materials for advanced ultra- supercritical steam turbines - advanced ultra ......

© 2017 Electric Power Research Institute, Inc. All rights reserved.

DOE Contract Number DE-FE0025064

Robert Purgert [email protected]

Principal InvestigatorEnergy Industries of Ohio

Horst [email protected]

Presenter Electric Power Research Institute

2017 Crosscutting Research Portfolio ReviewMarch 23, 2017

Pittsburgh, PA, USA

Materials for Advanced Ultra-supercritical Steam Turbines -

Advanced Ultra-supercritical Component Demonstration

2© 2017 Electric Power Research Institute, Inc. All rights reserved.

Goals: The A-USC ComTest Project will lead to…

Higher efficiency for new and existing fossil fuel plants – 10% above today’s new state-of-the-art coal power plants, and – 25% above that of the average power plants in the U.S. existing fleetLower emissions (NOx, SOx, CO2)Minimized risk for utilities desiring to build A-USC plantsDesign of world’s first integrated A-USC steam turbine at 760ºCAccelerated development of domestic supply chain for

advanced materials and components Validation of technology applicable to multiple fossil, nuclear,

and renewable power generation options, all targeted by the U.S. DOE NETL Cross-Cutting Research Technology Program


Presentation Outline

BackgroundProject OverviewAccomplishmentsFuture Work


Background


New A-USC Plant: Increasing Steam Conditions Dramatically Improve Efficiency and Reduce CO2 Emissions

Increased Efficiency is a Least Regret Strategy for CO2 ReductionStudies show A-USC = 10-35% reduction in CO2 compared to current plants

<600C (SC) 600-650C (USC)

700-760C(A-USC)

<600C (SC) 600-650C (USC)

700-760C(A-USC)


40

60

80

100

300

500

550 600 650 700 750 800

1100 1200 1300 1400

6

8

10

30

50

70

Stre

ss (M

Pa)

Average Temperature for Rupture in 100,000 hours (oC)

9-12Cr Creep-Strength Enhanced Ferritic Steels (Gr. 91, 92, 122)

Nickel-BasedAlloys

Std. 617CCA617

Inconel 740

Haynes 230

Advanced Austenitic Alloys (Super 304H, 347HFG, NF709, etc.)

Haynes 282

Average Temperature for Rupture in 100,000 hours (oF)

Stre

ss (k

si)

Materials Limit the Current Technology:Today’s State-of-the-Art (USC) Coal-Fired Power Plants are defined by steel technology

°

Steels = USC620°C (1150°F) Solid Soln’ = A-USC

~700°C (1300°F)

Age Hardenable = A-USC760°C (1400°F)

Minimum Desired Strength at Application Temperature

/740H


History of A-USC Materials Programs in U.S.ComTest is the Next Step for A-USC Technology


Background of A-USC Materials Programs

Present work builds upon 15-year effort supported by U.S. Department of Energy, Ohio Coal Development Office, and industry participants– Boiler Materials for Advanced Ultra-supercritical Coal Power PlantDOE Contract: DE-FG26-01NT41175OCDO Grant: CDO-D-05-02(A)

– Materials for Advanced Ultra-supercritical Steam TurbinesDOE Contract: DE-FE0000234OCDO Grant: CDO-D-05-02(B)


Tasks Completed in A-USC Materials Programs

General design studies show favorable economics

Welding Technology Developments

Fabrication Processes

Fireside Corrosion (High-Sulfur Coal & In-Plant Testing)

Steam-Side Oxidation

Turbine Component Scale-up


Next Step… Building Upon Prior Work

Fabrication

Field TestForging

Welding

New Materials

Federal – State – National Laboratory – Non Profit – For ProfitCost Sharing Consortium

Castings

15 Years ComTest


ComTest Project Overview


HIGH TEMPERATURE VALVE TEST

WATERBRAKE

STOP VALVE

CONTROL VALVE

MEMBRANE WALL AND

SUPERHEATER

NATURALGAS

EXHAUST

THICK WALL SECTION

STEAM FROM HOST AND/OR

PACKAGE BOILER

TEMPERATURE, PRESSURE

ADJUSTMENT

RETURN TO HOST

TEMPERATURE, PRESSURE

ADJUSTMENT

RETURN TO HOST

SV CV

STOP VALVE

CONTROL VALVE

Schematic of ComTest Pilot Plant Vision

A-USC Turbine

Superheater Header

ValvesMembrane Wall /

Superheater

Turbine InletConditions1400ºF, 600 psig, ~130,000 lb/hr

Superheater operating at 1400°F

and 1000 psi


ComTest Project TeamTeam Member Funder RoleUS DOE NETL FunderOCDO (Ohio) FunderEIO Prime Contractor & AdministrationEPRI Technical LeadGE Supply of Main ComponentsAECOM EPC ContractorYoungstown Thermal Host Site Owner (Primary)Southern Company Host Site Owner (Alternate)


Accomplishments


Accomplishments

Evaluated multiple potential host sites Identified viable host sites (Ohio and Alabama)Completed Pre-FEED and FEED tasksPrepared preliminary capital cost estimatesWorked with suppliers to develop supply chainDeveloped two-year test planStarted Detailed Engineering effort


Future Work


Next Steps

Confirm Phase 2 budgets – close budget gapFinalize testing scope and host site selection Identify funding sources for Phase 2 cost shareComplete Detailed Engineering effortDevelop procurement specifications for equipmentConfirm supply chain and fabrication methodsConstruct ComTest components and facilityOperate pilot plant for two years


A-USC ComTest ScheduleKey:

Deliverable (i.e. report)

Milestone (i.e. meeting, presentation)

• Pre-FEED

• NEPA

• FEED

• Detailed Engineering

• Procurement & Construction

• Operationa. Membrane Wall & SHb. Cycling Header & Valvesc. Steam Turbine

2015 2017 2018 20192016 2020

• Evaluation & Reporting

Prelim Cost Estimate

Final Report

NEPA Report

Final Cost Estimate

2021


A-USC ComTest Project Support AcknowledgementThis material is based upon work supported by the Department of Energy under Award Number DE-FE0025064 and the Ohio Development Services Agency under Grant Agreement Number CDO-D-15-01.

Disclaimer: This report was prepared as an account of work sponsored by an agency of the United States Government and an agency of the state of Ohio. Neither the United States Government nor any agency thereof, nor any of their employees, nor the state of Ohio nor any agency thereof, nor any of their employees, makes any warranty, express or implied, or assumes any legal liability or responsibility for the accuracy, completeness, or usefulness of any information, apparatus, product, or process disclosed, or represents that its use would not infringe privately owned rights. Reference herein to any specific commercial product, process, or service by trade name, trademark, manufacturer, or otherwise does not necessarily constitute or imply its endorsement, recommendation, or favoring by the United States Government or any agency thereof or by the state of Ohio or any agency thereof. The views and opinions of authors expressed herein do not necessarily state or reflect those of the United States Government or any agency thereof or the state of Ohio or any agency thereof.


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materials for advanced ultra- supercritical steam turbines - advanced ultra ......

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