status of global advanced ultra supercritical power plant
TRANSCRIPT
Status of Global Advanced Ultra Supercritical Power Plant Programs
Ram Narula President, Engineering & Environmental Consultant
Robert Purgert President, Energy Industry of Ohio
Jeffery Phillips Sr. Manager, Electric Power Research Institute
Harvey Wen Sr. Principal Engineer, Bechtel Power Corporation
Presented at the International Conference on Supercritical Technologies and Best Practices
New Delhi, India November 21-22, 2013
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Contents Technology Evolution
Drivers for A-USC Technology
Major Global A-USC Programs
Commentary
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Technology Evolution
Ever going Quest for higher efficiency 1882-Beginning of Coal Fired
Generation Early 1920s-PC Plants Introduced Late 1920s- Reheat Cycle
Introduced 1930s- Steam conditions reached
538C 1957- First SC, 120 MW, Philo
plant @31MPa/621C /566C/538C 1960- 325 MW Eddystone 1,
@35MPa/621C/566C/566C
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Technology Evolution - Continued Ever going Quest for higher efficiency
1996- 700C program started in Europe 2001- 760C program started in USA 2008- 700C program started in Japan 2010- 700C program started in China 2010- 700C program started in India
Reducing Coal Consumption, Emissions and Water use
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Drivers for Higher Efficiency
Competitive COE Lower Emissions including CO2 Optimum resource utilizations/
Transportation constraints International Obligations Energy Independence
Local/Global Drivers
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Major Global A-USC Programs
European Program 700C US DOE Program 760 C Japanese Program 700C Chinese Program 700C Indian Program 700C
Developing Ni-based Super Alloys
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The European AD 700 A-USC Program
1996- European program conceived 1998- 15 year, 6 phase COMTES launched with the goal of
a 550 MW @35 MPa/ 700C/720C demo plant by 2014 COMTES while successful encountered a few major
problems with thick walled 617 components necessitating additional testing
Eon, host utility put demo on hold because of high cost and flexible power requirements
Technical/Funding Constraints impeding Progress
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The European A-USC Program continued
Two new projects GKM HWT II and ENCIO (European Network for Component Integration & Optimization) underway (2010-2017) to: Verify design and material behavior of thick wall components
under real operating conditions Verify repair concepts and close open technical items post
COMTES 700 comprehensive analysis Minimize technical risks and reduce construction/operational
cost via various manufacturing options Test newly developed materials (617B, 263, HR6W and 625)
and weld filler materials at a new test facility at the 320 MW Unit 4 of ENEL’s Andrea Palladio plant in Fusina, Italy
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The European A-USC Program continued
Additional Challenge in Europe is the need for flexible fossil power generation due to rapid growth of renewables
Huge technical challenge for thick walled components & weldments to accommodate high load gradients, lower minimum load and frequent starts/shutdowns
Huge economical challenge due to fewer dispatch hours and high capital cost
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US A-USC Program
Primary Goals Materials Technology Evaluation Focus on nickel based alloys Develop fabrication/joining technologies for new alloys
Unique conditions for US program Higher temperature than European program needing
additional alloys Corrosion resistance for high sulfur/high moisture US
coals Collect data for ASME Code acceptance Includes analysis of impact of oxycombustion
Racing Towards 50% HHV efficiency
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US : A-USC Program For Boiler
New Alloys For Pressure Parts Superheaters/Reheaters need
High creep strength/long term stability Low coefficient of thermal expansion Low fireside corrosion
Low steam side oxidation/ exfoliations Weldability in thicker sections
Several alloys selected Most promising - Inconel 740, Haynes
230, Haynes 282
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Test section showing two types of dissimilar welds. (Source: Courtesy of Alstom)
US : A-USC Program – Continued For Steam Turbine
Alloys for Rotors, discs and blades The Cyclic nature of ST operation, dynamic and
centrifugal forces require Low cycle fatigue strength to avoid cracking Compatible thermal expansion coefficients
between differing materials Several alloys selected Most promising - Waspalloy, Nimonium 105,
Haynes 282
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US : A-USC Program – Continued Achievements & Next Steps
New materials developed, characterized Inconel 740 code certified for
section 1 in 2011 & got B31.1 approval in 2012
Gathering data for Haynes 282 certification
Longer term testing on going For future readiness, US may look
favorably at overseas consortia for component testing
Unfavorable market in US has brought new coal construction to a grinding halt
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Inconel 740 ®Pipe after Extrusion at Wyman-Gordon’s Houston works
The Japanese A-USC Program 2000- domestic equipment suppliers/ utilities program to develop
new materials 2006-Highest efficiency plant at OSOGO 2 2008 Government launched “Cool Earth Program” 700 C A-USC @
35 MPa/700C 46% efficiency by 2015 48% efficiency by 2020
2011- Earth Quake/tsunami – A setback Nuclear Fleet nearly shutdown Massive Gas fired built up Coal to Gas boiler conversion Improve reliability of existing coal fleet
Country in power Crisis
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The Japanese A-USC Program –Continued Unique Features
Use lower main steam pressure Minimizes use of Ni-based alloys by extending use of Ferretic and
austenitic steel to higher temperature Component testing will be in an existing turbine rotor test facility at
700C at full speed (electric heaters and vacuum) Boiler components test to include superheater panel, large
diameter safety and turbine bypass valves Test materials to include HR6W, HR35, Alloys 141, 263, 617 & 740 Testing to cover creep rupture, fatigue, oxidation and corrosion
properties Testing scheduled for 2014 to 2016 First demo plant target date of 2020 looks optimistic
A–USC development progressing
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Chinese A-USC Program 1992- started supercritical plants using imported technology 2004- domestic technology commercial 2010- founded national alliance for 700C A-USC Goals:
Design of A-USC plant R&D of high temp materials, large castings and forgings Demonstration of components (at CTH 700 facility) starting
2014 Construction & operation of a 660MW @35 MPa/700C plant
by 2021 Emphasis on domestically developed/modified materials
Emphasis on Local Manufacturing
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Chinese A-USC Program - Continued
Unique Features:
Develop indigenous materials as well as modify imported materials to enhance the desired properties
Optimize Alloys G115 and 740H A 10 tons/hr loop in an existing 320 MW, 2 pass facility On going testing of 617M, 740H, 749H and T24 Ni-Fe based modified super alloy GH 2984 being considered for use
to improve boiler efficiency (higher thermal conductivity than Alloys 617, 740 & N263)
Additional R&D underway for SH/RH pipe and headers, HP/IP rotors, casings, valves and fittings
Collect test data for 100,000 hours
Ni-based alloys being procured
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Indian A-USC Program 2003 electricity act to overcome power shortages Ministry of Power/CEA/PFC initiative for supercritical UMPPs National Mission under NAPCC for development of 700C A-USC MOU on Technology Collaboration between IGCAR/BHEL/NTPC
to develop A-USC technology signed in August 2010 Current SC plants (660/800 MW) limited to 25 Mpa, 565/593C First 800 MW A-USC targeted to come online in 2017(2021) Future capacity additions to be mainly supercritical Corrosion testing envisaged at an Indian plant based on
European COMTES materials (Alloy 617)
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Indian A-USC Program - Continued Unique Features: Steam parameters: 31 MPa, 710 °C, 720 °C Alloy 617 chosen as it is ASME code approved and
widely available Test loop to verify corrosion characteristics of
intended alloys under Indian coal combustion Alloy 617, SS304HCu, T91/T92, and T/P23 will be
tested Test loop to become operational in 2015
Steady progress. Acceleration through proactive projects.
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Indian A-USC Program - Continued Several projects on critical aspects initiated
Forged ingots of 617M and SS304HCu manufactured and characterized. Main material for rotor and blade will be 617M.
Long term testing of materials in progress Welding, bending trials of tubes carried out Thermal cycle designed Dissimilar welding for turbine rotors Thick walled superheater header HP Bypass valve
Project Design Document prepared
Focus on self reliance
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Commentary
European Program: Further post COMTES testing needed to validate
repair concepts and gather more data to reduce construction & operational costs
A full demo before 2023-2025 unlikely European financial situation, unfavorable coal
sentiment and economics of A-USC due to flexible fossil power requirements are clouding the viability of this technology in the near term.
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Commentary - Continued US Program: Considerable progress made in
development/ASME certification of superior Ni-based alloys
Unfavorable coal power outlook, cheaper shale gas and weak electric demand making COMTES funding a challenge
A full scale demo on line before 2025 unlikely.
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Commentary – continued
Japanese Program: 2011 earth quake and resultant shutdown
of nuclear fleet has changed national priorities
A traditional key driver behind Japanese technology development is export potential to US/Europe has dampened
While A-USC progressing, the 2020 target of full scale demo is unlikely
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Commentary – continued Chinese Program: Making rapid progress in executing its plans Actively procuring advanced materials from
abroad and testing/modifying imported materials While program details not in public domain,
challenges are technical not financial Highly likely to meet its target of full scale demo
plant by 2021.
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Commentary – Continued Indian Program: India’s need for additional power generating capacity
very high Work progressing steadily Indian consortium commitment is 7 years to design and
build after government’s final approval Planning Commission approval received in October 2013 Original target date of 2017 too optimistic. With critical
projects already taken up, a full scale demo by 2021 likely
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Thank you for Listening
Any Questions
Contact: rgnarula@ yahoo.com
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