malaysia power 2003-sc-presentation ag/2.1-mp-2003-sc.pdfmalaysia power 2003 kuala lumpur 28. –...

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Malaysia Power 2003Kuala Lumpur 28. – 29. April 2003

Supercritical Steam Power Plants -an Attractive Option for Malaysia?

Miro R. SustaIMTE AG Power Consulting Engineers

Switzerland

Peter LubyINGCHEM Technical Advisory Services

in Power GenerationCentral Europe

KL-April 2003 . 2

Advanced Coal Fired Power Generation Technologies

• Supercritical Steam (SC)• Ultra-SC (USC)• Pressurized Fluidized Bed Combustion (PFBC)• Integrated Gasification Combined Cycle (IGCC)• Hybrid Combined Cycle (HCC)• Direct Coal fired Combined Cycle (DCCC)• Molten Carbonate Fuel Cell (MCFC)• Magneto Hydrodynamics (MHD) Power Generation

© IMTE AG

KL-April 2003 . 3

SSC Power Plants Worldwide

0

100

200

300

400

500

600

700

E.Europe &Russia

USA Japan W.Europe OtherCounties

TotalWorldwide

No.

of U

nits

0

50

100

150

200

250

300

350

GW

No. of Units Total Power Output

© IMTE AG

KL-April 2003 . 4

What is Supercritical?

© IMTE AG

KL-April 2003 . 5


© IMTE AG

KL-April 2003 . 6


© IMTE AG

KL-April 2003 . 7

1

2 3

4 5

6

KL-April 2003 . 8

~

6

12

3

4 5

© IMTE AG

KL-April 2003 . 9

Supercrit

ical p

ressu

reSubcritical pressure

Critical point (22.1MPA, 373°C)

Enthalpy (kJ/kg)

Tem

pera

ture

(°

C)

Liquid + vapor

Vapor

Liquid Vapor

Isobaric processes in either subcritical or supercritical regime

© IMTE AG

KL-April 2003 . 10

Supercritical vs. Conventional

≈ 2.0≈ 710> 48.06-8700 / 700 / 7003651350700°C - SC≈ 2.2≈ 780> 42.05-7580 / 580 / 5802901300580°C - SC

≈ 2.4≈ 855< 40.04-6538 / 5381651100Conventional

SO2

(g/kWh)

CO2

(g/kWh)

Efficiency

(%)

AuxiliaryConsumption

(%)

SteamTemperature

(°C)

SteamPressure

(MPa)

Price

(US$/kW)

Plant Type

• Both, conventional (subcritical) and SC technology is commercially available in wide range of size.

• Compared with conventional power plant, SC technology with higherefficiency and consequently lower specific flue gas throughput is muchcleaner method of electricity generation.

• Conventional technology however, provides greater coal flexibility. • Higher temperatures encountered in SC units’ makes corrosion more

critical, thus coals with slugging or corrosion potential are less suitable for SC plants.

State-of-the-art SC power plants have an efficiency of about 46% and satisfy current emission standards worldwide.

© IMTE AG

KL-April 2003 . 11

Potential Increase in Efficiency through new Materials and Steam Parameters

3940414243444546474849

F12 F12 P91 NF616 AusteniticSteel

Inconel

Material

Effic

ienc

y (%

)

Potential Increase in Efficiency

© IMTE AG

KL-April 2003 . 12

49

48

50

47

46

45

44

43

42

41

0.4% +

2.1% +

167 bar,

538°C, 538°C Basis = 42%

250 bar,

540°C 560°C 1.5%+

1.1% +0.7% +

315 bar,

620°C, 620°C

350 bar,

700°C, 720°C

270 bar,

585°C, 600°C

300 bar,

600°C, 620°C

Flue gas cooling

Compo- nents pro- cess, pressure loss reduct.

0.8% +0.4% +

0.6% +

0.8% +

Double reheat

Steam turbine impro-

ve- ment

50

49

48

47

46

45

44

43

42

41

Efficiency Improvement Potential for Coal fired Steam Power Plants

Effic

ienc

y (%

)

© IMTE AG

KL-April 2003 . 13© IMTE AG

0102030405060708090

100

1988-> 1990-> 1992-> 1994-> 1996-> 1998-> 2000->

Year

%

Convetional SSC

Power Plant Availability ** Conventional vs. SC

SC

KL-April 2003 IMTE AG 14

Basic Alternatives of Boiler Arrangement

Courtesy of Siemens PG

Typical Drum Boiler Once Through – Benson Boiler

KL-April 2003 . 15

Benson Boiler – Basic Configurations

• Simple construction ofmembrane walls

• Lower erosion of heatingsurfaces by ash

• Smaller built-up area

• Dimensioning of convectionsection independent of furnace

• Shorter assembly times due toparallel assembly of first andsecond pass

• Lower overall height

100%

Height 70%

Height

Two-passSingle-pass

© IMTE AG


Height Comparison of 500MW Coal Fired Boilers

Single-pass Two-pass Horizontal

Height ratio3 : 2 : 1

Milan

Cathedral

Courtesy of Siemens PG


Cumulative Steam Capacity of Worldwide ordered Benson Boilers

220

180

140

100

60

20

1946 1956 1966 1976 1986 1996 1998Courtesy of Siemens PG

40

GW

Bituminous coal,with dry de-ashing

Bituminous coal / slag tapLignite

Oil or gas

CCGT Nuclear

KL-April 2003 . 18

Common Steam Turbine Capacities vs. Live Steam Pressure

0 200 400 600 800 1000

60 bar40 bar

90 bar100 bar

125 bar, reheat165 bar, reheat

245 bar, reheat

245 bar, 2 x reheat

315 bar, 2 x reheat

Supercritical

Supercritical

Supercritical

ST Capacity (MW)

Pres

sure

(ba

r)

© IMTE AG


Tandem Compound Steam TurbineTwo-Casing * Single-Flow

Applicable for the smallest utility ratings.


Tandem Compound Steam TurbineTwo-Casing * Double-Flow * LSB 750 mm –1000 mm * 170 bar /

565°C / 565°C

Applicable for 300 – 500 MW Units


Tandem Compound Steam TurbineThree-Casing * Four-Flow * LSB 750 mm – 850 mm * 170 bar / 565°C /

565°C



Tandem Compound Steam TurbineFour-Casing * Four-Flow * LSB 850 mm – 1000 mm * 245 bar / 565°C

/ 565°C


KL-April 2003 . 23

Tandem Compound Steam TurbineFour-Casing * Four-Flow * Double Reheat * 310 bar

Applicable for 900 - 1200 MW Units


Tandem Compound Steam TurbineFive-Casing * Six-Flow * Single Reheat * <310 bar

Applicable for < 1200 MW Units

. 252 ¼ Cr – 1Mo forging

9 Cr forgingMain steam governing valve

2 ¼ Cr – 1Mo forging

9 Cr forgingMain steam stop valve

12 Cr forgingRefractory alloy (R-26)

Rotating blade

1 ¼ Cr – ½ Mo cast steel

2 ¼ Cr – 1Mo cast steel

Outer casing

1/2 Cr – ½ Mo cast steel

2 ¼ Cr – 1Mo cast steel

No.2 blade ring


12 Cr cast steelNo.1 blade ring


12 Cr cast steelInner casing

2 ¼ Cr – 1 Mo cast steel

12 Cr cast steelNozzle chamber

Cr-Mo-V forgingNew 12 Cr forgingRotor

538°C600°CMain steam temperature

KL-April 2003 . 26

SC Power Plants Worldwide

© IMTE AG

0100200300400500600

Europe USA Japan Russia OtherCountries

TotalWorldwide

No.

of U

nits

KL-April 2003 . 27

SC Power Plants Worldwide

© IMTE AG

0100200300400500600

Europe USA Japan Russia OtherCountries

TotalWorldwide

No.

of U

nits

050100150200250300350

GW

No. of Units GW

KL-April 2003 . 28

Selected SC Power Plants

200443.5246 / 566 / 5662 x 800S. KoreaYonghungdo

200442.7279 / 542 / 5622 x 900ChinaWaigaoqiao

200047.0250 / 600 / 6103 x 700JapanTachibanawan-2

200146.0250 / 605 / 600600JapanMisumi 1

200146.0245 / 600 / 6002 x 500JapanIsogo 1 & 2

199444.0250 / 535 / 563700NetherlandsHemweg-8

199143.5250 / 540 / 540420DenmarkFynsvaeket – 7

198542.0270 / 540 / 540400DenmarkStudstrupvaerket

199245.3250 / 560 / 560415DenmarkEsbjerg 3

199847.0285 / 580 / 580410DenmarkNordjyllaend

200043.0266 / 545 / 5811000GermanyBoxberg

200245.2275 / 580 / 6001000GermanyNiederaussem

200042.4268 / 554 / 5542 x 800GermanyLippendorf

199343.0250 / 540 / 560500GermanyStaudinger Unit

199241.0250 / 544 / 5622 x 800GermanySchwarze Pumpe

Commercial Operation

Efficiency(%)

Steam Parameters(kPa / °C / °C)

Power Output(MW)

CountryPower Plant Name

© IMTE AG

KL-April 2003 . 29

1600 MW SCPP Schwarze PumpeGermany

Owner SVK SchwarzePumpe / VEAG

Fuel Lignite

Commercial operation

1997 / 1998

Steam parameters

250 bar544°C / 562°C

BoilerOT, GEC Alsthom/ EVT EV

Efficiency 41 %

KL-April 2003 . 30

Schwarze Pumpe

KL-April 2003 . 31

965 MW SCPP Niederaussem-KGermany

Owner RWE Energie

Fuel Rhenish raw lignite, LHV = 8 –10.5 MJ/kg


November 2002

Steam parameters

285bar, 580°C, 600°C

Boiler OT,Alstom ES/Bab-cock Kraftwerks-technik/Steinmueller

Efficiency 45.2 %

Owner RWE Energie



November 2002

Steam parameters

285bar, 580°C, 600°C


Efficiency 45.2 %

Owner RWE Energie



November 2002

Steam parameters

285bar, 580°C, 600°C


Efficiency 45.2 %

KL-April 2003 . 32

907 MW SCPP BoxbergGermany

Owner VEAG

Fuel Lignite


2000

Steam parameters

266bar, 545°C, 581°C

BoilerSteam turbine

OT, SteinmuellerSiemens HMN, 5-casing, 6 flow

Efficiency 42.7 %

KL-April 2003 . 33

965 MW SCPP NordjyllandsvaerketDenmark

Owner Elsam A/S

Fuel Bituminous coal


1998

Steam parameters

290bar, 582°C, 580°C, 580°C

BoilerBenson, single-pass, tower-type, fromBurmeister & Waine

Efficiency 47%

KL-April 2003 . 34

700 MW SCPP Hemweg-8Holland

Owner Energieprodukti-bedrijk UNA



1994

Steam parameters

260bar, 540°C, 568°C

Boiler Benson, two-passBabcock Energy,Stork Ketels

Efficiency 44.0%

KL-April 2003 . 35

1000 MW SCPP MisumiJapan

Owner Chubu ElectricPower Corporation



1998 - 2001

Steam parameters

250 bar, 605°C, 600°C

BoilerOnce – through, sliding pressure operation

Efficiency 46 %

KL-April 2003 . 36

Does SC Technology suit to Malaysia's Power Generation Environment?

0.20%6.80%13%

66%14%

NG Coal Hydro Oil Others

200231.1%3.9%3.8%

20.8%

40.4%

NG Coal Hydro Oil Others

2020

Present and Expected Fuel Split in Malaysia

© IMTE AG

KL-April 2003 . 37

Annual Savings

24.5

49.1

73.6

98.2

122.765.8

52.6

39.5

26.3

13.21

2

3

4

5

Pow

erO

utpu

t(G

W)

Mio US$ / Year

3% Improvement 6% Improvement

2.5 5 7.5 10 12

0.490.98

1.471.96

2.45

0.92

4.58

1.83

2.75

3.67

0.000.501.001.502.002.503.003.504.004.505.00

Power Output (GW)M

ioTo

ns/Y

ear

3% Improvement 6% Improvement

2.5 5 7.5 10 12.5

© IMTE AG

KL-April 2003 . 38

Example

3% - 6% efficiency improvement can save annually up to 3 millions metric tons of coal or between 100 Mio and 200 Mio US$ per each 10 GW power generation capacity.Basic data used for this calculation:

Coal LHV 28’000 MJ/ton, Load Factor 85%Coal Price 30 US$/ton

© IMTE AG

KL-April 2003 . 39

Early problems experienced with the first and second generation of SC and USC power plants are underway to be

overcome. Currently, SC and USC power plants with steam conditions

up to 300 bar, 600°C / 620°C have been matured and become high efficiency commercialized technology.

The largest commercial units with capacity of 1300 MW have reached ambitious efficiency of 47%.

SC and USC coal fired power plants will have broad prospects of development in this centaury.

Outlook for coal fired SC power plant technology is very positive and its further growth lies ahead.

Intensity of this growth will depend on the following factors:

© IMTE AG

KL-April 2003 . 40

Worldwide acceptance of SC and USC technology;Development of NG / Coal price ratio;Further improvement of availability and reliability;Further efficiency improvement; Operational characteristics;Emissions level (mainly CO2, SO2 and NOx);Life cycle costs.

© IMTE AG

KL-April 2003 . 41

New technologies have an impact on everything — from environmental quality to costs that consumers will ultimately

have to pay.

Thank you.

malaysia power 2003-sc-presentation ag/2.1-mp-2003-sc.pdfmalaysia power 2003 kuala lumpur 28. –...

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