WELCOME

TO
PRESENTATION ON

SUPERCRITICAL BOILER
By
OPERATION TEAM
1
APML,TIRODA
 Introduction to Supercritical
Technology
What is Supercritical Pressure ?

Critical point in water vapour cycle is a

thermodynamic state where there is no clear
distinction between liquid and gaseous state
of water.
Water reaches to this state at a critical
pressure above 22.1 MPa and 374 oC.

2
 Rankine Cycle Subcritical Unit
1 - 2 > CEP work
2 - 3 > LP Heating
3 - 4 > BFP work
4 - 5 > HP Heating
5 6 > Eco, WW
6 7 > Superheating
7 8 > HPT Work
8 9 > Reheating
9 10 > IPT Work
1011 > LPT Work
11 1 > Condensing

3
 Rankine Cycle Supercritical Unit
1 - 2 > CEP work

2 2s > Regeneration

2s - 3 > Boiler Superheating

3 4 > HPT expansion

4 5 > Reheating

5 6 > IPT & LPT Expansion

6 1 > Condenser Heat rejection

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 VARIATION OF LATENT HEAT
WITH PRESSURE
Absolute Saturation Latent Heat
Pressure Temperature (K J/Kg.)
(Bar) (oC)

50 264 1640
150 342 1004
200 366 592
221 374 0

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 Departure from Nucleate Boiling
Nucleate boiling is a type of boiling that takes place when the surface temp is
hotter than the saturated fluid temp by a certain amount but where heat flux
is below the critical heat flux. Nucleate boiling occurs when the surface
temperature is higher than the saturation temperature by between 40C to
300C.

WATER
DENSITY

STEAM

175 224

PRESSURE(ksc)
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 Supercritical Boiler Water Wall
Rifle Tube And Smooth Tube

7
 Natural Circulation Vs. Once Through
System

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 5710C To HP
Turbine To IP
Turbine 5690C
Mixer Header
5340C
4230C 5260C
4620C

Separator FRH

FSH 4730C

Platen
Heater
From CRH Line LTSH
3260C
4430C
LTRH
3240C

NRV
From FRS Line 2830C

2800C Economizer Economizer

Phase 1 Phase 2

Boiler Bottom Ring

Recirculation Pump Header
 Feed water control
In Drum type Boiler Feed water flow control by Three
element controller
1.Drum level
2.Ms flow
3.Feed water flow.
Drum less Boiler Feed water control by
1.Load demand
2.Water/Fuel ratio(7:1)
3.OHD(Over heat degree)

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 Difference of Subcritical(500MW)
and Supercritical(660MW)

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COMPARISION OF SUPER CRITICAL & SUB CRITICAL
DESCRIPTION SUPERCRITICAL SUB-CRITICAL
(660MW) (500MW)
Circulation Ratio 1 Once-thru=1
Assisted Circulation=3-4
Natural circulation= 7-8
Feed Water Flow -Water to Fuel Three Element Control
Control Ratio -Feed Water Flow
-MS Flow
(7:1)
-Drum Level
-OHDR(22-35 OC)
-Load Demand
Latent Heat Addition Nil Heat addition more
Sp. Enthalpy Low More
Sp. Coal consumption Low High
Air flow, Dry flu gas loss Low High
Continue..
DESCRIPTION SUPERCRITICAL SUB-CRITICAL
(660MW) (500MW)
Coal & Ash handling Low High

Pollution Low High

Aux. Power Low More
Consumption
Overall Efficiency High Low
(40-42%) (36-37%)
Total heating Low High
surface area Reqd (84439m2) (71582m2)
Tube diameter Low High
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Continue..
DESCRIPTION SUPERCRITICAL SUB-CRITICAL
(660MW) (500MW)
Material / Infrastructure Low High
(Tonnage) 7502 MT 9200 MT
Start up Time Less More

Blow down loss Nil More

Water Consumption Less More

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 Water Wall Design

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 WATER WALL ARRANGEMENT
Bottom spiral & top vertical tube furnace arrangement

Once through design feature is used for boiler water wall design

The supercritical water wall is exposed to the higher heat flux

Spiral tube wall design (wrapped around the unit) with high mass flow
& velocity of steam/water mixture through each spiral

Higher mass flow improves heat transfer between the WW tube and
the fluid at high heat flux.

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 SPIRAL VS VERTICAL WALL
VERTICAL WALL
Less ash deposition on wall
Less mass flow
More number of tubes
More boiler height for same
capacity
No uniform heating of tubes and
heat transfer in all tubes of WW
17
SPIRAL WALL
More ash deposition
More fluid mass flow
Less number of tubes
Less boiler height
Uniform heat transfer and
uniform heating of WW tubes
 Furnace Arrangement

SPIRAL TYPE

VERTICAL TYPE

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 Supercritical Sliding Pressure Boiler
Water Wall Design
Comparison of Vertical Wall and Spiral
Wall

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20
 Ash accumulation on walls
Vertical water walls Spiral water walls

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 Super Critical Boiler
Materials

22
 Advanced Supercritical Tube Materials
(300 bar/6000c/6200c)

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 Material Comparison

Description 660 MW 500 MW

Structural Steel Alloy Steel Carbon Steel
Water wall T22 Carbon Steel
SH Coil T23, T91 T11, T22
T91,Super 304
RH Coil H T22, T91,T11
LTSH T12 T11
Economizer SA106-C Carbon Steel
Welding Joints (Pressure Parts) 42,000 Nos 24,000 Nos

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 Steam Water Cycle
Chemistry Controls

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S. Parameter Sub Critical Super Critical
No.
Type of Boiler LP and HP dosing. Or No HP dosing
1 water All Volatile Treatment Combined water treatment (CWT).
treatment (Hydrazine + Ammonia)

Silica < 20 ppb in feed water and steam, Standard value <15 ppb in the cycle
2
< 250 ppb in boiler drum Expected value <10 ppb in the cycle
pH 9.0 - 9.5 for feed, steam & 9.0 9.6 for AVT(All volatile treatment)
3 condensate, 8.0 9.0 for CWT(Combine water
9.0 10.0 for Boiler drum treatment)
Dissolved < 7 ppb for feed. < 7 ppb for feed in case of AVT
4 Oxygen (DO) 30 150 ppb for feed in case of CWT
Cation (H+) <0.20 S/cm in the feed & steam Standard value <0.15 S /cm in the cycle
Conductivity cycle Expected value- <0.10 S /cm in the cycle
5

6 (CPU) CPU is optional CPU is essential for 100% flow.

Silica and TDS By maintaining feed water quality Blow down possible till separators are
7 control and functioning (upto 30% load).
By operating CBD
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 Advantages of SC Technology
I ) Higher cycle efficiency means
Primarily
less fuel consumption
less per MW infrastructure investments
less emission
less auxiliary power consumption
less water consumption
II ) Operational flexibility
Better temp. control and load change flexibility
Shorter start-up time
More suitable for widely variable pressure operation

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 ECONOMY
Higher Efficiency (%)
Less fuel input.
Low capacity fuel handling system.
Low capacity ash handling system.
Less Emissions.

Approximate improvement in Cycle

Efficiency
Pressure increase : 0.005 % per bar
Temp increase : 0.011 % per deg K

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 Increase of Cycle Efficiency due to Steam
Parameters
Increase of efficiency [%]

10
6,77
9
5,79
8 5,74
7 4,81
3,74
6 4,26
5 3,44 2,76
3,37
4
2,64
3
2,42 1,47
2 600 / 620
1,78 0,75
1 580 / 600

0 566 / 566
0 538 / 566
300
241 HP / RH outlet temperature [deg. C]
Pressure [bar] 175 538 / 538
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 Sub. vs. Supercritical Cycle
Impact on Emissions
Subcritical Supercritical
Plant Efficiency, %* 34 - 37 37 - 41
Plant Efficiency, Btu / kw-hr 10,000 - 9,200 9,200 - 8,300

Plant Efficiency, % 34% 37% 41%

Base Base-8% Base-17%

Fuel Consumption/Total Emissions
including CO2

30 * HHV Basis
 Challenges of supercritical technology

Water chemistry is more stringent in super critical once through

boiler.
Metallurgical Challenges
More complex in erection due to spiral water wall.
More feed pump power is required due to more friction losses in
spiral water wall.
Maintenance of tube leakage is difficult due to complex design of
water wall.
Ash sticking tendency is more in spiral water wall in comparison
of vertical wall.

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THANK YOU