Status of Global Advanced Ultra Supercritical Power Plant Programs

Ram Narula President, Engineering & Environmental Consultant

Robert Purgert President, Energy Industry of Ohio

Jeffery Phillips Sr. Manager, Electric Power Research Institute

Harvey Wen Sr. Principal Engineer, Bechtel Power Corporation

Presented at the International Conference on Supercritical Technologies and Best Practices

New Delhi, India November 21-22, 2013

1

Contents Technology Evolution

Drivers for A-USC Technology

Major Global A-USC Programs

Commentary

2

Technology Evolution

Ever going Quest for higher efficiency 1882-Beginning of Coal Fired

Generation Early 1920s-PC Plants Introduced Late 1920s- Reheat Cycle

Introduced 1930s- Steam conditions reached

538C 1957- First SC, 120 MW, Philo

plant @31MPa/621C /566C/538C 1960- 325 MW Eddystone 1,

@35MPa/621C/566C/566C

3

Technology Evolution - Continued Ever going Quest for higher efficiency

1996- 700C program started in Europe 2001- 760C program started in USA 2008- 700C program started in Japan 2010- 700C program started in China 2010- 700C program started in India

Reducing Coal Consumption, Emissions and Water use

4

Drivers for Higher Efficiency

Competitive COE Lower Emissions including CO2 Optimum resource utilizations/

Transportation constraints International Obligations Energy Independence

Local/Global Drivers

5

Major Global A-USC Programs

European Program 700C US DOE Program 760 C Japanese Program 700C Chinese Program 700C Indian Program 700C

Developing Ni-based Super Alloys

6

The European AD 700 A-USC Program

1996- European program conceived 1998- 15 year, 6 phase COMTES launched with the goal of

a 550 MW @35 MPa/ 700C/720C demo plant by 2014 COMTES while successful encountered a few major

problems with thick walled 617 components necessitating additional testing

Eon, host utility put demo on hold because of high cost and flexible power requirements

Technical/Funding Constraints impeding Progress

7

The European A-USC Program continued

Two new projects GKM HWT II and ENCIO (European Network for Component Integration & Optimization) underway (2010-2017) to: Verify design and material behavior of thick wall components

under real operating conditions Verify repair concepts and close open technical items post

COMTES 700 comprehensive analysis Minimize technical risks and reduce construction/operational

cost via various manufacturing options Test newly developed materials (617B, 263, HR6W and 625)

and weld filler materials at a new test facility at the 320 MW Unit 4 of ENEL’s Andrea Palladio plant in Fusina, Italy

8

The European A-USC Program continued

Additional Challenge in Europe is the need for flexible fossil power generation due to rapid growth of renewables

Huge technical challenge for thick walled components & weldments to accommodate high load gradients, lower minimum load and frequent starts/shutdowns

Huge economical challenge due to fewer dispatch hours and high capital cost

9

US A-USC Program

Primary Goals Materials Technology Evaluation Focus on nickel based alloys Develop fabrication/joining technologies for new alloys

Unique conditions for US program Higher temperature than European program needing

additional alloys Corrosion resistance for high sulfur/high moisture US

coals Collect data for ASME Code acceptance Includes analysis of impact of oxycombustion

Racing Towards 50% HHV efficiency

10

US : A-USC Program For Boiler

New Alloys For Pressure Parts Superheaters/Reheaters need

High creep strength/long term stability Low coefficient of thermal expansion Low fireside corrosion

Low steam side oxidation/ exfoliations Weldability in thicker sections

Several alloys selected Most promising - Inconel 740, Haynes

230, Haynes 282

11

Test section showing two types of dissimilar welds. (Source: Courtesy of Alstom)

US : A-USC Program – Continued For Steam Turbine

Alloys for Rotors, discs and blades The Cyclic nature of ST operation, dynamic and

centrifugal forces require Low cycle fatigue strength to avoid cracking Compatible thermal expansion coefficients

between differing materials Several alloys selected Most promising - Waspalloy, Nimonium 105,

Haynes 282

12

US : A-USC Program – Continued Achievements & Next Steps

New materials developed, characterized Inconel 740 code certified for

section 1 in 2011 & got B31.1 approval in 2012

Gathering data for Haynes 282 certification

Longer term testing on going For future readiness, US may look

favorably at overseas consortia for component testing

Unfavorable market in US has brought new coal construction to a grinding halt

13

Inconel 740 ®Pipe after Extrusion at Wyman-Gordon’s Houston works

The Japanese A-USC Program 2000- domestic equipment suppliers/ utilities program to develop

new materials 2006-Highest efficiency plant at OSOGO 2 2008 Government launched “Cool Earth Program” 700 C A-USC @

35 MPa/700C 46% efficiency by 2015 48% efficiency by 2020

2011- Earth Quake/tsunami – A setback Nuclear Fleet nearly shutdown Massive Gas fired built up Coal to Gas boiler conversion Improve reliability of existing coal fleet

Country in power Crisis

14

The Japanese A-USC Program –Continued Unique Features

Use lower main steam pressure Minimizes use of Ni-based alloys by extending use of Ferretic and

austenitic steel to higher temperature Component testing will be in an existing turbine rotor test facility at

700C at full speed (electric heaters and vacuum) Boiler components test to include superheater panel, large

diameter safety and turbine bypass valves Test materials to include HR6W, HR35, Alloys 141, 263, 617 & 740 Testing to cover creep rupture, fatigue, oxidation and corrosion

properties Testing scheduled for 2014 to 2016 First demo plant target date of 2020 looks optimistic

A–USC development progressing

15

Chinese A-USC Program 1992- started supercritical plants using imported technology 2004- domestic technology commercial 2010- founded national alliance for 700C A-USC Goals:

Design of A-USC plant R&D of high temp materials, large castings and forgings Demonstration of components (at CTH 700 facility) starting

2014 Construction & operation of a 660MW @35 MPa/700C plant

by 2021 Emphasis on domestically developed/modified materials

Emphasis on Local Manufacturing

16

Chinese A-USC Program - Continued

Unique Features:

Develop indigenous materials as well as modify imported materials to enhance the desired properties

Optimize Alloys G115 and 740H A 10 tons/hr loop in an existing 320 MW, 2 pass facility On going testing of 617M, 740H, 749H and T24 Ni-Fe based modified super alloy GH 2984 being considered for use

to improve boiler efficiency (higher thermal conductivity than Alloys 617, 740 & N263)

Additional R&D underway for SH/RH pipe and headers, HP/IP rotors, casings, valves and fittings

Collect test data for 100,000 hours

Ni-based alloys being procured

17

Indian A-USC Program 2003 electricity act to overcome power shortages Ministry of Power/CEA/PFC initiative for supercritical UMPPs National Mission under NAPCC for development of 700C A-USC MOU on Technology Collaboration between IGCAR/BHEL/NTPC

to develop A-USC technology signed in August 2010 Current SC plants (660/800 MW) limited to 25 Mpa, 565/593C First 800 MW A-USC targeted to come online in 2017(2021) Future capacity additions to be mainly supercritical Corrosion testing envisaged at an Indian plant based on

European COMTES materials (Alloy 617)

18

Indian A-USC Program - Continued Unique Features: Steam parameters: 31 MPa, 710 °C, 720 °C Alloy 617 chosen as it is ASME code approved and

widely available Test loop to verify corrosion characteristics of

intended alloys under Indian coal combustion Alloy 617, SS304HCu, T91/T92, and T/P23 will be

tested Test loop to become operational in 2015

Steady progress. Acceleration through proactive projects.

19

Indian A-USC Program - Continued Several projects on critical aspects initiated

Forged ingots of 617M and SS304HCu manufactured and characterized. Main material for rotor and blade will be 617M.

Long term testing of materials in progress Welding, bending trials of tubes carried out Thermal cycle designed Dissimilar welding for turbine rotors Thick walled superheater header HP Bypass valve

Project Design Document prepared

Focus on self reliance

20

Commentary

European Program: Further post COMTES testing needed to validate

repair concepts and gather more data to reduce construction & operational costs

A full demo before 2023-2025 unlikely European financial situation, unfavorable coal

sentiment and economics of A-USC due to flexible fossil power requirements are clouding the viability of this technology in the near term.

21

Commentary - Continued US Program: Considerable progress made in

development/ASME certification of superior Ni-based alloys

Unfavorable coal power outlook, cheaper shale gas and weak electric demand making COMTES funding a challenge

A full scale demo on line before 2025 unlikely.

22

Commentary – continued

Japanese Program: 2011 earth quake and resultant shutdown

of nuclear fleet has changed national priorities

A traditional key driver behind Japanese technology development is export potential to US/Europe has dampened

While A-USC progressing, the 2020 target of full scale demo is unlikely

23

Commentary – continued Chinese Program: Making rapid progress in executing its plans Actively procuring advanced materials from

abroad and testing/modifying imported materials While program details not in public domain,

challenges are technical not financial Highly likely to meet its target of full scale demo

plant by 2021.

24

Commentary – Continued Indian Program: India’s need for additional power generating capacity

very high Work progressing steadily Indian consortium commitment is 7 years to design and

build after government’s final approval Planning Commission approval received in October 2013 Original target date of 2017 too optimistic. With critical

projects already taken up, a full scale demo by 2021 likely

25

Thank you for Listening

Any Questions

Contact: rgnarula@ yahoo.com

26