Boiler Design of innovative600 °C- and 700 °C- Power Plants
Power Plants – Technology in Dialogue
22th April 2008, Power Plant Technology, Hannover
Liisa Mäenpää, Hitachi Power Europe GmbH
2Liisa Mäenpää / HPE Power Plants – Technology in Dialogue, Hannover, 22th April 2008
Boiler Design of innovative600 °C- and 700 °C- Power Plants
Introduction
Material selection
600 °C - and 700 °C - Technology
Design Aspects
Conclusion
Z
3Liisa Mäenpää / HPE Power Plants – Technology in Dialogue, Hannover, 22th April 2008
0
200
400
600
800
1000
1200
1400
1600
0.25 0.3 0.35 0.4 0.45 0.5 0.55 0.6
Net efficiency [-]
CO
2E
mis
sio
ns
[g/k
Wh
]
lignite(rhenish)
GasSource:
Marheineke T., Krewitt W., Neubarth J., Friedrich R., Voß A.IER-Bd. 74, IER, University of Stuttgart, Germany, 2000
Bituminouscoal
(Average)
Averageworldwide
Average China
Russia 2003
CO2 Emissions of Power Plantswith different Fuels
BAT600/620 °C 700/720 °C
1 RH
CurrentAverageEU15-countries
4Liisa Mäenpää / HPE Power Plants – Technology in Dialogue, Hannover, 22th April 2008
2000 2020 2050
with CCS
with improvedEfficiency Plants
CO
2E
mis
sio
ns
with current Technology Trend
Efficiency is the fast track – CCS achieves near Zero-Emission
Further CO2 Reduction: Carbon Capture
5Liisa Mäenpää / HPE Power Plants – Technology in Dialogue, Hannover, 22th April 2008
0
200
400
600
800
1000
1200
1400
1600
0.25 0.3 0.35 0.4 0.45 0.5 0.55 0.6
Net efficiency [-]
CO
2E
mis
sio
ns
[g/k
Wh
]
BAT600/620 °C
CurrentAverageEU15-countries
700/720 °C1 RH
+ 30 %
+ 44 %
Bituminouscoal
(Average)
Source:
Marheineke T., Krewitt W., Neubarth J., Friedrich R., Voß A.IER-Bd. 74, IER, University of Stuttgart, Germany, 2000
CO2 Emissions Increase of Power Plantswith Bituminous coal by applying CCS
Loss of efficiency is derived by Power demand for ASU and compression of CO2 for Oxyfuel
6Liisa Mäenpää / HPE Power Plants – Technology in Dialogue, Hannover, 22th April 2008
Boiler Design of innovative600 °C- and 700 °C- Power Plants
Introduction
Material selection
600 °C - and 700 °C - Technology
Design Aspects
Conclusion
7Liisa Mäenpää / HPE Power Plants – Technology in Dialogue, Hannover, 22th April 2008
Bruttoleistung der Anlage 500 - 600 MW
Zielwirkungsgrad 45 – 47 %
Dampfzustände
FD Turbineneintritt 285 bar / 600 °C
ZÜ Turbineneintritt 60 bar / 620 °C
Turmkessel „RKW Vorzugsvariante 600 MW“
Plant power output (gross) 500 - 600 MW
Efficiency (target) 45 – 47 % (el, net)
Steam conditions
HP Turbine inlet 285 bar / 600 °C
IP Turbine inlet 60 bar / 620 °C
Tower type boiler „Preferred Boiler Design 600 MW“
600 °C - Technology: NRW Power Plant Study
Walsum K. 10
1 x 790 MWel / 1 x 2143 t/h
HP : 603 ºC / 290 bar a
RH : 621 ºC / 75 bar a
Time of commissioning : 2009
PS Moorburg A/B
2 x 820 MWel / 2 x 2088 t/h
HP: 600 ºC / 276 bar a
RH: 610 ºC / 51 bar a
Time of commissioning: 2011/2012
PS Datteln
1100 MWel / 2939 t/h
HP: 600 ºC / 285 bar
RH : 620 ºC / 58 bar
Time of commissioning : 2011
8Liisa Mäenpää / HPE Power Plants – Technology in Dialogue, Hannover, 22th April 2008
600 °C - Technology: PS Datteln (1100 MW)
1100 MWel / 2939 t/h
Benson® steam generator
Bituminous coal
Design parameters:
HP: 600 ºC / 285 bar
RH: 620 ºC / 58 bar
Time of commissioning: 2011
Efficiency: > 45.5 % (el, net)
+ 80.0 m
+ 115.5 m+ 121.5 m
+ 0.0 m
16946
9Liisa Mäenpää / HPE Power Plants – Technology in Dialogue, Hannover, 22th April 2008
Existing PPExisting PP= 43 %
262 bar / 545 °C / 562 °C
X20CrMoV121
X20CrMoV121
13CrMo44
TodayToday = 45 – 47 %
285 bar / 600 °C / 620 °C
Austenitic
materialsP92
7CrMoVTiB 10 10
600 °C - Technology: Boiler materials
10Liisa Mäenpää / HPE Power Plants – Technology in Dialogue, Hannover, 22th April 2008
Three different versions for boiler design:
365 bar / 705 °C / 720 °C, single reheat
260 bar / 705 °C / 720 °C, single reheat
365 bar / 702 °C / 720 °C / 720 °C,
double reheat
Power Plant Study NRWPP700500 MWel
700 °C - Technology:Power Plant Study NRWPP700
Preferred boiler design:
365 bar / 705 °C / 720 °Csingle reheat
Base for current design offirst 700 °C – boiler.
Source: NRW Power Plant 700°C (NRWPP700)
Efficiency (target) 50 % (el, net)
11Liisa Mäenpää / HPE Power Plants – Technology in Dialogue, Hannover, 22th April 2008
HP-Part:Life steam pressure 365 barLife steam temperature 705 °C
RH-Part:Inlet pressure 74 barOutlet temperature 720 °C
Bituminous coalBenson® steam generator
First 700 °C - Power Plantscheduled for: 2014 (E.ON)
700 °C - Technology:steam generator for 500 MWel
12Liisa Mäenpää / HPE Power Plants – Technology in Dialogue, Hannover, 22th April 2008
20142014 = 50 %
365 bar / 705 °C / 720 °C
Ni-base-
materials
Ni-base-
materials
Martensiticmaterials,
Ni-base-materials
700 °C - Technology:Boiler materials
Austenitic
materialsP92
7CrMoVTiB 10 10
TodayToday = 45 – 47 %
285 bar / 600 °C / 620 °C
Existing PPExisting PP= 43 %
262 bar / 545 °C / 562 °C
X20CrMoV121
X20CrMoV121
13CrMo44
13Liisa Mäenpää / HPE Power Plants – Technology in Dialogue, Hannover, 22th April 2008
Boiler Design of innovative600 °C- and 700 °C- Power Plants
Z
Introduction
Material selection
600 °C - and 700 °C - Technology
Design Aspects
Conclusion
14Liisa Mäenpää / HPE Power Plants – Technology in Dialogue, Hannover, 22th April 2008
Component design in the creep regimeTools / Methods
Current-StateDesign based on formula whichare being defined by empirical
knowledge
p2
dps
zul
ierf
Perspectives
For components operating in the creep regime the inelastic Finite Element Analyseshave to be applied. Appropriate inelastic constitutive equations are necessary.
New methods for the design of high temperature components: European PressureEquipment Directive (PED) allows the use of Design by Analysis (DBA)-Methods.
Required research projects concerning inelastic constitutive equations have started.
Demand for 700 °C - Technologycannot be satisfied using the
existing design methods.
15Liisa Mäenpää / HPE Power Plants – Technology in Dialogue, Hannover, 22th April 2008
HPE – FEM Calculation of thick walledcomponents
Wall thickness:Calculation acc. EN 12952-3: s=100 mm
FEM: s= 77 mm
localcreepmax. 3,9 % at200.000 h
Membrane-creep0,6 %200.000 h
s = 77 mm
Example HP-Outlet header
16Liisa Mäenpää / HPE Power Plants – Technology in Dialogue, Hannover, 22th April 2008
Life time expectancy of superheater tubes
Reduction of life time ofsuperheater tubes by:- creep- fire side corrosion- steam side oxidation
Calculation program to estimate the life time of superheater tubes
considering all three influencing factors.
Each of the three mechanismsaffects the others.
Isolated consideration is notpossible.
17Liisa Mäenpää / HPE Power Plants – Technology in Dialogue, Hannover, 22th April 2008
Examples – Different materials
TP347H FG Super304H notshot peened
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time [h]
exp
en
ded
life
tim
e[%
]
TP347H FG Super304H notshot peened
18Liisa Mäenpää / HPE Power Plants – Technology in Dialogue, Hannover, 22th April 2008
Examples – Different materials
TP347H FG Super304H notshot peened
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time [h]
exp
en
ded
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tim
e[%
]
TP347H FG Super304H notshot peened
HR3C
Super304Hshot peened
19Liisa Mäenpää / HPE Power Plants – Technology in Dialogue, Hannover, 22th April 2008
Examples – Variations for design of superheatertubes
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time [h]
exp
en
ded
life
tim
e[%
]
Manufacturingtolerances
Designparameters
Steamtemperatureimbalances
Flue gastemperatureimbalances
20Liisa Mäenpää / HPE Power Plants – Technology in Dialogue, Hannover, 22th April 2008
Boiler Design of innovative600 °C- and 700 °C- Power Plants
Introduction
Material selection
600 °C - and 700 °C - Technology
Design Aspects
Conclusion
Z
21Liisa Mäenpää / HPE Power Plants – Technology in Dialogue, Hannover, 22th April 2008
Material selection – superheater and reheater tubes
0
50
100
150
200
250
300
460 480 500 520 540 560 580 600
105 h creep strength (mean values) in MPa
temperature °C
13CrMo4-5
16Mo3
ferriticmaterials
640 660 680 700 720 740620
Alloy 617modified
Sanicro 25expected
Exist
ing
Power
Plant
s
DMV 310N
Super 304H
HR3C
austeniticmaterials
7CrMoVTiB10-10
22Liisa Mäenpää / HPE Power Plants – Technology in Dialogue, Hannover, 22th April 2008
0
50
100
150
200
250
300
460 480 500 520 540 560 580 600
105 h creep strength (mean values) in MPa
temperature °C
13CrMo4-5
7CrMoVTiB10-10
16Mo3
ferriticmaterials
640 660 680 700 720 740620
DMV 310N
Super 304H
HR3C
austeniticmaterials
Alloy 617modified
Sanicro 25expected
Material selection – superheater and reheater tubes
600
°C–
Power
Plant
s
23Liisa Mäenpää / HPE Power Plants – Technology in Dialogue, Hannover, 22th April 2008
0
50
100
150
200
250
300
460 480 500 520 540 560 580 600
105 h creep strength (mean values) in MPa
temperature °C
13CrMo4-5
7CrMoVTiB10-10
16Mo3
ferriticmaterials
640 660 680 700 720 740620
DMV 310N
Super 304H
HR3C
austeniticmaterials
Alloy 617modified
Sanicro 25expected
Material selection – superheater and reheater tubes
700
°C–
Power
Plant
s
24Liisa Mäenpää / HPE Power Plants – Technology in Dialogue, Hannover, 22th April 2008
Material selection – fire side corrosion
Corrosion rate of austenitic materials with 18 % chromium
Source: Cutler, A.J.B., Flatley, T and Hay, K.A.: Fire-side corrosion in power-station boilers. Combustion (Dez.1980) S. 17-25
flue gas temperature
1400 °C
1200 °C
1000 °C
800 °C
600 °C – Technology
0
0.1
0.2
0.3
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0.7
0.8
580 590 600 610 620 630 640 650 660
material temperature [°C]
co
rro
sio
nra
te[m
m/1
0.0
00
h]
25Liisa Mäenpää / HPE Power Plants – Technology in Dialogue, Hannover, 22th April 2008
Material selection – fire side corrosion
Corrosion rate of austenitic materials with 18 % chromium
Source: Cutler, A.J.B., Flatley, T and Hay, K.A.: Fire-side corrosion in power-station boilers. Combustion (Dez.1980) S. 17-25
700 °C – Technology
580 590 600 610 620 630 640 650 660
material temperature [°C]
0
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0.6
0.7
0.8co
rro
sio
nra
te[m
m/1
0.0
00
h]
flue gas temperature
1400 °C
1200 °C
1000 °C
800 °C
26Liisa Mäenpää / HPE Power Plants – Technology in Dialogue, Hannover, 22th April 2008
Materials for 600°C - PowerPlant:
13CrMo4-5 (T1)
10CrMo9-10 (T11)
7CrMoVTiB10-10 (T24)
Material selection - membrane walls
Possible additionalmaterials for 700°C - PowerPlant:
VM12-SHC
X10CrWMoVNb9-2 (T92)
Alloy 617 (modified)
Ferritic
Martensitic
Nickel basealloy
27Liisa Mäenpää / HPE Power Plants – Technology in Dialogue, Hannover, 22th April 2008
Material selection – superheater and reheater
Materials for 600°C - PowerPlant:
Ferritic materials like
7CrMoVTiB10-10 (T24)
X20CrMoV12-1, VM12-SHC
TP 347H FG SP
Super 304 H SP
HR3C
Possible additionalmaterials for 700°C -Power Plant:
Sanicro 25
HR6W
Alloy 617 (modified)
Alloy 740, Alloy 263
Austenitic
Martensitic
Nickel basealloys
Austenitic
28Liisa Mäenpää / HPE Power Plants – Technology in Dialogue, Hannover, 22th April 2008
Material selection - headers and pipes
Materials for 600°C - PowerPlant:
X20CrMoV12-1
X10CrMoVNb9-1 (P91)
X11CrMoWVNb9-1-1 (E911)
X10CrWMoVNb9-2 (P92)
Possible additionalmaterials for 700°C -Power Plant:Alloy 617 (modified)
Alloy 263
HR6W
Martensitic
Nickel basealloys
Austenitic
29Liisa Mäenpää / HPE Power Plants – Technology in Dialogue, Hannover, 22th April 2008
Boiler Design of innovative600 °C- and 700 °C- Power Plants
Introduction
Material selection
600 °C - and 700 °C - Technology
Design Aspects
Conclusion
30Liisa Mäenpää / HPE Power Plants – Technology in Dialogue, Hannover, 22th April 2008
Conclusion
600 °C - boiler 700 °C - boiler
Biggest innovation of 700 °C -boiler lies in the materials !
New materials with higherstrength and corrosion/oxidation resistance needed.
Highest grade for materialsare the nickel base alloys.
Common for both boilers:
FEM-Calculations for thick walled components
Calculation program for life time expectancy of superheater tubes