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"SUPERCRITICAL BOILER" REQUIREMENTS for boiler design PHILOSOPHY. One percentage point lower than design point will incur additional fuel cost of Rs. 20 Crores in a year. At Sipat, we gain an efficiency of 2. Percentage point by adopting super critical technology in 1980 MW station.
"SUPERCRITICAL BOILER" REQUIREMENTS for boiler design PHILOSOPHY. One percentage point lower than design point will incur additional fuel cost of Rs. 20 Crores in a year. At Sipat, we gain an efficiency of 2. Percentage point by adopting super critical technology in 1980 MW station.
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"SUPERCRITICAL BOILER" REQUIREMENTS for boiler design PHILOSOPHY. One percentage point lower than design point will incur additional fuel cost of Rs. 20 Crores in a year. At Sipat, we gain an efficiency of 2. Percentage point by adopting super critical technology in 1980 MW station.
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Attribution Non-Commercial (BY-NC)
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Скачайте в формате PPT, PDF, TXT или читайте онлайн в Scribd
Steam cycle parameters: Optimumbest q Boiler and auxilieries : Most efficient lowest sp. Coal consumption i.e. q highest High availability Short start-up timeminimum start-up losses e.g. fuel oil consumption+ Quick load-following capability Flexible when coal of varying quality or fouling tendencies Sophisticated firing system minimise NOx emissions IMPORTANCE OF EFFICIENCY The cost of operating the Plant of 3 x 660 MW, one percentage point below the design point, will incur additional fuel cost of Rs. 20 Crores in a year. The indirect costs for Maintenance, Ash Dyke land etc. will give additional burden of Rs. 2 Crores in a year. The life time loss is Rs. 660 Crores for efficiency lower by one percentage point . At Sipat, we gain an efficiency of 2.5 percentage point by adopting super critical technology in 1980 MW station, thus saving Rs. 1650 Crores in its life time.
QUEST FOR EFFICIENCY IMPROVEMENT Supercritical parameters (Press. above 225Kg/cm2 and temperature above 374.15 C) is an effort in that direction. The selected supercritical parameters for Sipat Boiler are : Pressure : 256 kg/cm 2 Temperature : 540 C SH and 568C RH RANKINE CYCLE The Carnot Cycle is theoretically most efficient, but it is having practical difficulties. For steam power plant, practical thermal cycle was suggested by Rankine, called Ideal cycle or Rankine cycle. 3-3 BFP raises pressure from p2 to p1 3-4 Heating In feed heaters & eco 4 -1 Heating In boiler 1-2 Work done in Turbine from p 1 to p 2
1 2 3 3 4 T S T1 T2 p1 p2 THERMAL EFFICIENCY OF RANKINE CYCLE Q 1 -Q 2 W Useful work = ------- = --- = ---------------- Q 1 Q Heat supplied Rejected Heat = 1 - -------------------- Useful Heat T 1 - T 2 T 2 Carnot = -------- = 1 - ---
T 1 T 1 To achieve more efficiency T 2 should be as low as possible and T 1 should be as high as possible CYCLE THERMODYNAMICS ANALYSIS
q| How? P0| T0| Reheat one or two , Treheat| Regeneration - the best - More the better7 to 8 ? Higher P0(P0-Pc)|
8-10 heaters Pc+
METHODS OF INCREASING RANKINE CYCLE EFFICIENCY Raising supply temperature by super heating. Increasing the inlet temperature will raise the heat supply to the cycle more than the heat rejection.
Raising inlet pressure of steam : Increasing the pressure will mean increase in saturation temperature at which steam evaporates thus increasing the average inlet temperature (T 1 )
(Contd..) Dropping the final pressure (or temperature) at which heat is rejected. Regenerative Heating : Heating the feed water pumped to Boiler by bleeding steam from turbine. Reheat Cycle : Reheating of steam in boiler after it has already expanded in HP Turbine will avoid moisture formation in LT Turbine. Also, more heat content of steam before IP Turbine, will improve efficiency. WHY SUPERCRITICAL PRESSURE A Boiler operating at a pressure above critical point is called SUPERCRITICAL BOILER A point where boiling water and dry saturated lines meet so that associated latent heat is zero, this point is called Critical Point and occurs at 225 kg/cm2 (abs) 374.15 C temperature. CRITICAL CONDITION Definition CRITICAL is a thermodynamic expression describing the state of a substance beyond which there is no clear distinction between the liquid and gaseous phase. The critical pressure & temperature for water are Pressure = 225.56 Kg / cm2 Temperature = 374.15 C 0 100 200 300 400 500 600 SUPER CRITICAL BOILER CYCLE WITH SH, RH & Regeneration of SIPAT 3 x 660 MW 540C 568C Steam flow :2225 T/Hr Steam temp : 540 c Steam Pres : 256 kg/cm2 RH pre : 51.6 Kg/cm2 RH Temp : 568c Feed water Temp : 291c ENTROPY TEMP SUPERCRITICAL BOILER Supercritical pressure boiler has no drum and heat absorbing surface being, in effect, one continuous tube, hence called once through Supercritical pressure boilers. The water in boiler is pressurized by Boiler Feed Pump, sensible heat is added in feed heaters, economizer and furnace tubes, until water attains saturation temperature and flashes instantaneously to dry saturated steam and super heating commences. SUPERCRITICALTHERMAL CYCLE ADVANTAGES (1) Improvements in plant efficiency by more than 2 % Decrease in Coal Consumption Reduction in Green House gases. Overall reduction in Auxiliary Power consumption. Reduction in requirement of Ash dyke Land & Consumptive water.
SUPERCRITICAL ADVANTAGES (2) Sliding pressure operation because of Once through system . Even distribution of heat due to spiral wall arrangement leading to less Boiler tube failure, thereby improving system continuity and availability of the station. Low thermal stress in Turbine . The startup time is less for boiler.
SUPERCRITICAL DISADVANTAGES
Higher power consumption of BFP Higher feed water quality required. More complex supporting and framing in Boiler due to Spiral Wall tubes. Slight higher capital cost. COMPARISION OF THERMAL CYCLE EFFICIENCIES. OPEN CYCLE EFFICIENCY - 14.68 % WITH CONDENSER - 26.2 % WITH SUPER HEAT 30.75 TO 34.15 % WITH REHEAT - 34.2 TO 36.6 % WITH SUPER CRITICAL PARAMETERS- 36.0 TO 39.15 % INCREASE IN PLANT EFFICIENCY by SUPER CRITICAL PARAMETERS 1.5 0.9 0.6 3.2 167 bar 538/538c 250 bar 538/538 250 bar 540/560c 250 bar 580/600c 250bar 566/566 c 1 2 3 4 5 6 . Efficiency Increase C o p y r i g h t
A L S T O M
2 0 0 5
Well suited for < 2100 psi cycles Natural Circulation System To Superheater Risers Furnace or Combustor Econ Drum Downcomers C o p y r i g h t
A L S T O M
2 0 0 5
Optimum solution for reliable high pressure subcritical operation Controlled Circulation System To Superheater Furnace Econ Drum Downcomers BWCPs (Orifices) C o p y r i g h t
A L S T O M
2 0 0 5
Suitable for Sub and Supercritical Cycles Once-Through Circulation System Separator Furnace or Combustor Econ Circ. Pump Distribution Header To Superheater SLIDING PRESSURE OPERATION(SPO) Natural S.P.O.(NSPO) Turbine inlet valves :fully open during normal operation P live steam o steam flow C o p y r i g h t
A L S T O M
2 0 0 5
Sliding Pressure Supercritical Operation Pressure operation mode at boiler outlet 4350 3625 2900 2175 1450 725 0 p s i g )
1. No additional pressure loss between boiler and turbine qcycle | within (Pb.o. Pc) 2. Boiler Pr. at low loads : low FW pump auxiliary power consumption : low q | At full load : same for both Operating modes E.x. : 50% load , Power consumption in fixed Pr. operation (f . p. o) is double as in S.P.O 3. Lower Pr. at low loads less fatigue of Pr. part components e.g. boiler , turbine piping longer life of all components, Less wear of components Less Maintenance
N.C.B. with F.P.O :
- Pr. loss at turbine inlet for f.p.o significant temp+ - Higher Pr. loss higher temp+ - Different loads : Pr. loss = var, temp = var - Each load change Tt.i. = var - Permissible temp change at t.i. : LMITED load change in f.p.o : LIMITED
O.T.B with S.P.O Much larger permissible load transients (twice as high as in natural circulation boilers) A boiler requirement : maintain T0 = T0 rated within widest load change Special methods employed : Flue gas recirculation, Attemperators, Special heat exchangers In drum boilers: T0 + at loads < (50 60 )% In supercritical boilers : T0= T0 rated in entire controlled load range
Start up time and start up losses :
- Thick walled drum of n. c. boiler (thickness >200mm ,P > 180 bar ) : permits only small temp . gradients and a small no. of sharp changes Thin walled separating vessels of once through boilers : larger gradients and a small no. of sharp changes - This is increasingly more important as Tstart up + E.g. 48 hrs after shut down : boiler relatively cold : O.T.B start up ~ 80 min N.C.B start up ~ 210 min Disadvantage of NSPO:
Storage effect of boiler >>that of turbine This slows down load changes Turbine inlet valve opening = const Pr before turbine must first be raised or lowered . The same for the complete boiler. Requirements of electrical grid can hardly be fulfilled using NSPO REMEDY? Modified S.P.O. (MSPO) Modified SPO (MSPO)
With load variation admission cross section at turbine : altered briefly Accumulated steam in boiler : discharged at once Dynamic response of boiler : improved substantially Advantages of SPO: lost partly WHY NOT SLIDING Pr. OPERATION IN NATURAL CIRCULATION BOILERS?
P+ steam formation in down comers instabilities in circulation system P+ water surface in drum disturbed drum level control problems feed water control problems Drum : most critical thick walled component Tin drum = Ts = f(P) In S.P.O ,P= var Drum under highest thermal stresses Note: almost all natural circulation boilers operated in fixed Pr. mode and mostly for base load operation THANK YOU