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Bharat Heavy Electricals LimitedBharat Heavy Electricals Limited
International conference Thermal Power India ‐3
“Ultra Supercritical power plants”
ULTRA SUPER CRITICAL POWER PLANTS
Bharat Heavy Electricals LimitedBharat Heavy Electricals Limited
Introduction
•Energy, in general, and electricity in particular, plays a vital rolein improving the standard of life•World has abundant proven reserves of coal and thus coal‐based thermal power plants dominatebased thermal power plants dominate• The development of coal fired supercritical power planttechnology can be described as an evolutionary advancement
d i d hi h ffi itowards greater power output per unit and higher efficiency•Energy conversion efficiency of steam turbine cycle can beimproved by increasing the main steam pressure andtemperature
ULTRA SUPER CRITICAL POWER PLANTS
Bharat Heavy Electricals LimitedBharat Heavy Electricals Limited
IntroductionIntroduction
Worldwide energy and electricity consumption is projected tot l t f 2 2 5% b t d 2025grow at an average annual rate of 2‐2.5% between now and 2025
caused by increase of population (up to 7.5 billion) and increaseof consumption (mainly of China and India).
Coal offers an abundant, widely spread energy resource at quitebl i f i i l li I ill istable price, from many international suppliers. It will continue to
play a significant role in new generating capacity
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Bharat Heavy Electricals LimitedBharat Heavy Electricals Limited
Coal TechnologiesCoal Technologies
Integrated gasification combined‐cycle generation technology(IGCC)
Circulating fluidized bed combustion generation technologyCirculating fluidized bed combustion generation technology(CFBC and pressurized circulating fluidized bed combustioncombined‐cycle generation technology (PFBC‐CC)Supercritical and ultra supercritical generation technology(SC/USC)
ULTRA SUPER CRITICAL POWER PLANTS
Bharat Heavy Electricals LimitedBharat Heavy Electricals Limited
Advantages of Supercritical unitsAdvantages of Supercritical units
•Reduced fuel costs due to improved plant efficiency
•Significant improvement of environment by reduction in CO2emissions
•Plant costs less than other clean coal technologies•Plant costs less than other clean coal technologies
•Much reduced NOx, SOx and particulate emissionsMuch reduced NOx, SOx and particulate emissions
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Bharat Heavy Electricals LimitedBharat Heavy Electricals Limited
Efficiency gain due to Supercritical parametersEfficiency gain due to Supercritical parameters
•Supercritical units have higher plant efficiency than that ofsubcritical units because of higher steam parameters.
• The Gross plant efficiency is around 40‐41% for supercritical unitswith steam parameters of 24 7MPa/565 /593 which is aboutwith steam parameters of 24.7MPa/565 /593 , which is about2%‐3% higher than that (38%) of sub‐critical unit with steamparameters of 16.7MPa/537/537•The Gross plant efficiency is around 41‐42% for ultra‐supercriticalunits with steam parameters of 28MPa/593 /593 ,which isabout 3‐4% higher than that of the above supercritical unitsabout 3‐4% higher than that of the above supercritical units.
•The advanced ultra supercritical units have reached an overallplant efficiency of 47% to 49% in the world.
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Bharat Heavy Electricals LimitedBharat Heavy Electricals Limited
National mission on enhanced energy efficiencyNational mission on enhanced energy efficiency
•Increasing efficiency of existing power plants, using cleantechnologies and switching to fuels other than coal
•Adoption of super critical boiler, wherever cost effective andotherwise suitableotherwise suitable
•Adoption of ultra‐super critical boiler when their commercialviability under Indian conditions is establishedy
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Source : CEA
Bharat Heavy Electricals LimitedBharat Heavy Electricals Limited
What is supercritical parametersp p
As the fluid pressure increases, Latent Heat(Enthalpy of Steam –Enthalpy of Water)( py py )reduces.
At Critical point it becomes zero.
In physical terms at this pressure watertransforms to steam spontaneously.
4.3
1015202530354045SUPER CRITICAL STEAM PARAMETERS:
PARAMETERS MORE THAN CRITICAL STATE• STEAM PRESSURE > 221.2 BAR mp
rove
men
t %
05
500 MW 800 MW
STEAM PRESSURE 221.2 BAR• STEAM TEMPERATURE > 374.15 Deg C
Subcritical170 ata / 537 °C / 537 °C
Super Critical247 ata / 565 °C / 593 °C
Im
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INCREASE IN PRESSURE & MAIN AND REHEAT TEMP. > 537 Deg CRESULTS IN SIGNIFICANT IMPROVEMENT IN HEATRATE
Bharat Heavy Electricals LimitedBharat Heavy Electricals Limited
Parameters for Ultra supercritical PlantsParameters for Ultra supercritical Plants
•There is no clear definition of ‘ultra‐supercritical’There is no clear definition of ultra supercriticalconditions, However Plants operating above 275 kg/cm2pressure and MS/RH temperatures of 593°C and above aregenerally called ultra super criticalgenerally called ultra super critical.
•World over, many Ultra super critical power plants ranging350MW to 1000MW are under operation/construction.p /
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Bharat Heavy Electricals Limited
Development of SC/USC TechnologyDevelopment of SC/USC Technology• Supercritical steam cycle technology has been used for decades and is
becoming the system of choice for new commercial coal‐fired plants in manybecoming the system of choice for new commercial coal‐fired plants in manycountries.
• Recent plant built in Europe and Asia use supercritical boiler‐turbinetechnology and China has made this standard on all new plant 600MWe andtechnology and China has made this standard on all new plant 600MWe andupwards.
• Research and development is under way for ultra‐supercritical units operatingat even higher efficiencies potentially up to around 50%at even higher efficiencies, potentially up to around 50%.
• The introduction of ultra‐supercritical technology has been driven over recentyears in countries such as Denmark, Germany and Japan, in order to achieveimproved plant efficiencies and reduce fuel costsimproved plant efficiencies and reduce fuel costs.
• Research is focusing on the development of new steels for boiler tubes and onhigh alloy steels that minimise corrosion.
• These developments are expected to result in a dramatic increase in the
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• These developments are expected to result in a dramatic increase in thenumber of SC plants and USC units installed over coming years.
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Present status of SC/USC Coal fired UnitsPresent status of SC/USC Coal‐fired Units
• Supercritical and ultra‐supercritical units have been developedp p pinto proven mature and commercialized advanced technologiesin the world
O 600 iti l l fi d it h b f ll• Over 600 supercritical coal‐fired units have been successfullyinto commercial operation for decades worldwide
• About 60 ultra‐supercritical units in operation worldwidep p• The 1000MW class ultra‐supercritical units with steam
parameters of 31MPa/600 /600 are being developed ini d i l iindustrial economies
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Parameters of Some SC/USC Plants/Country Power Plant Unit Rating
Mwe net (Gross)
Steam Pressure (Bar)
Main Steam
Temp. (oC)
Reheat RH1 Steam
Temp. (oC)
Reheat RH2 Steam
Temp. (oC)
Efficiency (% net LHV)
Denmark Avedorevaerket 2 390 300 580 600 ‐‐‐‐‐ 48.3
Denmark Nordjylland 3 411 285 580 580 580 47
Denmark Skaerbeaek 3 411 290 582 580 580 49
Holland Hemweg 8 630 260 540 568 ‐‐‐‐‐ 42
Finland Meri Pori 550 244 540 560 ‐‐‐‐‐ 45
Germany Staudinger 509 262 545 562 ‐‐‐‐‐ 43
Germany Niederaussem K 965 275 580 600 ‐‐‐‐‐ 45.2
Japan Tachibanawan 1050 250 600 610 ‐‐‐‐‐ 43.5
Japan Isogo 600 266 600 610 ‐‐‐‐‐ Not Available
China Changshu 600 259 569 569 ‐‐‐‐‐ 42
China Wangqu 600 247 571 569 ‐‐‐‐‐ 43
USA Tanners Creek 580 241 538 552 566 39.8
ULTRA SUPER CRITICAL POWER PLANTS
USA Duke Power 1120 241 538 538 ‐‐‐‐‐ Not Available
Bharat Heavy Electricals Limited
Comparison of some state of the art steam plantsComparison of some state‐of‐the‐art steam plants
Plant Steam ConditionMpa/ oC/oC
Net Thermal efficiency, %
HHV LHV
T hib 24 1/600/610 42 1 44Tachibanawan(Japan)
24.1/600/610 42.1 44
Tanners Creek (USA)
24.1/538/552/566 39.8 42(USA)
Nordjylland 3 (Denmark)
29.0/582/580/580 45 47.0
Niederaussem K (Germany)
27.5/580/600 42.5 45.2
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Efficiency vs. EmissionsEfficiency vs. Emissions
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Typical efficienciesTypical efficiencies
Pulverized coal option Steam Conditions Typical Efficiency (% HHV)
Sub critical
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Levelised cost of electricity (CoE) for nominalLevelised cost of electricity (CoE) for nominal 600MWe (A European comparison)
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Relative efficiency improvement with parameters
ULTRA SUPER CRITICAL POWER PLANTS
Bharat Heavy Electricals LimitedBharat Heavy Electricals Limited
Evolution of Steam Power Stations Efficiency Worldwide
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Bharat Heavy Electricals Limited
Supercritical Technology Indian scenarioSupercritical Technology – Indian scenario• Supercritical technology being adopted to enhance
efficiency, reduce coal consumption and GHG emission
• 660/ 800 MW units planned in big way.• Parameters adopted 247 ata / 537/565 OC & 247 ata / 565/ 593• Parameters adopted 247 ata / 537/565 OC & 247 ata / 565/ 593
OC
• Eight units of 660 MW under execution at Sipat and Barhg p• Two units of 800MW under execution at Krishnapattnam• Ultra Mega Projects, 4000 MW each, envisaged with
supercritical units.
• 4 projects already awarded to IPPs through tariff basedcompetitive bidding
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competitive bidding.
• Many more supercritical units in pipeline.
Bharat Heavy Electricals Limited
Supercritical Technology – Indian scenario (Cont..)
Wid l l t l t (At t bi d)• Widely prevalent cycle parameters (At turbine end):– Pressure: 246 ‐250 kg/cm2– Temperature: 537/566 deg C (In 660MW Sipat & Barh –I TPS)
565/593 deg C (In 660 MW Barh‐II and2 X 800MW Krishnapattnam)
• Parameters adopted for 800MW are 247kg/cm2 /565/593 deg C.
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Bharat Heavy Electricals Limited
Ultra Mega Power ProjectsUltra Mega Power Projects
Ministry of Power Central Electricity Authority and PFC areMinistry of Power, Central Electricity Authority and PFC areworking together to facilitate development of Ultra Mega PowerProjects with super critical parameters and capacity of about4000 MW each under Tariff based competitive bidding route.
Being large in size these projects will meet the power needs ofBeing large in size, these projects will meet the power needs ofnumber of states through transmission of power on regional andnational grids.
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Identified Ultra Mega Projects State Project Location Status
Chattisgarh Akaltara Pithead ‐g
Gujarat Mundra coastal Awarded to Tata
Karnataka Tadri coastal ‐
Madhya Pradesh Sasan Pithead Awarded to Reliance
Maharashtra Giriye coastal ‐
Andhra Pradesh Krishnapatnam coastal Awarded to RelianceAndhra Pradesh Krishnapatnam coastal Awarded to Reliance
Orissa Bhedabahal(Sundergarh district)
Pithead ‐( g )
Tamil Nadu Cheyyur coastal ‐
Jharkhand Tilaiyya Pithead LOI issued to Reliance
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Typical Comparison of ParametersS b iti l S iti lSubcritical vs. Supercritical
Parameter Unit 500MW 660MW 800MW
Main Steam Pressure ATA 170 247 247
M i S T 0C 537 565 565Main Steam Temp. 0C 537 565 565
Main Steam Flow T/Hr 1515 1960 2340
Reheat Pressure ATA 40.5 50.4 56.6
Reheat Temperature 0C 537 593 593
Reheat Flow T/Hr 1335 1625 1940
CRH Pressure ATA 45 56 0 61 5CRH Pressure ATA 45 56.0 61.5
Cold Reheat Temp. 0C 336 336 348
Final FW Temp. oC0C 253 290 290
BMCR Flow T/hr 1625 2120 2600
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Bharat Heavy Electricals Limited
Power Cycle EquipmentPower Cycle Equipment
EQUIPMENT 500 MW SUB CRITICAL 800 MW SUPER CRITICAL
BOILER Drum Type Once Through Type
TURBINE 1HP + 1IP + 1LP 1HP + 1IP+ 2LP
CONDENSER One Two
GENERATOR 588 MVA 950 MVA
LP HEATERS 3 Nos 4 Nos
HP HEATERS TWO ( 2X50% EACH) THREE ( 2X50% EACH)( ) ( )
DEAERATOR ONE ONE
CONDENSATE EXTN. PUMPS 3 x 50% 3 x 50%
BOILER FEED PUMPS 2 x 50%(TD) / 1 x 50% (MD) 2 x 50 % (TD) / 1 x 35 %MD
VACUUM PUMPS 2x100%2 x 100%
(For Each Condenser)
CONDENSATE POLISHING UNIT 2 x 50% 4 x 25%
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Bharat Heavy Electricals Limited
Typical 800 MW CycleTypical 800 MW Cycle
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Bharat Heavy Electricals Limited
Reference HBD for 800MWReference HBD for 800MW
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Reference HBD for 660MW
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Bharat Heavy Electricals Limited
Improvement in Gross plant efficiencyImprovement in Gross plant efficiency
40 5
41.0
41.5
%)
39.0
39.5
40.0
40.5
t efficiency (%
37.0
37.5
38.0
38.5
Gross Plan
36.5
500 MW/ 170ATA/ 537/537
500 MW/ 170ATA/ 537/565
600 MW/ 170ATA/ 537/537
600 MW/ 170ATA/ 537/565
660 MW/ 247ATA/ 565/593
800 MW/ 247ATA/ 565/593
800 MW/ 280ATA/ 593/593
Parameters
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Bharat Heavy Electricals Limited
Coal ConsumptionCoal Consumption
0.660
0.630
0.640
0.650
/KW‐hr
0.600
0.610
0.620
nsum
ption kg/
0 570
0.580
0.590
Coal Con
0.560
0.570
500 MW/ 170ATA/ 537/537
500 MW/ 170ATA/ 537/565
600 MW/ 170ATA/ 537/537
600 MW/ 170ATA/ 537/565
660 MW/ 247ATA/ 565/593
800 MW/ 247ATA/ 565/593
800 MW/ 280ATA/ 593/593
Parameters
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Parameters
Bharat Heavy Electricals Limited
Supercritical BoilersSupercritical Boilers
• Supercritical pressure boiler has no drum and heat absorbingsurface being, in effect, one continuous tube, in which the water& steam generated in the furnace water walls passes throughonly once hence called ‘Once through Supercritical pressureonly once hence called Once through Supercritical pressureboilers’
• The water in boiler is pressurized by Boiler Feed Pump, sensibleheat is added in feed heaters, economizer and furnacetubes, until water attains saturation temperature and flashesinstantaneously to dry saturated steam and super heatinginstantaneously to dry saturated steam and super heatingcommences.
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Supercritical
Steam GeneratorsSeparators Collecting vessel vessel
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Once ‐through Operating RangeOnce through Operating Range
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Low Load System with Circulating Pump
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Boiler ParametersBoiler Parameters
B il
Unit 500 MW660 MW800 MWDescription
BMCRBMCRBMCR-Boiler Parameters
162521002585t/hSH steam flow /
kg/cm2(a) 179256256SHO pressure
oC
oC
254291294Feed water temp
540/540568/596568/596SHO/RHO temp.
temp.
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SIEMENS ReferencesSIEMENS ReferencesFor Super Critical Steam Turbine
Plant Name Country MW First operation
M.S. Pr.(bar) / MS Temp. (°C) / HRH Temp. (°C)
Kw Schwarze Pumpe1,2 Germany 823 1997 253.08 544 562
Boxberg Q Germany 910 2000 252.58 541 578
Isogo Japan 600 2001 251.00 600 610
NiederauBem K Germany 1027 2002 251.00 576 599
Wai Gao Qiao 1,2 China 900 2003 249.60 538 566
Wai Gao Qiao 3,4 China 1000 2007 270 600 600
Kogan Creek Australia 750 2007 250.00 540 560
h 1 2 3 4 Chi 1000 2006 262 50 600 600Yuhuan 1,2,3,4 China 1000 2006 262.50 600 600
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Large capacity Supercritical Sets
660MW Steam turbine: With Supercritical parameters
g p y p
Module Combination• HP : H30-100• IP : M30-63• LP : N30-2x12.5
Salient Feature: 247 t M i St PSalient Feature:
• New series of HP & IP modules for supercritical parameters• Higher size LP module
247 ata Main Steam Pressure565 0C Main Steam Temperature593 0C Hot reheat Temperature
Order received for NTPC 2x660 MW Barh Extn. • Higher size LP module
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Bharat Heavy Electricals Limited
Large capacity Supercritical Sets800MW Steam turbine: With Supercritical parameters
Module Combination
Salient features:
• HP : H30-100 (H70-V4)• IP : M30-100 (I60-V2)• LP : N30-4x8 (L4x8)
Salient features:•New series of HP, IP modules for super critical parameters• 4 cylinder turbine (2 LP’s)
246 ata Main Steam Pressure565 0C Main Steam Temperature593 0C Hot reheat Temperature4 cylinder turbine (2 LP s)
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Large capacity Supercritical SetsRating - 800 MW Generator Module - THDF 125/67
Large capacity Supercritical Sets
Parameters -
Voltage - 27 KVVoltage 27 KV
Insulation - Micalastic
Gas Pressure - 5 Bar
Excitation - Brushless
Transport wt. - 443 Tons
Stator Cooling - DM water
Rotor Cooling - Hydrogen
Transportation - By Road
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Bharat Heavy Electricals Limited
Large capacity Supercritical Sets
STEAM SURFACE CONDENSER
Large capacity Supercritical Sets
FOR 660 MW TG SET
• ONE CONDENSER PER SET
• SINGLE / DOUBLE PASS CONDENSERSINGLE / DOUBLE PASS CONDENSER
• CONDENSER IS SOLID SUPPORTED
• LP HEATER NO.1 IS LOCATED INSIDE
• CONDENSER NECK
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Large capacity Supercritical Sets
DESIGN FEATURES OF CONDENSER FOR 800 MW TG SET
• TWO CONDENSERS CONNECTED TO TWO
LP TURBINES
• SINGLE PASS
•SOLID SUPPORTED WITHOUT ANY EXPN•SOLID SUPPORTED WITHOUT ANY EXPN.JOINT BETWEEN TURBINE & COND.
•CONDENSERS IN SERIES WITH DIFFERENTBACK PRESSURES (
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Pumps for Supercritical Power PlantsPumps for Supercritical Power Plants
• BHEL entered into collaboration with M/S Mitsubishi Heavy/ yIndustries, Japan for
‐BFPs
‐ Booster Pumps
‐ CEPs &
CWPs for Super Critical power plants‐ CWPs for Super Critical power plants.
• Range from 660MW to 1000MW.
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Bharat Heavy Electricals Limited
Pump Models for 660MWPump Models for 660MW
PUMP MODEL Q(m3/hr) H (mlc) N (rpm)PUMP MODEL Q(m3/hr) H (mlc) N (rpm)
BFP MDG 405 1385 3315 5730
BP MLC 400 1385 160 1475
CEP 145 RND 1015 345 1470
CWP 72 MN 30000 27 370
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Bharat Heavy Electricals Limited
Pump Models for 800MWPump Models for 800MW
PUMP MODEL Q(m3/hr) H (mlc) N (rpm)PUMP MODEL Q(m /hr) H (mlc) N (rpm)
BFP MDG 455 1605 3310 5100
BP MLC 450 1605 240 1475
CEP 145 RND 1210 350 1470
CWP 78 MN 35000 29 329
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Bharat Heavy Electricals Limited
Development of Materials for SC/USC parameters
• For adopting SC/USC parameters, superior material arep g / p , prequired
• Some of the critical materials are Boiler quality plates andP91 C iti l i iP91 Critical piping
• These material are not indigenously available and have to beessentially importedy p
• There is a need to join hands with the countries which havealready developed these materials
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Concluding RemarksConcluding Remarks• Electric power generation in India will continue to be
dominated by coal‐fired power generation for at least nextdominated by coal fired power generation for at least next30‐40 years
• Development and application of clean, high efficiency, largecapacity, coal‐fired power generation technology is a long‐term strategic task for India
• In order to meet our increasing demand for electric power asIn order to meet our increasing demand for electric power, aswell as to improve coal utilization efficiency and reducepollutant emissions from coal‐fired power plants, we have tod l d ti iti l / Ult iti l itdevelop domestic supercritical / Ultra supercritical units
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Bharat Heavy Electricals Limited
ULTRA SUPER CRITICAL POWER PLANTS