status of advanced ultrasupercritical pulverised coal
TRANSCRIPT
Status of
advanced ultrasupercritical
pulverised coal technology
Kyle Nicol
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Webinar 9th
October 2013
Contents
PART 1 Introduction
Steam and efficiency
High temperature components: manufacture, service and
microstructure
PART 2 Material research programmes
Collaboration
A typical material research programme
Programmes in EU, USA, Japan, China, India and Russia
PART 3 Conclusions
Research spin-off technologies
Comparison
International collaboration?
To AUSC and beyond
Final remarks
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Steam and efficiency
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Superheater
temperature
and pressure
Coal
consumption
(gCOAL
/kWh)
Efficiency
(LHV, net,
hard coal)
Subcritical
≤540°C and
<22.1 MPa
≥380 <35%
Supercritical
(SC)
540-580°C
and 22.1-25
MPa
380-340 35-40%
Ultra
Supercritical
(USC)
580-620°C
and 22-25
MPa
340-320 40-47%
Advanced
Ultra
Supercritical
(AUSC)
700-725°C
and 25-35
MPa
320-290 47-52%
Steam and efficiency
Superheater
temperature
and pressure
Coal
consumption
(gCOAL
/kWh)
Efficiency
(LHV, net,
hard coal)
Material in high
temperature
components
Subcritical
≤540°C and
<22.1 MPa
≥380 <35%
Low alloy CMn and Mo
ferritic steels
Supercritical
(SC)
540-580°C
and 22.1-25
MPa
380-340 35-40%
Low alloy CrMo steels
and 9–12% Cr
martensitic steel
Ultra
Supercritical
(USC)
580-620°C
and 22-25
MPa
340-320 40-47%
Improved 9–12% Cr
martensitic steels
and austenitic steels
Advanced
Ultra
Supercritical
(AUSC)
700-725°C
and 25-35
MPa
320-290 47-52%
Nickel alloys
and advanced 10-12%
Cr steels
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High temperature components: Lots of them
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He
ade
rs a
nd
p
ip
ew
ork
Steam turbine: blades, rotors, casing
Valves: bypass, control, safety Superheater and reheaters
High temperature components: Manufacture
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Welding: GMAW, SAW,
GTAW/TIG, SMAW…
Blast furnaces Fabrication: extrusion, cast, forge…
Heat treatment Machining
High temperature components: Service
Constant stress = creep damage
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Cyclic stress = fatigue damage
Steam cycle = steamside oxidation & erosion
Boiler = fireside corrosion &
erosion
High temperature components: Service
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Superheater tubes =
steamside oxidation
+ fireside corrosion
+ constant stress
+ erosion
(+ cyclic stress)
Steam turbine casing =
steamside oxidation
+ erosion + constant stress
High temperature components: Microstructure
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Microstructure determines
properties
Microstructure depends on
complex manufacturing
process
Many materials available
Collaboration
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General AUSC material research programme
STAGE 1 Small-scale laboratory tests 8-13 years
a. Mechanical tests
b. Chemical tests
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General AUSC material research programme
STAGE 1 Small-scale laboratory tests 8-13 years
a. Mechanical tests
b. Chemical tests
STAGE 2 Large-scale components test facility (CTF)
a. Design and build 4-5 years
b. Operate and evaluate 3-5 years
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General AUSC material research programme
STAGE 1 Small-scale laboratory tests 8-13 years
a. Mechanical tests
b. Chemical tests
STAGE 2 Large-scale components test facility (CTF)
a. Design and build 4-5 years
b. Operate and evaluate 3-5 years
STAGE 3 Full-scale demonstration plant (FSDP)
a. Design and build 4-6 years
b. Operate and evaluate 6 years
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Europe
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FSDP: Operation
FSDP: Build
HWT I: Phase 2
MACPLUS
NextGenPower
COMTES+: ENCIO
COMTES+: HWT II
IMPACT
CRESTA
HWT I : Phase 1
AD700-4: E.ON50+
AD700-4: NRWPP700
AD700-3: COMTES700
AD700-3: ETR
MARCKO 700
COST 536
AD700-2B
AD700-2A
KOMET 650
MARCKO DE 2
AD700-1B
AD700-1A
COST 522
COST 501
COMTES700
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E.On 50+
Full scale
demonstration
plant (FSDP)
2006 - 2008
550 MW
50.2% efficiency
(net, bituminous
coal, LHV)
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COMTES+ strikes back
COMTES+ (HWTII and ENCIO)
NextGenPower
CRESTA
KMM-VIN WG2
IMPACT
And others
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Candidate materials
Components Candidate alloys
Header inlet
Superheater 1, 2, 3
and 4 P91, P92, Alloy 617 and Alloy 617m
Reheater 1.1 and 1.2 13CrMo4-5 and Alloy 617m
Header outlet
Superheater 1, 2, 3
and 4 P92, Alloy 617, Alloy 617m and Alloy 263
Reheater 1.1 and 1.2 Alloy 617m
Pipes
Superheater 1 T92
Superheater 2 Alloy 617m, Alloy 174
Superheater 3 Alloy 617m, Alloy 174, HR3C
Superheater 4 Inconel 740
Reheater 1.1 Alloy 617m, HR3C, S304, T91, 10CrMo9.10
Reheater 1.2 Alloy 617m
Casing
Outer casing Cast steel (9-10% Cr)
Inner casing Alloy 625 (cast), welded with 9-10%
martensitic steel
Valve casing Alloy 625 (cast)
Weld-on ends Alloy 617m
Rotor HP and IP Alloy 617 welded with 2% chromium /10%
chromium steel
Blades HP and IP Chromium steel, Nimonic80, Waspaloy 18
USA
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Demonstration plant: Operation
Demonstration plant: Build
Demonstration plant: Design and
permit
Component test facility: Operate
Component test facility: Build
Component test facility: Design
Materials R&D programme (tasks
1-8)
Candidate materials
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Component Candidate material
Economiser CS
Membrane walls T23, T92
Superheater panels S304H, Inconel 617, Inconel 740
Superheater platens 347 HFG, Inconel 617, Inconel 740
Superheater finish third Inconel 740
Superheater finish in Inconel 740
Superheater finish out Inconel 740
Reheat low temp 1 T23, P91
Reheat low temp 2 S304H
Reheat pendants S304H
Reheat platens S304H, HR120, Inconel 617, Alloy 230
Valves Haynes 282
Blades
Haynes 282, Alloy 617, Alloy 263, Sanicro 25,
Inconel 740 and Alloy 625, austenitic steel,
martensitic steel
Casing Haynes 282, Alloys 617, Alloy 263, Sanicro 25,
Inconel 740, Alloy 625, ferritic steel
Rotor Alloy 617, Alloy 625, ferritic steel
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Japan
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Demonstration plant: Operation
Demonstration plant: Design and build
Turbine rotor test: Rotating test
Turbine rotor test: Test rotor produtction
Turbine rotor test: Test facility build
Turbine rotor test: Test facility design
Boiler component test: Test
Boiler test: Component produtcion and installtion
Boiler component test: Component design
Boiler component test: Facility design
Vavlve: Trial manufatcure
Valve: Material testing
Turbine: Cooling, seals and some mechanical test
Turbine: Fabrication process
Turbine: Long term creep rupture test
Turbine: Material development
Boiler: Fabrication process
Boiler: Long term creep rupture test
Boiler: Material development
System design
Prior R&D
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Candidate materials
Component Steam
temp Materials
Membrane
walls <650°C Conventional ferritic steels
Tube
(superheater
s and
reheaters)
>700°C
Nickel based: HR35, Alloy 617, Alloy 263, Alloy 740,
Alloy 141, USC141, USC800
Nickel/Iron based: HR6W
Pipe and
headers
<650°C Ferritic steels: B9Cr (high Boron), LC9Cr (low Carbon)
and SAVE12AD
>650°C Austenitic steels: 18-8 series and 25 Cr20Ni
750°C Nickel based: HR35 and Alloy 617 (B)
Nickel/Iron based: HR6W
Valve bodies >700°C Alloy 625
Casing inner >700°C Alloy 625, Inconel 740, Alloy 617
Casing outer <650°C 12% chromium steels
Blades
(nozzle) 750°C
Nickel based: USC141
(Nickel alloys from gas turbines could be used)
Rotor >750°C Nickel based: FENIX-700, LTES and TOS1X
Bolts >700°C Nickel based: USC800, USC141
Nickel alloys in pink and green
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China
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MSW: 3 Product supply yo the market
MSW: 2D Evaluation of product
MSW: 2C Meterials/product application study
MSW: 2B Product industrial trial
MSW: 2A Materials pilot plant trial
MSW: 1B Materials laboratory investigation
MSW: 1A Candidate materials selection
5.3 Demonstration unit: Operation and summary
5.2 Demonstration unit: Construction of the project
5.1 Demonstration unit: Preparation
4.3 CTF-700: Build and test
4.2 CTF-700: Final design
4.1 CTF-700: Preliminary design and host site selection
3.6 High temperature and high pressure valves
3.5 High temperature pipes and fittings
3.4 Turbine key components
3.3 Turbine forgings
3.2 Boiler key components
3.1 Boiler tubes
3. Key components
2. Developing high temperature materials
1. Overall programme design
Candidate materials
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Component Candidate materials
Water cooling tubes T91, HCM12
Pipe and header P91, P92, G115/G112,
GH2984G, CCA617CN
Tube and pipe GH2984G
Tube (superheater
and reheater)
T91, T92, NF709R, Sanicro25,
GH2984G, Inconel740HM
Material research programmes
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Russia
India
Research spin-off technologies
Plant configuration
Inline (EU)
Compact (EU)
CCHLPA (China)
Advanced steam cycles
Master cycle (EU)
Topping cycle (USA)
New 650ºC steels
MARBN (Japan)
G115/G112 (China)
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Comparison
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Research topic EU USA Japan China
Retrofit to older units No No Yes No
Cyclic operation Yes Yes No No
Oxyfuel Yes No No No
High sulphur coal firing on fireside
corrosion No Yes No No
Biomass co-firing on fireside corrosion Yes No Yes No
Waste co-firing on fireside corrosion Yes No No No
Coatings Yes Yes Yes No
New 650°C steels Yes Yes Yes Yes
New nickel/iron alloys No No Yes Yes
New nickel alloys No No Yes No
Welded rotors Yes Yes Yes Yes
Comparison
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China: Stage 3b (operate FSDP)
China: Stage 3a (build FSDP)
China: Stage 2 (CTF)
China: Stage 1 (inc long-term creep)
China: Stage 1 (exc long-term creep)
India: Stage 3b (operate FSDP)
India: Stage 1, 2 and 3a (build FSDP)
Japan: Stage 3b (operate FSDP)
Japan: Stage 3a (build FSDP)
Japan: Stage 2 (CTF)
Japan: Stage 1 (inc long-term creep)
Japan: Stage 1 (exc long-term creep)
USA: Stage 3b (operate FSDP)
USA: Stage 3a (build FSDP)
USA: Stage 2 (CTF)
USA: Stage 1 (inc long-term creep)
EU: Stage 3b (operate FSDP)
EU: Stage 3a (build FSDP)
EU: Stage 2 (CTF)
EU: Stage 1 (inc long-term creep)
EU: Stage 1 (exc long-term creep)
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Comparison
EU USA Japan China
Full-scale
demonstration plant
capacity (MWe)
500 350-1000 600 600-660
Full-scale
demonstration plant
steam parameters
(°C/°C/MPa)
705/720/35 700/730/35 700 700/720/35
Estimated full-scale
capacity (MWe) 500-1000 550-1100 600 600
Estimated full-scale
steam parameters
(°C/°C/MPa)
705/720/35
700-
730/730-
760/35
700/720/720/35 700/720/35
Estimated full-scale
efficiency (%, net,
hard coal)
>50 (LHV) 45-47
(HHV) 46-50 (LHV) >50 (LHV)
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International collaboration?
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To AUSC and beyond
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Increasing superheat steam from 700ºC will continue to
increase efficiency up to ~900ºC
AUSC technology first generation to utilise super alloys
800ºC: More Advanced Ultra Supercritical (MAUSC)?
900ºC: Even More Advanced Ultra Supercritical (EMAUSC)?
Final remarks
700ºC superheat steam is proving technically viable
Net electrical efficiency ~50% (net, LHV, hard coal)
Commercial AUSC power plant possibly in 2031
Dependent on economics at time and place of build
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Next Webinar
Coal prospects in Southern Africa
Wednesdays 13 November 2013
Paul Baruya
34
Thank you for listening
Questions?
Kyle Nicol
DDI+44(0)20 8246 5275
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