Seminar Report

On

SUPERCRITICAL TECHNOLOGY IN POWER

PLANT
Submitted to
UNIVERSITY OF PUNE
Submitted By

Mr. GANESH VASANT NIRGUDE

DEPARTMENT OF MECHANICAL
ENGINEERING ShriChhatrapatiShivaji College Of
Engineering
Shrishivajinagar (Rahuri Factory),
Tal: Rahuri, Dist: Ahmednagar.

Academic Year 2012-2013

ShriChhatrapatiShivaji College Of Engineering
Shrishivajinagar (Rahuri Factory),
(Recognized by Pune University)

Department of Mechanical Engineering,

CERTIFICATE

This is to certify that the seminar report entitled

SUPERCRITICAL TECHNOLOGY IN POWER

PLANT
Is submitted as partial fulfillment of curriculum of T.E. Mechanical
Engineering. Conferred by the University of Pune.

By Mr. GANESH VASANT NIRGUDE

Prof . Shelke S.V.

Prof. Pandharkar U.J

(Seminar Guide)

(Seminar Co-

ordinator)
Prof.Dongare A.D.
(Head of department)

University of Pune

CERTIFICATE
This is to certify that
Mr. GANESH VASANT NIRGUDE
Student of T.E. Mechanical engineering was examined in the
seminar Presentation entitled
On 23 / 10/ 2012

SUPERCRITICAL TECHNOLOGY IN
POWER PLANT
At
Department of Mechanical Engineering,

Shri Chhatrapati Shivaji College Of Engineering.

Prof.Shelke S.V.

Prof.Pandharkar. U.J

(SeminarGuide)

(Seminar Co-ordinator)

ACKNOWLEDGEMENT
Every orientation work has imprint of many people and this work is no
different. This work gives me an opportunity to express deep gratitude for
the same.
While preparing seminar report I received endless help from number of
people. This report would be incomplete if I dont convey my sincere
thanks to all those who were involved.
First and foremost I would like to thank my respected guide Prof. .Seminar
coordinator Prof.Pandharkar U.J. and HOD Prof.Dongare

A.D.

(Department of Mechanical Engineering) for giving me an opportunity to

present this seminar and there indispensable support, priceless suggestions
and valuable time.
Finally, I wish to thanks my friends and my family for being supportive of
me, without whom this seminar would not have seen the light of day.
Every work is an outcome of full-proof planning, continuous hard work
and organized effort. This work is a combination of all the three put
together sincerely.
Mr. Nirgude Ganesh Vasant

SR
NO
1

TOPIC
ABSTRACT
INTRODUCTION

PAGE
NO
1-5

1.1Basic rankine cycle

1.2Energy Analysis of the Rankine Cycle
2

SUPERCRITICAL RANKINE CYCYLE

2.1Supercritical technology
2.2 Efficiency
2.3 Definition
DESIGN AND WORKING

6-8

3.1 Boiler Design

i.
Boiler shell

9-10

3.2 Working
4

MATERIAL SELECTION
4.1 Metallurgical Problems
4.2 Materials used

11-13

SUPERCRITICAL BOILERS
5.1 A typical Supercritical Boilers

14-15

5.2 Super and Sub Critical Boilers (comparative study)

6

ADVANCE IN SC TECHNOLGY AND FUTURE IN INDIA

6.1 Natural Gas Production with a Supercritical Geothermal

16

Power
7
8

CONCLUSION

17
18

REFERENCES

LIST OF CONTENENT
ABSTRACT
This paper reviews the major technical and performance aspects of a coal fired plan
using the supercritical technology. These include the turbine-generator set, the oncethrough boiler, and operational issues such as load change, fuel flexibility, and water.
Reviewing the possibilities for the design and manufacture of components for
supercritical-fired plants in developing countries, the paper notes that the differences
between sub critical and supercritical power plants are limited to a relatively small
number of components; primarily the feedwater pumps and the high pressure feedwater
train equipment. All of the remaining components, common both types of plants, can be
manufactured in developing countries. The paper concludes with a review of the
Schwarze Pumpe - the world's largest supercritical lignite fired steam power plant.The
primary purpose of the study is to assess whether supercritical thermalplant technology
is a proven and mature commercial technology and whether .They operate at
supercritical pressure. In contrast to a "subcritical boiler", a supercritical steam
generator operates at such a high pressure (over 3,200 psi or 22 MPa) that actual
boiling ceases to occur, the boiler has no liquid water - steam separation. There is no
generation of steam bubbles within the water, because the pressure is above the critical
pressure at which steam bubbles can form. It passes below the critical point as it does
work in a high pressure turbine and enters the generator's condenser. This results in
slightly less fuel use and therefore less greenhouse gas production. The term "boiler"
should not be used for a supercritical pressure steam generator, as no "boiling" actually
occurs in this device.

1 INTRODUCTION
1.1 Basic Rankine Cycle:
The Rankine cycle is the oldest functional heat cycle utilized by man. The
Rankine cycle is the very a basic vapor power cycle which is adopted in all the thermal
power plants. It is a four step process (Figure 1.1) which involves the heating of the
working fluid to its saturation temperature and vaporizing it isothermally, expanding
the vapor on a turbine (work cycle), condensing the steam isothermally to the liquid
phase and pumping it back to the boiler.

Figure 1.1.1 Basic Rankine Cycle

Figure 2 represents the temperature-entropy diagram for the simplest version of
the Rankine cycle. Although this simple version is rarely used it gives a very clear
and simple picture on the working of the cycle.
Process 1-2 is the pumping of the working fliud (water) into the boiler
drum. The power required is derived from the overall power developed. Process
2-3 is the heating of the water upto its saturation temperature (100C at 1 atm
pressure for water) is reached and then isothermal heating of the water where the
phase change from liquid to vapor occurs. Points 3 lie on the saturated vapor line.
The steam here is completely dry. Process 3-4 is the adiabatic expansion of the

vapor/steam on the turbine to obtain mechanical work. It is an isentropic process.

The temperature of the steam is reduced and it falls below the saturated vapor
line. The dryness fraction is reduced to less than one and a mixed liquid vapor
phase is present. Process 4-1 is the condensation process. This mixture is
condensed in a condenser isothermally and brought to the liquid phase back to the
pump.

FIGURE 1.1.2 Temperature vs. Entropy diagram for Rankine cycle

The steam is however, usually, superheated so as to obtain more work output.
Increasing the superheat to greater extent would lead to more work output.
However the energy spent in superheating the fuel is also high. The overall effect
is an increase in the thermal efficiency since the average temperature at which the
heat is added increases. Moisture content at the exit of the steam is decreased as
seen in the figure 1.3.
Superheating is usually limited to 620C owing to metallurgical considerations.

Figure1.1.3 Rankine cycle with superheating

1.2 Energy Analysis of the Rankine Cycle:

All four components in the Rankine Cycle (pump, boiler, turbine and
condenser) are steady flow devices and thus can be analyzed under steady flow
processes. K.E and P.E changes are small compared to work and heat transferred and is
thereby neglected.
Thus the steady flow equation (per unit mass) reduces to:
Q+hini = W+hfinal
Boiler and condenser do not involve any work and pump and turbine are assumed
to be isentropic. The conservation of Energy relation for each device is expressed
as follows:
Steam turbine:
As the expansion is adiabatic (Q=0) and isentropic (S3=S4), then,
W3-4=Wturbine= (h3-h4) kJ/kg

Condenser:
Heat rejected in the condenser, Q4-1+h4=h1+W4-1
Since W4-1=0, Q4-1=h1-h4

Thus,
Q4-1=-(h4-h1) kJ/kg

Pump:
Work required to pump water:
Wpump=h1-h2 kJ/kg (-ve work)

Boiler:
Heat added in boiler:
Q2-3=h3-h2 kJ/kg=h3-h1-Wpump kJ/kg

Thus, the Rankine Efficiency=Work done/Heat added

= (h3-h4-Wp) / (h3-h1-Wp)
Neglecting feed pump work as it is very small compared to other quantities, the
efficiency reduces to:
rankine= (h3-h4) / (h3-h1).

1.3 Factors increasing the Rankine Efficiency:

i.

Lowering the condenser pressure:

Lowering the condenser pressure would lead to the lowering of temperature os

steam. Thus for the same turbine inlet state, more work is obtained at lower
temperatures.
This method though cannot be extensively used as it reduces the dryness
fraction x of the steam. This is highly undesirable as it decreases the turbine efficiency
is reduced due to excessive erosion of the turbine blades.
ii.
Superheating the steam to high temperature:
There is an increase in the work output if superheating of steam is done. It
increases the thermal efficiency as the average temperature at which heat is added
increases.
There is also another benfit of superheating; the steam at the exit of the turbine
is drier than in case of non superheated steam.

10

iii.

Increasing the boiler pressure:

Increasing the boiler pressure raises the average temperature at which heat is

added and thereby increases the theramal efficiency. However the dryness fraction
decreases for the same exit temperature of the boiler. This problem can be solved by
employing reheating procedure. If however the boiler pressure is raised to supercritical
point greater efficiency is obtained as the latent heat absorbed during phase change is
reduced to zero.

SUPERCRITICAL RANKINE CYCYLE

2.1 Supercritical technology:

When temperature and pressure of live steam are increased beyond the critical
point of water, the properties of steam will change dramatically. The critical point of
water is at 374 C and 221.2 bar (218 atm), Figure 2.1, and it is defined to be the point
where gaseous component cannot be liquefied by increasing the pressure applied to it.
Beyond this critical point water does not experience a phase change to vapor, but it
becomes a supercritical fluid. Supercritical fluid is not a gas or liquid. It is best
described to be an intermediate between these two phases. It has similar solvent power
as liquid, but its transport properties are similar to gases.

11

Figure 2.1.1 Phase diagram of water

2.2Efficiency:
The Rankine cycle can be greatly improved by operating in the supercritical
region of the coolant. Most modern fossil fuel plants employ the supercritical Rankine
Steam Cycle which pushes the thermal efficiency of the plant (see equation 4) into the
low to mid 40% range.
supercritical = (h2-h1-h3+h4 )/( h2-h1)

-(eqn 4)

2.2 Definition:

12

Figure 2.2.1 T-S diagram for supercritical Rankine cycle

For water, this cycle corresponds to pressures above 221.2 bar and temperatures
above 374.15C (647.3 K). The T-S diagram for a supercritical cycle can be seen in
Figure 6. With the use of reheat and regeneration techniques, point 3 in Figure 2.1,
which corresponds to the T-S vapor state of the coolant after it has expanded through a
turbine, can be pushed to the right such that the coolant remains in the gas phase. This
simplifies the system by eliminating the need for steam separators, dryers, and turbines
specially designed for low quality steam.

Material Concerns:
The primary concern with this cycle, at least for water, is the material limits of
the primary and support equipment. The materials in a boiler can be exposed to
temperatures above their limit, within reason, so long as the rate of heat transfer to the
coolant is sufficient to cool the material below its given limit. The same holds true
for the turbine materials. With the advent of modern materials, i.e. super alloys and
ceramics, not only are the physical limits of the materials being pushed to extremes, but
the systems are functioning much closer to their limits. The current super alloys and

13

coatings are allowing turbine inlet temperatures of up to 700C (973 K). the fourth
generation super alloys with ruthenium mono-crystal structures promise turbine inlet
temperatures up to 1097C (1370 K). Special alloys like Iconel 740, Haynes 230,
CCA617, etc. are used.

The metallurgical challenges faced and solutions:

Normal Stainless steel proves of absolutely no use in building SC and USC

Boilers.
The high temperature and pressure in the boiler induce huge amount of stresses
and fatigue in the materials. Also chances of oxidation are very high at such high

temperature and pressure.

To resist these stress levels and oxidation different advanced materials and alloys

should be introduced.
Also they should me machinable and weldable. This is a great metallurgical
challenge.

3 DESIGN AND WORKING

3.1 Boiler Design:
The design of Super and Ultra supercritical boilers (also called as Benson
Boiler) is very critical as the working pressures of these boilers are very high. The
boiler shells, the economizer unit, super heaters, air preheaters are specially designed.
Their location is also of great significance.
i.
Boiler shell:
As shown in the figure 3.1 the geometry of the boilers and the configuration of
the inlets determine the recirculation pattern inside boiler. The intensive recirculation
created in the symmetric boiler results in a more uniform temperature field, lower

14

temperature peaks, moderate oxygen concentration and complete burnout of the

combustible gases and char

Fig 3.1.1 Predicted Recirculation inside the combustion chamber

Table 3.1 lists the peak temperatures and burnout for designs A, B and C. the table also
lists the standard deviations of the predicted temperature and oxygen fields. The lowest
values for C indicate the higher degree of homogeneity. Thus the symmetrical boiler
seems to be the most suitable design.

ii.

Location of burners:
The number of burners in the boiler shell is also of prime importance. Amongst

all of them the downfired boilers are most suitable and advantageous. Table 3.2 gives a
clear idea.
iii.
Boiler dimensions:
One of the most important advantages of HTAC applications are high heat
fluxes. Thus, compact combustion chambers can be built and the investment costs can
be lowered. The fourth calculation series was carried out in order to find the
combustion chamber dimensions which can, on one hand, ensure an efficient heat
exchange between combustion gas and water/steam mixture and on the other hand,
ensure high values of firing density. Three different sizes are tested and they are named
in as the small boiler, the medium size boiler and the large boiler .It has been observed
(see Table 3.3) that the small boiler is too short. At the top a region of high

15

temperatures exists and its enthalpy cannot be efficiently used. On the contrary, in the
large boiler although the heat fluxes are uniform, they are two times lower than in the
medium size boiler. Therefore, the medium size boiler configuration is chosen for
further investigations.

Firing Density

Small boiler
774

Medium size boiler

238

Large boiler
89

kW/m3
Outlet temperature,

1805

1558

1299

K
Table3.1.1 Results of the boiler size determination
3.2 Working:
As already discussed, the working of Supercritical Boilers is similar to the
working of sub-critical boilers. It works on the supercritical rankine cycle. Most
supercritical boilers are being run at operating pressures above of 235 bars. The
working of ultra supercritical boilers has operating pressures above 273 bars
4

MATERIAL SELECTION

4.1 Metallurgical Problems:

The available materials today like stainless steel which are usually used for
boiler parts are not suitable for SC and USC boilers. They do not have the enough creep
strength to resist the high pressure. Also there is high rate of oxidation at such high
temperature and pressures which are beyond the capability of these materials to resist.
Capable, qualified materials must be available to the industry to enable development of
steam generators for SC steam conditions. Major components, such as infurnace tubing
for the waterwalls, superheater/ reheater sections, headers, external piping, and other
accessories require advancements in materials technology to allow outlet steam
temperature increases to reach 760C (1400F). Experiences with projects such as the
pioneering Philo and Eddystone supercritical plants and the problems with the stainless
steel steam piping and superheater fireside corrosion provided a valuable precautionary
lesson for SC development. Industry organizations thus recognized that a thorough

16

program was required to develop new and improved materials and protection methods
necessary for these high temperature steam conditions.
4.2 Materials used:
The materials used should be sustainable to the very high pressure being
developed and should not get oxidized due to the very high temperature. Different high
temperature materials are being used like 9 to 12% ferritic steels T91/P91, T92/P92,
T112/P122 steel, Advanced Austenitic alloys TP347, HFG, Super 304, Nickel and
chrome-nickel super alloys like Inconel 740.
Table 4.2 gives a very brief idea about the boiler materials used for different
parts of the boiler.

Heat surface
Economiser
Furnace Walls
Super
heater/Reheater

Tube material
SA-210 C
SA-213 T12
SA-213 T12
SA-213 T23
SA-213 TP 304H
SA-213

Header material
SA-106 C
SA-106 C
SA-335 P12
SA-335 P91
SA-335 P911

TP347HFG
SUPER 304H
Steam Piping
SA 335 P91
Table 4.2.1 Materials for different boiler parts

The materials for the other parts of the power plant (like turbine) also must be
sustainable for the super critically heated steam. The following table gives a detail idea
on the turbine materials of a plant operating on a supercritical cycle. (Table 4.3)

17

Component

1,050 F

1,150 F

Casings

CrMoV (cast)

910% Cr (W)

(shells, valves,
steam chests,
nozzles)

10CrMoVMb

12CrW (Co)
CrMoWVNbN

1,300 F
CF8CPlus

CCA61
7

CCA617

Inconel
740

Inconel
625
Nimonic
263

Bolting

422

912% CrMoV

912%
CrMoV

CrMoWVNbN

Nimonic 80A

Rotors/Discs

Nozzles/Blade
s

Nimoni
c 105

Nimonic
115

Nimoni
c 115

Waspalo
y

U700
CCA61
7

912 % CrWCo

CCA617

12CrMoVNb
N

12CrMoWVNb
N

Inconel
625

422

912% CrWCo

10CrMoVNb
N

10CrMoVCbN

Wrought
Ni-based

18

CF8CPlus

Nimonic
105

1CrMoV

Table 4.2.2 Materials for other parts

1,400
F

Inconel
740
Wrough
t
Nibased

The following figures show some of the materials used for SC and USC boilers. Iconel
740 is widely used for steam pipings in almost all of them.

Figure 4.1 TP347HFG

Figure 4.2 Iconel 740

5 SUPERCRITICAL BOILERS
5.1 A typical Supercritical Boilers:
Largest CFB and first supercritical CFB sold to date is the Lagisza 460 MWe
unit Ordered by Poludniowy Koncern Energetyczny SA (PKE) in Poland. The design is
Essentially complete with financial closing expected in the first quarter of 2006 at
which time Fabrication and construction will commence. The largest capacity units in
operation today are the two (2) 300 MWe JEA repowered units which were designed to
fire any Combination of petroleum coke and bituminous coals. The physically largest
Foster Wheeler boilers in operation are the 262 MWe Turow Units 4, 5, and 6 which
were designed to fire a high moisture brown coal. The design and configuration of these
units with Compact solids separators and INTREX heat exchangers were used as the
basis for the Lagisza design as well as for this study. The Lagisza design was adjusted
to accommodate a typical bituminous coal and the steam cycle.

19

Figure 5.1.1 The Lagisza 300 MWe plant in Pola

5.2 Super and Sub Critical Boilers (comparative study):
There are many advantages of super critical boilers over normal
subcritical boilers, the prime advantage being the increased efficiency and reduced
emissions. There are many more advantages like no need of steam dryers, higher
operating pressures leading to more work output etc.
It is thus very important to have a comparative study of both the
boilers.
Technology

Efficiency (%)

Ultra Supercritical
3335

Supercritical

Steam

Typical emissions

pressure/temperature
>242
bar
and

SO2-0.408 kg/MHh

593.33C

NOx-0.286
kg/MWh

3640

>221.2
537C

bar

and

CO2-0.96 T/MWh
SO2-0.431 kg/MHh
NOx-0.304
kg/MWh

20

Subritical

165 bar 537C

4245

CO2-1.02 T/MWh
SO2-0.445 kg/MHh
NOx-0.31 kg/MWh
CO2-1.02 T/MWh

Table 5.2.1 Comparison of sub and supercritical boilers

ADVANCE IN SC TECHNOLGY AND FUTURE IN INDIA

6.2 Supercritical Boilers in India:

There havent been any supercritical boilers in use in India so far. The European
countries, USA, Japan have been using supercritical technology since the last two
decades. However, there are upcoming projects to build power plants working under
the supercritical technology in India.
The National Thermal Power Corporation (NTPC) had entrusted a techno
economic study to M/s EPDC for super-critical Vs Sub-critical Boilers for their
proposed Sipat STPS (4x500 MW) in Madhya Pradesh.
M/s EPDC has recommended that a first step to the introduction of supercritical technology, the most proven steam conditions may be chosen and the most
applicable steam conditions in India shall be 246 kg/cm2, 538 C/566 C. With these
steam parameters, M/s EPDC has estimated that the capital cost for a supercritical
power station (4x500 MW) shall be about 2% higher than that of sub-critical power
plant but at the same time the plant efficiency shall improve from 38.64% to 39.6%.

21

Being a pit head thermal power project, the saving in fuel charges is not justified by
increase in fixed charges.
Here are some upcoming projects in India:

North Karanpura, Jharkhand 3x660 MW

Darlipali, Orissa 4x800 MW

Lara, Chattisgarh 5x800 MW

Marakanam, Tamilnadu 4x800 MW

Tanda-II, Uttar Pradesh - 2x660 MW

Meja, Uttar Pradesh - 2x660 MW

Sholapur 2x660 MW

New Nabinagar-3x660 MW

Many more projects including 800 MW ultra super critical units under
consideration
7

CONCLUSION

The supercritical Rankine cycle, in general, offers an additional 30% relative

improvement in the thermal efficiency as compared to the same system operating in the
subcritical region. The cycle has been successfully utilized in fossil fuel plants but the
current available materials prohibit reliable application of the supercritical cycle to
nuclear applications. There is much work to be done in order to advance materials to
the point where they will be able to reliably withstand the stresses of a supercritical
environment inside a nuclear reactor for a designed life span of 60 years.
Supercritical boiler technology has matured, through advancements in design
and materials. Coal-fired supercritical units supplied around the world over the past
several years have been operating with high efficiency performance and high
availability.

22

REFERENCES
1. Design Aspects of the Ultra-Supercritical CFB Boiler; Stephen J.
Goidich, Song Wu, Zhen Fan; Foster Wheeler North America Corp.
2. Novel conceptual design of a supercritical pulverized coal boiler utilizing
high temperature air combustion (HTAC) technology; Natalia SchaffelMancini, Marco Mancini, Andrzej Szlek, Roman Weber; Institute of
Energy Process Engineering and Fuel Technology, Clausthal University of
Technology, Agricolastr. 4, 38678 Clausthal-Zellerfeld, Germany; 6
February 2010.
3. Supercritical (Once Through) Boiler Technology; J.W. Smith, Babcock
& Wilcox, Barberton, Ohio, U.S.A.; May 1998.
4. Steam Generator for Advanced Ultra-Supercritical Power Plants 700 to
760C; P.S. Weitzel; ASME 2011 Power Conference, Denver, Colorado,
U.S.A; July 12-14, 2011.
5. Supercritical boiler technology for future market conditions; Joachim
Franke and Rudolf Kral; Siemens Power Generation; Parsons Conference;
2003.

23

6. Steam Turbine Design Considerations for Supercritical Cycles; Justin

Zachary, Paul Kochis, Ram Narula; Coal Gen 2007 Conference;1-3
August 2007.
7. Technology status of thermal power plants in India and opportunities in
renovation and modernization; TERI, D S Block, India Habitat Centre,
Lodi Road, New Delhi 110003.
8. Applied Thermodynamics; Dr. H.N Sawant; January 1992; revised July
2004.
9. http://en.wikipedia.org/wiki/Boiler#Supercritical_steam_generator

24