03a Boiler-Parameters P-Bader E

Boiler Parameters –
Optimized Energy Efficiency for Higher Profitability?
Philipp Bader, Vice President System Unit CSP, HZI

HZI Client Event 2016: Optimized Energy Efficiency for Higher Profitability 1
Parameters to influence energy efficiency
Efficiency
Superheater design
Experience with different materials
Material choice, lifetime and total cost
Operating cost Invest cost Reference case:
Ferrybridge & Dublin: Plants with

maximized energy efficiency
Conclusion
Energy Efficiency
Life steam parameters
Low excess air Feedwater

Flue gas temp. temp.
boiler outlet
Condensate
preheater
Air preheating
Exhaust steam
pressure
Energy Efficiency
Base case Variation Increase generator output

1 flue gas temperature boiler outlet 180°C 160°C 1.6%
2 O2 concentration in flue gas (dry) 7.2 vol.-% 3.9 vol.-% 1.9%
3 life steam parameters 40 bara / 400°C 40 bara / 420°C 0.9%
HP : 90 bara / 400°C; LP : 16bara /
8 steam reheating - 310°C 8.1%
HP : 100 bara / 425°C; LP : 24bara /
9 steam reheating - 310°C 11.8%
10 feedwater temperature 130°C 140°C, flue gas boiler outlet 180°C 0.7%
11 feedwater temperature 130°C 140°C, flue gas boiler outlet 187°C 0.12%
12 temperature secondary air (preheating with steam 5 bara) 20°C 120°C 0.65%
13 coolling flue gas in condensate preheater 0°C 30°C 1.4%
14 steam parameters outlet turbine 0.1 bara / 45.8°C 0.08 bara / 41.53°C 1.8%
15 pressure 2nd steam extraction turbine 5.0 bara 4.0 bara 0.48%
18.0%
16.0% 15.4%
Increase generator output
14.0%
11.8%
12.0%
10.0% 9.2%
8.1%
8.0% 6.6%
6.0%
4.0% 3.25%
1.6% 1.9% 1.4% 1.8%
2.0% 0.9% 0.7%
0.12% 0.65% 0.48%
0.0%
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15
Energy Efficiency
Conventional – Conservative: 40 bar / 400 °C

Higher steam temperature has the most significant impact on efficiency… but also bears a
high corrosion risk
Increase up to 460 °C
Risk manageable – with adequate superheater design
Operating and investment cost highly depend on superheater material – superheater
is a wearing part
Increase up to 500 °C
Difficult to handle with today’s technology
Need for completely different superheater concepts
The Four Superheater Design Rules
Low flue gas velocity with an even distribution
Put tubes, more specifically bundles, in wind shadow of each other
Low wall temperatures – Avoid combination of high flue gas and steam temperatures. No
corrosion zone in “ Flinger diagram”
 final superheater in current flow
 final superheater in second or third place
Material choice
Material Tests & Results
Tested Materials
• 16Mo3, Alloy 310, Inconel 625, Inconel 686
Experimental conditions
• Wall temperature (Tw) > 450 °C
• Flue gas composition HCl/ SO2…
• Experimental period 1, 2, 3, 6 & 12 months
Evaluation of corrosion x
• Measurement of wall thickness (by HZI / ZHAW),
coating thickness: Micrometer, Ultrasonic coating
gauge
Installation of test devices in TREA Breisgau (DE),

horizontal pass between EV and SH
Corrosion diagram for superheaters

500
Transitional Corrosion
Area Area
450
400 °C / 40 bar
400
Tube wall temp. [°C]
430 °C / 70 bar
350
Test conditions
300
250
"Non" Corrosion
Area
200
300 400 500 600 700 800 900 1000 1100
Flue gas temp. [°C]
Corrosion rate in mm/a (projected from 6 month measurements with rapping)

Material 16MO3 Alloy 310 Inconel Inconel
625 686
Calculated from maximal 2.3 1.2 0.8 0.3

measured value
Calculated from average of 2.0 1.0 0.3 0.2

4 highest values measured
Corrosion rate results as expected 16MO3 >> Alloy 310 > Inc 625 > Inc 686
 only Inc 686 shows a high corrosion resistance in the critical zone
Results from Plants in Operation: Riverside
Riverside: 3 x 81 MWth / 69 MWel

72 bar / 427 °C  27 % Electrical Efficiency (net)
5 years of operation (by Jan 2016)
Final superheater (Inconel 686 cladding): No corrosion detectable
Intermediate superheater (no cladding): Minimal corrosion rate ~ 0.1-0.2 mm/y
~ Evenly distributed
Results from Plants in Operation: Roosendaal
Roosendaal: Electricity production + hot water – 2 x 19 t/h / 62MWth / 30 Mwel

62 bar / 422 °C  24 % Electrical Efficiency (net)
4.5 years of operation (by Jan 2016)
Final superheater (Inconel 625): Minimal corrosion rate detected
Material Choice, Lifetime and Cost
Specific price :
Material price basis Jan 2016 (Inconel price is on a

very low price level at the moment)
Size final superheater approx. 400 m2
European manufacturing
Superheated steam temp. up to 460 °C
Expected corrosion rates based on material tests &
results from plants in operation
Material Choice, Lifetime and Cost
Material final Wall thickness Corrosion rate Expected Unit price Specifique price
superheater lifetime material & per year
fabrication
[mm] [mm/y] [years] [EUR/m 2] [EUR/m 2*y]
16 MO3 (Asia) 7 2.0 2.0 290 145
16 MO3 (EU) 7 2.0 2.0 400 200
Alloy 310 6.3 1.1 3.0 1000 333
Inc 625 5.6 0.5 4.0 1600 400
Inc 686 5.6 0.3 6.0 2100 350
Superheater lifetime vs. cost for exchange
European approach :
Combination of Inconel 625 / 686. Protect the last rows of the final superheater
with Inconel 686 – long life time / low exchange frequency
American approach :
Superheater in 16 MO3 – high exchange frequency
Materials Choice, Lifetime and Cost
Conclusions increase superheater temp. up to 460 °C
Corrosion risk is manageable – respect design rules
Different design & exchange strategies are possible
Alloy 310 material is an alternative to Inconel (with increasing material prices Alloy 310
gets more attractive)
Remember! – Material prices are highly volatile
Reference Plants
Ferrybridge 430 °C – 72 bar
Dublin 443 °C – 62 bar
Maximizes Generation of Electricity
Ferrybridge, UK
Key Figures Energy Efficiency Superheater

2 process trains, one turbine Net electrical efficiency: > 31% Material: Alloy 310
Waste capacity 2 * 31.3 t/h Expected lifetime: 5 years
1’500 t/d, 500’000 t/a
Thermal capacity 2 * 117.4 MW
Ferrybridge, UK
High steam parameters

72 bar / 430 °C
High efficiency turbine with

large end stage blades
Isentropic efficiency > 89%
District heating Low back pressure

connection (p=0.07 bar a @ 10 °C)
 Large ACC
Energy recovery from

clean flue gas into
condensate
Ferrybridge, UK
Inconel 625
Alloy 310
Dublin, Ireland
Key Figures Energy Efficiency Superheater

2 process trains, one turbine Net Electrical efficiency: > 30% Material: 16MO3
Waste capacity 2 * 32.5 t/h Expected lifetime: 3 years
1’560 t/d, 520’000 t/a
Thermal capacity 2 * 102.5 MW
Dublin, Ireland
High steam parameters

62 bar / 443 °C High efficiency turbine with
large end stage blades
Isentropic efficiency > 89%
Low back pressure

(p=0.055 bar a @ 10 °C)
 Sea water cooling
District heating
connection
Dublin, Ireland
Inconel 625
16 MO3
Conclusion
Efficiency Large size plants can reach an efficiency

(net power output) > 30%
Steam temperatures up to 460 °C are

technically possible with a reasonable
lifetime
Operating cost Invest cost Superheater lifetime and total cost is a

trade off between:
- design
- material choice
- exchange philosphie
Thank you!

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Boiler Parameters –

Optimized Energy Efficiency for Higher Profitability?

Philipp Bader, Vice President System Unit CSP, HZI

Parameters to influence energy efficiency

Experience with different materials

Material choice, lifetime and total cost

Operating cost Invest cost Reference case:

Ferrybridge & Dublin: Plants with

Life steam parameters

Low excess air Feedwater

Base case Variation Increase generator output

Conventional – Conservative: 40 bar / 400 °C

Low flue gas velocity with an even distribution

Put tubes, more specifically bundles, in wind shadow of each other

Installation of test devices in TREA Breisgau (DE),

Corrosion diagram for superheaters

Corrosion rate in mm/a (projected from 6 month measurements with rapping)

Calculated from maximal 2.3 1.2 0.8 0.3

Calculated from average of 2.0 1.0 0.3 0.2

Riverside: 3 x 81 MWth / 69 MWel

Roosendaal: Electricity production + hot water – 2 x 19 t/h / 62MWth / 30 Mwel

Material price basis Jan 2016 (Inconel price is on a

Superheater lifetime vs. cost for exchange

Conclusions increase superheater temp. up to 460 °C

Corrosion risk is manageable – respect design rules

Different design & exchange strategies are possible

Remember! – Material prices are highly volatile

Ferrybridge 430 °C – 72 bar

Dublin 443 °C – 62 bar

Key Figures Energy Efficiency Superheater

High steam parameters

High efficiency turbine with

District heating Low back pressure

Energy recovery from

Key Figures Energy Efficiency Superheater

High steam parameters

Low back pressure

Efficiency Large size plants can reach an efficiency

Steam temperatures up to 460 °C are

Operating cost Invest cost Superheater lifetime and total cost is a

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