Академический Документы
Профессиональный Документы
Культура Документы
India have a considerable potential for adding up new power generation capacity based on coal, having proven reserves of over 202 billion tones. Substantial demand for adoption of supercritical steam technology is developing, driven largely by the need to minimize the environmental impact of power generation by achieving higher efficiencies of energy conversion. In Asia, particularly in India and the Far East, environmental requirements are tightening and look set to tighten further. The conventional power plant will not be able to meet the environmental norms and efficiency demands of the future.
Plant costs comparable with sub-critical technology and less than other clean coal technologies
Very low emissions of nitrogen oxides (NOx) sulfur oxides (SOx) and particulates achievable using modern flue gas clean-up equipment.
Initial data on two experimental 12 Cr ferritic steels indicate that they may be capable of long-term service up to 650 degrees Celsius, but more data are required to confirm this.
Advanced austenitic stainless steels for reheater and super-heater tubing are available for service temperatures up to 650 degrees Celsius and possibly 700 degrees Celsius. The ASME Boiler Code Group has approved none of these steels so far. Higher strength materials are needed for upper water construction of plants with steam pressures above 24 Mpa. A high strength 1-1/2 percent Cr steel recently ASME Code approved as T-23 is the preferred candidate material for this application. Field trials are in progress.
Several units of 250 MW size have been deployed in Europe and the U.S. Larger units of 400-600 MW have been designed and could potentially make use of the higher efficiency super critical steam cycles.
R&D IN METALLURGY
The main R&D efforts are in Japan, the USA (funded by the US Department of Energy, USDOE) and Germany (including the MARCKO Program). Japanese manufacturers claim to have already demonstrated materials suitable for 650C steam temperatures. Furnace wall tubing, T23, developed by Sumitomo Metal industries and MHI, and 7Cr. Mo.V.Ti.B1010 (Ti: titanium; B: boron), developed by Mannesmann and Valourec, are the most likely materials to be selected for steam conditions up to 625C/325 bar.
Short-term creep rupture data suggest that these steels may have equivalent creep properties to T91 steel whilst requiring no post-weld heat treatment. For steam conditions >625C/325bar stronger materials will be required. Candidate materials currently at the most advanced stage of development are P92, P122 and E911. All three steels offer considerably enhanced creep-rupture properties over more conventional equivalent steels, T91 and X20Cr.Mo.V121, but all require post-weld heat treatment during fabrication
R&D IN METALLURGY
Contd...
More highly alloyed steels under development, such as NF709, HRBC and HR6W, may allow operation at steam temperatures of 630C, but again more advanced work is needed. The recent ASTM/ASME-approved P92 and P122 steels should allow construction of thick-section components and steam lines for PF plant operating with steam parameters up to 325bar/610C. Circumferential water wall cracking has been the major source of boiler tube failures for supercritical units. The objective of EPRI project on this aspect was to determine the root cause(s) of the circumferential cracking experienced on the fireside of water wall tubes of supercritical steam boilers in the United States. Information is now available from detailed monitoring to provide guidance on controlling these failures.
Boiler Design
Considerable research effort into plant damage, including thermal fatigue has been under way, aimed at supporting existing operating plant. This is leading to new designs of, for example, headers and steam chests that are much more resistant to thermal fatigue and where thermal fatigue can be better predicted. To prevent problems, multiple components can be used to reduce component sizes and hence wall thickness.
New alloys based upon 10% Cr. Mo.W.V.Nb.Ni B (W: tungsten; Nb: niobium) are becoming available for turbine rotors and casings for construction of 300-325bar/600-610C steam turbines. Creep testing to 40,000h, together with large-scale fabrication trails, has so far demonstrated reliable results. Hence, turbine parameters of 600C/325bar can be considered achievable. By the addition of cobalt to 12%Cr.W steel (i.e. NF 12 and HR 1200), Japan expects to be able to manufacture steam turbines capable of handling final steam conditions of 650C/325bar. A number of design changes are also being developed to allow higher temperatures and pressures to be used are (a) (b) (c) (d) Partial triple-casing on turbines or use of inlet guide vanes to reduce the peak pressures seen by the HP cylinder Steam inlets and valves welded rather than flanged to give reduced leakage and fewer maintenance problems Use of heat shields and cooling steam in the IP turbine inlet New blade coatings to reduce solid particle erosion where high-velocity inlets are used to minimize pressure effects
Advanced control techniques should be developed to optimize plant operation and maintenance. These include intelligent control systems to: Maintain uniform temperatures across the boiler by control of burner parameters Minimize carbon-in-ash or NOx formation in the same way Better match of load and firing during load changes, to avoid temperature excursions and improve ramp rates Improve reliability and repeatability of cycling procedures Condition-monitor both boiler and turbine components Forecast damages accumulation and allows targeted preventative maintenance. Ensure higher reliability of temperature sensors Monitor high temperature fire side corrosion in super-heater section March towards maximum allowable operating point from metallurgical point of view requires use of advanced control, as normal PID control is intolerable. These are; Fuzzy logic control, State Variable Control, Predictive Adaptive Control etc.
However, in order to be commercially viable, supercritical cycles need to be of a certain size, and also to be able to generate hightemperature steam. For all the above cycles, one or both of these factors have been missing to date, so no supercritical version has been constructed.
Transfer of Supercritical / Ultra- Supercritical (SC/ USC) Technology from a developed economy to India vis--vis an imported SC/USC
Tables 1 & 2
The cost data has been obtained through literature survey for the following four main variants of SC / USC plants.
The cost figures in $/kW is worked out in table below for the components available in India. Average figures indicating cost of all major components/ sub systems in case of import from USA, Europe & Japan i.e. the countries of origin for the above three variants of SC / USC are also calculated at this table.
Availability of various components of supercritical / ultrasupercritical Technologies suitable for high ash Indian coals is given at this Table. Country wise (USA, Europe, Japan) variation in cost structure of major components of SC / USC technology is also worked out at the following Table
Tables 3&4
PF 610Super-critical PF fired unit with 246 kg/Cm2, 566/ 5930C(Refer Fig. 4.2) Normal pace3 and years
Accelerated TOT3 years PF 710Ultra-supercritical PF fired unit with 300 kg/Cm2, temperature up to 7100C (Refer Fig. 4.3) Normal pace6 and years Accelerated TOT5 years TRANSPARANCIES
Overall SC/ USC Power plant cost analysis results and discussions
An analysis of the results of the table 3 shows that specific cost ( Rs. Cr. per
MW @ Rs.45/ US $ ) of the following variance of a Sub-critical and three types of Imported SCU / USC units may be worked out as under: PF 5405.058 PF 5805.396 PF 6105.454 PF 7109.635
CONTD
For the indigenous development through a systematic transfer of technology (TOT), the corresponding figures are: PF 5402.713 PF 5802.988
PF 6103.114
PF 710 6.687 This cost does not include the cost of transfer of technology and the time required for TOT and consequent add on to the cost. In case of partial import, the cost shall lie between above two sets of figures.
CONTD
Country wise variation in cost structure of imported SC / USC plants suitable for using above referred technologies. The same is summarized as below:
Cost of indigenous SC plant (PF 580246 b and 538/565 C) suitable for Indian coals using about 70% indigenous materials, would be of the order of 3 Cr./MW at todays exchange rate (Cost of TOT shall be extra)
TECHNO-ECONOMIC ANALYSIS
Techno-economic studies were carried out by EPDC of Japan for:
(a) (b)
Pit head station specifically Sipat STPP of NTPC Load-centered station (coastal), about 1200 km from coal source
Following five cases based on steam conditions were analyzed: Case 1: 169 kg/Cm2 & 538/5380C Case 2: 246 kg/Cm2 & 538/5380C Case 3: 246 kg/Cm2 & 538/5660C Case 4: 246 kg/Cm2 & 566/5660C Case 5: 246 kg/Cm2 & 566/5930C
Tables 5&6
Cost of generation is highest for ROM coal fired load center SCU with land transport of coal.
Parameters selected for super critical unit firing ROM coal at Pithead station as the most optimum for Indian conditions is that of Case 3: 246 kg/Cm2 & 538/5660C.