advanced capture technologies
TRANSCRIPT
Babcock-Hitachi Europe GmbHBabcock-Hitachi Europe GmbH
Manufacturers’ know how onadvanced capture technologiesManufacturers’ know how onadvanced capture technologies
- Higher efficiency towards zero emission -
02.12.2005Dr. Andreas ReidickKlaus-Dieter Rennert
Babcock-Hitachi Europe GmbH
Research steps on the way to the CO2-free power station
Ref: BMWi AG 4 „Zukünftige Technologien“
Efficiency
Emissions
Time
ReadyReady--forfor--thethe--market, market, COCO22--freefree
fossil power stationsfossil power stations
Demonstration
Components forCO2 operating processes
Basics of CO2 capture
Increase of efficiency
Babcock-Hitachi Europe GmbH
CO2 Emission of Bituminous Coal Power Stations
300
400
500
600
700
800
900
1000
1100
1200
25 30 35 40 45 50 55 60
Overall Efficiency (%)
AverageEU
Thermieultimo
Average EU2010
Thermie 700, 2 RH
CO
2Em
issi
ons
(g/k
Wh)
Reference P.S.NRWReference P.S.NRW
Ref: Thermie Forschungsprojekt 700°C-Kraftwerk
State of the Art
Babcock-Hitachi Europe GmbH
Incre
ase of
effic
iency
Reference Power Station NRW (550 - 600 MW)
AD 700
Altbach 2 (300 MW)Staudinger 5 (550 MW) Rostock (550 MW)
Bexbach 1 (750 MW)
CWH 3 (100 MW)
Bayer Dormagen (125 t/h)
Iskenderun (600 MW)
Torre Nord(660 MW)
Leininger (450 MW)
Amager (260 MW)
Studstrup (350 MW)
Midamerican (790 MW)
Genesee (251 MW)
Kogan Creek(750 MW)
180 220 240 260 280 300 380
700
620
600
580
560
540
Hitachi-Naka #1 (1000MW)
Tachibana Wan #2 (1050MW)
Matsuura #2 (1000MW)
Shinchi #1 (1000MW)Noshiro #1 (600MW)
Hekinan #2 (700MW)
Nanao-Ohta #1 (500MW)
Future potential
High Efficient Steam Generators
Supe
rhea
terO
utle
t Tem
pera
ture
(°C
)
Superheater Outlet Pressure (bar)
sub-critical super-critical
Lippendorf (2 x 930 MW)
Niederaußem K (1000 MW)
Boxberg (900 MW)
Neurath F/G (1100 MW)
Schkopau (2 x 400 MW)
Haramachi #2 (1000MW)
Babcock-Hitachi Europe GmbH
Neurath F,G (BoA2), 2x 1100 MW
• 2 x 1100 MWel / 2 x 2959 t/h
• Once-through steam generator, Benson®
• Lignite
• Steam parameters:SH: 600 °C / 272 barRH: 605 °C / 55.3 bar
• Commissioning: 2010/2011
Babcock-Hitachi Europe GmbH
HARAMACHI POWER STATION UNIT No. 2
Unit Capacity 1,000 MWel
Evaporation 2,890 t/h
Steam Pressure 25.9 Mpa
Steam Temperature 604 / 602 °C
Fuel Bituminous Coal
Commissioning 1998
Utility:
TOHOKU ELECTRIC POWER CO.
Japan
Babcock-Hitachi Europe GmbH
flue gas
s = f (allowable stress)
corrosion layer
Superheater/ Reheater Tubes
steam
tube wall
Inner Oxide layer
OuterOxide layer
steam oxydation
corrosion
Babcock-Hitachi Europe GmbH
Magnetite Scale in an Elbow
Spalling of outer oxide layer
Babcock-Hitachi Europe GmbH
Tube Internal Surface Shot Blasting Procedure
Tube
Shot Particle
Compressed Air including shot particle
material
Circumferential Blasted Nozzle
Shot Blasting Conditions (BHK Facility)
Shot Particle Material : SUS304 particle Φ 0.5 x 0.5L
Max. Blasting Pressure : 7 bar
Nozzle Movement Velocity : 100~800mm/min
Air Flow : max. 9m3/min
Babcock-Hitachi Europe GmbH
The effect of the shot blastingThe effect of the shot blasting
MetalMetal
Schematic
Grain boundary
Shot blasted50µm
・Step1: The crystal grains are collapsed ・Step2: Cr2O3 is formed with the result that the oxidizing velocity is very slow ・Step3: The scale growth is suppressed.
(Fe,Cr)3O4
Cr2O3
Fe3O4
Effect of Shot Blasting after 34412 Operating h Super 304 H, 586 °C Steam
Outer Scale
Inner Scale
Original MaterialMetal
50µm
Thin Cr2O3layer
Outer Scale
Inner Scale
Metal
(Fe,Cr)3O4
Fe3O4 O2-
Fe2+
Grain boundary
Schematic
and the supply of Cr to the scale is promoted.
Diffusion of Cr
The layer where the crystal grains were collapsed.Cold worked
layer
Babcock-Hitachi Europe GmbH
National and European Research Programs
Babcock-Hitachi EuropeSuperheaterTubing Sheets
Influence of Coldforming on CreepBehaviour of Austenitic Steels and Nickel Base Alloys
3.2003 – 2.2006VGB-
FDBR-AiFProgram
V & MHeader, PipingCriteria for Demage Evaluation in High Temperature Components of martensitic9-11 % Cr-Steels
1.2005 – 12.2007A 229
SZMFHeader, PipingOptimization of Welding Joints and Prevention of HAZ – Creep by Means of Strength Properties
7.2004 – 6. 2007A 221
V & MHeader, PipingEvaluation of Scatterband of HeatresistingMaterials Concerning Creep Behaviour withData-Mining-Methode
1.2005 – 6.2006A 198
Babcock-Hitachi EuropeHeader, PipingLongitutinal Welded PipesCompletely new heattreated P 91 and E 911
7.2002 – 12.2005A 196
Babcock-Hitachi EuropeMembrane Wall, Header, PipingVM 124.2002 – 3.2006A 180
Babcock-Hitachi EuropeSuperheaterTubingInside cladded Tubes1.2002 – 12.2004A 176
ChairmanshipSteam GeneratorComponents
MaterialPeriodProgram
Babcock-Hitachi Europe GmbH
Boiler SectionBabcock-Hitachi Europe
Header, Piping, Superheater
Tubing
Nickel Base Alloys,Austenitic Steels
1.1998 – 12.2004
1.2002 – 12.2006
AD700 Phase 1 AD 700 Phase 2
Alstom(Switzerland)
Header, PipingMartensitic Steels1.2005 – 12.2008COST
536
VGB
Membrane Wall, Header, Piping,
SuperheaterTubing
7CrMoVTiB10-10, P 92, HCM 12, Alloy 617, HR3C, DMV310N, Sanicro25, A7403.2005 – 3.2009COMTES
700
RWE Power/VGBHeader, Piping,
SuperheaterTubing
Nickel Base AlloysAustenitic Steels
1.1998 – 6.2005KOMET
650 I and II
Babcock-Hitach EuropeMembrane Wall, Header7CrMoVTiB10-10, P 92, VM 12, Alloy 6179.2004 – 9.2008MARCKO
700
ChairmanshipSteam GeneratorComponents
MaterialPeriodProgram
National and European Research Programs
Babcock-Hitachi Europe GmbH
500 °C500 °C
550 °C
580 °C580 °C 590 °C590 °C
630 °C630 °C
13CrMo4-513CrMo4-5
7CrMoVTiB10-10
HCM 12HCM 12 VM 12VM 12
Alloy 617Alloy 617
MARCKO 1
MARCKO 700
Considering the material properties :Oxidation in SteamCreep Strength
Considering the material properties :Oxidation in SteamCreep Strength
Materials for Membrane walls
Design temperatures according EN 12952
Babcock-Hitachi Europe GmbH
580 °C580 °C
600 °C
625 °C625 °C 635 °C635 °C
735 °C735 °C
X20CrMoVNi11-1X20CrMoVNi11-1
P 91
E 911, P 92E 911, P 92 VM 12VM 12
Alloy 617Alloy 617
MARCKO 1
MARCKO 700
Considering the material properties :Oxidation in SteamCreep Strength
Considering the material properties :Oxidation in SteamCreep Strength
Materials for Headers and Piping
735 °C735 °C
Alloy 263Alloy 263
Design temperatures according EN 12952
Babcock-Hitachi Europe GmbH
600 °C600 °C
615 °C
635(645*) °C635(645*) °C 670 °C
770 °C770 °C
X20CrMoVNi11-1X20CrMoVNi11-1
z.B. X3CrNiMoN17-13
z.B. S 304 Hz.B. S 304 H z.B. HR3Cz.B. HR3C
Alloy 617Alloy 617
MARCKO 1 MARCKO 700
Considering the material properties :
Oxidation in Steam
High-Temperature Corrosion in Flue Gas
Creep Strength
Considering the material properties :
Oxidation in Steam
High-Temperature Corrosion in Flue Gas
Creep Strength
770 °C770 °C
Alloy 263Alloy 263
700 °C700 °C
* Bituminous coal firing systems with contents of sulphur until approx. 1 %
Design temperatures according EN 12952
Materials for Reheater and Superheater Tubes
Sanicro25 under investigationSanicro25 under investigation
Babcock-Hitachi Europe GmbH
State of development and research need of new materials
Before the background of the requirements of the European “DGRL” and the European product standards
Chemical Composition
Physical and chemical Properties
Mechanical / Technological Properties (Short time) (Long-term)(Aging)
Creep characteristics
Fatigue properties
Rupture mechanic properties
Processing qualification deformation (cold u. warmly), Welding(Attributes HAZ and weld material, cracking hot and cold)
Evaluation of the material and construction unit characteristics(security concept)
Manufacture concept raw material
Manufactering concept, for example Welding instructions, Procedure qualifications
Order prescriptions, Quality requirements, Inspection requirements
Babcock-Hitachi Europe GmbH
nichterfüllt
läuft
erfüllt
DMV66 modA263Tub
ManufacturingConcept
Properties of Welding Joints and Heat Affected Zones
Creep Properties atleast 30.000 h forrupture
Creep Properties atLeast 10.000 h forrupture
Mechanical-Techno-logical Properties, incl. Aging
Physical/ChemicalProperties
ChemicalComposition
F92T/P 92Tub
SumS304,HR3C,
347Tub
DMV310,304,347Tub
San25Tub
VM 12 For
VM12 Pipe
617Forg
617Pipe
7Cr For
7Cr Tub
Materials
Requirements
Status of Investigations
available
planned
running
Babcock-Hitachi Europe GmbH
Planned Projects within COORETEC - Initiative
PeriodInstituteTitelNo
01.06-12.08IGZFP/BAM
Non Destructive Testability of Thick Components of Ni-base Alloys and Welding Joints
TD-1
06.06-06.10MPA Stuttgart
Strength and Deformation Behaviour of Nickel Base-Alloys Tubings, Pipings,and Forgings
DE-4
06.06-06.10MPA Stuttgart
Strength and Deformation Behaviour of 12%Cr-Steel Forgings
DE-3
01.06-12.09Tu DarmstadtProperties of Superheater Tubing Materials afterColdforming
DE-2
06.06-08.09Uni StuttgartCorrosion and Slagging Behaviour of 700°C-MaterialsDE-1
Babcock-Hitachi Europe GmbH
X20CrMoV121
X20CrMoV121
13CrMo44
AustenitP92
7CrMoVTiB 10 10
Ni-Basis-
MaterialsNi-Basis-
Materials
VM12
Best Available Technology for Bituminous Coal
η = 43 % η = 45 – 47 % η = 50 %262 bar / 545 °C / 562 °C 285 bar / 600 °C / 620 °C 358 bar / 700 °C / 720 °C
todaytoday 20102010 20152015
Babcock-Hitachi Europe GmbH
CO2 Emissions in GermanyReplacement of Bituminous Coal P.S. by BAT
CO
2ou
t of H
ard
Coa
lP.S
. (t/h
)
0
5000
10000
15000
20000
25000
2005 2010 2015 2020 2025 2030
RKW AD700
CO2 freeplants
Year
-- BituminousBituminous coalcoal --
Babcock-Hitachi Europe GmbH
Available technology, Lignite
today 2010today 2010η = 42 % η = > 43 %
260 bar / 554 °C / 583 °C 286.1 bar / 600 °C / 610 °C
AustenitP91
13CrMo44
E911
(P92)Super 304H
HR3C
7CrMoVTiB 10 10
Babcock-Hitachi Europe GmbH
CO2 Emission in GermanyReplacement of Lignite P.S. by BAT
0
5000
10000
15000
20000
25000
2005 2010 2015 2020 2025 2030
CO2 freeplants
CO
2 ou
t of L
igni
teP.
S. (t
/h)
Year
-- LigniteLignite --
BoA II /Boxberg R
Babcock-Hitachi Europe GmbHBabcock-Hitachi Europe GmbH
Dr. Andreas ReidickKlaus-Dieter Rennert
Babcock-Hitachi Europe GmbH
Reference Power Station of
North Rhine Westphalia
Reference Power Station of
North Rhine Westphalia
Babcock-Hitachi Europe GmbH
Target of the Concept Study
Investigation of the viability of an ultra modern power plant
remarkable reduction of emissions
economical conditions of the liberalised market
Babcock-Hitachi Europe GmbH
Participants
Steering Committeemanufacturers, utilities, members of ministries,
association of bituminous coal, mining union
Scientific investigations
RWI, Wuppertal-Institut,University of Essen
Manufacturers Utilities
Babcock-Hitachi Europe GmbH
Reference Power Plant - Boiler Concepts
550 MW * 292,5 bar * 600 / 620 °C
Cost – Comparison
Tower: 100 % Two Pass: + 3 % Horizontal fired: + 8 %
Babcock-Hitachi Europe GmbH
• Single unit with gross capacity of 500 - 600 MW• overall efficiency of 45 - 47%• Power consumption < 8.5 %• Steam parameters
– HP at turbine inlet 285 bar / 600 °C– RH at turbine inlet 60 bar / 620 °C
• Design coal South African• Condenser pressure approx.: 45 mbar• Cooling tower
Tower Type Boiler – “RKW Preferred Variant 600 MW”
Babcock-Hitachi Europe GmbH
700
750
800
850
900
45.9 46.1 46.2 46.5 47.3
Specific Cost vs. Efficiency
EUR/kWgross
Efficiency
BasedBased on 2003 on 2003