Super-Critical Boiler

SUPERCRITICAL
By
BOILER
Ashvani Shukla
C&I
BGR ENERGY
INTRODUCTION TO SUPERCRITICAL
TECHNOLOGY
What is Supercritical Pressure ?
Critical point in water vapour cycle is a
thermodynamic state where there is no clear
distinction between liquid and gaseous state
of water.
Water reaches to this state at a critical
pressure above 22.1 MPa and 374 oC.
2
RANKIN CYCLE
SUBCRITICAL
UNIT
1 - 2 > CEP work

2 - 3 > LP Heating
3 - 4 > BFP work
4 - 5 > HP Heating
5 6 > Eco, WW
67>
Superheating
7 8 > HPT Work
8 9 > Reheating
9 10 > IPT Work
1011 > LPT Work
3
11 1 > Condensing
RANKINE CYCLE SUPERCRITICAL

UNIT
1 - 2 > CEP work
2 2s > Regeneration
2s - 3 > Boiler Superheating
3 4 > HPT expansion
4 5 > Reheating
5 6 > IPT & LPT Expansion
6 1 > Condenser Heat

rejection
VARIATION OF LATENT HEAT

WITH PRESSURE
Absolute
Pressure
(Bar)
Saturation
Temperature
(o C)
Latent Heat
(K J/Kg.)
50
150
200
221
264
342
366
374
1640
1004
592
0
Departure from Nucleate

Boiling
NUCLEATE BOILING IS A TYPE OF BOILING THAT TAKES PLACE WHEN THE
SURFACE TEMP IS HOTTER THAN THE SATURATED FLUID TEMP BY A
CERTAIN AMOUNT BUT WHERE HEAT FLUX IS BELOW THE CRITICAL HEAT
FLUX. NUCLEATE BOILING OCCURS WHEN THE SURFACE TEMPERATURE IS
HIGHER THAN THE SATURATION TEMPERATURE BY BETWEEN 40C TO 300C.
DENSITY
WATER
STEAM
6
175 224
Supercritical Boiler Water

Wall
Rifle Tube And Smooth Tube
NATURAL CIRCULATION VS.

ONCE THROUGH SYSTEM
5710CTo HP
Turbine
Mixer
Header
4620C
4230C
To IP
Turbin 5690C
e
5340C
5260C
Separator
FR
H
4730C
FS
H
Platen
Heate
r
From CRH
Line
3240C
From FRS
Line
2800C
Boiler
Recirculation
NRV
LTRH
LTSH
4430C
3260C
2830C
Economize
r Phase 1
Bottom
Ring
Economizer
Phase 2
FEED WATER CONTROL
In Drum type Boiler Feed water flow control

by Three element controller
1.Drum level
2.Ms flow
3.Feed water flow.
Drum less Boiler Feed water control by
1.Load demand
2.Water/Fuel ratio(7:1)
3.OHD(Over heat degree)
10
DIFFERENCE OF
SUBCRITICAL(500MW) AND
SUPERCRITICAL(660MW)
11
COMPARISION OF SUPER CRITICAL & SUB

CRITICAL
DESCRIPTION
SUPERCRITICAL
(660MW)
Circulation Ratio
Feed Water Flow Control
-Water to Fuel
Ratio
(7:1)
-OHDR(22-35 OC)
-Load Demand
Latent Heat Addition
Nil
Heat addition more
Sp. Enthalpy
Low
More
Sp. Coal consumption
Low
High
Air flow, Dry flu gas loss
Low
High
SUB-CRITICAL
(500MW)
Once-thru=1
Assisted Circulation=3-4
Natural circulation= 7-8
Three Element Control
-Feed Water Flow
-MS Flow
-Drum Level
CONTINUE..
DESCRIPTION
SUPERCRITICAL
(660MW)
SUB-CRITICAL
(500MW)
Coal & Ash handling
Low
High
Pollution
Low
High
Aux. Power
Consumption
Low
More
Overall Efficiency
High
(40-42%)
Low
(36-37%)
Total heating
surface area Reqd
Low
(84439m2)
High
(71582m2)
Tube diameter
Low
High
13
CONTINUE..
DESCRIPTION
SUPERCRITICAL SUB-CRITICAL
(660MW)
(500MW)
Material / Infrastructure
(Tonnage)
Low
7502 MT
High
9200 MT
Start up Time
Less
More
Blow down loss
Nil
More
Water Consumption
Less
More
14
Water Wall Design
15
WATER WALL ARRANGEMENT
Bottom spiral & top vertical tube furnace arrangement
Once through design feature is used for boiler water wall

design
The supercritical water wall is exposed to the higher

heat flux
Spiral tube wall design (wrapped around the unit) with

high mass flow & velocity of steam/water mixture
through each spiral
Higher mass flow improves heat transfer between the

16
WW tube and the fluid at high heat flux.
SPIRAL VS VERTICAL WALL

VERTICAL WALL
SPIRAL WALL
Less ash deposition on

wall
More ash deposition
Less mass flow
More fluid mass flow
More number of tubes
Less number of tubes
More boiler height for

same capacity
Less boiler height
Uniform heat transfer

and uniform heating of
WW tubes
No uniform heating of
tubes and heat transfer
in all tubes of WW
17
FURNACE ARRANGEMENT
SPIRAL TYPE
VERTICAL TYPE
18
Supercritical Sliding Pressure

Boiler Water Wall Design
Comparison of Vertical Wall
and Spiral Wall
19
20
Ash accumulation on
Vertical water walls
walls Spiral water walls
21
Super Critical Boiler

Materials
22
Advanced Supercritical Tube Materials

(300 bar/6000c/6200c)
23
MATERIAL COMPARISON
Description
660 MW
500 MW
Structural Steel
Alloy Steel
Carbon Steel
Water wall
T22
Carbon Steel
SH Coil
T23, T91
T11, T22
RH Coil
T91,Super 304
H
T22, T91,T11
LTSH
T12
T11
Economizer
SA106-C
Carbon Steel
Welding Joints (Pressure Parts)
42,000 Nos
24,000 Nos
24
Steam Water Cycle

Chemistry Controls
25
S. Parameter
No.
1
Silica
< 20 ppb in feed water and steam, Standard value <15 ppb in the cycle
< 250 ppb in boiler drum
Expected value <10 ppb in the cycle
pH
9.0 - 9.5 for feed, steam &

condensate,
9.0 10.0 for Boiler drum
< 7 ppb for feed.
9.0 9.6 for AVT(All volatile treatment)

8.0 9.0 for CWT(Combine water
treatment)
< 7 ppb for feed in case of AVT
30 150 ppb for feed in case of CWT
Cation (H+)
Conductivity
<0.20 S/cm in the feed & steam

cycle
Standard value <0.15 S /cm in the cycle
5
6
(CPU)
CPU is optional
CPU is essential for 100% flow.
Dissolved
Oxygen (DO)
LP and HP dosing. Or
All Volatile Treatment
(Hydrazine + Ammonia)
Super Critical
Type of Boiler
water
treatment
3
4
Sub Critical
No HP dosing
Combined water treatment (CWT).
Expected value- <0.10 S /cm in the cycle
Silica and TDS By maintaining feed water quality Blow down possible till separators are
control
and
functioning (upto 30% load).
By operating CBD
26
ADVANTAGES OF SC TECHNOLOGY
I ) Higher cycle efficiency means
Primarily
less fuel consumption
less per MW infrastructure investments
less emission
less auxiliary power consumption
less water consumption
II ) Operational flexibility
Better temp. control and load change flexibility
Shorter start-up time
More suitable for widely variable pressure operation
27
ECONOMY
Higher Efficiency (%)
Less fuel input.
Low capacity fuel handling system.
Low capacity ash handling system.
Less Emissions.
Approximate improvement in Cycle
Efficiency
Pressure increase : 0.005 % per bar
Temp increase
: 0.011 % per deg K
28
INCREASE OF CYCLE EFFICIENCY DUE

TO STEAM PARAMETERS
Increase of efficiency [%]
10
6,77
5,79
5,74
4,81
3,74
4,26
6
5
3,44
3,37
2,64
1,47
2,42
2,76
600 / 620
1,78
0,75
580 / 600
566 / 566
0
300
Pressure [bar]
0
241
175
538 / 538
538 / 566
HP / RH outlet temperature [deg. C]
29
Sub. vs. Supercritical Cycle

Impact on Emissions
Plant Efficiency, %*
Plant Efficiency, Btu / kw-hr
Plant Efficiency, %
Fuel Consumption/Total Emissions
including CO2
* HHV Basis
Subcritical
34 - 37
10,000 - 9,200
Supercritical
37 - 41
9,200 - 8,300
34%
37%
41%
Base
Base-8%
Base-17%
30
CHALLENGES OF
SUPERCRITICAL TECHNOLOGY
Water chemistry is more stringent in super critical once

through boiler.
Metallurgical Challenges
More complex in erection due to spiral water wall.
More feed pump power is required due to more friction

losses in spiral water wall.
Maintenance of tube leakage is difficult due to complex

design of water wall.
Ash sticking tendency is more in spiral water wall in

comparison of vertical wall.
31
THANK YOU

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What are the advantages of supercritical technology over subcritical technology?

What are the advantages of supercritical technology over subcritical technology?

What are the challenges faced in supercritical technology?

What are the challenges faced in supercritical technology?

SUPERCRITICAL

1 - 2 > CEP work

RANKINE CYCLE SUPERCRITICAL

1 - 2 > CEP work

2s - 3 > Boiler Superheating

3 4 > HPT expansion

5 6 > IPT & LPT Expansion

6 1 > Condenser Heat

VARIATION OF LATENT HEAT

Departure from Nucleate

Supercritical Boiler Water

NATURAL CIRCULATION VS.

FEED WATER CONTROL

In Drum type Boiler Feed water flow control

3.Feed water flow.

Drum less Boiler Feed water control by

3.OHD(Over heat degree)

COMPARISION OF SUPER CRITICAL & SUB

Feed Water Flow Control

Latent Heat Addition

Heat addition more

Sp. Coal consumption

Air flow, Dry flu gas loss

Coal & Ash handling

Blow down loss

Water Wall Design

WATER WALL ARRANGEMENT

Bottom spiral & top vertical tube furnace arrangement

Once through design feature is used for boiler water wall

The supercritical water wall is exposed to the higher

Spiral tube wall design (wrapped around the unit) with

Higher mass flow improves heat transfer between the

SPIRAL VS VERTICAL WALL

Less ash deposition on

More ash deposition

Less mass flow

More fluid mass flow

More number of tubes

Less number of tubes

More boiler height for

Less boiler height

Uniform heat transfer

Supercritical Sliding Pressure

Super Critical Boiler

Advanced Supercritical Tube Materials

Welding Joints (Pressure Parts)

Steam Water Cycle

9.0 - 9.5 for feed, steam &

9.0 9.6 for AVT(All volatile treatment)

<0.20 S/cm in the feed & steam

Standard value <0.15 S /cm in the cycle

CPU is essential for 100% flow.

Expected value- <0.10 S /cm in the cycle

INCREASE OF CYCLE EFFICIENCY DUE

Sub. vs. Supercritical Cycle