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, ISSN 0976 6359(Online) Volume 3, Issue 2, May-August (2012), IAEME TECHNOLOGY (IJMET)
ISSN 0976 6340 (Print) ISSN 0976 6359 (Online) Volume 3, Issue 2, May-August (2012), pp. 422-430 IAEME: www.iaeme.com/ijmet.html Journal Impact Factor (2012): 3.8071 (Calculated by GISI) www.jifactor.com
IJMET
IAEME
Abstract
Coal fired power generation is switching over to supercritical (SC) and ultra supercritical (USC) plants which operate with steam on higher temperature and above critical pressure to produce power output at higher thermal efficiency. Due to involvement of high heat resistant material, manufacturing cost of the components of supercritical plants are increases, but due to higher efficiency its operating cost is low as compare to subcritical plants. An analysis has been made in the study to explore the possibilities of operating power plants with steam at higher temperature and pressure. Due to high efficiency of this plant 15 % lower co2 emission is achieved by high steam parameters as compare to subcritical plants. Analysis shows that for different operating condition of boilers and turbine, if there is an increment in the load of boiler and drop in the load of turbine higher efficiency is obtained. There are two parameters boiler maximum continuous rating (BMCR) and turbine maximum continuous rating (TMCR) are varied by increasing the value of steam flow rate of superheaters and reheaters. By increasing or decreasing these values we can find out which condition is best for power generation. A comparative study between subcritical and supercritical boilers and analysing the performance of boilers, Factor affecting efficiency of boilers has carried out with identification and analysis for improved working of supercritical plants.
Keywords:
Supercritical-Boilers, steam-turbine, BMCR, TMCR, rankine cycle, superheaters
Introduction:
Supercritical is a thermodynamic phase that describes the state of a substance where there is no clear distinction between liquid phase and gaseous phase. (i.e. they are a homogeneous fluid). Water reaches this state at a pressure above 22.1 MPa (221 bar), also known as supercritical pressure of water. Beyond this pressure, it is a homogeneous mixture of water and steam, as shown in Fig-1. Up to an operating pressure of around 19 MPa in the evaporator part of the boiler, there is a non-homogeneous mixture of water and steam in the evaporator. Up to an operating pressure of around 19 MPa in the evaporator part of the boiler, there is a non-homogeneous mixture of water and steam in the evaporator. Up to an operating pressure of around 19 MPa in the evaporator part of the boiler, there is a non-homogeneous mixture of water and steam in the evaporator. In this case, a drum-type boiler is used because the steam needs to be separated from water in the drum of the boiler before it is superheated and led into the turbine. Above an
422
International Journal of Mechanical Engineering and Technology (IJMET), ISSN 0976 6340(Print), ISSN 0976 6359(Online) Volume 3, Issue 2, May-August May August (2012), IAEME
operating pressure of 22.1 MPa in the evaporator part of the boiler, the cycle medium is a single single-phase fluid with homogeneous properties and there is no need to separate steam f from water in a drum.
Fig-1. Water Phase Diagram Once-through through boilers are therefore used in supercritical cycles. A critical point can be illustrated on a Rankine cycle, on which a typical steam turbine power plant operates. At working pressures in excess excess of this critical pressure, the Rankine cycle becomes supercritical cycle. The region below critical point is the subcritical region having a non-homogeneous homogeneous mixture of water and steam. Figure-2 Figure 2 shows the supercritical Rankine cycle. Point A on the T-S S diagram represents the critical point. Based on the operating pressures, there are two basic boiler technologies employed in the modern coal-fired coal power plants. These are Subcritical and Supercritical Subcritical boilers operate below 220 bars, the supercritical pressure of water. This means that there is a non nonhomogeneous mixture of water and steam in the evaporator part of the boiler. In this case a drum drum-type boiler is used because the steam needs to be separated from water before it is superheated and led into the turbine. The remaining water in the drum re-enters enters the boiler for further conversion to steam. The water circulation system can be a natural circulation or a forced (assisted) circulation circulation.
Steam Conditions
Todays supercritical coal fired power plants permits efficiencies that exceed 45%, depending on cooling conditions. Options to increase the efficiency above 50 % in ultra-supercritical supercritical power plants rely on elevated steam conditions as well l as on improved process and component quality. Steam conditions up to 30 MPa/600C/620C are achieved using steels with 12 % chromium content. Up to 31.5 MPa/620C/620C is achieved using Austenite, which is a proven, but expensive material. Nickel-based Nickel based alloys, e.g. Inconel, would permit 35 MPa/700C/720C, 720C, yielding efficiencies up to 48%.
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International Journal of Mechanical Engineering and Technology (IJMET), ISSN 0976 6340(Print), ISSN 0976 6359(Online) Volume 3, Issue 2, May-August (2012), IAEME
BOILER LOAD CONDITIONS Boiler Maximum Continuous Rating (BMCR): Boiler Maximum Continuous Rating (BMCR)
is the maximum rating specified for the boiler. This corresponds to 109.94% of Turbine maximum continuous rating. Turbine Maximum Continuous Rating (TMCR): Turbine Maximum Continuous Rating (TMCR) is the basis of steam generator output and is equal to the turbine generator maximum guaranteed rating.
BFP
Economizer
Separator
Superheater
Division Superheater
Platen Superheater
Final Superheater
HP TBN
Water separator
HP BPV
Reheater
IP
t
Evaporator BCP Deaerator
LP
Condenser
Economizer
COP HP HTR BFP LP BPV LP HTR Fig-3 Cycle of supercritical power plant
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International Journal of Mechanical Engineering and Technology (IJMET), ISSN 0976 6340(Print), ISSN 0976 6359(Online) Volume 3, Issue 2, May-August (2012), IAEME
(1 L ) X 100 [%] H f + Ba
.......................................1
Where, H f : Higher heating value of fuel [J/kg] Ba : Total heat credit [J/kg]
Load
80
100 supercritical
120
(b) Furnace (Radiation) The radiation heat absorption of subcritical boiler in furnace is less than that of supercritical boiler at every load.
Load 80
100
120
subcritical
supercritical
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International Journal of Mechanical Engineering and Technology (IJMET), ISSN 0976 6340(Print), ISSN 0976 6359(Online) Volume 3, Issue 2, May-August (2012), IAEME
(c) Furnace (Convection) The convection heat absorption of supercritical boiler in furnace is twice more than that of subcritical boiler.
20
40
120
(d) Primary Superheater The heat absorption rate in primary superheater of supercritical boiler is twice more than that of subcritical boiler.
(e) Secondary superheater The heat absorption rate in secondary superheater of subcritical boiler is 3 times more than that of supercritical boiler.
Load
80 supercritical
100
120
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International Journal of Mechanical Engineering and Technology (IJMET), ISSN 0976 6340(Print), ISSN 0976 6359(Online) Volume 3, Issue 2, May-August (2012), IAEME
(f) Final Superheater The heat absorption rate in final superheater of subcritical boiler is approximately the same that of supercritical boiler.
40
60 Load subcritical
80 100 supercritical
120
(g) Primary Reheater The heat absorption rate in primary reheater of subcritical boiler is 10 times more than that of supercritical boiler.
20
40
60 subcritical
Load
80 supercritical
100
120
(h) Final Reheater The heat absorption rate in final reheater of subcritical boiler is much more than that of supercritical boiler.
40
60 subcritical
Load
80 supercritical
100
120
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International Journal of Mechanical Engineering and Technology (IJMET), ISSN 0976 6340(Print), ISSN 0976 6359(Online) Volume 3, Issue 2, May-August (2012), IAEME
(i) Air Preheater The heat absorption rate in air preheater of subcritical boiler is much more than that of supercritical boiler.
40
60 subcritical
Load
80 100 supercritical
120
(j) Heat Absorption Rate of Each Part in Boiler The heat absorption rate in water wall of supercritical boiler is approximately twice more than that of subcritical boiler. The heat absorption rate in economizer of subcritical boiler is approximately 4 times more than that of supercritical boiler.
Efficiency of Boiler
The boiler efficiency of supercritical boiler is a little lower than that of subcritical boiler.
100 80 60 40 20 0 Subcritical
Boiler Efficiency
Total Loss
Supercritical
CONCLUSIONS Analysis shows that higher output can be obtained with high temperature steam at supercritical pressure comparing with the output of subcritical units operating with same steam flow rates. Thermal efficiency of supercritical plant is high as well as emission is also reduced due to higher efficiency. Performance of supercritical boiler is calculated by different graphical representation and it is compared to subcritical boilers curves. The increased pressure also increases cycle efficiency and, although this effect is a second-order effect compared with the effect of temperature, it can still make 428
International Journal of Mechanical Engineering and Technology (IJMET), ISSN 0976 6340(Print), ISSN 0976 6359(Online) Volume 3, Issue 2, May-August (2012), IAEME an important contribution to increasing overall plant efficiency. However Supercritical boilers operate in a higher pressure and temperature zone as compared to subcritical boilers leading to increased thermal efficiencies. REFERENCES 1. Bejan A., Tsatsaronis, G., and Moran A., 1996, Thermal Design and Optimization, Wiley, New York. 2. Kotas T.J., 1985, The Exergy method of Thermal Power analysis, Butterworth. 3. Nag P.K., Power plant engineering, 2nd Ed., Tata Mc Graw Hill, New York, 1995. 4. Dr. gupta A.V.S., second low analysis of super critical cycle. 5. Viswanathan, R., 2001, Boiler materials for ultra supercritical coal power plants, USC Materials quarterly report, EPRI Inc., Oct-Dec 2001. 6. Kiameh, P. (2002), Power Generation Handbook, McGraw-Hill Handbooks. 7. Rajput, R.K. (2001), Thermal Engineering, Laxmi, New Delhi. 8. Babcock & Wilcox power generation groups technical papers.
Operating condition
BMCR
Steam flow superheater kg/hr Steam flow reheaters kg/hr 0 Steam temp. superheater c 0 Steam temp. reheaters c 0 Reheat entering temp. c Reheat entering pressure bar 0 Feed water temperature c Boiler efficiency % 2225,000 1741,820 540 568 299 45.39 289.64 86.28
Table 2
performance
load Steam flow superheater kg/hr Steam flow reheaters kg/hr 0 Superheater outlet temp. c Superheater outlet press. bar 0 Reheat inlet temp. c 0 Reheat otlet temp. c Reheat inlet pressure bar Reheat oulet pressure bar Reheat pressure drop. bar 0 Feed water temperature c Fuel fired kg/hr Efficiency % BMCR 2225,000 1,741,820 540 250 299 568 46.37 44.71 1.65 289.64 471800 86.28 TMCR 2,023,750 1,678,370 540 248.48 296 568 44.80 43.21 1.58 286.23 438100 86.29 429 80%TMCR 1,572,470 1,328,960 540 232.35 281 568 35.49 34.21 1.27 270.35 354900 86.69 60%TMCR 1,158,410 996,950 540 174.92 286 568 26.56 25.56 1.0 254.09 272400 86.88
International Journal of Mechanical Engineering and Technology (IJMET), ISSN 0976 6340(Print), ISSN 0976 6359(Online) Volume 3, Issue 2, May-August (2012), IAEME
Table 3
performance
load Steam flow superheater kg/hr Steam flow reheaters kg/hr 0 Superheater outlet temp. c Superheater outlet press. bar 0 Reheat inlet temp. c 0 Reheat otlet temp. c Reheat inlet pressure bar Reheat oulet pressure bar Reheat pressure drop. bar 0 Feed water temperature c Fuel fired kg/hr Efficiency % 50% TMCR 963,760 836410 540 147.30 289 568 22.15 21.29 .86 244.34 231100 86.85 30% TMCR 596,100 517200 540 91.0 294 540 13.33 12.77 .55 219 147300 86.24 Both HPH out 1,839,500 1,784,200 540 246.98 309 568 48.52 46.86 1.66 196.15 463100 87.31
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