Huaneng Shangdong Ruyi 2X600MW Coal-Fired Power Plant

Course Title

Super Critical Coal Fired Boiler Equipment and System

Course Coordinator
Dr. Nasir Hayat

Mechanical Engineering Department

Contact: nasirhayat@uet.edu.pk
Cell: 03004313910
Syed Nadeem Abbas Shah
Cell: 03316942934

Mechanical Engineering Department

University of Engineering and Technology, Lahore
Huaneng Shangdong Ruyi 2X600MW Coal-Fired Power Plant
Critical Pressure

 Critical pressure for

water is 220.6 bar.

 Super critical unit:

Operating pressure is more
than 220.6 bar.

Figure 1 T-S Diagram

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University of Engineering and Technology, Lahore
Huaneng Shangdong Ruyi 2X600MW Coal-Fired Power Plant
Supercritical steam cycle history

The Rankine cycle is the most widely used steam/water cycle used for power generation, and is
typical for solid fuel fired power plants. The process is carried out reversibly since the fluid cycles
among liquid, two-phase and vapour states. A closed condensing cycle provides enhanced
efficiency, as it also allows for close control of water chemistry required for high pressure, high
temperature cycles, and favours a minimum of makeup water. An additional improvement is the
use of regenerative feed water heating, which uses extraction steam from various stages in the
turbine to heat the feed water as it is pumped from the condenser to the economizer.
Cycle thermodynamic efficiency is improved by increasing the temperature of the heat source
for a constant heat sink temperature. This temperature can be increased when the feedwater
pressure is increased because the boiler inlet pressure sets the saturation temperature in the
Rankine cycle (see Figure 2). If the pressure is increased above the critical point of 220 bar (3200
psi), the addition of heat no longer results in a typical boiling process in which there is defined
interface between the steam and water. Rather, the fluid can be treated as a single phase. This is
referred to as a supercritical steam cycle, originally referred to as the Benson® Super Pressure
Plant when first proposed in the 1920s. The first commercial unit featuring a supercritical cycle
and two stages of reheat was placed in service in 1957 using B&W technology.

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University of Engineering and Technology, Lahore
Huaneng Shangdong Ruyi 2X600MW Coal-Fired Power Plant
In general, with equivalent plant parameters (fuel type, heat sink temperature, etc.) the
supercritical steam cycle generates about 4% more net power than the subcritical pressure
regenerative Rankine steam cycle. These factors, along with component design limitations,
must be considered in a cycle analysis where the objective is to optimize the thermodynamic
efficiency within the physical and economic constraints of the equipment. In addition, there are
constraints imposed by the economics of fuel selection and the environmental impacts of fuel
combustion that impact the design of the boiler/turbine regenerative system.

Mechanical Engineering Department

University of Engineering and Technology, Lahore
Huaneng Shangdong Ruyi 2X600MW Coal-Fired Power Plant
Differences between sub-critical and Super-critical
Description OT SCU Sub-Critical
Furnace Sizing Decided by Fuel and Gas side Same

Water and Steam

mixture Fixed
Supercritical fluid Variable evaporation evaporation point
Evaporator point Superheated steam at evaporator Saturated steam at
outlet BENSON Technology evaporator outlet
Natural / controlled
circulation

Replaced by smaller Separators and Required for water and

Drum collecting vessel. Required only during steam separation at all
low loads (about 35-40%) loads
Low Load and Start up System Required Not Applicable
Economiser Same Same
SH and RH Sizing Same Same

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University of Engineering and Technology, Lahore
Huaneng Shangdong Ruyi 2X600MW Coal-Fired Power Plant

Description OT SCU Sub-Critical

Pulveriser Sizing Same Same

Fans. RAPH & ESP and ducts Same Same

Feed water and steam temperature controls

Controls Base
are different

Water tratment and water chemistry AVT and Oxygenated water treatment. Generally AVT

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University of Engineering and Technology, Lahore
Huaneng Shangdong Ruyi 2X600MW Coal-Fired Power Plant
Operating regimes

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Huaneng Shangdong Ruyi 2X600MW Coal-Fired Power Plant
Types of boilers

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University of Engineering and Technology, Lahore
Huaneng Shangdong Ruyi 2X600MW Coal-Fired Power Plant
Supercritical Boilers - Salient features

 No thick walled drum. Instead , smaller separator vessels are provided

 Types of evaporator system:
High mass flux spiral wall
Medium mass flux vertical wall with orifice
Low mass flux vertical wall
 Normal operation is on once-through mode.
Operates under circulation mode during start up and low loads ( below 35-40% TMCR)
 Higher grade materials required to meet higher steam parameters
 Control philosophy is different from drum type boiler

Mechanical Engineering Department

University of Engineering and Technology, Lahore
Huaneng Shangdong Ruyi 2X600MW Coal-Fired Power Plant
Benefits
 Improved cycle efficiency results in lower fuel cost, reduced emission of gases like CO2,
NOx and SOx, reduced emission of particulates etc.
 Better start up and load change rates due to absence of thick walled drum
 Better suited for sliding pressure operation
 Wide steam temperature control range for SH and RH

Mechanical Engineering Department

University of Engineering and Technology, Lahore
Huaneng Shangdong Ruyi 2X600MW Coal-Fired Power Plant
Furnace Design

FEGT = IDT - 50 K

FEGT = Furnace exit gas temperature, Deg K

IDT = Initial deformation temperature of ash, Deg K

Furnace design and size are decided by coal and ash quality

Mechanical Engineering Department

University of Engineering and Technology, Lahore
Huaneng Shangdong Ruyi 2X600MW Coal-Fired Power Plant
Evaporator wall design
Key Issues

1. Heat absorption variation and resulting temperature difference at furnace wall outlet
2. Boiling crisis like DNB and dry out and associated wall temperatures

Mechanical Engineering Department

University of Engineering and Technology, Lahore
Huaneng Shangdong Ruyi 2X600MW Coal-Fired Power Plant
Evaporator systems

Mechanical Engineering Department

University of Engineering and Technology, Lahore
Huaneng Shangdong Ruyi 2X600MW Coal-Fired Power Plant
Types of Supercritical Boilers Reported in Recent Literature

Schematics of furnace and combustion system of the down-fired 600MWe supercritical boiler as well as the
monitoring port layout in industrial experiments (dimensions in mm). [1]

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University of Engineering and Technology, Lahore
Huaneng Shangdong Ruyi 2X600MW Coal-Fired Power Plant

Schematic diagram of the large-scale 261 MWe CFB COMPACT boiler. [2]

Mechanical Engineering Department

University of Engineering and Technology, Lahore
Huaneng Shangdong Ruyi 2X600MW Coal-Fired Power Plant

Flow and heat transfer experimental system. [3]

Mechanical Engineering Department

University of Engineering and Technology, Lahore
Huaneng Shangdong Ruyi 2X600MW Coal-Fired Power Plant

Schematics of the furnace and combustion system of the down-fired boiler

(dimensions in mm). [4]
Mechanical Engineering Department
University of Engineering and Technology, Lahore
Huaneng Shangdong Ruyi 2X600MW Coal-Fired Power Plant

600 MW supercritical CFB boiler structure design. [5]

Mechanical Engineering Department

University of Engineering and Technology, Lahore
Huaneng Shangdong Ruyi 2X600MW Coal-Fired Power Plant

Schematic diagram of the boiler. [6]

Mechanical Engineering Department
University of Engineering and Technology, Lahore
Huaneng Shangdong Ruyi 2X600MW Coal-Fired Power Plant

Furnace structure sketch of 600 MW supercritical CFB

boiler. [7]
Mechanical Engineering Department
University of Engineering and Technology, Lahore
Huaneng Shangdong Ruyi 2X600MW Coal-Fired Power Plant
References
1. Kuang, Min, et al. "Experimental study on combustion and NOx emissions for a down-
fired supercritical boiler with multiple-injection multiple-staging technology without
overfire air." Applied Energy 106 (2013): 254-261.
2. Krzywanski, J., et al. "A generalized model of SO 2 emissions from large-and small-
scale CFB boilers by artificial neural network approach Part 2. SO 2 emissions from
large-and pilot-scale CFB boilers in O 2/N 2, O 2/CO 2 and O 2/RFG combustion
atmospheres." Fuel Processing Technology 139 (2015): 73-85.
3. Yang, Dong, et al. "Experimental investigation on heat transfer and frictional
characteristics of vertical upward rifled tube in supercritical CFB boiler." Experimental
Thermal and Fluid Science 35.2 (2011): 291-300.
4. Kuang, Min, Zhengqi Li, and Qunyi Zhu. "Evaluation on cold modeling flow field for a
down-fired 600MWe supercritical boiler with multi-injection and multi-staging: A
burner location experimental optimization and its validation by real-furnace
measurements." Experimental Thermal and Fluid Science 45 (2013): 213-220.
5. Pan, Jie, et al. "Thermal-hydraulic analysis of a 600 MW supercritical CFB boiler with
low mass flux." Applied Thermal Engineering 32 (2012): 41-48.

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University of Engineering and Technology, Lahore
Huaneng Shangdong Ruyi 2X600MW Coal-Fired Power Plant
6. Shu, Zheng, et al. "Development of a distributed-parameter model for the evaporation
system in a supercritical W-shaped boiler." Applied Thermal Engineering 62.1 (2014):
123-132.
7. Pan, Jie, Gang Wu, and Dong Yang. "Thermal-hydraulic calculation and analysis on
water wall system of 600 MW supercritical CFB boiler." Applied Thermal Engineering
82 (2015): 225-236.

Mechanical Engineering Department

University of Engineering and Technology, Lahore