cycle power plants (CCPP) hold

leading position among the possible means of efficiency

improvement for the fossil-fuel power generation. The increase

of efficiency to 55-60 % has been obtained due to the increase

of steam initial temperature to 1500 ºС upstream of the gas

turbine. In the meantime, the initial steam temperature for

majority of the steam turbine units (STU) stands at 540-560 ºС.

As a result, the efficiency of steam turbine power plant (STPP)

stands at the level of 38-39 %. The efficiency of main and

auxiliary equipment of STPP is close to limiting value, that

prevents substantial efficiency improvement of the unit due to

further upgrading of equipment.

There are high chances that coal will remain one of the key

types of fossil fuel for thermal power plant (TPP) due to its

considerable reserves and low cost. Its share growth is

suggested in fuel balance. The popular means of emission

abatement as well as purification, utilization and disposal of

combustion products at the coal power plants are extremely

capital-intensive and energy-consuming. In most cases, they

double plant construction costs and consume about 10% of

energy output. Therefore, the efficiency improvement of the

energy production, leading to the polluting emissions’ decrease

due to less fuel consumption, is of key importance in coal

generation.

Thus, the raising of initial steam parameters is a key method of

the efficiency substantial improvement of the energy

production at STU.

At present, the development of the most advanced ultra-

supercritical power plants is in progress. Steam initial pressure

upstream of a turbine reaches 35 MPa, and its temperature is

equal to 700-720 ºС. The specified technology has not yet

reached the industrialization stage. Intensive work in this

direction is in progress in EU, USA, Japan and China. They

adopted special programs, determining the principal directions

for the development of ultra-supercritical power plants.

Steam superheat to 700-720 ºС with simultaneous raising of

pressure to 35 MPa allows to achieve power plant efficiency

factor about 49-51 % [1-3], that is close to efficiency factor of

CCPP with lower-temperature (about 1100 ºС) gases for the

present gas turbine units. Fig. 1 shows steam-turbine

technology evolution in relation to steam initial parameters,

corresponding values of the power plant efficiency and

construction material types used for high-temperature elements

production [4, 5].

Figure 1: STPP efficiency improvement at time scale with

class indication of materials in use



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Adoption of technology concerned directly depends on

generation of new refractory and high temperature resistant

materials, which would provide continuous safe operation of

equipment at high temperatures and pressures of a steam.

Note that the generation of new materials with required

properties provides only technical capability of practical

realization of power plant with ultra-supercritical steam

parameters. Not least important is the cost of such power

plants. It will be determined by the cost of high temperature

resistant materials in use. Change in price of the used

construction materials is shown in Fig. 2 [6], suggesting that

materials in operation at a temperature about 700 ºС are

presently more expensive than those used in units developed

with ultra-supercritical steam parameters.

Figure 2: Change in price of materials depending on working

temperature

Fig. 3 shows weighting structure of the used materials,

classified at different levels of initial parameters. [7].

Represented data testifies that when passing from supercritical

to ultra-supercritical steam parameters, a nickel-rich refractory

and high temperature resistant steels and alloys prevail on the

list of useable construction materials.

Figure 3: Weighting structure of materials in use depending on

steam initial parameters

Owing to high cost of the high temperature resistant materials

and their essential share within metal expenses, one of the key

directions for the development of power plants with ultra-

supercritical steam parameters is working-out of technical

solutions allowing to decrease the number of used expensive

steels and alloys while power plant equipment manufacturing,

therewith reducing the capital costs.

Fig. 4 shows diagram of distribution of high temperature

resistant materials over the main elements of power plant with

ultra-supercritical steam parameters [4]. It is apparent that most

of the nickel alloys are applied for high temperature main steam

and reheat piping. Therewith, about 20% of the cost of ultra-

supercritical power plant fall to share of steam-piping system

[6].

Figure 4: Conditional diagram of distribution of refractory and

high temperature resistant materials over the main elements of

power plant

Actually, when using tower-type boiler (Fig. 5), the length of

the main steam piping may be 150 m and more at power plant

with a capacity of 660-1000 MW. In this regard, the vital task

is to shorten the distance between the superheat outlet headers

and the inlet port of steam turbine.

Figure 5: Example of standard steam turbine and tower boiler

arrangements

It follows, that technical solutions, allowing to reduce the total

length of these lines, will considerably cheapen the

construction of power plants with ultra-supercritical steam



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parameters. The length of main steam piping and reheat piping

is determined by design of the main equipment – boiler and

turbine – and their relative position.

POSSIBLE CONSTRUCTION SOLUTIONS FOR BOILER

UNITS WITH ULTRA-SUPERCRITICAL STEAM

PARAMETERS

Considering that shortening of the main steam and reheat

piping appears to be the relevant objective in the result of

transition to a new working temperature level, developments in

this area were carried out back in the middle of the 20th century.

Boiler “PK-37” can be mentioned as an example of the first

arrangement solution. It was developed in the 60s at Machine

Engineering Plant in Podolsk (Fig. 6 [8]) and made as inverted

conventional arch boiler.

Figure 6: Inverted (U-shaped) boiler PK-37 arrangement:

sectional drawing:

1 – economizer; 2, 4 – transition section; 3, 5 – primary

superheater; 6 – convective superheater; 7 – platen superheater;

8 – lower radiant section; 9 – upper radiant section;

10 – division wall; 11 – turning chamber wall

At present time, Alstom Power Company works on a similar

project of power plant (Fig. 7).

Figure 7: Power plant arrangement with inverted boiler by

Alstom Power Company

Horizontal vertical tube boiler with horizontally-oriented

furnace chamber (Benson boiler) may serve as an example of

another approach implementation (Fig. 8).

Figure 8: The sectional drawing of horizontal Benson boiler

arrangement

Originally, the given solution was engineered for CCPP by

Siemens, but then the project was reoriented to building of a

power plant with steam parameters equal to 35 MPa, 700/720

ºС. Example of the power plant arrangement with such boiler

unit is shown in Fig. 9 [9].

Figure 9: The arrangement of power plant with horizontal

boiler



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Although both versions provide considerable length reduction

of high temperature pipelines, they have some disadvantages,

which make their maintenance difficult. Therefore, inverted

arrangement (Fig. 6 and Fig. 7) impedes combustion of coal

fuel that is the most perspective for ultra-supercritical power

plants. This is due to the fact that ash hopper is in the area of

primary superheater, and successive passage of two corners by

combustion products will inevitably deflect current lines,

potentially throwing them in ash hopper, what can lead to heat

loss and extra difficulties in providing bottom ash-handling

system. An additional point to emphasize is that inverted

conventional arch boiler has burner units located in the upper

part of boiler plant, which complicates the supply of pulverized

coal.

The horizontal arrangement of boiler unit does not have the

above-mentioned disadvantages, however, in this case ash and

slag removal is also more complicated than for standard design.

In order for ash to be removed effectively from boiler gas duct

(Fig. 8 and Fig. 9) lower furnace wall shall have a slope of 50-

60º, resulting in high-elevation furnace and terminal hea-ders,

what leads to increasing length of high temperature pipelines.

Creative approach to solving the problem of shortening the

main steam piping was made by the Chinese specialists. In

cooperation with Siemens Company, they developed a project

of split-level steam turbine plant, consisting of high-potential

(higher-level) and low-potential parts of STP (Fig. 10) [10].

The given steam turbine is designed for a power plant having a

capacity of 1350 MW with steam initial parameters equal to 30

MPa and 600 ºС. The distinctive feature of the given project is

the double resuperheat with the following parameters: 9.17

MPa/620 ºС during the first reheat and 2.25 MPa/610 ºС –

during the second reheat. Feed water temperature is equal to

310 ºС, condenser backpressure is 4 kPa. At these parameters,

efficiency factor is 48.92 % [10].

Figure 10: Split-level arrangement of steam turbine

In this case, sections of connecting steam pipelines are

considerably shortened and thus, pipe manifold cost declines

and loss of pressure reduces. However, the arrangement suffers

from a number of shortcomings. The main of them are the

necessity of steelwork hardening to install high-level turbine,

the necessity of applying of two generators, duplication of

control and lubrication system and other systems, maintenance

and repair complexity. All of these require technical and

economic analysis at subsequent stages of project

implementation.

Thus, although there is some development basis on the given

subject, the issue of optimal arrangement solution for power

plant boiler unit with ultra-supercritical steam parameters

remains relevant.

In order to beef up knowledge about possible construction

solutions concerning arrangement of steam boilers, thermal,

aerodynamic and design calculations of boiler unit different

versions were performed. Projecting was conducted for

Kuznetsk coal-fired (type D) power plant with a capacity of

1000 MW. These are critical parameters of the power plant

engineered: initial temperature and pressure are equal to 710 ºС

and 35 MPa respectively, single reheat is applied to 720 ºС at

a pressure of 7 MPa, feed water temperature is equal to 315 ºС,

condenser backpressure is 4 kPa. At these parameters, power

plant net efficiency is 51 %.

Following the elaboration, overall dimensions of steam boilers

were calculated. According to this information, a study of

possible arrangement solutions was undertaken. Table 1 shows

construction diagrams and length of pipelines for different

versions.



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Table 1: Alternative arrangement solutions for boiler and steam turbine plants with ultra-supercritical steam parameters

Conventional arch boiler, horizontal arrangement T-shaped boiler, horizontal arrangement

Live steam piping length: 53.8 m;

Reheat steam piping length: 51.9 m;

Total length: 105.7 m.



Total length: 150 m.

Conventional arch boiler, standard arrangement T-shaped boiler, standard arrangement






Total length: 187.8 m

Conventional arch boiler, inverted arrangement

(U-shaped)

T-shaped boiler, inverted arrangement



Total length: 80 m.


Reheat steam piping length: 50 m;


Tower-type boiler Horizontal boiler






Total length: 63 m.



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It follows as a consequence that change in boiler design

arrangement significantly affects the length of the main steam

piping. Among the considered versions, the maximum length

of pipelines is typical for tower boiler, and minimum length of

pipelines is typical for horizontal boiler. As a whole, inverted

arrangements appear perspective enough. For this reason, the

subject of further detailed research was focused on the given

conceptions.

M-TYPE BOILER UNIT WITH ULTRA-SUPERCRITICAL

STEAM PARAMETERS

As was shown, inverted arrangements provide considerable

length reduction of main steam piping and reheat piping.

However, it is reasonable to suppose that T-shaped

arrangement is the most favorably priced solution among all

inverted arrangements considered, since the burning of a large

amount of coal (incl. low-ash coal), the problem of erosive

wear of the heating surface becomes of key importance.

However, it is obvious that T-shaped arrangement requires

major optimization.

M-type boiler unit is the result of T-shaped boiler design

review. Structural shape of M-type boiler is shown in Fig. 11.

Applying of inverted furnace chamber assumes top-bottom

flow of flue gases. Burners and nozzles are located in the upper

third part of furnace, and the flue gas outlet – in its lower third

part. Such furnace chamber design allows to locate live steam

and reheat steam terminal headers significantly lower than in

standard boilers because of lower location of sloping gas ducts.

The primary and secondary superheaters are spaced between

two opposite sloping gas ducts, that provides for terminal

headers location nearly on the same level.

Figure 11: M-type boiler with ultra-supercritical steam parameters

Boiler is designed with a single furnace, turbine is installed

near boiler along the rear furnace wall, down and convection

passes. The proximity of terminal headers and turbine allows

to reduce the length of steam pipelines and total metal

consumption of a boiler. Superheater and reheater outlet

headers are designed underneath the sloping gas ducts, not in

the upper part.

The given solutions make it possible to decrease the installation

level of terminal headers from 70 m to 20 m, that provides the

total length reduction of steam pipelines 2.5-3 times compared

to inverted conventional arch arrangement of a boiler with the

same capacity.

Location of burners at the top of boiler furnace with flue gases

output at its bottom predetermines fuel particle residence time

expansion in furnace chamber, that leads to an increase in

degree of fuel burn-up and, as a result, to reduction of

combustibles content in slag and flue ash, i.e. combustible loss

is reduced.

We may refer to the advantages of М-type arrangement those

fact that its applying allows to reduce fly ash with flue gases

approximately by 15 % due to their separation upstream of gas

port and further flow through ash hopper, followed by

reduction of fly ash wear of the convective heating surfaces.

Compared to inverted conventional arch and tower-type

arrangements, the installation area of platen superheaters is

expanded as well.

Furnace chamber dimensions of М-type boiler in horizontal

section are 14640 × 26840 mm. Pulverized coal combustion

takes place within vertical vortex system. Sixteen pulverized-

coal burners with opposite-fired shifted arrangement are

located at two levels. Secondary air nozzles (16 pcs) are also

located at two levels: nozzles of the second level are installed



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downward, and nozzles of the first level are located opposite

and upward. Secondary air nozzles (8 pcs) with opposite

shifted arrangement are located at one level upward. Burners

and nozzles are located in such a way that every set of burners

and nozzles (2 pulverized-coal burners, 2 secondary air nozzles

and tertiary air nozzle) would create 2 opposite vertical

vortices. Pulverized-coal burners and air nozzles are installed

on the front and rear walls. Pulverized-coal combustion takes

place in vertical-horizontal tangential flame (Fig. 12). Eight

pairs of vertical vortices are formed on all fronts.

Figure 12: Straight-flow burners and nozzles arrangement at

M-type boiler with ultra-supercritical steam parameters in even

vertical sections of the furnace

Boiler is designed for bottom-ash removal: at the elevation of

11.15 m front and rear walls taper off at an angle 52º, forming

hopper work points.

At the bottom of furnace chamber, flue gases are divided into

two streams, either of which turns to sloping gas duct. Such gas

stream movement contributes to additional separation of ashes,

reducing fly ash. On sidewalls before turn to sloping gas ducts,

furnace walls form aerodynamic noses providing more

proportional sweep of high pressure and low pressure platen

superheaters.

Divided into two streams at furnace chamber outlet, flue gases

pass through sloping gas ducts. In the left sloping gas duct in

the direction of gases, 1st and 2nd stages of high pressure platen

superheater (live steam) are located in line. In the right sloping

gas duct in the direction of gases, low pressure platen

superheater (reheat steam, 2nd stage) and low pressure

convective superheater (3rd stage) are located in line.

Downstream of sloping duct, gases enter convective passes. In

the left convective pass in the direction of gases, five

economizer tube banks are located. In the right convective pass

in the direction of gases, regulated stage of low pressure

convective superheater (1st stage) and four economizer tube

banks are located. Stringed tubes of economizer and outlet

tubes are located in turning chamber. Due to different number

of economizer tube banks at left and right part of down taking

duct, identical heat absorption can be achieved in both gas

ducts. Then flue gases pass three re-generative air heaters in a

parallel way.

Boiler is designed as gas-tight. The gas-tightness of furnace

chamber is provided by membrane walls. Also walls of sloping

gas ducts, turning chamber and convective pass, and

economizer tube banks are screened with membrane panels.

According to calculations, boiler gross efficiency is 93.07 %,

and estimated fuel consumption – 91.13 kg/s.

HORIZONTAL BOILER WITH ULTRA-SUPERCRITICAL

STEAM PARAMETERS

The second long-term construction solution to reduce the

length of steam pipelines is the horizontal arrangement of a

boiler unit. In this regard, the detailed research and engineering

study of the given version were conducted. Engineering study

of horizontal steam boiler was also conducted for power plant

with ultra-supercritical steam parameters having nominal

capacity of 1000 MW.

Combustion products flow over the heating surface is ordinary.

Flue gases downstream of furnace, successively pass over

platen superheater, primary superheater, the second and the

first stages of reheater, economizer and regenerative air heater.

Principal organization scheme of gas circuit with indication of

temperatures is shown in Fig. 13.

Compared to classic arrangement, the developed boiler unit has

a distinctive feature of slag removal arrangement, with ash

hoppers located along the full length of furnace chamber, what

exerts a significant impact on flow structure in boiler furnace.

In the course of boiler unit design research, three tasks

concerning furnace volume were completed: optimal position

in terms of flow structure and angle of slope for burner units

were determined; new construction of ash hoppers was

presented, providing minimum draft-pressure drop; unique

design of gas duct turn after furnace chamber was worked out,

providing minimum velocity profile variation after turn to

reduce non-uniform heat flow distribution over economizer

heating surface. In order to tackle the given issues 3D modeling

technologies were applied. Software application ANSYS CFX

was used for modeling.



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Figure 13: Principal organization scheme of gas circuit of horizontal boiler

In terms of numerical study, different structural variations of

the horizontal boiler were examined. The following parameters

varied: turn shape, furnace chamber dimensions, burner units

location, ash hopper shape. Fig. 14 shows two versions of

horizontal boiler with different shape of ash hopper and burners

location.

Figure 14: 3D models of horizontal boiler versions

Experimental modelling of the combustion process in furnace

is very expensive. On the other hand numerical investigation of

such complicated process requires validation experiments [11-

18]. Pre-assessment of furnace aerodynamic efficincy could be

done without firing by aerodynamic venting of the boiler flow

path. Calculations showed that in-line arrangement of ash

hoppers along furnace chamber allows to align vortex

formation and achieve its stability. Fig. 15 shows current lines

for the variant under consideration.

Figure 15: Aerodynamic 3D modeling results of furnace chamber



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Changes in vortex formation are shown in Fig. 16, with indication of the vector velocity field in three different sections along the

length of furnace chamber.

1st level of burners 3rd level of burners 4th level of burners

Figure 16: Vector velocity fields in three sections along the length of furnace chamber of horizontal boiler

Taking into account heat-recovery surfaces, the total length of

a boiler unit reaches 85.5 m; construction area required for its

installation is nearly twice the size of classic arrangements.

Therewith, terminal headers reach 34.5 m, providing length

reduction of high temperature pipelines almost by half. Apart

from that, there is a possibility of terminal headers lead to the

lower part of tube banks of convective heat-transfer surfaces,

so that they reach the level of 16 m. In this case, the total length

of main steam piping and reheat piping are shortened almost

four times compared to classic design of a boiler unit. Thus,

horizontal boiler unit makes it possible to reduce the share of

capital costs, which falls on high temperature pipelines, to 25

% of the initial share, providing cost reduction of the whole

power plant by 10-12 %.

Three-dimensional aerodynamic and one-dimensional heat and

hydraulic calculations showed the perspective of the given

design arrangement. Boiler efficiency reached 93.1 %.

The developed basic mutual arrangement of boiler and steam

turbine is shown in Fig. 17.

Figure 17: Power plant arrangement with horizontal steam boiler

Turbine unit is to be located along the boiler nearby its

superheater surfaces. This solution allows to reduce the length

of the main steam piping from 150 m to 70 m compared to

tower-type arrangement.

CONCLUSION

One way to improve economic feasibility of change-over to

ultra-supercritical steam parameters for coal-fired power plants

is the revision of series of fundamental construction solutions.

Almost 20% of overall cost of power plant with ultra-



9306

supercritical steam parameters fall on the steam pipelines. It is

demonstrated that changes of the boiler unit structural shape,

and mutual arrangement mode of the main equipment

determine the length of steam pipelines. Thus, the length of

main steam piping and reheat piping can be greater than 150 m

for power plants having a capacity of 600 MW or higher with

classic tower-type boilers. By contrast, when changing boiler

unit arrangement it is possible to shorten the distance from

superheater headers to turbine steam inlet more than two times.

In this paper two versions of a boiler unit are presented: М-type

and horizontal. Both constructions provide considerable length

reduction of the main steam pipelines (from 150 m to 50-70 m).

When passing to horizontal arrangement, the flow structure in

boiler unit circuit changes significantly. Therefore, for the

given version the extension study of furnace chamber

aerodynamics, based on 3D modeling, was conducted. Burner

units arrangement was developed as well as the ash hopper

design that affects greatly aerodynamics.

Heat and aerodynamic calculations proved high efficiency of

the solutions proposed. Efficiency of both boiler unit versions

(М-type and horizontal) exceeds 93 %.

ACKNOWLEDGEMENTS

The research has been carried out in the Moscow Power

Engineering Institute with financial support from the Russian

Federation represented by the Ministry of Education and

Science of the Russian Federation under Agreement

No.14.574.21.0098 on Grant Provision dated August 22, 2014,

for the purpose of implementation of the Federal Target

Program “Research and Development in Priority Growth Fields

of Russian Science and Technology Sector for 2014-

2020”.Unique identifier of the applied research:

RFMEFI57414X0098.

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Documents

oilers’ Advanced Constructive Solutions for the Ultra ... power plant arrangement with horizontal steam boiler has been developed. If the solutions under consideration are used,