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The Benson boiler is the most widely used type of once-through boiler due to its high capacity and excellent operating characteristics. It can operate at steam pressures up to 350 bar and temperatures over 600°C. About a quarter operate at supercritical pressures. Benson boilers are highly efficient and can undergo rapid load changes. They have proven performance with over 1,000 units installed worldwide, making them popular in Europe, Japan, and South Africa. The document discusses the boiler's design capabilities and flexibility to use various fuels.
The Benson boiler is the most widely used type of once-through boiler due to its high capacity and excellent operating characteristics. It can operate at steam pressures up to 350 bar and temperatures over 600°C. About a quarter operate at supercritical pressures. Benson boilers are highly efficient and can undergo rapid load changes. They have proven performance with over 1,000 units installed worldwide, making them popular in Europe, Japan, and South Africa. The document discusses the boiler's design capabilities and flexibility to use various fuels.
The Benson boiler is the most widely used type of once-through boiler due to its high capacity and excellent operating characteristics. It can operate at steam pressures up to 350 bar and temperatures over 600°C. About a quarter operate at supercritical pressures. Benson boilers are highly efficient and can undergo rapid load changes. They have proven performance with over 1,000 units installed worldwide, making them popular in Europe, Japan, and South Africa. The document discusses the boiler's design capabilities and flexibility to use various fuels.
by JOACHIM FRANKE and RUDOLF KRAL BENSON BOILER Power for generations Excellent performance features make the Benson boiler the most widely used type of once-through boiler 1 of 4 Siemens power journal online, October 2001 With a total of more than 1,000 units having established a proven track record over many years in the power generation industry, the Benson boiler is the most commonly used type of once-through boiler. It operates at power levels of up to 1300 MW, steam pressures of up to 350 bar and steam temperatures of up to more than 600C. About a quarter of the units operate at supercritical pressures. Given its performance features and op- erating characteristics, it is no surprise that Benson technology has been success- ful. Up to now, its use has been most wide- spread in central Europe, Japan and South Africa, but numerous countries are show- ing growing interest in this technology. Convincing Technology Steam generators using the Benson de- signone pass through the evaporator section and variable endpoints of evapora- tionincorporate features which are criti- cal to economic success in todays compet- itive power markets. These features in- clude a highly efficient steam/water cycle as a result of supercritical pressures and high steam temperatures, ability to undergo rapid load changes due to a design that allows unconstrained thermal expansion and a variable-pres- sure operating mode in the part-load range, BENSON BOILER Best Choice High capacity and excellent operating characteristics are main features of the Benson boiler, making it the most widely used type of once-through boiler by Dr. JOACHIM FRANKE, expert on Benson boiler technology, in charge of licensing and continued development of this steam generator type, Siemens Power Generation and RUDOLF KRAL, expert for steam generator technology in the engineering sector and technical consultant to Benson licensees, Siemens Power Generation insensitivity of steam out- put and superheated steam temperature to fluctuating fuel properties. Benson boilers are equally well suited for both subcritical and supercritical pressures; steam pressure is limited al- most solely by the properties of the materials used. Due to a design that allows uncon- strained thermal expansion no drum, low storage mass- esBenson boilers are ideal for use in the mid- and peak- load operating ranges. The variable-pressure operating mode prevents stressing of the steam turbine materials due to changes in temperature. Environmental protection also benefits due to the low specific exhaust gas emissions achieved as the result of high efficiencies, as well as through the use of low-NO x combus- tion methods and proven, powerful flue-gas cleaning processes. Performance Features Highest Steam Pressures and Temperatures Supercritical steam pres- sures were already being used in central Europe in the 1960s, while superheated steam tem- peratures remained in the 540C/560C range until the mid-1990s. The 550-MW Unit 5 Steam Turbines & Power Plants Furnace of a 930-MW lignite- fired unit under construction 2 of 4 Siemens power journal online, October 2001 at the Staudinger power plant in Germany is representative of this level of technolo- gy with supercritical steam pressure at full load and outlet temperatures of 545C (with HP superheater) or 562C (with re- heater). Other features of this unit include variable-pressure operation and a net effi- ciency of 43%. At these steam temperatures, well- proven and cost-effective ferritic materi- als are adequate for the end stages of the high-pressure and reheater heat-ex- change surfaces. At higher temperatures, more advanced ferritic chromium steels are required for the thick-walled compo- nents, while austenitic materials are re- quired for the final superheater heat-ex- change surfaces. The value of such materi- als has been proven over many years of service in the Benson boilers of the Danish Nordjyllandsvaerket and Skaerbekvaerket power plants, for example, at steam tem- peratures of 580C. Operating experience at 600C has to date been gained only from boilers in Japan. Today, state-of-the-art developments in materials permit steam temperatures of up to 600C (with HP superheater) or 620C (with reheater). Variable Designs Depending on plant-specific require- ments, Benson boilers are of single- or double-pass design. The single-pass steam generator has clear operational advantages when coals with a high ash content or severely corro- sive ash are used, since there is no reversal of the flue gases and thus no additional ash concentration in the vicinity of the heat-exchange surfaces. All modern Euro- pean lignite-fired steam generators are therefore of the single-pass design. Other advantages of this type of steam genera- tor include single-wall design with its fa- vorable unconstrained thermal expansion characteristic. The double-pass steam generator is characterized by its low height and a com- pact combustion chamber which, along with the two separate flue-gas paths, pro- vides advantages in terms of installation options. Moreover, the separate cross sec- tions of the second pass and combustion chamber make it possible to optimize the configuration of the convective heat-ex- change surfaces, and thus also their size. A typical example of the double-pass design is the hard-coal-fired steam generator at the Hemweg power plant in The Nether- lands. Flexible Use of Fuel Since Benson boilers can be designed to accommodate a wide range of coal types, plant operators are able to use the lowest- priced coal available. The combustion chamber size and shape, the firing system and the thermodynamics of the boiler are then matched to the combustion proper- ties of the range of fuels in question. Due to the variable endpoint of evaporation, the combustion chamber can be dimen- Steam Turbines & Power Plants Staudinger plant, Unit 5 550 MW el ; hard-coal-fired 417 kg/s main steam 285 bar, 545C/562C Germany Nordjyllandsvaerket plant 410 MW el ; imported coal 270 kg/s main steam 310 bar, 582C/580C Denmark Hemweg plant 660 MW el ; imported coal 530 kg/s main steam 261 bar, 540C/540C The Netherlands sioned solely in accordance with the corre- sponding firing characteristics. One advantage of Benson boiler opera- tion is that the required steam output and main steam temperature are always achieved, even if the properties of the coal are highly variable. A prime example is the Benson boiler at the Staudinger power plant, which is capable of firing a wide range of coalsfrom highly volatile hard coals up to and including anthracitein its amply dimensioned combustion cham- bers with opposed firing. Benson boilers can be outfitted with various types of firing systems. In addi- tion to conventional pulverized-coal fir- ing, systems with liquid-ash separation, with circulating fluidized beds, for exam- ple, as well as systems for firing biomass can be used. Examples are the boiler with liquid-ash removal at the 660-MW Ibben- bren power plant that has two slag-tap furnaces with a common gas radiation chamber, as well as the boiler with circu- lating fluidized-bed firing at the 100-MW Moabit power plant. At the Moabit plant the fluidized-bed coolers, in addition to the walls of the combustion chambers and the ash cyclone, are also utilized as evaporators. In Demand Worldwide In Germany, hard-coal-fired Benson boilers in the 800-MW to 1000-MW out- put range have been operating successful- ly and at high availability levels for several years. The two 930-MW units at the Lip- pendorf power plant achieved this same output using lignite, a much more prob- lematic fuel. A steam generator of the same capacity is also installed at the Box- dorf power plant. These Benson boilers are among the largest in the world, with a combustion chamber cross section of 2424 m and a boiler height of more than 160 m. As early as the 1950s and 1960s, a num- ber of power plants built in the U.S. were operating at supercritical steam pressure. Since the boilers used at that time were only marginally suitable for variable-pres- sure operation, American manufacturers today are also setting their sights on mod- ern Benson boiler technology. Although the American market has seen almost no new plants built since the mid-1980s, this technology is being used successfully for export. In Japan, the development trend in re- cent years has been toward very high steam pressures and temperatures. Since 1980, once-through boilers have been es- sentially the only type used in power plants in Japan, about half of them Ben- son boilers operating at supercritical pres- sures. Steam generators operating super- heated steam temperatures of 600C and with capacities of up to 1000 MW have al- ready been in operation for many years. In Japan, traditional preference has been giv- en to the double-pass design, such as that used at the Hekinan power plant. Due to the low ash content of the coals used, the operational advantages of the single-pass design with regard to wear and tear of the heat-exchange surfaces would not be sig- nificant. Steam Turbines & Power Plants Ibbenbren plant 750 MW el ; anthracite 600 kg/s main steam 220 bar, 530C/530C Germany Hekinan plant 700 MW el ; imported coal 639 kg/s main steam 255 bar, 543C/569C Japan Lippendorf plant 930 MW el ; lignite 672 kg/s main steam 285 bar, 554C/583C Germany 3 of 4 Siemens power journal online, October 2001 Steam Turbines & Power Plants 4 of 4 Siemens power journal online, October 2001 At the beginning of the 1970s, South Africa recognized the advantages of Ben- son boiler technology. Since that time, twenty-four large units with ratings be- tween 500 and 730 MW have been outfit- ted with Benson boilers. The single-pass design is preferred due to the high ash content of the coal in that region. In China, both drum-type and once- through boilers are used for unit ratings of up to 300 MW. In the future, plants in the 700/900-MW class will be designed only for supercritical steam pressures and tem- peratures. A supercritical, hard-coal-fired, double-pass Benson boiler is currently be- ing designed for the 700-MW Taishan plant. Outlook on Further Development Worldwide use of the Benson boiler is in no small measure the result of ongoing efforts at Siemens Power Generation to further develop this technology. The ex- panded knowledge base obtained through detailed studies, particularly of the heat transfer mechanisms within the combustion chamber tubes, has made an important contribution to this effort. New evaporator designs with vertical tubing will continue to improve operating behavior and make manufacture of the boilers more cost-effective. An initial ref- erence boiler that employs this new evap- orator design is already under develop- ment for refurbishment of a coal-fired 300-MW steam generator in China. The Benson boiler is also ideally suited for even higher steam pressures and tem- peratures (designs for temperatures of 700C with plant efficiencies of more than 50% are being studied as part of the EUs THERMIE project) due to its variable, freely expandable construction and high operat- ing flexibility. I Licensees for Benson Boiler Manufacture FLS milj (Burmeister & Wain) Babcock-Hitachi Kawasaki Heavy Industries Babcock Borsig Power (Deutsche Babcock, Steinmller) Mitsui Babcock Energy BHEL Ansaldo Babcock & Wilcox Foster Wheeler Austrian Energy & Environment Denmark Japan Germany England India Italy USA Austria Leading manufactur- ers around the world are marketing the advantages of Ben- son boiler technolo- gy through licensing agreements. At Siemens, activities related to the Ben- son boiler include boiler design, ther- modynamic and hy- draulic design, start- up systems, control concepts and oper- ating principles. Hekinan Hemweg Staudinger Ibbenbren Lippendorf Nordjyllandsvaerket