Malaysia Power 2003-SC-Presentation AG/2.1-MP-2003-SC.pdfMalaysia Power 2003 Kuala Lumpur 28. –...
Transcript of Malaysia Power 2003-SC-Presentation AG/2.1-MP-2003-SC.pdfMalaysia Power 2003 Kuala Lumpur 28. –...
1
Malaysia Power 2003Kuala Lumpur 28. – 29. April 2003
Supercritical Steam Power Plants -an Attractive Option for Malaysia?
Miro R. SustaIMTE AG Power Consulting Engineers
Switzerland
Peter LubyINGCHEM Technical Advisory Services
in Power GenerationCentral Europe
KL-April 2003 . 2
Advanced Coal Fired Power Generation Technologies
• Supercritical Steam (SC)• Ultra-SC (USC)• Pressurized Fluidized Bed Combustion (PFBC)• Integrated Gasification Combined Cycle (IGCC)• Hybrid Combined Cycle (HCC)• Direct Coal fired Combined Cycle (DCCC)• Molten Carbonate Fuel Cell (MCFC)• Magneto Hydrodynamics (MHD) Power Generation
© IMTE AG
KL-April 2003 . 3
SSC Power Plants Worldwide
0
100
200
300
400
500
600
700
E.Europe &Russia
USA Japan W.Europe OtherCounties
TotalWorldwide
No.
of U
nits
0
50
100
150
200
250
300
350
GW
No. of Units Total Power Output
© IMTE AG
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What is Supercritical?
© IMTE AG
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What is Supercritical?
© IMTE AG
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What is Supercritical?
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1
2 3
4 5
6
KL-April 2003 . 8
~
6
12
3
4 5
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Supercrit
ical p
ressu
reSubcritical pressure
Critical point (22.1MPA, 373°C)
Enthalpy (kJ/kg)
Tem
pera
ture
(°
C)
Liquid + vapor
Vapor
Liquid Vapor
Isobaric processes in either subcritical or supercritical regime
© IMTE AG
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Supercritical vs. Conventional
≈ 2.0≈ 710> 48.06-8700 / 700 / 7003651350700°C - SC≈ 2.2≈ 780> 42.05-7580 / 580 / 5802901300580°C - SC
≈ 2.4≈ 855< 40.04-6538 / 5381651100Conventional
SO2
(g/kWh)
CO2
(g/kWh)
Efficiency
(%)
AuxiliaryConsumption
(%)
SteamTemperature
(°C)
SteamPressure
(MPa)
Price
(US$/kW)
Plant Type
• Both, conventional (subcritical) and SC technology is commercially available in wide range of size.
• Compared with conventional power plant, SC technology with higherefficiency and consequently lower specific flue gas throughput is muchcleaner method of electricity generation.
• Conventional technology however, provides greater coal flexibility. • Higher temperatures encountered in SC units’ makes corrosion more
critical, thus coals with slugging or corrosion potential are less suitable for SC plants.
State-of-the-art SC power plants have an efficiency of about 46% and satisfy current emission standards worldwide.
© IMTE AG
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Potential Increase in Efficiency through new Materials and Steam Parameters
3940414243444546474849
F12 F12 P91 NF616 AusteniticSteel
Inconel
Material
Effic
ienc
y (%
)
Potential Increase in Efficiency
© IMTE AG
KL-April 2003 . 12
49
48
50
47
46
45
44
43
42
41
0.4% +
2.1% +
167 bar,
538°C, 538°C Basis = 42%
250 bar,
540°C 560°C 1.5%+
1.1% +0.7% +
315 bar,
620°C, 620°C
350 bar,
700°C, 720°C
270 bar,
585°C, 600°C
300 bar,
600°C, 620°C
Flue gas cooling
Compo- nents pro- cess, pres- sure loss reduct.
0.8% +0.4% +
0.6% +
0.8% +
Double reheat
Steam turbine impro-
ve- ment
50
49
48
47
46
45
44
43
42
41
Efficiency Improvement Potential for Coal fired Steam Power Plants
Effic
ienc
y (%
)
© IMTE AG
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0102030405060708090
100
1988-> 1990-> 1992-> 1994-> 1996-> 1998-> 2000->
Year
%
Convetional SSC
Power Plant Availability ** Conventional vs. SC
SC
KL-April 2003 IMTE AG 14
Basic Alternatives of Boiler Arrangement
Courtesy of Siemens PG
Typical Drum Boiler Once Through – Benson Boiler
KL-April 2003 . 15
Benson Boiler – Basic Configurations
• Simple construction ofmembrane walls
• Lower erosion of heatingsurfaces by ash
• Smaller built-up area
• Dimensioning of convectionsection independent of furnace
• Shorter assembly times due toparallel assembly of first andsecond pass
• Lower overall height
100%
Height 70%
Height
Two-passSingle-pass
© IMTE AG
KL-April 2003 IMTE AG 16
Height Comparison of 500MW Coal Fired Boilers
Single-pass Two-pass Horizontal
Height ratio3 : 2 : 1
Milan
Cathedral
Courtesy of Siemens PG
KL-April 2003 IMTE AG 17
Cumulative Steam Capacity of Worldwide ordered Benson Boilers
220
180
140
100
60
20
1946 1956 1966 1976 1986 1996 1998Courtesy of Siemens PG
40
GW
Bituminous coal,with dry de-ashing
Bituminous coal / slag tapLignite
Oil or gas
CCGT Nuclear
KL-April 2003 . 18
Common Steam Turbine Capacities vs. Live Steam Pressure
0 200 400 600 800 1000
60 bar40 bar
90 bar100 bar
125 bar, reheat165 bar, reheat
245 bar, reheat
245 bar, 2 x reheat
315 bar, 2 x reheat
Supercritical
Supercritical
Supercritical
ST Capacity (MW)
Pres
sure
(ba
r)
© IMTE AG
KL-April 2003 IMTE AG 19
Tandem Compound Steam TurbineTwo-Casing * Single-Flow
Applicable for the smallest utility ratings.
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Tandem Compound Steam TurbineTwo-Casing * Double-Flow * LSB 750 mm –1000 mm * 170 bar /
565°C / 565°C
Applicable for 300 – 500 MW Units
KL-April 2003 IMTE AG 21
Tandem Compound Steam TurbineThree-Casing * Four-Flow * LSB 750 mm – 850 mm * 170 bar / 565°C /
565°C
Applicable for 500 – 700 MW Units
KL-April 2003 IMTE AG 22
Tandem Compound Steam TurbineFour-Casing * Four-Flow * LSB 850 mm – 1000 mm * 245 bar / 565°C
/ 565°C
Applicable for 700 – 900 MW Units
KL-April 2003 . 23
Tandem Compound Steam TurbineFour-Casing * Four-Flow * Double Reheat * 310 bar
Applicable for 900 - 1200 MW Units
KL-April 2003 IMTE AG 24
Tandem Compound Steam TurbineFive-Casing * Six-Flow * Single Reheat * <310 bar
Applicable for < 1200 MW Units
. 252 ¼ Cr – 1Mo forging
9 Cr forgingMain steam governing valve
2 ¼ Cr – 1Mo forging
9 Cr forgingMain steam stop valve
12 Cr forgingRefractory alloy (R-26)
Rotating blade
1 ¼ Cr – ½ Mo cast steel
2 ¼ Cr – 1Mo cast steel
Outer casing
1/2 Cr – ½ Mo cast steel
2 ¼ Cr – 1Mo cast steel
No.2 blade ring
1 ¼ Cr – ½ Mo cast steel
12 Cr cast steelNo.1 blade ring
1 ¼ Cr – ½ Mo cast steel
12 Cr cast steelInner casing
2 ¼ Cr – 1 Mo cast steel
12 Cr cast steelNozzle chamber
Cr-Mo-V forgingNew 12 Cr forgingRotor
538°C600°CMain steam temperature
KL-April 2003 . 26
SC Power Plants Worldwide
© IMTE AG
0100200300400500600
Europe USA Japan Russia OtherCountries
TotalWorldwide
No.
of U
nits
KL-April 2003 . 27
SC Power Plants Worldwide
© IMTE AG
0100200300400500600
Europe USA Japan Russia OtherCountries
TotalWorldwide
No.
of U
nits
050100150200250300350
GW
No. of Units GW
KL-April 2003 . 28
Selected SC Power Plants
200443.5246 / 566 / 5662 x 800S. KoreaYonghungdo
200442.7279 / 542 / 5622 x 900ChinaWaigaoqiao
200047.0250 / 600 / 6103 x 700JapanTachibanawan-2
200146.0250 / 605 / 600600JapanMisumi 1
200146.0245 / 600 / 6002 x 500JapanIsogo 1 & 2
199444.0250 / 535 / 563700NetherlandsHemweg-8
199143.5250 / 540 / 540420DenmarkFynsvaeket – 7
198542.0270 / 540 / 540400DenmarkStudstrupvaerket
199245.3250 / 560 / 560415DenmarkEsbjerg 3
199847.0285 / 580 / 580410DenmarkNordjyllaend
200043.0266 / 545 / 5811000GermanyBoxberg
200245.2275 / 580 / 6001000GermanyNiederaussem
200042.4268 / 554 / 5542 x 800GermanyLippendorf
199343.0250 / 540 / 560500GermanyStaudinger Unit
199241.0250 / 544 / 5622 x 800GermanySchwarze Pumpe
Commercial Operation
Efficiency(%)
Steam Parameters(kPa / °C / °C)
Power Output(MW)
CountryPower Plant Name
© IMTE AG
KL-April 2003 . 29
1600 MW SCPP Schwarze PumpeGermany
Owner SVK SchwarzePumpe / VEAG
Fuel Lignite
Commercial operation
1997 / 1998
Steam parameters
250 bar544°C / 562°C
BoilerOT, GEC Alsthom/ EVT EV
Efficiency 41 %
KL-April 2003 . 30
Schwarze Pumpe
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965 MW SCPP Niederaussem-KGermany
Owner RWE Energie
Fuel Rhenish raw lignite, LHV = 8 –10.5 MJ/kg
Commercial operation
November 2002
Steam parameters
285bar, 580°C, 600°C
Boiler OT,Alstom ES/Bab-cock Kraftwerks-technik/Steinmueller
Efficiency 45.2 %
Owner RWE Energie
Fuel Rhenish raw lignite, LHV = 8 –10.5 MJ/kg
Commercial operation
November 2002
Steam parameters
285bar, 580°C, 600°C
Boiler OT,Alstom ES/Bab-cock Kraftwerks-technik/Steinmueller
Efficiency 45.2 %
Owner RWE Energie
Fuel Rhenish raw lignite, LHV = 8 –10.5 MJ/kg
Commercial operation
November 2002
Steam parameters
285bar, 580°C, 600°C
Boiler OT,Alstom ES/Bab-cock Kraftwerks-technik/Steinmueller
Efficiency 45.2 %
KL-April 2003 . 32
907 MW SCPP BoxbergGermany
Owner VEAG
Fuel Lignite
Commercial operation
2000
Steam parameters
266bar, 545°C, 581°C
BoilerSteam turbine
OT, SteinmuellerSiemens HMN, 5-casing, 6 flow
Efficiency 42.7 %
KL-April 2003 . 33
965 MW SCPP NordjyllandsvaerketDenmark
Owner Elsam A/S
Fuel Bituminous coal
Commercial operation
1998
Steam parameters
290bar, 582°C, 580°C, 580°C
BoilerBenson, single-pass, tower-type, fromBurmeister & Waine
Efficiency 47%
KL-April 2003 . 34
700 MW SCPP Hemweg-8Holland
Owner Energieprodukti-bedrijk UNA
Fuel Bituminous coal
Commercial operation
1994
Steam parameters
260bar, 540°C, 568°C
Boiler Benson, two-passBabcock Energy,Stork Ketels
Efficiency 44.0%
KL-April 2003 . 35
1000 MW SCPP MisumiJapan
Owner Chubu ElectricPower Corporation
Fuel Bituminous coal
Commercial operation
1998 - 2001
Steam parameters
250 bar, 605°C, 600°C
BoilerOnce – through, sliding pressure operation
Efficiency 46 %
KL-April 2003 . 36
Does SC Technology suit to Malaysia's Power Generation Environment?
0.20%6.80%13%
66%14%
NG Coal Hydro Oil Others
200231.1%3.9%3.8%
20.8%
40.4%
NG Coal Hydro Oil Others
2020
Present and Expected Fuel Split in Malaysia
© IMTE AG
KL-April 2003 . 37
Annual Savings
24.5
49.1
73.6
98.2
122.765.8
52.6
39.5
26.3
13.21
2
3
4
5
Pow
erO
utpu
t(G
W)
Mio US$ / Year
3% Improvement 6% Improvement
2.5 5 7.5 10 12
0.490.98
1.471.96
2.45
0.92
4.58
1.83
2.75
3.67
0.000.501.001.502.002.503.003.504.004.505.00
Power Output (GW)M
ioTo
ns/Y
ear
3% Improvement 6% Improvement
2.5 5 7.5 10 12.5
© IMTE AG
KL-April 2003 . 38
Example
3% - 6% efficiency improvement can save annually up to 3 millions metric tons of coal or between 100 Mio and 200 Mio US$ per each 10 GW power generation capacity.Basic data used for this calculation:
Coal LHV 28’000 MJ/ton, Load Factor 85%Coal Price 30 US$/ton
© IMTE AG
KL-April 2003 . 39
Early problems experienced with the first and second generation of SC and USC power plants are underway to be
overcome. Currently, SC and USC power plants with steam conditions
up to 300 bar, 600°C / 620°C have been matured and become high efficiency commercialized technology.
The largest commercial units with capacity of 1300 MW have reached ambitious efficiency of 47%.
SC and USC coal fired power plants will have broad prospects of development in this centaury.
Outlook for coal fired SC power plant technology is very positive and its further growth lies ahead.
Intensity of this growth will depend on the following factors:
© IMTE AG
KL-April 2003 . 40
Worldwide acceptance of SC and USC technology;Development of NG / Coal price ratio;Further improvement of availability and reliability;Further efficiency improvement; Operational characteristics;Emissions level (mainly CO2, SO2 and NOx);Life cycle costs.
© IMTE AG
KL-April 2003 . 41
New technologies have an impact on everything — from environmental quality to costs that consumers will ultimately
have to pay.
Thank you.