toshiba’s energy solution - ambasada japonii w polsce toshiba sasaki.pdf · toshiba in thermal...

© 2014 Toshiba Corporation

TOSHIBA’s Energy Solution

Japan-Poland Clean Coal Seminar2014

2nd June, 2014

Takashi SASAKI

Technology Executive

Power Systems Company

Toshiba Corporation

© 2014 Toshiba Corporation 2 This document is CONFIDENTIAL and is the INTELECTUAL PROPERTY of TOSHIBA

CORPORATION. It must not be copied, loaned or transferred, nor must the information it

contains be disclosed to third parties without its written permission.

Today’s Contents

1. Toshiba in Thermal Power Energy Sector

2. Enhancement of thermal Power plant

Ultra Super Critical (USC)

Advanced Ultra Super Critical (A-USC)

3. Carbon Capture Technologies

Post Combustion Capture

Novel thermal Power System with CCS

4. Conclusions




Today’s Contents








4. Conclusions




TOSHIBA’s Business segments

Energy & Infrastructure

Community Solutions HeaIthcare

Lifestyle

*FY2013 data

26%

19%

Others

Total sales: $65B

Electronic Devices

6%

18%

24%

7%




Committed to power solutions

Hydro

Toshiba: “One-stop solution” provider in power business

Geothermal Wind

CCS (CO2 capture)

Nuclear Fuel cell

Mega solar

Smart grid

Thermal




Turbine Power Plants Supplied by TOSHIBA

1,904 units Rich Experiences all over the world from 1927 No.1 market share in North America in the past decade

The First Shipment

1927

171GW




(Among Major Manufacturers during 1988～2008(20yrs))

Leader in World Wide Share

Toshiba is the Leading Player of Supercritical Steam Turbines

:81 units in the world except China

World Share of Supercritical Steam Turbine

Data extracted from

McGraw Hill Data

52% 22%

19%

7%

TOSHIBA

Wold Wide Share Share in Japan

27%

18% 16%

16%

14%

9% TOSHIBA

Company A Company B

Company C

Company D

Company E

Company X

Company Y




Today’s Contents








4. Conclusions




Efficiency Enhancement Continuously striving for performance improvement

Develop higher temperature and higher pressure turbine

The Highest Efficiency 42% as USC (600 ℃ )

Performance Improvement

Effi

cie

ncy

(%)

(HH

V)

Advanced-Ultra Super Critical

Ultra Super Critical

Main Steam Pressure (MPa) 20 30 40

42

43

44

48

45

41

40

46

47

A-USC

USC

SC

46%

42%

(MST/RST)

(600/610℃)

(700/720 720℃)

(538/566℃)

USC

(593/593℃)




Toshiba USC Development Trend

1990 1995 2000

538/566C

MST / RST

TSURUGA #1

500MW

(24.1MPag 566/566℃)

HEKINAN #1

700MW

(24.1MPag 538/566℃)

NOSHIRO #2

600MW

(24.1MPag 566/593℃)

HARAMACHI #1

1000MW

(24.5MPag 566/593℃)

NANAO OHTA #2

700MW

(24.1MPag 593/593℃)

J-Power TACHIBANAWAN #1

1050MW

(25MPag 600/610℃)

HEKINAN #4,#5

1000MW

(24.1MPag 566/593℃)

566/566C

566/593C

593/593C

600/610C

2005 2010

TAIZHOU #1&2

1000MW

(25MPag 600/600℃)

IATAN 914MW

(24.6MPag 582/582℃)

MAIDURU #2

900MW

(24.5MPag 595/595℃)

MST: Main Steam Temperature

RST： Reheat Steam Temperature

2015

SAMCHEOK #1&2

1022MW

(24.6MPag 600/600℃)

(Year)




Customer: Tohoku Electric

Power Co., Japan

Taking Over: Dec. 1994

Turbine: Tandem Compound,

Four Flow, Reheat Type

(TC4F-42”)

Output: 600 MW

Main Steam: 24.1MPag, 566 C

Reheat Steam: 593 C

Rotation Speed:3000 rpm

NOSHIRO #2 POWER PLANT(JAPAN)

Benchmark Power Plants with High Steam Parameters




Customer: Hokuriku Electric

Power Co., Japan

Taking Over: July 1998

Turbine: Tandem Compound


(TC4F-40”)

Output: 700 MW

Main Steam: 24.1MPag , 593C

Reheat Steam: 593 C


NANAO OHTA #2 POWER PLANT (JAPAN)





Customer: Chubu Electric

Power Co., Japan

Taking Over: November 2001（#4)

November 2002（#5)



(TC4F-40”)

Output: 1000 MW

Main Steam: 24.1MPag, 566 C

Reheat Steam: 593 C


Hekinan #4,5 POWER PLANT(JAPAN)





Customer: Electric Power

Development Co.,

(J-Power), Japan

Taking Over: July 2000

Turbine: Cross Compound,


(CC4F-48 inch)

Output: 1050 MW

Main Steam: 25MPag, 600 C

Reheat Steam: 610 C

Rotation Speed: 3600 rpm / 1800rpm

TACHIBANA BAY #1 POWER PLANT (JAPAN)






Customer: KOREA SOUTHERN POWER

Turbine: Tandem Compound Four Flow Ti 48inch

Generator: 2 X 1230MVA

Output: 2 X 1022MW

Steam Conditions: 24.6MPag, 600/600 C

Rotational Speed: 3600rpm

Commercial Operation: 2015 (scheduled)




Enhancement of steam temperature

<Sub critical>

CrMoV Steel

<Super Critical>

12Cr steel

・High chromium

・Nb,N added

<Ultra Super Critical>

New 12Cr steel

・Co,B added

・W increase

・Mo decrease

<Super Critical /

Ultra Super Critical>

Mod. 12Cr steel

・W added

Characteristics of Rotor Material

CrMoV

12Cr

Mod. 12Cr

Ma

teria

l S

tre

ng

th

550 575 600 625 650 Steam Temp. (degC)

New 12Cr

1970s Early 1990s

Late 1990s

(cre

ep r

uptu

re s

trength

)

Required strength




Enhancement of unit capacity U

nit

Cap

acit

y(M

W)

1000

Steel Steel Titanium

1200

800

600

Last stage blade line up

of steam turbine

First unit Taking over 1994 2005

Full Scale Test Facility

Material

Blade Length (for 50Hz/60Hz)

2010

High reliability

High efficiency

42/35inch 48/40inch 58/48inch Computed Fluid

Dynamics Simulation




A-USC(Advanced Ultra Super Critical) System

0

2

4

6

8

10

12

14

16

20 30 40 Main Steam Pressure (MPa)

Rela

tive I

mpro

vem

ent of E

ffic

iency Dh

/h

(%

)

538/566C

700/720/720C A-USC Double Reheat

600/610C

Steam Turbine

●High temperature material

●Turbine Structure / Flowpath

Overall system

●Steam condition

●Heat balance

Steam Valve

●High temperature

material

■R&D Requirements

USC

SC

USC

566/566/566C Double Reheat




Customer: Chubu Electric Power

Co., Japan

Taking Over: Unit #1: Jun 1989

Unit #2: Jun 1990


Four Flow,

Double Reheat Type

(TC4F-33.5”)

Output: 700 MW

Main Steam: 31.0 MPag , 566 C

Reheat Steam: 566 / 566 C


Kawagoe #1,2 POWER PLANT(JAPAN)

Double Reheat Plant : TOSHIBA’s proven technology




Transition of Steam Turbine Materials in TSB

650

600

575

550

525

500

1960 1970 1980 1990 2000 2010 2020 1950

625

（year）

750

725

700

675

1000MW

25MPa

593/593℃

Mod-12Cr Steel

New-12Cr Steel

CrMoV Steel

12Cr Steel

USC

Sub / Super Critical

375MW

16.7MPa

566/538℃

500MW

24.1MPa

566/566℃

Nickel-based alloys

A-USC

35MPa

700/750/750℃




Development of High Temperature Material Characteristics of Rotor Material

CrMoV

Ma

teria

l S

tre

ng

th

550 600 650 Steam Temp. (degC)

New

12Cr

750 700

Nickel based

Alloy

Rotor

Weight: 14ton

Welded rotor

Casing

Weight: 9ton

Verify manufacturability of

Ni based alloys in actual size

3t

14t

Gas

Turbine

Steam

Turbine

Forged block mass

(cre

ep r

uptu

re s

trength

)

12Cr

Mod. 12Cr

Required

strength




Conceptual design of A-USC Steam Turbine

A-USC (1000MW Class, 35MPa, 700/720/720 C) turbine

Welded Rotor

Ni based Alloy－Ferritic Steel

Inner Casing

Ni Based Alloy

Main steam 35MPa 700C

2nd reheat steam 3MPa 720C

1st reheat steam 10MPa 720C

Boiler Boiler




Today’s Contents








4. Conclusions




Carbon Capture Technologies

Boiler DeNOx EP FGD

CO2 Separation

CO2 H2O N2

H2O N2

O2

Coal Air

Boiler

EP FGD

CO2 H2O O2

H2O

Coal ASU

Air O2

Ga

sif

ier

Coal ASU

Air O2

CO2

Separation

CO2 CO H2O H2

H2O CO2 H2 H2

Gas Turbine

CO2

Separation


CO2

Shift Reaction

EP・FGD

CO2

CO2

Oxy-Fuel Combustion

Pre Combustion Capture

Advantages

- Applies widely to thermal PP

(New, Retro, CC, Industrial)

- Proven technology

Challenges

-Energy Required for capture

-Cost of Capture Equipment

Advantages

- Size of capture equipment is

small (No N2 to separate)

- Boiler size smaller

Challenges

-Energy Required for ASU

-Cost for ASU

-CO2 purity

ASU: Air Separation Unit FGD: Fuel Gas Desulphurization EP: Electrostatic Precipitator

Advantages

-Size of capture equipment is

small (High pressure syngas)

Challenges

-Energy Required for ASU

-Operational Flexibility

-Cost of overall plant equipment




Integration with Power System ・ Heat & Mass Balance ・ System Operation

Integration with Exhaust System ・ DeNOx, FGD, EP Requirements ・ Pressure Losses, etc.

Knowledge of both Efficient Power Plant Cycle

and Carbon Capture Technology is required

FGD

EP

DeNOx

Boiler Steam Turbine

Generator

Condenser

Steam Extractions

Stack

Exhaust

Carbon Capture System ・ Integrated arrangement with Power Island Components

Post Combustion

Carbon Capture System

Str

ipp

er

CO2

Compressor Re-

boiler Ab

so

rbe

r

Easy Integration with Existing Plants




Mikawa PCC Pilot Plant

Summary of Results (as of May, 2014)

Plant Outline

・ Cumulative 8125 hours of operation

・ CO2 Recovery Energy: less than 2.4 GJ/ t-CO2

(@90% CO2 Capture, CO2 Conc. approx. 12%)

・ Verified system stability over 2800 hours of

continuous operation.

Commenced: September 29, 2009

Carbon Capture Post Combustion Capture

Technology: Amine-based Chemical Absorption

(Toshiba’s Solvent System)

Capture Capacity: 10 ton-CO2 / day

Flue Gas Flow: 2100 Nm3 / hour

Mikawa Coal Fired Power Plant

PCC Pilot Plant




CCS Plant Design Examples

CCS (Ready ) Plant Design for

New Build Power Plants (500MW Class)

･Full CO2 Capture (90%)

･Space for CCS nearly equal

Space for Power Block

CCS Retrofit Design onto

Existing Power Plants (550MW Class)

･300t/day (3%) CO2 Capture Planning

Power Output Loss Augmented by

Steam Turbine Uprate / Modification

･3000t/day (30%) CO2 Capture Planning

New Build Retrofitting

Examples for Coal Fired Thermal Power Plants

300t/day Carbon

Capture Plant

Boiler

CCS Power

Block




・ Novel system for producing cheap, clean electricity from fossil fuels.

・Generates zero atmospheric emissions (100% carbon capture)

・Produces electricity at a lower cost compared to existing technologies.

Supercritical CO2 Circulated Cycle Thermal Power Plant

High Pressure CO2

100% Carbon Capture

Fuel Fuel flexibility

(Natural gas, Coal syngas)

Target Efficiency 60%

（including Carbon Capture)





Gas and Steam Conditions

Pre

ssu

re(M

Pa)

0 Temperature(degC)

500

（30MPa,1150℃）

1500

10

20

30

Gas Turbine

A-USC

USC

SC CO2 Cycle

Improve efficiency

1000

<New technology>

① Combustor

･Oxy-fuel combustion

･High‐pressure combustor

② Supercritical CO2 Cycle

･High pressure & temperature

High energy density

5m

15m Steam Turbine

CO2 Turbine

250MW Class





CO2Turbine

R&D Status

Success in Combustion

Aug 2013 in California

25MW Class Design Complete

・Blade Cooling system

(Gas Flow Balance, Coating)

・Rotor System Dynamics

Combustor

Verified stability of combustion

・Low level vibration

・High combustion efficiency

Summary of Results (as of May, 2014)

Combustor Rotor

(Nickel based Alloy)




Enhancement of thermal power plant efficiency

Broad experiences of USC

Advanced Technologies for A-USC

Reduction in CO2 emission

Post Combustion Capture Technology

Super Critical CO2 Circulated Cycle

Conclusion

TOSHIBA contributes to improvement of

coal fired thermal power plants

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