ULTRA SUPERCRITICAL BOILERS

K.C.RAO
Date 05th Mar, 2013

INTRODUCTION TO L&T- MHI

BOILERS

KCR | March 05, 2013

L&T-MHI Boilers (LMB)

L&T

MHI

51%

49%

Larsen & Toubro

Ltd., India

Mitsubishi Heavy
Industries, Japan

L&T-MHI Boilers Pvt. Ltd. Incorporated

LMB
L&T-MHI Boilers
Pvt. Ltd., India

Apr 18, 2007

Complete Technology Transfer of Supercritical Boilers to Joint Venture

More than 2000 Employees
KCR | March 05, 2013

Joint Venture Highlights

Product Range

Supercritical Boilers of 500 MW &

above (including Pulverizers)

License

Exclusive in India
Non exclusive outside India

Term

20 years

Technology

Complete Transfer of Technology

To JV

Joint Venture Highlights

Manufacturing
Capacity

Investment

Training

4000 MW Equivalent

INR 750 Crores

Extensive Training in Japan

Scope of Business EPC

basis
Engineering
&
Designing
Procurement

Marketing

Manufacturing

Quality & Safety

Scope of LMB
Installation

Renovation &
Modernization

After Sales
Services

Commissioning

PROJECT & OFFICE LOCATIONS

KCR | March 05, 2013

Project Sites and Office locations

ENGINEERING &
MARKETING OFFICE
FARIDABAD

2 x 700 MW
NPL - RAJPURA

HEAD OFFICE

2 x 660 MW
JAYPEE NIGRIE

VADODARA
3 x 660 MW
MAHAGENCO KORADI

ENGINEERING CENTRE,
CHENNAI
FACTORY HAZIRA,
SURAT

PULVERIZER GROUP
POWAI

BOILER OUTSOURCING
TRICHY

OFFICES
PROJECTS

Projects Under Execution

Jaypee
Nigrie
2x660 MW

MahaGenco
Koradi
3x660 MW

Nabha Power
Ltd, Rajpura
2x700 MW

Boiler Overview Unit-1 JAYPEE NIGRIE

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10

Boiler Overview Unit-2- JAYPEE NIGRIE

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11

CONTENTS
1. What is USC Boiler
2. Trends of USC units
3. Supply records of USC
4. Feature of USC Boiler
5. Impact on present SC design
KCR | March 05, 2013

12

What is USC Boiler?

Subcritical :
Pressure
: 16.7 M pa
Temperature: 538/538 Deg-C or 538/560 Deg-C

Supercritical(SC) :
Pressure
: 24.1 M pa
Temperature: 538/560 Deg-C to 566/593 Deg-C

Ultra Supercritical(USC):
Pressure
: 24.1 to 31.0 M pa
Temperature: 593/593 Deg-C to 600/620 deg.c
KCR | March 05, 2013

13

1. What is USC Boiler

2. Trends of USC units
3. Supply records of USC
4. Feature of USC Boiler
5. Impact on present SC design
KCR | March 05, 2013

14

Evolution of Steam Pressure & Temperature

of Thermal Power Plant in Japan
25.0MPag
600/610

31.0MPag
566/566/566

25.0MPag
600/620

Gas
24.5MPag

24.5MPag
566/593

600/600( USC)

24.1MPag
566/566

24.1MPag
538/566

Coal

24.1MPag
538/538 (SC)

Oil
1970

1980
1990
2000
Year of Commercial Operation
KCR | March 05, 2013

2010
15

Thermal Efficiency improved

by Steam Conditions
Latest Project in India

Heat rate difference of turbine

(relative)

(%)
0.3
0.3
1.3

MPa x degC
25.1x600/620
25.1x600/610
24.5x600/600

USC

566/593

0.8

566/566

0.9

538/566

0.8

538/538

1.7

SC

Note:

BASE
16.7
24.2
Steam pressure (MPa abs.)
KCR | March 05, 2013

The values in diagram are typical

HR differences respect to steam
pressure and temperature. Actual
heat rate may differ and shall be
determined based on a given
design condition.
16

Technoeconomic comparison Subcritical Vs Supercritical Vs Ultra Supercritical Boilers

Capacity
Fuel
Fuel GCV

: 700 MW
: Indian coal with 42 % ash
: 3300 kCal/kg

Description

Unit

Subcritical
16.7 M pa
538/538
deg.c

Supercritical
24.1 M pa
566/593
deg.c

Ultra
Supercritical
24.1 M pa
600/600 deg.c

Reduction
Sub Vs SC

Reduction
Sub Vs USC

Turbine Heat
rate

kCal / kWh

1918

1838

1814

80(4.2%)

104(5.5%)

Boiler
efficiency

87 %

87%

87%

Plant heat rate

kCal / kWh

2207

2113

2085

94(4.2%)

121(5.5%)

Coal
consumption

MM T/Annum

3.676

3.524

3.477

0.152(4.2%)

0.199 (5.5%)

Ash Generation

MM T/Annum

1.544

1.48

1.46

0.064(4.2%)

0.084 (5.5%)

CO2

MM T/Annum

7.278

6.981

6.888

0.297(4.2%)

0.39 (5.5%)

SOx

MM T/Annum

0.0230

0.0221

0.0218

0.0009(4.2%)

0.0012 (5.5%)

* Calculation with 90% PLF

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17

Technoeconomic comparison Subcritical Vs Supercritical

Fuel

: Indian coal with 42 % ash and GCV of 3300kCal/kg

DSCRIPTION

700 MW
SUBCRITICAL VS
SUPERCRITICAL
IN CRORES

700 MW
SUBCRITICAL VS
SUPERCRITICAL
IN CRORES

700 MW
SUBCRITICAL VS
SUPERCRITICAL
IN CRORES

COAL COST

1500 RS/TON

2000 RS/TON

2500 RS/TON

Reduction in Coal cost per annum

22.8

30.4

38

Carbon credit benefit per annum

@10Euro/MT ( 1Euro= Rs.60)

17.8

17.8

17.8

Total cost Benefit per annum

40.6

48.2

55.8

NPV considering plant life of 30 years with 5

% escalation in coal cost ( Sub
Vs SC) COAL COST

301

402

502

NPV considering plant life of 30 years with 5

% escalation in coal cost ( Sub
Vs SC) COAL COST & CDM BENEFIT

537

637

737

KCR | March 05, 2013

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Technoeconomic comparison Subcritical Vs Ultra Supercritical

Fuel

: Indian coal with 42 % ash and GCV of 3300kCal/kg

DSCRIPTION

COAL COST

700 MW
700 MW
700 MW
SUBCRITICAL VS
SUBCRITICAL VS
SUBCRITICAL VS
ULTRA SUPERCRITICAL ULTRA SUPERCRITICAL ULTRA SUPERCRITICAL
IN CRORES
IN CRORES
IN CRORES
1500 RS/TON

2000 RS/TON

2500 RS/TON

Reduction in Coal cost per annum

29.8

39.8

49.8

Carbon credit benefit per annum

@10Euro/MT ( 1Euro= Rs.60)

23.4

23.4

23.4

Total cost Benefit per annum

53.2

63.2

73.2

NPV considering plant life of 30 years

with 5 % escalation in coal cost ( Sub
Vs USC) COAL COST

394

526

658

NPV considering plant life of 30 years

with 5 % escalation in coal cost ( Sub
Vs USC) COAL COST & CDM BENEFIT

703

835

967

KCR | March 05, 2013

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Technoeconomic comparison Supercritical Vs Ultra Supercritical

Fuel : Indian coal with 42 % ash and GCV of 3300kCal/kg
DSCRIPTION

COAL COST

700 MW
700 MW
700 MW
SUPERCRITICAL VS
SUUPERCRITICAL VS SUUPERCRITICAL VS
ULTRA SUPERCRITICAL ULTRA SUPERCRITICAL ULTRA SUPERCRITICAL
IN CRORES
IN CRORES
IN CRORES
1500 RS/TON

2000 RS/TON

2500 RS/TON

Reduction in Coal cost per annum

Carbon credit benefit per annum
@10Euro/MT ( 1Euro= Rs.60)

7.05
5.5

9.4
5.5

11.75
5.5

Total cost Benefit per annum

NPV considering plant life of 30 years
with 5 % escalation in coal cost ( Sub
Vs USC) COAL COST

12.55
93

14.9
124

17.25
155

NPV considering plant life of 30 years

with 5 % escalation in coal cost ( Sub
Vs USC) COAL COST & CDM BENEFIT

166

197

228

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1. What is USC Boiler

2. Trends of USC units
3. Supply records of USC
4. Feature of USC Boiler
5. Impact on present SC design
KCR | March 05, 2013

21

MHI Reference List of USC Boilers

MHI/LMB has adequate experience for over 600/600 boiler.
Customer Station

MW

Steam Condition (0C)

Fuel

C/O

Soma Joint EPCO Shinchi #2

1,000

538/566

Coal

1995

Tohoku EPCO Haramachi #1

1,000

566/593

Coal

1997

Chugoku EPCO Misumi #1

1,000

600/600

Coal

1998

Hokuriku EPCO Tsuruga #2

700

593/593

Coal

2000

Kyusyu EPCO Reihoku #2

700

593/593

Coal

2003

Kansai EPCO Maizuru #1

900

595/595

Coal

2004

Tokyo EPCO Hirono #5

600

600/600

Coal

2004

China Yuhuan (4 units)

Licenser

1,000

600/600

Coal

2006

China Taizhou (2 units)

Licenser

1,000

600/600

Coal

2007

PJ in China (15 units)

Licenser

600, 660

600/600

Coal

2007~

China Jinling (1 units)

Licenser

1,000

600/600

Coal

2009

China Chaozhou (2 units) Licenser

1,000

600/600

Coal

2010

866

538/566

Coal

(2012)

660, 700

565/593

Coal

(2013
)

P.T. Paiton Energy Paiton III

Projects in India (11 units)

KCR | March 05, 2013

22

MHI Reference List of USC Turbines

MHI/LMTG has plenty of experience for over 600/600 steam
turbines.
Customer Station

MW

Steam Condition (0C)

Fuel

C/O

Chubu EPCO Hekinan #3

700

538/593

Coal

1993

Hokuriku EPCO Nanao-Ota #1

500

566/593

Coal

1995

EPDC Matsuura #2

1,000

593/593

Coal

1997

Chugoku EPCO Misumi #1

1,000

600/600

Coal

1998

EPDC Tachibanawan #2

1,050

600/610

Coal

2000

Kansai EPCO Maizuru #1

900

595/595

Coal

2004

Tokyo EPCO Hirono #5

600

600/600

Coal

2004

600

600/600

Coal

2007

China Yingkou (2 units)

Licenser

China Kanshan (2 units)

Licenser

600

600/600

Coal

2008

China Heyuan (2 units)

Licenser

600

600/600

Coal

2009

ENEL Torrevaldaliga Nord (3 units)

678

600/610

Coal

2009

XCEL Comanche #3

830

566/593

Coal

2010

Tokyo EPCO Hirono #6

600

600/600

Coal

(2013)

1000

600/600

Coal

(2015/6)

Korea EWP Danjin (2 units)

KCR | March 05, 2013

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Chubu EPCO Misumi #1

Chubu EPCO Misumi #1

Turn Key 1000MW Coal-Fired Supercritical Plant including Major BOPs
Customer: Chugoku Electric Power Company
MAJOR SPECIFICATIONS
CUSTOMER
:Chugoku EPCO.
COMMERCIAL OPERATION :
1998.06.30
CAPACITY
: 1000MW
STEAM CONDITION: 24.5MPa x
600/600degC
STEAM TURBINE : Cross Compound
BOILER MCR
: 2,900t/h
FUEL
: Coal
BOP
: FGD, SCR, EP
-SCOPE OF MHI
BOILER, TURBINE-GENERATOR, DCS,
EP, FGD, SCR, COAL HANDLING SYS.,
ERECTION, COMMISSIONING

KCR | March 05, 2013

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Kansai EPCO Maizuru #1

Kansai EPCO Maizuru #1

Turn Key 900MW Coal-Fired Supercritical Plant
Customer: Kansai Electric Power Company
MAJOR SPECIFICATIONS
CUSTOMER
: Kansai EPCO.
COMMERCIAL OPERATION : 2004.08.12
CAPACITY
: 900MW
STEAM CONDITION
: 24.5MPa x
595/595degC
BOILER MCR
: 2,570 t/h
FUEL
: Coal
STEAM TURBINE
: Cross
Compound,
4 Exhaust
Flows
-SCOPE OF MHI
BOILER, TURBINE-GENERATOR, DCS,
SCR, ERECTION, COMMISSIONING

KCR | March 05, 2013

25

Tokyo EPCO Hirono #5

Tokyo EPCO Hirono #5

Turn Key 600MW Coal-Fired Supercritical Plant
Customer: Tokyo Electric Power Company
MAJOR SPECIFICATIONS
CUSTOMER
: Tokyo EPCO.
COMMERCIAL OPERATION : 2004.07.12
CAPACITY
: 600MW
STEAM CONDITION
: 24.5MPa
x 600/600degC
BOILER MCR
: 1,770 t/h
FUEL
: Coal
STEAM TURBINE
: Tandem
Compound,
2 Exhaust Flows
-SCOPE OF MHI
BOILER, TURBINE-GENERATOR, DCS,
EP, FGD, SCR, ERECTION,
COMMISSIONING

KCR | March 05, 2013

26

1. What is USC Boiler

2. Trends of USC units
3. Supply records of USC
4. Feature of USC Boiler
5. Impact on present SC design
KCR | March 05, 2013

27

Features of MHI USC Coal-Fired Boiler

[1] Water Wall
Vertical with rifled tubes

[2] High Steam Temperature

600 / 600deg-C class
High Temp. Resistant Material
(18Cr-25Cr Austenitic Steel)

[4] Low NOx system

[3] Twin Fire Voltex

A-PM burner
A-MACT
Rotary Separator Pulverizer

KCR | March 05, 2013

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Design Feature of Mitsubishi

Twin fire-vortexes design

No Final SH out temp. imbalance

-Controlled by each side SH spray

No Final RH out temp. imbalance

-Controlled by each side damper

No criss-cross arrangement
-One internal link / header
per a fire voltex

Lower heat input per each burner

-Heat input is half of single fire-voltex
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History of Tube Material MHI Field Test for

Supercritical Boilers
80

85

90

95

00

SA213T23
2.25Cr 0.1Mo 1.6W
HCM9M
9Cr 2Mo
SA213T91
9Cr 1Mo
HCM12
12Cr 1Mo 1W
HCM12A (Code Case 2180)
11Cr 0.4Mo 1.9W
Super 304 (code Case 2328)
18Cr 10Ni 3Cu
HR3C (SA213TP310HCbN)
25Cr 20Ni Nb

Factory Test ,

Actual Boiler Test ,

KCR | March 05, 2013

Practical Use

30

Ultra Supercritical Sliding Pressure Boiler

High Temperature Resistant Material
MHI has, in association with the tubes and pipes manufacturers,
strived to continuously develop new grades of materials for use
in high temperature applications.
Improved creep and fatigue resistance suitable for cyclic
operations.
High strength in high temperature zone
Use of advanced materials such as
Code Case 2115
Code case 2328
SA-213T92 and SA-335P92
Code Case 2199 (SA-213T23)
KCR | March 05, 2013

25Cr Austenitic
18Cr Austenitic
9Cr Ferrite
2 1/4Cr Ferrite

Ultra Supercritical Sliding Pressure Boiler

High Temperature Resistant Material
Superheater

Reheater

Eco.

WW

3rd SH 2nd SH 1ry SH 2nd RH 1ry RH

25Cr
18Cr

Code Case 2115

Code Case 2328
SA213TP347H

9Cr

SA213T91(unheated
zone)

2.25Cr

SA213T22

1Cr

SA213T12

Carbon
Steel

SA192
SA210

KCR | March 05, 2013

Ultra Supercritical Sliding Pressure Boiler

High Temperature Resistant Material

CC2115
CC2328

or

CC2199
or
SA-213T22
SA213-T22
SA213-T12
SA210-C or
SA210-A1

KCR | March 05, 2013

33

History of Mitsubishi Low NOx Combustion

Technology
Continuous Improvement following Japanese
Regulation.
600

NOx (ppm @6%O2)

500

400

la
no
it
ne
vn
o
C

re
nr
u
B

400ppm

300ppm
300

R
G
S
200

re
nr
u
B

re
M nr
P u
B

100

0
1975

1980

1985

Regulation in Japan for Coal Firing Boiler

PM Burner
+ MACT

1990

PM Burner + MACT
(Low Excess Air Ratio = 1.15)

1995
Year

KCR | March 05, 2013

200ppm

2000

2005

2010

LMB Coal Combustion Technology

Low Pollutant
High Efficiency

Coal
Combustion
Technology

Circular Coner Firing

(CCF)
Low NOx Bunrer

(PM Burner)

Best Mix of Advanced

Combustion Technology

In Furnce Nox
Removal System

(MACT)
High Performance
Vertical Mill

(MRS Mill)
NOx Removal
Technology in
Flue Gas
KCR | March 05, 2013

Dry Selective Catalytic

NOx Removal System
(SCR)

CCF :

Circular Corner Firing

Features of CCF
High Ignitability and Combustibility
High Occupation rate of Fire Vortex in Furnace
Uniform Heat Flux Distribution
Means...
Low NOx &
Unburnt Carbon
High Efficiency
Good Operability
Laminar Air
Low Slagging
Injection
Tendency
KCR | March 05, 2013

AA

Low NOx PM Burner : Pollutant Minimum

KCR | March 05, 2013

PM
Burner
Waak
Flame

PM Burner
Average NOx

Weak

Conventional
Single Burner

Conc
Flame

Conc

NOx Level (ppm)

Coal flame composed by

Conc
: Fuel Rich Good Ignition
Weak
: Fuel Lean Moderate Combustion
Divided flame achieves simultaneously;
- Stable Ignition and Combustion
- Low NOx Combustion

3-4
7-8
Primary Air / Coal Ratio

LMB Firing system

Low NOx Burners (PM burners)

Conc
Weak
Conc

High ignitiability even under low-O2

condition
Application for all solid fuel (incl. low
combustive fuel)

PM : Pollution Minimum

PM burner with vertical waterwall

KCR | March 05, 2013

MACT : Mitsubishi Advanced Combustion Technology

(In-furnace NOx Removal System)
[Advantages of
MACT]
No additional cost of
Ammonia Injection
or Catalyst.
No emission of
Substance Matter
No change of
Boiler Efficiency and
Flue Gas Flow
Stable and Reliable
Combustion in
Furnace
Applicable to
all fossil fuels,
Gas, Oil, Coal, etc.

Furnace Outlet

NO

NHi

50

40

10

100

N2
50

Combustion
Completion
Zone

Additional
Air

30
70

20

Concept of
NOx Reduction

Reductive
DeNOx
Zone
Main Burner
Combustion
Zone
(Ex. Air < 1.0)

2ry
Air

Main
Burner

LMB Firing system

MACT system in-furnace DeNOxCn"Hm"+O2 CO2+H2O
Cn'Hm'+O2 CO2+H2O
CO+H2+O2 CO2+H2O
NHi+O2
NO+N2

Additional Air
CnHm+O2 H2+CO2+Cn'Hm'
Cn'Hm'+NO NHi+N2+Cn"Hm"

Main Burner
CnHm+O2 CO2+H2O
N+O2
NO

Furnace Outlet

Combustion
Completion
Zone
Reductive
DeNOx
Zone
Main Burner
Combustion
Zone

KCR | March 05, 2013

Combustion
Air

MRS Mill : Mitsubishi Rotary Separator

(High Performance Vertical Mill)
Effective Classification
of Coarse Particles

Good Ignition &

Combustion
ow Unburnt Carbon)

Pulverized
Coal

Rotary Separator

Hot Air

Raw Coal

1. What is USC Boiler

2. Trends of USC units
3. Supply records of USC
4. Feature of USC Boiler
5. Impact on present SC design
KCR | March 05, 2013

42

Boiler Design for USC 600/600

To meet with the elevated steam condition from present 566/593 to 600/600, following
design change is required. It can be modified based on our existing design.
Modified Point of 600/600 Case
3SH <Tube>

Increase the No. of tubes

Tube material is same

3SH <Outlet HDR>

Increase diameter
Header material is same
2RH <Tube>
Increase the No. of tubes
Tube material is same
2RH <Outlet HDR>
Increase thickness
Header diameter is same
Header material is same
KCR | March 05, 2013

43

What next to Ultra Super Critical

KCR | March 05, 2013

44

What Next to Super Critical

Efficiency improvement
ADVANCED ULTRA SUPERCRITICAL TECHNOLOGY


With pressures up to 30 MPa & Temperatures 700 / 700 Deg.C

Cycle efficiency up to 50% on LHV basis

INTEGRATED GASIFICATION COMBINED CYCLE (IGCC)



Using super high temperature GTs ( 1700 deg. c class)

Cycle efficiency up to 55% on LHV basis

KCR | March 05, 2013

45

What Next to Super Critical

Emission improvement
ADVANCED ULTRA SUPERCRITICAL TECHNOLOGY


Cumulative CO2 emissions reduction by 20-25 %

By using OXY fuel combustion CO2 emissions reduction by 90%

Reduction of Sox, Nox & SPM levels proportional to Eff. Improvement

INTEGRATED GASIFICATION COMBINED CYCLE (IGCC)



Cumulative CO2 emissions reduction by 25-30%

By using Pre combustion recovery method CO2 emissions reduction by 90%

Reduction of Sox, Nox & SPM levels to 4-5 PPM

KCR | March 05, 2013

46

What Next to Super Critical

CO2 Reduction Roadmap for Coal-fired Power Generation

Source : From MHI Technical review

KCR | March 05, 2013

47

Advantages of A-Ultra Super Critical Technology

Increase in plant Efficiency:
Type

Parameter

Efficiency
LHV BASIS

Sub Critical

16.6MPa /538 / 538C

38-40%

Super Critical

24 MPa / 566 /593C

40-42%

Ultra Super
Critical

25~30 MPa /600 /620C

43-46%

A-Ultra Super
critical

25~30 MPa /700 /700C

46-50%

Lesser emissions:
These increases in plant efficiency can reduce CO2 emissions by a
ratio of 2 to 1 (i.e. a one percentage point increase in efficiency
reduces emissions by around two percent). Improved efficiencies also
reduce the level of other pollutants and overall fuel use.
KCR | March 05, 2013

48