This document provides an overview of supercritical boiler technology. It begins with definitions of critical pressure and how it differs from subcritical boilers. It then compares the Rankine cycles of subcritical versus supercritical units. Key differences highlighted include higher efficiencies, less emissions, and operational flexibility of supercritical units. The document discusses water wall designs, materials requirements, water treatment needs, and operational challenges of supercritical boilers. Overall it provides a high-level introduction to supercritical boiler technology.
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2. 2
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.
6. 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.
6
Departure from Nucleate
Boiling
PRESSURE(ksc)
DENSITY
WATER
STEAM
175 224
9. From CRH Line
From FRS Line
Boiler
Recirculation Pump
Economizer
Phase 1
Economizer
Phase 2
LTRH
LTSH
4430C
FRH
Platen
Heater
Mixer Header
FSH
To HP
Turbine To IP
Turbine
Separator
Bottom Ring
Header
2830C
3260C
4230C
4730C
4620C
5340C
5260C
5710C
5690C
3240C
2800C
NRV
10. 10
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)
12. COMPARISION OF SUPER CRITICAL & SUB
CRITICAL
DESCRIPTION SUPERCRITICAL
(660MW)
SUB-CRITICAL
(500MW)
Circulation Ratio 1 Once-thru=1
Assisted Circulation=3-4
Natural circulation= 7-8
Feed Water Flow
Control
-Water to Fuel
Ratio
(7:1)
-OHDR(22-35 OC)
-Load Demand
Three Element Control
-Feed Water Flow
-MS Flow
-Drum Level
Latent Heat Addition Nil Heat addition more
Sp. Enthalpy Low More
Sp. Coal consumption Low High
Air flow, Dry flu gas loss Low High
16. WATER WALL ARRANGEMENT
16
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.
17. 17
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
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
26. 26
S.
No.
Parameter Sub Critical Super Critical
1
Type of Boiler
water
treatment
LP and HP dosing. Or
All Volatile Treatment
(Hydrazine + Ammonia)
No HP dosing
Combined water treatment (CWT).
2
Silica < 20 ppb in feed water and steam,
< 250 ppb in boiler drum
Standard value <15 ppb in the cycle
Expected value <10 ppb in the cycle
3
pH 9.0 - 9.5 for feed, steam &
condensate,
9.0 – 10.0 for Boiler drum
9.0 – 9.6 for AVT(All volatile treatment)
8.0 – 9.0 for CWT(Combine water
treatment)
4
Dissolved
Oxygen (DO)
< 7 ppb for feed. < 7 ppb for feed in case of AVT
30 – 150 ppb for feed in case of CWT
5
Cation (H+)
Conductivity
<0.20 µS/cm in the feed & steam
cycle
Standard value <0.15 µS /cm in the cycle
Expected value- <0.10 µS /cm in the cycle
6 (CPU) CPU is optional CPU is essential for 100% flow.
7
Silica and TDS
control
By maintaining feed water quality
and
By operating CBD
Blow down possible till separators are
functioning (upto 30% load).
27. 27
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
28. 28
ECONOMY
Higher Efficiency (η%)
•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
30. 30
Sub. vs. Supercritical Cycle
Impact on Emissions
Plant Efficiency, %*
Plant Efficiency, %
Fuel Consumption/Total Emissions
including CO2
Subcritical Supercritical
34 - 37 37 - 41
Plant Efficiency, Btu / kw-hr 10,000 - 9,200 9,200 - 8,300
34%
Base
37%
Base-8%
41%
Base-17%
* HHV Basis
31. 31
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.
