Proceedings of the ASME 2015 Power Conference
POWER2015
DEVELOPING GREEN, HIGHLY EFFICIENT COAL-FIRED
POWER TECHNOLOGIES
Feng Weizhong
General Manager
Shanghai Waigaoqiao No.3 Power Generation Co., Ltd.
Shanghai, China 200137
ABSTRACT:
Optimization and innovation of all systems are needed to
increase the energy saving and reduce emissions in coal-
fired power plants. Design changes can be made that are
inexpensive, low risk and effective.
A series of optimization and innovation designs have been
developed to significantly increase the efficiency of
2x1000MW ultra supercritical (USC) units in China. The
turbine efficiency limitations due to solid particle erosion
are eliminated by these improvements. The normal
deterioration of the turbine efficiency has also been
eliminated.
The units net efficiency at the rated operation conditions
including the Flue Gas Desulphurization (FGD) and
Selective Catalytic Reduction (SCR) systems now exceeds
46.5% for a single reheat system.
Key Words: efficiency improvement, ultra-supercritical,
innovation.
1. BACKGROUND
Global climate change concerns are requiring the electric
power industry to improve emission reductions and
environmental protection. The Chinese government has
committed to reducing the CO2 emissions per unit GDP in
2020 by 40%-45% relative to 2005.
In addition, coal is not only the most important primary
energy source in the world, but is also the largest source of
CO2 emissions and air pollution. Recently, higher levels of
haze have made coal the focus of conflict.
Chinas energy resources structure is Deficient in Oil, Lean
in Gas and Rich in Coal", so Chinas coal-fired power
capacity has reached 900GWe. Therefore, to reduce the
conflict between the environment and the continued
development of the electric power industry, the only choice
is to develop more efficient coal-fired power systems.
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June 28-July 2, 2015, San Diego, California
POWER2015-49551
2. HIGH EFFICIENCY OF COAL-FIRED POWER
The construction of very efficient large Super Critical/Ultra
Super Critical (SC/USC) units with the shutting down of old
low efficiency units has improved the average efficiency
and reduced the environmental impact of Chinas thermal
power generation industry over the last decade. However,
the potential for further structural improvements will be less
as the small low efficiency units are closed down.
The electric power industry has discussed developing new
Advanced-Ultra Super Critical (A-USC) high efficiency
power plants using high temperature 700C steam units.
Since the end of the last century, many countries have been
developing 700C high efficiency A-USC units.
The theoretical net efficiency of 700C, single reheat units
can be 46-47% (including the FGD and SCR systems) with
20C cooling water temperatures, which is 3~3.2% higher
than that of 600C units.
However, the materials and costs of 700C units have
limited their development. The first 700C high efficiency
A-USC demonstration unit has been postponed, so, the
possibility of commercialization of 700C A-USC units
before 2020 is unlikely. Thus the Chinese power industry
cannot expect to install 700C A-USC units to improve
energy savings and reduce emissions before 2020.
The second solution to continue making energy efficiency
gains and reducing environmental impacts is using
Integrated Gasification Combined Cycles (IGCC) systems.
In 2007, Mitsubishi Heavy Industries of Japan constructed
the most efficient IGCC demonstration unit (250MW), at the
Nakoso power plant. In November, 2012, China Huaneng
Group also constructed an IGCC demonstration unit
(265MW) in TianJin. However, there are still a lot of
technical and budget bottlenecks for IGCC units; much
 more development is needed for commercialization of IGCC
units.

To find workable solutions to our energy and environmental

challenges, we examined existing mechanical and thermal
systems in modern SC/USC units. Our research group has
made significant progress in identifying energy-saving
improvements that can be used in the design,
commissioning, operation and control of the existing
systems.

We determined that further advances in energy efficient

USC coal-fired power plants can be successfully developed
using a comprehensive approach consisting of innovation
and optimization of all plant systems. These solutions
resulted in reduced energy use and emissions. These
developments have the additional benefit of relatively low
cost.

The theoretical net efficiency of 600C USC, single reheat

units is 43~43.5% (including FGD and SCR systems) with
20C cooling water.

The systems at two 6001000MW ultra supercritical units

in the Shanghai Waigaoqiao No.3 Power Plant (WGQN3)
were analyzed at the commissioning to reduce energy use
and emissions through optimization and innovation projects,
which improved the units efficiency. Fig. 1

At present, the theoretical net efficiency (including the FGD

and SCR systems) has been upgraded to 46.5%, which is far
higher than such plants worldwide and comparable to the
target efficiency of the 700 plan. Figure 1. Shanghai Waigaoqiao No.3 Power Plant

3. SHANGHAI WAIGAOQIAO NO.3 POWER PLANT

IS AN OUTSTANDING EXAMPLE OF HOW TO
IMPROVE THE EFFICIENCY FOR EXISTING USC Main steam pressure 28 MPa
UNITS Reheat steam 6.4 Mpa/603
pressure/temperature
3.1 MAIN EQUIPMENT OF THE WAIGAOQIAO NO.3
POWER PLANT
Feedwater temperature 298
Designed startup mode Startup with circulating
3.1.1 Boiler pumps
The plant uses a licensed Alstom boiler. The boiler is a Design coal, heating China ShenfuDongsheng
tower type, ultra-supercritical, single reheat boiler with a value bituminous coal, 21-23
built-in separator, spiral water wall with sliding operation, kJ/kg
single furnace corner tangential firing and open Design efficiency 93.75%
arrangement, balanced draft, solid slag disposal, and Pulverizers Medium speed pulverizer,
pulverized coal firing (see Table1).
5 operation/1 standby
3.1.2 TURBINE:
De-Nox SCR
The turbine is a licensed Siemens turbine, a 1000MW single De-sulfuration FGD
shaft unit with four cylinders, four exhausts, and double Maximum continuous 2955 T/H
backpressures (see Table 2). evaporation
Main steam temperature 605
WGQN3 strove to improve the net power generation Table 1. WGQN3 Alstom Boiler Design Specifications
efficiency during the design and construction through
technical innovation and system optimization. These efforts
greatly improve

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 the plant efficiency. The annual average net operating pressure), reducing the turbine exhaust parameters and using
efficiency of WGQN3 increased from 42.73% in 2008 to double reheat are not possible for either an operating power
44.5% in 2011 and the annual average specific coal plant or a new plant once the equipment has been selected.
consumption reduced from 287.44 g/kWh in 2008 to 276.02 Thus the plant efficiency for an existing design can only be
g/kWh in 2011 (see Table 3). increased by identifying and reducing losses in the
equipment and systems. Figure 2. shows the innovative
Rated output 1000 MW systems and then net efficiency increments for the WGQN3.
Rated steam flow 2738.6 T/H
4.1 BOILER
VWO output 1059.97 MW2955 T/H 4.1.1 Heat Losses in the Flue Gas and Heat
Recovery Systems

Frequency control Control valve/overload The heat losses in the flue gas can account for 80% of all
valve losses for the boiler. Thus methods are needed to minimize
Main steam temperature 600 this loss. In addition the flue gas enthalpy and temperature
are increased by the ID and FGD boost fans, with
Rated main steam 25.86 MPa
pressure temperature rises to up to 10 which is quite large. Due to
Reheat steam 600 the relatively low flue gas temperature, which is normally
temperature 130 , or less, the useable energy is quite limited.
Extraction stages 8
Cooling water 19double The most difficult issue is that the heat recovery heat
temperature and design exchanger surface will be strongly corroded by the sulfur
backpressure backpressure 4.19/5.26 with sulfate from SO2, SO3 and NH4HSO4 after installing a
kPa SCR denitration system. Fly ash in the flue gas will also
Design heat rate 7320 kJ/kWh increasingly stick to heat exchanger surfaces, with the
Boiler feedwater pump 1100% turbine driven combination of the alkaline ash and the sulfuric acid
pump, no motor driven forming a concrete like material, which is hard to remove.
This material will then affect the flow. A German system
pump
addresses these problems by using a heat exchanger made of
Condensate pump 2100% anti-corrosion plastic.
Feedwater preheater 3100%one string, tube
sheet preheater However the thermal conductivity and the strength of the
HP bypass/LP bypass 100%/65% plastic are low, so the system is very large and expensive.
Table 2. WGQN3 Siemens Steam Turbine Steel heat recovery heat exchangers have been used in Japan
with the condensation reduced by limiting the flue gas. The
sulfur content in the coal must also be strictly controlled.
Since a lot of Chinas coal has high sulfur content, and these
systems are expensive, they cannot be used in China.

Thus, the problem has been addressed in a different way.

Year 2008 2009 2010 2011 The basic concept is to have a method to prevent the heat
Actual average net 42.73 43.53 43.79 44.50 exchanger surface from accumulating sulfur deposition with
efficiency (Including
an acid resistant material in the lower temperature section.
FGD & SCR), %
The heat exchanger is then located in the low ash zone
Actual average specific 287.44 282.16 279.39 276.02
coal consumption, between the booster fan and FGD tower, which reduces
g/kWh abrasion and the risk of ash accumulation and blockage.
Table 3 Net efficiency and specific coal consumption
improvement through innovation and optimization In addition, the heat generated by the induced fan and the
booster fan is also recovered using a finned heat exchanger
These efficiencies were at annual average load of 75%. If to improve the efficiency. The recovered heat is transferred
this efficiency was converted to the design conditions, the to the condensate so the low pressure extracted steam can be
net efficiency would be 46.5%. returned to the turbine at higher temperature to reduce the
turbine heat rate.

4. MAJOR ENERGY CONSERVATION AND Two FGD heat recovery systems were put into operation in
EMISSION REDUCTION IMPROVEMENTS IN THE June and October, 2009. They have been very successful.
WAIGAOQIAO NO.3 POWER PLANT They have experienced only a limited amount of corrosion,
The conventional approaches for improving the efficiency, which is not enough to impact the design life of the system.
such as increasing the steam parameters (temperature and
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 The unit efficiency is improved by 0.4% by this system,
with the water injection for the FGD reduced by 45 T/h.
Figure 2. Innovative Systems and Their Net Efficiency Increments at WGQN3
4.1.2 AIR PREHEATER SEALING
The rotating air preheater is typical for large boiler. The
Waigaoqiao No.3 power plant uses a rotor rotating type of
air-preheater with a diameter of 17 m and height of 2.5 m.
The design air leakage is less than 5% and is still less than
6% after one year operation.
There are many advantages of the rotor rotating type air pre-
heater, but the non-linear mushroom deformation of the
rotor during the operation makes the clearances between the
rotating and stationary parts difficult to control which
increases the air leakage. The air leakage then consumes
more power due to the increased air flow rate with the
power increasing related to the air leakage rate to the third
power. The heat transfer rate is also reduced which will
reduced the boiler efficiency.
The air leakage was reduced by adding a Flexible Sealing
System. The system did change the original equipment
design as the seal has a controlled wear rate and is flexible
enough to seal the radial, axial and circumferential
clearances. The seal is flexible enough to compensate for the
non-linear changes between the rotating and stationary parts,
so the air leakage is significantly reduced.
With this seal the unit power consumption rate was below
3.5% at the rated operating condition (including the FGD
and SCR systems). When the seal was first applied to only
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the cold ends of the preheaters of unit one, the air leakage
rate was only 4% and the power use without FGD was
3.01%. After the seals were installed in the hot ends and
along the axial directions, the power use was further reduced
to 2.7% without the FGD power. The boiler hot air
temperature also increased which increased boiler efficiency
with a unit efficiency increase of 0.29%.
4.1.3 BOILER STARTUP ENERGY CONSERVATION
SYSTEM
The startup of large super and ultra supercritical units
consumes large quantities of water, electric power, oil, coal
and steam. Also, the unit is more susceptible to damage
during this time, compared to normal operating conditions,
due to the effect of the sticky flue gas constituents (a result
of firing oil), on the precipitator. At many plants, this oil
build up is avoided by switching off the precipitator during
the oil firing, and combined oil-coal firing period. This
causes the pollutant emissions to increase during this phase.
The startup procedures for once through boilers used
worldwide were analyzed to find the best method. The result
was that traditional startup method was completely replaced
by a new startup method that is more effective.
1Boiler filling without the boiler feedwater pump, start
up and flushing without ignition.
This system can be flushed without starting the boiler
feedwater pump or igniting the burners to heat the boiler.
This saves large quantities of fuel and power and is easy to
control. The high temperature water in contact with the
 flushed heating surfaces creates two-phase flow which
greatly improves the flushing effect.
(2Once through boiler startup with steam heating and
stable combustion.
This startup method reduces the oil consumption by more
than one order of magnitude. This procedure not only
changes the original cold boiler startup to hot startup but
also makes the air flue gas operating conditions better than a
traditional hot startup, and improves the boiler ignition
condition for stable combustion. This method reduces the
minimum stable boiler operating conditions without oil
firing to less than 20% Boiler Maximum Continuous Rating
(BMCR), and greatly improves the boiler start up.
(3) Canceling the boiler circulating pumps and applying
lower feedwater flow during the drainage startup.
This technique simplified the startup and operating
procedures and improved the safety and reliability while
reducing the startup losses. This method had a shorter hot
startup time with fewer losses than with conventional
circulating water pumps. This startup procedure greatly
simplified the whole procedure, greatly shortened the startup
time, and greatly reduced the startup power usage,
especially the station power and the oil for ignition, while
the safety was enhanced. At present, regardless of the unit
condition, including cold startup, the time from boiler
ignition to generator synchronization can be controlled
within 120 minutes. The oil consumption is less than 20
tons, the station power consumption is 80000 kWh, and the
coal consumption is 200 tons (including the heating steam).
4.2 TURBINE
4.2.1 OPTIMIZATION OF THE MAIN STEAM
PARAMETERS AND THE OPERATING MODE
The super and ultra-supercritical turbines supplied by
Siemens did not have any control stages with the sliding
operating. To further improve the economics during turbine
load variations, Siemens provided Chinese market with
ultra-supercritical turbines fitted with an overload valve for
grid frequency regulation and overload control in China.
There is an additional port in the HP turbine right after the
5th blading stage. The overload valve is placed between the
additional port and downstream of the main stream stop
valves.
For normal operations, the main steam control valve and the
overload valve work together for load control. Loads
changes can be fulfilled by opening the overload valve and
closing the control valves. The turbine efficiency is reduced
when the overload valve opened so the overload valve is
opened and closed quickly with only a small opening. One
drawback is that this can lead to the erosion and leakage.
To avoid opening of the overload valve during normal
operations, the design and control were optimized as
follows: First, carefully set the main steam design pressure
by setting the opening point of the overload valve to the
rated load point corresponding to the summer season
maximum cooling water temperature.
Thus the overload valve should not open for most of the
year when the load demand is equal to and lower than this
rated output.
Second, the turbine load control is based on an energy
saving turbine load adjustment method of adjusting the
extraction steam rate so that the main control valves are
fully open and the overload valve is always closed. This
eliminated the throttling loss across the valves. This method
changes the turbine frequency regulation method by
controlling the steam extraction for the feedwater reheaters.
This method can vary the turbine output and satisfy the load
demand by adjusting the boiler combustion rate.
This frequency regulation enables fast response to load
demand changes for even relatively large load ranges. This
frequency regulation method has been demonstrated at the
two units in the Waigaoqiao No. 3 power plant. At present,
the load change rate for frequency control can surpass 15
MW/min.
These optimizing and operating changes improved the unit
efficiency by 0.22%. However, these improvements will not
be reflected in unit performance tests at the rated condition.
4.2.2 OPTIMIZATION AND ENERGY SAVINGS IN
THE BOILER FEED WATER PUMP AND ITS
SYSTEM
The design and operating experience of large American and
German SC and USC feedwater systems were analyzed.
Waigaoqiao No. 3 power plant with its 1 x 100% turbine
driven feedwater pump (BFPT) which is being used for the
first time in China without an electrically driven pump. This
BFPT has its own condenser and starts up with the steam
from the neighboring unit.
During the startup phase, once the boiler is generating
enough steam, the pumps steam source is switched back to
its own steam supply (cold reheat). This makes better use of
the boilers steam which, in a traditional system, would be
exhausted to the unit condenser by the LP bypass. This
greatly reduces the energy use during the startup phase.
A German Alstom turbine selected for the boiler feedwater
pump has an efficiency of 86.7%. In addition, the turbine is
equipped with a control valve and a control stage specially
designed for the cold reheat steam as shown in Fig. 3.
In addition, use of the lower speed startup for the boiler
feed pump and use of its entire speed range significantly
reduces startup energy use and increases the unit
efficiency. This also simplifies the system control
strategy and eliminates the risk of minimum flow valve
leakage while enhancing the operating safety. Compared
to similar units, this boiler feed water pump increases the
unit efficiency by 0.117%.

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 Figure 3. Configuration of the Control Valve and Control
Nozzles for the BFPT

4.2.3 GENERALIZED REGENERATION THEORY

Generalized regeneration theory is an expansion of classical
thermodynamics theory. The key point is that the classical
regeneration cycle with the feedwater as the heat carrier is
expanded to a generalized regeneration cycle with the water,
air and coal entering the boiler as the heat carriers. This
expansion of the heat carrier concept was improved even
more through increased use of steam extraction, which
further reduces the turbine exhaust losses.

The theory was used to modify the Waigaoqiao No. 3 unit

with a series of new systems that improved the efficiency.
Taking the air into the boiler as an example, the system
matched extracted steam to the air preheaters to heat the air
into the boiler, which recovers energy from the extracted
steam and improves the boiler combustion efficiency at the
same time.

Unlike traditional steam-air heaters, this system does not

increase coal consumption. The system improves the safe
operation of the air preheaters and the unit operating
efficiency. This system increased the unit net efficiency by
more than 0.42%.

Generalized regeneration theory can be applied to all coal-

fired units to further improve their thermal efficiency and
reduce their environmental impact in a number of ways.

4.2.4 FLEXIBLE REGENERATION SYSTEM

This method expands the traditional feed water regeneration
systems. An additional adjustable high pressure steam
extraction point is added to maintain the final feedwater
temperature, or at least minimize the temperature drop,
during low load operation. In addition, the temperature drop
of the flue gas downstream of the boiler economizer at low
load conditions can be reduced so that the problem of
having to turn off the SCR at low loads is resolved. Thus the Figure 4. The oxidates deposited in boiler tubes and SPE
unit environment protection is significantly improved. Also, of the turbine blading and erosion of the bypass
the fast response of the extraction steam pressure by the
control valve means that the unit frequency response is
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 faster. The use of more bleed steam at low load
conditions also improves efficiency. The higher air and
feedwater temperatures at the water wall inlet during low
operation improve the combustion stability and
efficiency, and the water dynamics. At 75% load rate,
this system improves the unit operation efficiency by
0.2%.
4.3 EFFICIENCY PRESERVATION OF ULTRA
SUPERCRITICAL UNITS
At higher steam temperature and pressure, especially the
steam temperature, Ultra-supercritical units can have new
problems with one outstanding problem being the steam-
side oxidization of the piping and subsequent SPE (solid
particle erosion) of the turbine blades, which threatens
the safe and economic operation of the units. Fig. 4. The
oxidates deposited in boiler tubes and SPE of the turbine
blading and erosion of the bypass
The startup time and the bypass time have also been
shortened. Steam heating during startup contributes to low
load stable combustion by providing a hot environment for
boiler startup before ignition, by heating the whole boiler
with the steam instead of oil and coal. This protects the
boiler convection surface after ignition from overheating,
during the time before it starts steaming; when the water in
the water wall is still not saturated. It also slows the rate of
high temperature oxidation, and keeps the oxidates from
peeling off when the convection surface is suddenly cooled
by the steam after evaporation begins.
After 30 months operating, the tubes in the third superheater
and the second reheater have been checked. There was not
any indication of oxidation and deposits as shown in Fig.5
and 6. with the tubes looking brand new.

This issue often occurs during unit startup. The oxidates on

the boiler steam side peel off due to the heat shock to the
boiler. Depending on the conditions, the oxidates are either
deposited in the tubes or form particles that flow with the
steam. Serious deposits can result in tube failure. Particles
carried by the moving steam will create serious problems
and the efficiency will irreversibly decrease. The solid
particles also erode the sealing surface of the bypass valve
plug during startup, which causes leakage and part of the
steam to bypass the turbine, this leak-by reduces the plant
efficiency. Chinas super and ultra supercritical units have
had serious problems, with the efficiency of some units
reduced by 4% after 2 years operation. Figure 5. Superheater 3 tubes of the Waigaoqiao No.3
Power Plant
The oxidization of the steam side of the tubes and the
resulting SPE must be prevented to maintain the plant
efficiency. This needs a comprehensive plan that includes
equipment selection, system design, installation and
commissioning, operations and the control strategy. 10 years
of research has led to a set of steps that have been
implemented in this project. First, the water wall is blown
out with highly superheated steam during construction with
sufficient flow momentum (K factor) in the water wall outlet
region by increasing the blowing strength.

A high momentum flushing system was developed for the

startup process incorporating a large capacity bypass system
that used load variations, flow parameter variations and flow
circuit changes prior to turbine startup with a special bypass
operation mode to remove the oxidates from the heating
surface before each startup. These particles often deposit in
locations including some in the zero velocity zone that go
directly to the condenser. The unit safety and efficiency are Figure 6. Reheater 2 tube of the Waigaoqiao No.3 Power
ensured by carefully cleaning the oxidates in the system to Plant
prevent oxidates and particles from emerging at high
temperatures and high loads. The configuration design and After 30 months operating, the turbine first IP blading was
control strategy has eliminated the erosion of the bypass checked. As illustrated in Fig 7., the blading is also like
valve plugs. brand new. A performance test indicated that the turbine
efficiency had not decreased since the first startup.
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 technical preparations in the AD 700 USC development
plan, there are still material and cost problems. According to
the current progress, commercial operation is not expected
within 10 years. In order to speed up the carbon reductions
in the electric power industry, designer need to explore
potential energy savings in all respects and develop new
systems to challenge efficiency limits and develop efficient
thermal power plants based on available systems. Our
experience with the Waigaoqiao No.3 power plant shows
that there is still much room for additional energy savings in
existing systems in terms of the equipment, design,
commissioning, operation and control systems, optimization
and innovations as a way to reduce energy use. This is the
Figure 7. First IP blading after 30 months operation best solution to quickly to lower costs and risks. The plant
efficiency was increased by more than 3% which is
equivalent to that of the USC temperature being increased
4.4 CENTRALIZED VARIABLE FREQUENCY from 600 to 700. These systems are principally used,
STATION POWER SYSTEM most easily, in newly constructed units. But also can be
extended to existing units to generate improvement of more
Variable frequency power was used to power most motors in than 2%.
the plant in a centralized variable frequency station power
system. In China, coal-fired power plants supply 70% of the
electricity. The grid frequency is mainly regulated by the
coal fired units. The unit load in Shanghai then fluctuates
between 40% and 100%, so the auxiliary equipment is
expensive and not reliable. Centralized variable frequency
turbine-generator systems were built for each unit to supply
various frequency power to each motor that followed the
changes load and reduced the power consumption. After the
centralized variable frequency power systems were put into
operation in 2013, the station power consumption was
reduced from 3.5% to less than 2% (including the FGD and
SCR systems). This method can also improve the main unit
efficiency.

4.5 APPLICATION OF THESE SYSTEMS IN OTHER

PLANTS

Most of these systems are universal and can be applied in

new units as well as retrofits of existing units; thus they are
of great significance for improving the efficiency of the
whole industry.

These systems have been applied in other power plants as

well as the Shanghai Waigaoqiao No.3 power plant. Some
of these systems including the flexible regeneration system,
energy balanced FGD system, air preheater sealing method,
energy saving frequency regulation and the unconventional
start-up method have already been successfully applied in
the Tongshan coal-fired power plant.(2 existing 1000 MW
USC units ) of the Huarun Electric Power Group in china.
Performance tests shows that the unit efficiency of
Tongshan power plant has been improved by 1.5% by these
improvements.

5. CONCLUSIONS
Recognizing that character of Chinas energy resources
structure is Deficient in Oil, Lean in Gas and Rich in
Coal, clean utilization of coal must be the priority of
Chinas energy development strategy. Due to insufficient

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