Oktober 2005

Boiler Designs for the

AD700 Power Plant
G. Weissinger, Dr. Q. Chen
ALSTOM Power Boiler GmbH
 Overview

n Boundary Design Conditions

n Involved Partners in Boiler Design Group

n Two selected Boiler Designs

n Design Problems / Possible Solutions
n Material Selection
n Critical Components

n Ongoing Activities
 Overview

n Boundary Design Conditions

n Involved Partners in Boiler Design Group

n Two selected Boiler Designs

n Design Problems / Possible Solutions
n Material Selection
n Critical Components

n Ongoing Activities
 AD700 Boiler Design
Design Coal and Coal Range

Design Coal Coal Range

South Africa
min. max.
Kleinkopje Coal
LHV MJ/kg 23.9 22.6 28.9
Moisture % ar 8.3 7.0 15.9
Ash % ar 15.9 5.9 17.4
Fixed Carbon % ar 62.5 50.5 71.6
Volatiles % ar 21.6 20.3 34.1
Sulphur % ar 0.7 0.3 1.7
HGI - 51 44 59

058 272p
 AD700 Boiler Design
Steam Parameter (400 MW, Single RH)

Load (net) MW 400

HP steam flow t/h 991
Feed water temperature C 330
HP steam Feed water pressure bar 401
HP outlet temperature C 702
HP outlet pressure bar 358
RH steam flow t/h 782
RH inlet temperature C 424
RH steam RH inlet pressure bar 73
RH outlet temperature C 720
RH outlet pressure bar 71

001 1051p
 AD700 Boiler Design
Steam Parameter (1,000 MW, Double RH)
Load (gross) MW 1,000
Steam flow t/h 2,012
Feed water temperature C 350
HP steam Feed water pressure bar 403
Outlet temperature C 702
Outlet pressure bar 383
Steam flow t/h 1,808
Inlet temperature C 493
IP steam Inlet pressure bar 124
Outlet temperature C 720
Outlet pressure bar 118
Steam flow t/h 1,460
Inlet temperature C 446
LP steam Inlet pressure bar 25
Outlet temperature C 720
Outlet pressure bar 24
001 1052p
 AD700 Boiler Design
Design Boundary Conditions

400 MW (net)
Unit Size
1,000 MW (gross)
400 mg/Nm and 5 % unburned carbon
Emissions
based on design coal

Flue Gas Velocity < 14 m/s

Flue Gas Temperature < 1,170 C for tube transverse pitch < 350 mm

Flue Gas Exit

110 C
Temperature
Sliding Pressure
From 100 % to 40 %
Operation

Pressure Parts Design According to EN 12952 code

001 1053p
 Overview

n Boundary Design Conditions

n Involved Partners in Boiler Design Group

n Two selected Boiler Designs

n Design Problems / Possible Solutions
n Material Selection
n Critical Components

n Ongoing Activities
 AD700 Boiler Design
Matrix of Contractors and Boiler Types

400 MW (net) 1,000 MW (gross)

Tower Two Pass Tower Two Pass
ABB Enertech 2RH, TF
Ansaldo 2RH, OWF
Babcock Kraftwerkstechnik 1RH, OWF
Mitsui Babcock 1RH, OWF
Siemens KWU 1RH, OWF
Alstom Energy Systems 1RH, TF
Babcock Wilcox Spain 1RH, OWF
Steinmller 1RH, OWF
Stork 2RH, OWF

1RH = Single Reheat 2RH = Double Reheat

TF = Tangential Firing OWF = Opposed Wall Firing
001 1054p
 Overview

n Boundary Design Conditions

n Involved Partners in Boiler Design Group

n Two selected Boiler Designs

n Design Problems / Possible Solutions
n Material Selection
n Critical Components

n Ongoing Activities
 AD700 Boiler Design
400 MW Tower Boiler

Eco

RH 1
HP Steam
SH 3 358 bar
702 C
RH 2 991 t/h
SH 4
SH 2 RH Steam
SH 1 71 bar
Evaporator
(walls) 720 C
782 t/h
Feedwater
330 C

0.0 m
022 148p
 AD700 Boiler Design
1,000 MW Two Pass Boiler

HP Steam
383 bar
702 C
2,012 t/h

IP-RH Steam
118 bar
720 C

LP-RH Steam
24 bar
720 C

Feedwater
350 C

022 149p
 Overview

n Boundary Design Conditions

n Involved Partners in Boiler Design Group

n Two selected Boiler Designs

n Design Problems / Possible Solutions
n Material Selection
n Critical Components

n Ongoing Activities
 AD700 Boiler Design
H/P Diagram
4,000 . . . .
750 C
.
RH 2 .
kJ/kg . . 700 C .
. . . . .
. . .
. 650 C . SH 4
3,600 . .
.
.
. . .
. . .. . . 600 C
. .. . . SH 3
. . .. .
. RH 1 . 550 C
. . ...
. . . SH 2
3,200 . . .
. 500 C . SH 1 Wall
. Evaporator Outlet

450
2,800 C

2,400
Enthalpy

Evaporator

2,000 400 C

375 C
. .
.. 350 C
1,600 .. .. ECO
.
. 100 %
. 80 % 300 C
. 60 %
1,200
40 % 250 C

200 C
800
150 C

100 C
400
.
0 50 100 150 200 250 300 bar 400
002 562py Pressure
 AD700 Boiler Design
Q/T-Diagram for BMCR
2,600
2,400
2,200 Flue gas
2,000
Temperature (C)

1,800 Furnace

1,600
1,400 SH-2
SH-4
1,200
RH-2
1,000
SH-3
800 RH-1
600 Water steam
ECO
400 Air preheater
200
0
0 10 20 30 40 50 60 70 80 90 100 110 120

002 559p
Effective heat pick up (%)
 AD700 Boiler Design
Design Problems and possible Solutions
l Very small pinch point temperatures at ECO and RH1
Finned tubes for ECO and part of RH1
l Very limited heat pick up at ECO and therefore
ineffective surface design
Limitation of sliding pressure range only to 60 %
l Large steam temperature drop at evaporator outlet
during transition from once-through to recirculation
mode
Increase of furnace outlet temperature and limitation
of the coal range
Preferred in a base load operation
001 1055p
 Overview

n Boundary Design Conditions

n Involved Partners in Boiler Design Group

n Two selected Boiler Designs

n Design Problems / Possible Solutions
n Material Selection
n Critical Components

n Ongoing Activities
 AD700 Boiler Design
400 MW Tower Boiler Material Selection
Heating Surface Header

15 Mo3 Eco ECO: WB36 (Inlet/Outlet)

T91 RH 1: 13 CrMo 44 (Inlet)

S304H SB RH 1 P92 (Outlet)

HR3C
Alloy 174 SH 3 SH 3: Alloy 617 (Inlet/Outlet)
Alloy 617

RH 2: P92 (Inlet)
Alloy 617 RH 2 Alloy 617 (Outlet)

Alloy 740 SH 4 SH 4: Alloy 617 (Inlet)

Alloy C263 (Outlet)
S304H SB SH 2 SH 2: Alloy 617 (Outlet)

022 150p
 AD700 Boiler Design
Comparison of Material Selection (400 MW, Single Reheat)

250 bar / 540 C / 560 C 280 bar / 600 C / 620 C 360 bar / 700 C / 720 C

Ferritic Ferritic Ferritic

100 % 80 % 60 %

Ni-base
Austenitic
16 % Austenitic
20 %
24 %

001 1050p
 Overview

n Boundary Design Conditions

n Involved Partners in Boiler Design Group

n Two selected Boiler Designs

n Design Problems / Possible Solutions
n Material Selection
n Critical Components

n Ongoing Activities
 AD700 Boiler Design
Critical Components and possible Solutions
Water Wall:
T23 and T24 insufficient against steam oxidation
and insufficient strength for relevant steam conditions
Qualification of HCM12 and Alloy 617

Final HP Outlet Header:

Alloy 617 insufficient strength for relevant steam conditions
Qualification of Alloy C263

Final SH and RH Tubes:

insufficient knowledge of the flue gas side corrosion
and steam side oxidation behaviour
Investigation of corrosion and oxidation behaviour
in power plants
001 1056p
 AD700 Boiler Design
State of Material Development

Water Wall Materials:

HCM 12 and Alloy 617 are being tested in the current R & D
projects (AD700-2, COMTES700, MARCKO 700)

Heating Surface Materials:

Various advanced austenitic steels and nickel-based materials
are being tested in the current R & D projects
(up to 720 C steam temperatures)
(AD700-2, Weisweiler, Esbjerg, COMTES700)

Header and Piping Materials:

Alloy 617 mod. is being tested in the current R & D projects
(MARCKO, COMTES700)

001 779p
 Overview

n Boundary Design Conditions

n Involved Partners in Boiler Design Group

n Two selected Boiler Designs

n Design Problems / Possible Solutions
n Material Selection
n Critical Components

n Ongoing Activities
 AD700 Boiler Design
Amager Test Rig

Position of
test panel

Alloy 617

HCM12

022 152p
 AD700 Boiler Design
Material Test Loop in Power Plant Avedre

022 153p
 AD700 Boiler Design
Material Test Loop in Power Plant Weisweiler
Material Test Loop for 720C Steam Temperature
installed in the final superheater of the lignite fired PS Weisweiler
Outlet header
Boiler front wall

Boiler rear wall

Tube Material in Section a: X20CrMoV121
Tube OD 38 mm b: AC66
c: Alloy 617
d: Thermie 740
e: Alloy 263 540 C

720 C

c d e c
M

b a
480 C

20,850 mm

Flue gas 1,050 C Inlet header

022 151p
 AD700 Boiler Design
Esbjerg 720 C - Test Rig

075 286px
 AD700 Boiler Design
Components Test Facility COMTES700

011 613pz
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