Introduction of the state-of-the-art technology of IHI for Ultra · PDF file · 2013-09-27The first USC unit in Japan, ... IGCC Technologies is suitable for coal with lower ash fusion

Copyright © 2008 IHI Corporation All Rights Reserved.

2009.7.27

Power Plant Division

Introduction of the state-of-the-art technology of IHI for Ultra-SuperCritical

power plant

CCT

Information Exchange Workshop 2009

Shinagawa Prince Hotel

Shin_ichi

TAKANO

kyoyopro

テキストボックス

Japan: Reference 2

1. Improvement of steam conditions

2Copyright © 2008 IHI Corporation All Rights Reserved.


Improvement of steam conditions

Development of Steam Conditions in Japan

Year of Initial Operation

5

10

15

20

25

600

550

500

450

400

ST

EA

M T

EM

P. (

oC

)

ST

EA

M P

RE

SS

. ( M

Pa

)

‘55 ‘60 ‘65 ‘70 ‘90 ‘95 2000

30

~16.6

24.1

31.0

4.1

~

450

482485

538

566 ~ 593

610

620

STEAM TEMP.

STEAM PRESS.

2005

Sub Critical Super Critical


Coal Fired USC Power Plant in Japan


Supplied by ＢＨＫ

Supplied by ＩＨＩSupplied by ＭＨＩ

21 USC Coal Fired Power Plant is under commercial operation21 USC Coal Fired Power Plant is under commercial operation


non-USC

USC

Half of total electricity is now generated by

USC unit in Japan

Half of total electricity is now generated by

USC unit in Japan

Development of Coal Fired Power Plant in Japan



Thermal Efficiency Improvement by Applying USC Steam Condition


15

Main Steam Pressure (MPa)

24.1 24.5 29.4 34.3

5

Base : 566/566 C

593/593 C600/600 C 610/610 C630/630 C

700/700/650 C

0

10

700/720/720 C (EU AD700 Target)

750/760 C(USA DOE Target)

Developing Tech.

Level

Present Tech. Level

700/750/750 C(A-USC Tech. Dev. Pro. Final Target)

Th

erm

al E

ffic

ien

cy

Imp

rove

me

nt

(R

ela

tive

%)

Isogo New No.226.3 MPa600/620C

Isogo New No.126.6MPa600/610C

Tachibana-Wan25.0 MPa600/610C

2. Development of USC technology



The core factors in USC technology are …

Development of USC technology

1. Enlarge the capacity

(600MW-->1000MW)-

Large-scale Boiler (Furnace, Piping, HDR, Steel structures…)

-

Large-sized auxiliary equipment (Pulverizer, Fans, Burners, Sootblower…)

-

Imbalance of heat absorption in FUR and HRA (Heat surface arrangement)

2. Improve the steam conditions

(566oC --> 620oC)-

Development of new material(High temp. strength, Steam side oxidation, High temp coal ash corrosion)

-

Optimize the heating surface arrangement

3. Advanced combustion technology

(Reduction of emission)-

Develop the low-emission burner together with boiler

-

Firing with wide range coal characteristic

-

Stabilized combustion system

4. The cutting edge control technology

(Automatic reliable operation)-

Sliding Pressure Operation

-

Dry / Wet Conversion

-

Start-up / Shut-down Operation


YEAR '81'82'83'84'85'86'87'88'89'90'91'92'93Remark

(milestone)

COD 1993.4COD 1993.4

ITEMS

• Survey of USC in overseas

• Boiler design Conceptual and basic design of USC

•

Practical application

of advanced materials

Study of coal ash high temp. corrosion

Superheater, reheater materials

Piping and vessel materials

• Development of new valves & Boiler Circulation Pump

• International USC researchproject (EPRI RP1403)

Up to 1993

Delivered 1st

593oC Coal Fired USC

in JAPAN

Delivered 1st

593oC Coal Fired USC

in JAPAN

(1)Lab Study(2)9Cr-1Mo(3)Probe test(4)Mn-Mo steel(5)TP310 NbN

(1) (3)(2) (4) (5)

'94


Tech. Development of Boiler Material


Development details for austenitic steels for boiler applicationReference:Development of USC plants (Phase-2), The thermal and nuclear power, vol.52, 2001, Prepared by EPDC/BHK/MHI/IHI/HITACHI/TOSHIBA

18Cr-8Ni,C<0.08

18Cr-8Ni

AISI 302

18Cr-8NiTi

18Cr-8NiNb

18Cr-8NiMo

22Cr-12Ni

AISI 304

AISI 321

AISI 347

AISI 316

AISI 309

-C

+Ti

+Nb

+Mo

+Cr+Ni 25Cr-20Ni

H Grade0.04～0.10C

AISI 310

AISI 304HAISI 321HAISI 347HAISI 316H

(100～120)

(80)

18Cr-8NiNb

ASME TP347HFG

18Cr-8NiNbTi

TEMPALOYA-1(METI-SUS321J1HTB)

Cu Alloyed

18Cr-8NiCuNbN

SUPER304H(METI-SUS304J1HTB)

(CC2328)

25Cr-20NiNbN

HR3C(METI-SUS310J1TB)

(CC2115)

(147)

(136)

(168)

(181)

Figure in ( ) shows creep rupture strength at 600℃×105 hours

3.3　 Material selection of USC boiler



Development details for ferritic steels for boiler application

3.4　 Material selection of USC boiler

ASME T22STBA24

2.25Cr-1Mo 2.25Cr-1MoV+V

+Mo

9Cr-2MoVNb9Cr-1Mo

12Cr

ASME T9STBA26

AISI 410

9Cr-2MoHCM9M

(METI-STBA27)

EM12(NFA49213)

9Cr-1MoVNbTEMPALOY F-9

+V+Mo+Nb

+V+Nb

HCM2SASME T23

METI-STBA24J1

2.25Cr-1.5WVNb

12Cr-1MoV 12Cr-1MoWV

12Cr-0.5Mo+Mo

+Mo+V

9Cr-1MoVNb

ASME T91METI-STBA28

ASME P91METI-STPA28

12Cr-1Mo-1WVNb

9Cr-0.5Mo-1.8WVNbNF616

ASME T92METI-STBA29

12Cr-0.5Mo-1.8WVNbTB12

12Cr-0.7Mo-1WCuVNb

TEMPALOY F-12M

12Cr-0.5Mo-2WCuVNb+W

-C+W+Nb

-C

-Mo+W+Cu

12Cr-WCoNiVNbNF12

12Cr-WCoVNbSAVE12

+W+Co

+W+Co

HT91(DIN X20CrMoV121)

HT9(DIN X20CrMoWV121)

HCM12(METI-SUS410J2TB) ASME T122

METI-SUS410J3TB

HCM12A

+V +W-Mo +Nb

+W-Mo

+Cu

V,Nb Optimized

35MPa 60MPa 100MPa 140MPa 180MPa

Creep rupture strength at 600℃×105hours

Reference: Development of USC plants (Phase-2), The thermal and nuclear power, vol.52, 2001, Prepared by EPDC/BHK/MHI/IHI/HITACHI/TOSHIBA



Development of USC technologyMaterial Selection


3. IHI USC PC firing boilers


IHI USC PC firing boilers

◆Market Backgrounds-

IHI has full knowledge right in USC technologies.

-

The first USC unit in Japan, Hekinan No.3, was started commercial operation in 1993.

-

We have accumulated various technologies and experience through

about 20 years.

-

The biggest market share of USC plant in Japan. (43%)

-

The largest capacity unit in Japan. (1,050MW Tachibana-Wan No.1)

-

The highest steam conditions unit in Japan. (620oC Isogo NEW No.2)

-

We can put together with different turbine supplier. (GE, Siemens, TSB, HTC, etc.)

◆IHI Design Features-

FURNACE : Spiral pass with smooth tubes

-

COMBUSTION : Wall (Opposed) firing with IHI low-NOx burners

-

PARALLEL PASS : STC damper controls RH steam temperature

-

BOUNDARY AIR : Minimize the slagging and corrosion on furnace wall

-

STARTUP SYSTEM : We have various designs with and without BRP

-

MATERIAL : Fit to use CC2328 (Super304H) in Final SH and RH


Plant MW Evaporation Steam conditions COD

Hekinan

No.3 700MW 2,250 t/h 24.6MPa/538/593C 1993

Noshiro

No.2 600MW 1,860 t/h 24.6MPa/566/593C 1994

Nanao-Ohta

No.2 700MW 2,120 t/h 24.6MPa/593/593C 1998

Tachibana-Wan

No.1 1050MW 3,000 t/h 25.0MPa/600/610C 2000

Hekinan No.4 1000MW 3,050 t/h 24.1MPa/566/593C 2001

Hekinan No.5 1000MW 3,050 t/h 24.1MPa/566/593C 2002

Tomato

Azuma

No.4 700MW 2,040 t/h 25.0MPa/600/600C 2002

Isogo NEW

No.1 600MW 1,710 t/h 26.6MPa/600/610C 2002

Isogo NEW

No.2 600MW 1,670 t/h 26.3MPa/600/620C 2009

Maizuru

No.2(Erect. Stage)

900MW 2,570 t/h 24.5MPa/595/595C 2010

IHI USC PC firing boilers

IHI’s Existing USC Boiler


4. A-USC Technology (700oC Research)


A-USC Technology (700oC Research)

Boiler

35MPa, 700oC

Steam Turbine

Boiler

25MPa, 600oC

Steam Turbine

USCNet Thermal Efficiency

42%（HHV）

A-USCNet Thermal Efficiency

46～48%（HHV）

Advantage of A-USC Technology


Net

The

rmal

Effi

cien

cy（H

HV

）

Year

A-USC Technology DevelopmentA-USC Technology (700oC Research)

Source:http://www.meti.go.jp/committee/materials2/data/g90617aj.html

A-USC

IGCC

IGFC

USC


Applicability of Coal properties

■A-USC Technologies is suitable for coal with higher ash fusion temp.

IGCC Technologies is suitable for coal with lower ash fusion temp.

日本に輸入可能な

石炭量

USC向き

炭種

56%

IGCC向き

炭種

44% (灰融点1400℃を

境に分類した場合)

0.5

1.0

1.5

2.0

2.5

3.0

1,100 1,200 1,300 1,400 1,500 1,600 1,700

灰の融点［ ℃］

燃料

比（固

定炭

素／

揮発

分）

USC向き炭種

IGCC向き炭種

0.5

1.0

1.5

2.0

2.5

3.0

1,100 1,200 1,300 1,400 1,500 1,600 1,700


燃料

比（固

定炭

素／

揮発

分）

USC向き炭種

IGCC向き炭種日本に輸入可能な

石炭量

USC向き

炭種

56%

IGCC向き

炭種

44% (灰融点1400℃を

境に分類した場合)

0.5

1.0

1.5

2.0

2.5

3.0

1,100 1,200 1,300 1,400 1,500 1,600 1,700


燃料

比（固

定炭

素／

揮発

分）

USC向き炭種

IGCC向き炭種

0.5

1.0

1.5

2.0

2.5

3.0

1,100 1,200 1,300 1,400 1,500 1,600 1,700


燃料

比（固

定炭

素／

揮発

分）

USC向き炭種

IGCC向き炭種

0.5

1.0

1.5

2.0

2.5

3.0

1,100 1,200 1,300 1,400 1,500 1,600 1,700


燃料

比（固

定炭

素／

揮発

分）

USC向き炭種

IGCC向き炭種

0.5

1.0

1.5

2.0

2.5

3.0

1,100 1,200 1,300 1,400 1,500 1,600 1,700


燃料

比（固

定炭

素／

揮発

分）

USC向き炭種

IGCC向き炭種

Ash Fusion Temp. [℃]

Fix

ed

Ca

rbo

n/V

ola

tile

Ma

tte

r

For IGCC

For A-USC

For A-USC

For IGCC

Coal imported to Japan



Usability of existing system at Application of A-USC Technologies

■A-USC technologies achieve economical replacement of existing old unit due to wide range of usable property

7% 19% 14% 5% 15% 5% 5% 6% 11%8% 3%2%

揚運

貯炭給水ボイラ

排煙

処理

ダクト

煙突

タービン

発電機

冷却水

系統

灰

処理

電気

設備

計装

制御

地盤

改良

建築

構造

7% 19% 14% 5% 15% 5% 5% 6% 11%8%3%

2%7% 19% 14% 5% 15% 5% 5% 6% 11%8%

3%

2%

揚運

貯炭給水ボイラ

排煙

処理

ダクト

煙突

タービン

発電機

冷却水

系統

灰

処理

電気

設備

計装

制御

地盤

改良

建築

構造

UsableExistingPropertyfor A-USC

Cost of Thermal PowerUnit

Coal Handling

WaterPrep.

BoilerAQCS DUCT

StackTurbineGenerator

CoolingWater

AshHandling

ElectricalEquip.

Control

Civil

Building




Mitsubishi Heavy Industries

METI

Fuji Electric Systems

Hitachi

Babcock Hitachi

Toshiba

Sumitomo Metals

IHI

NIMS Material Analysis

Boiler

Material

Turbine

Boiler

Turbine

Turbine

Boiler, Turbine

Coordination

Structure of 700oC Research

METINIMS

: Ministry of Economy, Trade and Industry: National Institute for Materials Science

ABB Japan Bailey Valve


2008 2009 2010 2011 2012 2013 2014 2015 2016

System Design System Design, Economics

Boiler

Technology

MaterialLarge Steam Pipe, High Temp. Tube

Long Term Test (

30000～70000

hour)

Manufacturing Welding, Pipe Bending etc

Turbine

TechnologyMaterial

Material Test, Trial Manufacturing

Rotor, Casing, Bolt etc

Long Term Test (

30000～70000

hour )

Valve Technology Material Test, Trial Manufacturing

Boiler Components & Small Turbine Test

Plan, Design Manufacture Test


Development Plan for National Project


5. Conclusion


Conclusion

We have already launched on new research for actual work of 700 oC

class steam unit which

will contribute to saving our environment for future generations.

The Coal fired units having with USC steam condition are going on successful commercial operation over 15 years and now 620 oC

reheat unit is in the

commercial operation.

Thermal efficiency has been increased by improvement of steam conditions as application of USC conditions with outstanding performance and high availability.

A-USC (35MPa, 700～750oC)750

700

650

600

550

15 20 25 30 35Steam Pressure (MPa)

Ste

am

Te

mp

era

ture

(oC

)Sub

critical

USC

SC

Isogo NEW No.2

http://www.IHI.co.jp

Documents

Introduction of the state-of-the-art technology of IHI for Ultra · PDF file · 2013-09-27The first USC unit in Japan, ... IGCC Technologies is suitable for coal with lower ash fusion