materials technology to enable high-efficiency advanced
TRANSCRIPT
J. Shingledecker, R. Purgert, V. Cedro EPRI, EIO, NETL
“Advanced Technologies & Best Practices for Supercritical Thermal Power Plants.” Partnership to Advance Clean Energy – Deployment
(PACE-D) Technical Assistance Program (U.S. AID) November 21-22, 2013: New Delhi, India
Materials Technology to Enable High-Efficiency Advanced Ultrasupercritical (A-USC) Steam
Power Plants
2 © 2013 Electric Power Research Institute, Inc. All rights reserved.
U.S. Department of Energy (US DOE) / Ohio Coal Development Office (OCDO) A-USC Steam Boiler and Turbine Consortia
Castings
Fabrication
Field Test Forging
Welding
New Materials
Fede
ral –
Sta
te –
Nat
iona
l Lab
orat
ory
Non
Pro
fit –
For
Pro
fit
Cos
t Sha
ring
Con
sort
ium
3 © 2013 Electric Power Research Institute, Inc. All rights reserved.
Increasing Steam Temperature and Pressure Increases Thermal Efficiency and Decreases Emissions
Note: HHV Basis
“Least Regret” Strategy for CO2 Reduction
4 © 2013 Electric Power Research Institute, Inc. All rights reserved.
40
60
80
100
300
500
550 600 650 700 750 800
1100 1200 1300 1400
6
8
10
30
50
70
Stre
ss (M
Pa)
Average Temperature for Rupture in 100,000 hours (oC)
9-12Cr Creep-Strength Enhanced Ferritic Steels (Gr. 91, 92, 122)
Nickel-BasedAlloys
Std. 617CCA617
Inconel 740
Haynes 230
Advanced Austenitic Alloys (Super 304H, 347HFG, NF709, etc.)
Haynes 282
Average Temperature for Rupture in 100,000 hours (oF)
Stre
ss (k
si)
Materials Limit the Current Technology
°
Steels = USC 620°C (1150°F)
Solid Soln’ = A-USC ~700°C (1300°F)
Age Hardenable = A-USC 760°C (1400°F)
Minimum Desired
Strength at Application
Temperature
5 © 2013 Electric Power Research Institute, Inc. All rights reserved.
Primary Technical Goals of US A-USC Materials Programs
• Materials Technology Evaluation • Focus on nickel-based alloys • Development of fabrication and joining technology for new alloys
•Unique Conditions for US Program Considerations • Higher-temperatures than Other International Programs (760°C versus 700°C) means additional alloys are being evaluated
• Corrosion resistance for US coals • Data for ASME code acceptance of new materials • Phase II Boiler work includes Oxycombustion
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Comparison between two leading candidates: 740H & 617
Higher Allowable Stress for Inconel 740H = Thinner Pipe Walls
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Higher-strength alloys provide an avenue for cost savings
704/704°C 732/760°C
704/704°C 732/760°C
If you have to pay for nickel, make the most of it!
Main steam and reheat piping comparison for 740H and 617 at
704/704°C
8 © 2013 Electric Power Research Institute, Inc. All rights reserved.
U.S. DOE/OCDO: A-USC Steam Boiler Consortium
2: Material Properties
3: Steamside Oxidation
4: Fireside Corrosion
5: Welding
6: Fabricability
7: Coatings
8: Design Data & Rules (including Code interface)
1: Conceptual Design
Develop the materials technology to fabricate and operate an A-USC steam boiler with
steam parameters up to 1400°F (760°C)
9 © 2013 Electric Power Research Institute, Inc. All rights reserved.
Most of the fundamental materials & fabrication work is complete for boiler materials
Basic Design
Welding Technology
Lab testing In-Plant Testing
Demonstrations for Fabrication
10 100 1000 10000 100000 100000010
100
1000
10000
100000
1000000 Grain Size < 100µm Grain Size > 100µm
Pre
dict
ed R
uptu
re L
ife (h
rs) -
eq.
1
Rupture Life (hrs)
Slope = 0.93
+/- factor of 2
Open Symbols = Ongoing Test
Long-term creep data & analysis
2µmMicrostructural Development
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Extensive databases for long-term material behavior
20000 24000 28000
10074,000hrs (700oC)
617 Average 617 Stress -20% CC617
Stre
ss (M
Pa)
LMP C=20
617 + CCA617
64,000hrs (650oC)
Long-term creep strength of CCA617
10 100 1000 10000 100000 100000010
100
1000
10000
100000
1000000 Grain Size < 100µm Grain Size > 100µm
Pre
dict
ed R
uptu
re L
ife (h
rs) -
eq.
1
Rupture Life (hrs)
Slope = 0.93
+/- factor of 2
Open Symbols = Ongoing Test
Post-assessment test for long-term creep in 740/740H
Creep-rupture failure map for
HR6W Haynes 230 Welds
10,000 hr steam oxidation data Super 304H
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In-Plant Testing: 760°C (1400°F) Operating Steam Corrosion Test Loop
• Phase 1 – Extensive laboratory testing – Air-cooled probes in boiler – Steam-cooled loop (high S coal)
• 2nd Steam Loop now installed and operating (8,000hrs+). – Planned duration extended until 2014 – World’s first steam loop operating at
760°C (1400°F) – Initial evaluations = little to no wastage
Prior to Welding Being Welded After Assembly
Fabrication in Alstom Chattanooga TN shop
Materials include:
740H, CCA617, HR6W, Super 304H, Coating, Overlays, and Others
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Highlights: World’s First Inconel®740H Pipe Extrusion
• Special Metals (Huntington, WV) & Wyman-Gordon (Houston, TX) Project
not consortium funded • 15-inch (381mm) O.D. X 8-
inch (203mm) I.D. X 34-1/2 feet (10.4m) long
• Larger forging window for Inconel 740H compared to CCA617 (same size pipe extrusion was shorter, 8.9m) Inconel®740H Pipe after
Extrusion at Wyman-Gordon
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Major Step: Code Case 2702 (Inconel®740H) now Approved (2011) for Use in Section I and B31.1
• Maximum Use Temperature: 800°C (1472°F) • Rules for:
– Chemistry – Heat-treatment – Welding – Post-weld heat-
treatment – Cold-forming – Weld strength reduction
factors Additional Research Continues to
Extend the Maximum Use Temperature
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Welding Advancements for Nickel-based Alloys
B.A. Baker, et al. Welding and Repair Technology for Power Plants, Tenth International EPRI Conference. June 26-29, 2012 Marco Island, FL USA.
76mm (3”) wall thickness full circumferential pipe weld in Inconel 740H
~50mm (2”) SAW & SMAW
Welds in CCA617
Process Optimization, Dissimilar Metal Welds (DMWs),
Repeatable Qualifications, Repair
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DOE/OCDO A-USC Steam Turbine Consortium Phase II
• Selected Materials from Phase I • Rotor/Disc Testing (full-size forgings, environmental interaction) • Blade Alloy Testing (and erosion resistant coatings) • Cast Casing Scale-Up Alloy Testing • Casing Welding and Repair
1400°F (760°C) Steam Turbine Conceptual Design (HP) – Bolted Construction
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A-USC Turbine Highlight Haynes 282 Rotor Scale-Up
World’s First Haynes 282 Triple Melt Ingot
Two ingots now produced:
1. Chemical homogeneity / grain size / defects evaluation
2. Disc forging in 2014
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Casting scale-up and turbine casing welding is progressing
Haynes 282 centrifugal
casting: 635kg (1,400lbs)
300mm3
Simulated casting weld defect repair
~2700kg (6,000lb) Valve Body Planned for late 2013
Haynes 282 and Alloy 263 Step Castings 135-450kg sizes (300 to 1,000 lbs)
740H Pipe to 282 Casting Weld Ongoing
Long-term creep of
weldments & microstructural
assessment
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Next Steps: ComTest 1400 U.S. Utility Perspective
• Evaluation of advanced materials and components under coal fired, A-USC conditions.
• Minimize risk for a utility desiring to build an A-USC Plant. – Demonstrate turbine operation – Demonstrate reliability and safety – thick-section piping – Understand manufacturing and cost
• Evaluation of the constraints in the supply chain
• Validation of fabrication techniques, and the ability to construct, install and repair ComTest with on-site labor.
19 © 2013 Electric Power Research Institute, Inc. All rights reserved.
Specific Goals
• Boiler: Design, install, start-up, operate and cycle high temperature nickel components (740H & others)
• Large diameter piping • Header and tubes (gas fired heater) • Superheater materials exposure (at pressure)
• Turbine: Design, install, start-up, operate and cycle full size Steam Valves & COMTEST steam turbine for 760°C (1400°F). – Periodic testing of steam valves at high temperature – Materials & coatings – Turbine architecture – Oxidation, deposits, SPE – NDE/NDT
• Fabrication methods & supply chain for super-alloys Proposed ComTest 1400 Turbine
20 © 2013 Electric Power Research Institute, Inc. All rights reserved.
ComTest 1400 Schematic
HOT REHEAT
L.P. TURBINEI.P. TURBINEH.P. TURBINE
COLD REHEAT
BOILER FEED PUMP
GENERATORFEEDWATER TO BOILER
MAIN STEAM
FEEDWATERHEATERS
CO
MTE
ST
SU
PE
RH
EA
TER
BYPASS
1400F, 2400-3500 PSIA100,000 LB/HR
SV CV
HP, HT VALVE TEST
PRESSURE LET-DOWN SYSTEM WITH
DESUPERHEAT
AUXILLIARYREHEATER
NATURALGAS
EXHAUST
1400F, 700 PSIA
BYPASS
DE
SU
PE
RH
EA
TER
BFW
GEN
SV CV
COMTEST TURBINE
SV CV
AU
XIL
LIA
RY
SU
PE
RH
EA
TER
NA
TUR
AL
GA
S
EX
HA
US
T
BFW
1300F, 2400-3500 PSIA100,000 LB/HR
Unique feature compared to other component tests:
•Higher-Temperature operation 760°C (1400°F)
•Turbine Demonstration
•Aux. Heaters for cycling / control independent from boiler
21 © 2013 Electric Power Research Institute, Inc. All rights reserved.
ComTest 1400
MAIN STEAM
COMTEST SUPERHEATER
GAS FIRED SUPERHEATER TURBINE
VALVE TEST
GAS FIRED REHEATER
TO EXISTING AQCS
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ComTest 1400 - Schedule
Task 1 is underway and has proven to be challenging
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Alternative Power Cycles Need Advanced (A-USC) Materials Technology NET Power Cycle 25MW Demo (2014-15) Gas-Fired 100% Carbon Capture Modified
CO2 Brayton Cycle is planning to use Inconel 740H for High-Temperature CO2 piping
Scale-up to 250MW will require large diameter nickel-based alloy
piping
Partners: NET Power, CB&I, Toshiba, Excelon
Partners: NREL, Echogen, Dresser Rand, Abengoa Solar, Sandia, Unv. of Wisc.,
EPRI, Barber-Nichols
DOE Sun-Shot Solar Powered CO2 Brayton Cycle – Pilot plant needs materials for
700°C+ piping and valves
24 © 2013 Electric Power Research Institute, Inc. All rights reserved.
Summary
• Consideration of higher-strength alloys provides an economic benefit for any A-USC Plant
• U.S. Program continues to make progress on the materials technology for A-USC – In plant testing for corrosion – Welding technology – Rotor scale-up and testing – Casing scale-up
• Planning work for a 760°C (1400°F) test facility is ongoing • Alternative power cycles can (and will) benefit from this
technology