ADVANCED

CLEAN TECHNOLOGY
FOR
POWER GENERATION

u ltra s u percritical b oiler s

b oiler s ol u tion s for a world
OF ENERGY
Burmeister & wain energy a/s .......it all began in 1843

Burmeister & Wain Energy A/S is a Danish company with many
years of experience as a supplier of high-tech solutions for the
power generation industry.
The company dates back to a period when Denmarks industrial
development had not yet gained momentum. The history of the
company began in 1843 when a young and enterprising engineer,
Hans Heinrich Baumgarten, was awarded a royal license to establish
a machine shop in Copenhagen.
In 1846 he went into partnership with Carl Christian Burmeister.
Baumgarten retired in 1861 and was succeeded in 1865 by William
Wain, and the company Burmeister & Wain was finally founded in
1872 soon becoming the largest and most important enterprise in
the iron industry of Denmark.
The first once-through Benson boiler was supplied to Masned
Power Station in 1960 and in 1997 the first Ultra Supercritical (USC)
boiler in Europe was supplied to Skrbk Power Station unit 3.
This was followed by the second USC boiler in 1998, Nordjylland
Power Station unit 3 - with a net efficiency above 47% establishing
a world record. In 2001 the first USC Boiler with a unique multi-fuel
firing system was supplied to Avedre Power Station unit 2. The
boiler can utilize coal, HFO, NG and wood pellets as fuel. With the
possibility of operating at full load on 73% biomass as fuel input,
the unit is the largest biomass boiler in the world.

In 1980 Burmeister & Wain Energy A/S (BWE) was established as

an independent company, and in 2002 it was acquired by the Italian
company STF SpA.

The boiler history of Burmeister & Wain has its origins in the
second half of the 19th century when the company supplied steam
for the industrial revolution in Denmark in the shape of marine
boilers, industrial boilers and power station boilers. Throughout
the following century, the company continued to develop the boiler
technology and in 1955 a Benson license for once-through boilers
was acquired.
Vision Advanced Clean Technology in
Boiler Design
To remain a leading supplier of boiler and
environmental technology through technology Fossil fuels and especially coal will be the
supply and engineering services to national main energy source to cover the increased
and international clients. demand for power generation for many years
to come in a growing world.
To be a significant international player in
the upgrading of existing boilers for higher The BWE Advanced Clean Technology in
efficiencies, lower emissions or for conversion boiler design is an important factor in meeting
to alternative fuels. the worlds CO2 reduction target.

To be a significant European player providing By introducing the best available technology

services and maintenance to utilities directly both in new power plants and when retrofitting
or through alliances. existing, the plant efficiency is increased
and consequently the CO2 emissions are
reduced.
. this to ensure and
enjoy a better future The BWE Ultra Super Critical Flex Boiler is
a solution to utilize fossil and biomass fuels
in USC boilers maximizing efficiency, fuel
flexibility and use of renewables.

The first step to make Carbon Capture

and Storage (CCS) viable is to maximize
efficiency.

BWE benefits from being part of the history of The BWE USC Flex boiler and its
power generation in Denmark high efficiency makes the subsequent
implementation of the CCS technology
Since the energy crisis of the early 70s, Danish power industry has been focusing on the feasible.
environment, fuel flexibility and efficiency.

The collaboration of BWE with local utilities has allowed our company to acquire direct
experience with different fuels, biomass combustion, co-combustion, high efficiency and load
flexibility.

BWE is ready to export the Danish example in power generation to the worldwide market.
Sub, Super and Ultra Supercritical Boilers
The background for the USC process is the well-known Rankine
steam cycle which was further developed by BWE during the 1980s BWEreferences
51
and 90s in the form of the Benson, once through principle, from Skrbk3* Avedre2*

PlantEfficiency(LHV)%
49
the subcritical through the supercritical to the ultra supercritical Nordjylland3
47
design. PortoTolle
45
Fyn7
43
Staudinger/Rostock**
41
Asns5
39
Walsum9
37

35
1975 1980 1985 1990 1995 2000 2005 2010 2015 2020
* Natural gas/HFO firing
** Partial scope Year

During the transition period from subcritical to USC, the net

electrical efficiency has increased from 40% to 49%. This transition
process itself has been a step-wise progress and the outcome is
now a success on all major technical features, i.e. the water/steam
process, pulverized fuel combustion and heat transfer.

During the period the steam temperature has increased from

540 C to 600 C and the pressure from 200 bar to 305 bar.

Skrbk Power Station owned by DONG Energy

The history of the Benson once-through
boiler system - supplied on a license from Siemens since 1955
Asns Power Station unit 2 Asns Power Station unit 3 Fyn Power Station unit 7 Nordjylland Power Station unit 3
150MWe, 1961 250MWe, 1967 400MWe, 1991 415MWe, 1998

Operational flexibility in modern coal fired power stations

Modern coal fired power stations should be able to follow demand changes rapidly and at the same time ensure reliability and availability

The Benson Technology and the developed control philosophy follow this need.
Decades of experience designing and manufacturing
once-through USC boilers

The main design features of the Ultra Supercritical boiler are:

One pass tower type design

Superheaters and economizers in horizontal tubing
Tangential firing system with circular burners

This design is chosen because it gives the most compact,

material-saving design. Process and operational wise, it also gives
the advantage of a symmetrical and well defined flue gas flow,
which will lead to a more homogeneous temperature profile of the
flue gas and of the water/steam.

In order to control the steam outlet temperatures in an economical

way, an FGR (Flue Gas Recirculation) system can be installed.

The BWE design consists in a fully drainable tower type boiler for
Ultra Supercritical installations adaptable both for the single and for
the double reheat water/steam cycle. For efficiency reasons BWE
recommends the single train air/gas flue gas path.

The boilers are equipped with a complete BWE multi-fuel Low-NOx

firing system and an SCR system capable of bringing the NOx
emission as far down as 50 mg/Nm3. Avedre Power Station, owned by DONG Energy
Standard size BWE USC boilers
BWE has three 400 MWe size USC references.

Using the design and operation experience from these, BWE has
developed a standard coal fired 400 MWe net USC Boiler.

3D model of a standard
660 MWe size boiler island.

BWE has also developed a standard 660 MWe size boiler.

Due to its long experience with USC boiler design and available
3D model of a standard
engineering resources, the company is also qualified for the supply
400 MWe size boiler island. of larger size boilers, such as the 800 and 1100 MWe class
Best Available Technology

The plant efficiency can be increased by:

raising live steam parameters (temperature and pressure)
reducing the condenser pressure by means of a cold and effective cooling
media - preferably sea water
using reheat or maybe double reheat
optimizing the feed water temperature
selecting the single train mono component solution for the air/flue gas path
and thereby reducing the auxiliary power
increasing the boiler efficiency

The boiler efficiency can be increased by:

reducing the flue gas exit temperature by means of an effective air preheater
reducing Unburned Carbon (UBC) in the fly ash by an effective combustion
reducing the air excess and thereby obtaining a reduced flue gas loss
reducing the leakage in the air preheater
reducing the pressure loss of the water/steam cycle

The USC boiler with a PF combustion system will still be the simplest and most
efficient way of using coal for power generation.
Combustion system
The design idea of the combustion system is to establish the best possible
conditions for Low NOx combustion. The circular burners are placed in
the corners of the furnace. Above each burner are OBA (Over Burner Air)
openings, and at the top of the furnace OFA (Over Furnace Air) openings,
which together with the air split in the burners establish the air staging.

Tangential firing
Up to 6 burner levels
n*4 Low NOx BWE Circular Burners (3 air stages)
Single Burner Concept (full control of coal / air ratio)
Low Air Excess 1.15 (full load)
OBA (protection of membrane walls)
OFA (air staging)
Low NOx Combustion and a wide range of fuels
The BWE Low NOx burner can be applied for fuels in fluid,
gaseous and pulverized form.

One burner may operate on any of the 3 types of fuels.

BWE has references on hard coal, HFO, NG, pelletized peat

& biomass (wood & straw).
Improved SCR built in
The installation of an SCR becomes mandatory. Tower type boilers are
suitable for easy installation of SCR.

The split ECO improves SCR operation (320 to 400 C) in full load range.

The design of an SCR without bypass prevents leakage in bypass dampers

and results in proper heating of SCR during start up.

In addition a flue gas recirculation system improves SCR operation at low

load.
Regenerative Air-preheaters and Gas-Gas heaters
Regenerative heat exchangers play an important role in fossil fuels
steam power plants as air preheaters (APH) and as gas-gas heaters
(GGH) in emission control plants such as FGD plants and tail-end
SCR plants.

The BWE APH and GGH heat exchangers operate according to the
rotating, regenerative, counterflow principle. Heat transfer elements
placed as a matrix in an open rotor transfer heat from one gas
sector to another when slowly rotating.

The heaters are equipped with various sealing systems in order to Quad sector type APH and single train solution
minimize the leakage of air to flue gas or untreated gas to treated
gas. The secondary air section is divided into two sections embracing
the primary air section which reduces the air leakage.

This single train train design can improve the overall efficiency of
approximately 0.2%.
Improved sealing system for APH & GGH
Automatic leakage control system
In order to minimize the leakage between the gas
flows which is not beneficial for the overall plant
efficiency, BWE has developed a highly efficient
sealing system for the radial sector seal plates.

The Active Leakage Control is an important feature

for rotating regenerative heat exchangers and BWEs
inductive system has proved to be particularly
suited for this application.

Cold condition Hot condition

The system:

is insensitive to gas properties and fly ash content

requires very little maintenance being a none contact system

has proved to have a very high reliability

has been in continuous development since 1978

High pressure piping design
BWE has a long-standing experience in design, manufacturing and
delivery of high pressure piping systems including spherical TEEs
and hangers.

Highly sophisticated software tools with integration between 3D

modeling (PDMS) and pipe stress analysis (RORHII) ensure an
efficient and reliable design according to state-of-the-art design
codes like EN 13480-3 and ASME B31.1.

Spherical TEE

Safety valve arrangement

The boilers are equipped with safety valve arrangements according to EN 12952-10

2 x HP combined controlled bypass and safety valve (Hydraulic Spring loaded)

2 x RH safety valves (Hydraulic Spring loaded)

The 100% combined HP bypass and safety valves secure sufficient cooling of the RH
heating surfaces during turbine trip. Furthermore, the arrangement of the steam lines
is simplified.

The LP-bypass valves dumping the steam to the condenser normally have a capacity
Pipe routing in 3D system (PDMS) of 60-70%.
Improved design and
material development
The improvements in the steam cycle and the related development of
new materials have also been accompanied by major improvements
in the design of boilers, turbines and other main components of the
power plant.

The main design challenge in USC boilers can be found in the thick
walled steam headers, the superheaters and the furnace walls.

The challenges are connected with the selection of materials and

manufacturing methods. In drum boilers, it is possible to make
the boiler pressure system in normal ferritic materials. For the
higher pressures and temperatures in the USC boiler, new ferritic/
martensitic high-temperature steels like the P91 and P92 have been
developed for commercial use.

For the final stages in the superheaters, a line graine austenitic

material like TP347HFG or Super304 has been selected as having
the necessary creep rupture strength and high temperature corrosion
resistance. By only using the austenitic materials in the relatively
thin walled tubes, the problem with thermal fatigue is minimized.
Nordjylland Power Station Unit 3 -1998
State of the art Clean Coal Technology
USC Coal fired Boiler - double RH 415 MWe
Nordjylland Power Station near Aalborg (Denmark), owned by
Vattenfall, represents the latest technological development with
respect to coal fired units and consists of an Ultra Supercritical
(USC) boiler with full flue gas cleaning, i.e. NOx, dust and SO2
removal. In addition to producing electricity to the public grid,
the plant also supplies heat to local district heating companies.
The plant was put into commercial operation in 1998.

Operational results:

Size 415
Type Tower
RH Cycle Double
FW temperature 298 C
HP pressure 290 bar
HP/RH temperature 582/580/580
Plant efficiency 47%

More than 65,000 of operational hours have proven: Plant efficiency > 47% Availability > 98%
Boiler
The boiler of Nordjylland Power Station unit 3 is a supercritical,
once-through tower boiler of the Benson type with double reheat.
The furnace walls are designed as membrane walls with helical
tubing. By using special materials, it has been possible to design
the boiler to very advanced steam data.

A flue gas recirculation system (FGR), including reheat of the flue

gas in a special sector in the quad sector air heater, is installed as
part of the control of the IP outlet temperature.

Low-NOx tangential firing system single train solution

The USC boiler of Unit 3 was designed with special attention to
minimizing the emission of nitrogen oxides (NOx). The tangentially
fired boiler with four levels of burners includes Over Burner Air
(OBA) nozzles above each burner and Over Fire Air (OFA) nozzles
above the upper level of burners. This concept of air staging brings
the NOx level below 475 mg/Nm3.
Avedre Power Station Unit 2 - 2001

USC Multi fuel Boiler 415 MWe

Avedre Power Station Unit 2, owned by DONG Energy, is one of
the most efficient, fuel flexible, and environmentally friendly power
plants in the world. In addition to generating electricity, the plant
supplies heat to the Copenhagen district heating network as well.

The main plant of Avedre Power Station is the Ultra Supercritical

(USC) unit incorporating a BWE once-through, Benson, tangentially
fired boiler.

The plant has a total output of 415 MWe. Of these more than 300
MWe can be achieved by biomass firing (wood pellets).

Operational results:

Size 415
Type Tower
RH Cycle Single
FW temperature 320 C
HP pressure 305 bar
HP/RH temperature 582/600
Plant efficiency 49%
Boiler
The boiler of Avedre Power Station unit 2 is a supercritical,
once-through tower boiler of the Benson type with single
reheat. The furnace walls are designed as membrane walls with
helical tubing. By using special materials, it has been possible
to design the plant to the very advanced steam data (HP: 305
bar, 582 C and RH: 74 bar, 600 C with the biomass boiler
in operation).

Multi Fuel Firing System

The USC boiler of Unit 2 has been designed with a unique
multi-fuel firing system which makes it possible to utilize: coal,
HFO, NG and wood pellets as fuels.

All these fuels can be burned in the same burners. These are
placed at four levels in the corners of the large furnace, having
a low thermal loading. The air staging is carried out through
the burners as primary, secondary and tertiary air and above
the burners as Over-Burner-Air (OBA) as well as Over-Fire-Air
(OFA). This concept of air staging ensures the low primary
formation of NOx.
STF S.p.A. BWE
Via Robecco, 20 Burmeister & Wain Energy A/S
20013 Magenta (MI) Italia Lundtoftegrdsvej 93A
Tel: +39 02 972091 DK-2800 Kgs. Lyngby - Denmark
Fax: +39 02 9794977 Tel: +45 39 45 20 00
www.stf.it Fax: +45 39 45 20 05
e-mail: stf@stf.it www.bwe.dk
e-mail: info@bwe.dk
BWE Energy India Pvt. Ltd
No. 43, KB Dasan Road
Teynampet
Chennai - 600 018
TamilNadu, India
Tel: +91 44 24 32 8101/2
Fax: +91 44 24 32 8103
e-mail: info@bweenergy.in