International Journal of Mechanical Engineering and Technology (IJMET), ISSN 0976 INTERNATIONAL JOURNAL OF MECHANICAL ENGINEERING AND 6340(Print),

, ISSN 0976 6359(Online) Volume 3, Issue 2, May-August (2012), IAEME TECHNOLOGY (IJMET)

ISSN 0976 6340 (Print) ISSN 0976 6359 (Online) Volume 3, Issue 2, May-August (2012), pp. 422-430 IAEME: www.iaeme.com/ijmet.html Journal Impact Factor (2012): 3.8071 (Calculated by GISI) www.jifactor.com

IJMET
IAEME

PERFORMANCE ANALYSIS OF SUPERCRITICAL BOILER

Sanjay Kumar Patel1
University institute of technology Rajiv Gandhi Proudyogiki Vishwavidyalya Bhopal, India Email- sanjay.ermech@gmail.com

Dr. A.C. Tiwari2

University institute of technology Rajiv Gandhi Proudyogiki Vishwavidyalya Bhopal, India Email- aseemctiwari@yahoo.com

Abstract
Coal fired power generation is switching over to supercritical (SC) and ultra supercritical (USC) plants which operate with steam on higher temperature and above critical pressure to produce power output at higher thermal efficiency. Due to involvement of high heat resistant material, manufacturing cost of the components of supercritical plants are increases, but due to higher efficiency its operating cost is low as compare to subcritical plants. An analysis has been made in the study to explore the possibilities of operating power plants with steam at higher temperature and pressure. Due to high efficiency of this plant 15 % lower co2 emission is achieved by high steam parameters as compare to subcritical plants. Analysis shows that for different operating condition of boilers and turbine, if there is an increment in the load of boiler and drop in the load of turbine higher efficiency is obtained. There are two parameters boiler maximum continuous rating (BMCR) and turbine maximum continuous rating (TMCR) are varied by increasing the value of steam flow rate of superheaters and reheaters. By increasing or decreasing these values we can find out which condition is best for power generation. A comparative study between subcritical and supercritical boilers and analysing the performance of boilers, Factor affecting efficiency of boilers has carried out with identification and analysis for improved working of supercritical plants.

Keywords:
Supercritical-Boilers, steam-turbine, BMCR, TMCR, rankine cycle, superheaters

Introduction:
Supercritical is a thermodynamic phase that describes the state of a substance where there is no clear distinction between liquid phase and gaseous phase. (i.e. they are a homogeneous fluid). Water reaches this state at a pressure above 22.1 MPa (221 bar), also known as supercritical pressure of water. Beyond this pressure, it is a homogeneous mixture of water and steam, as shown in Fig-1. Up to an operating pressure of around 19 MPa in the evaporator part of the boiler, there is a non-homogeneous mixture of water and steam in the evaporator. Up to an operating pressure of around 19 MPa in the evaporator part of the boiler, there is a non-homogeneous mixture of water and steam in the evaporator. Up to an operating pressure of around 19 MPa in the evaporator part of the boiler, there is a non-homogeneous mixture of water and steam in the evaporator. In this case, a drum-type boiler is used because the steam needs to be separated from water in the drum of the boiler before it is superheated and led into the turbine. Above an

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International Journal of Mechanical Engineering and Technology (IJMET), ISSN 0976 6340(Print), ISSN 0976 6359(Online) Volume 3, Issue 2, May-August (2012), IAEME May August
operating pressure of 22.1 MPa in the evaporator part of the boiler, the cycle medium is a single single-phase fluid with homogeneous properties and there is no need to separate steam f from water in a drum.

Fig-1. Water Phase Diagram Once-through boilers are therefore used in supercritical cycles. A critical point can be illustrated on a Rankine through cycle, on which a typical steam turbine power plant operates. At working pressures in excess of this critical excess pressure, the Rankine cycle becomes supercritical cycle. The region below critical point is the subcritical region having a non-homogeneous mixture of water and steam. Figure-2 shows the supercritical Rankine cycle. Point homogeneous Figure 2 A on the T-S diagram represents the critical point. Based on the operating pressures, there are two basic boiler S technologies employed in the modern coal-fired power plants. These are Subcritical and Supercritical coal Subcritical boilers operate below 220 bars, the supercritical pressure of water. This means that there is a non nonhomogeneous mixture of water and steam in the evaporator part of the boiler. In this case a drum drum-type boiler is used because the steam needs to be separated from water before it is superheated and led into the turbine. The remaining water in the drum re-enters the boiler for further conversion to steam. The water circulation system enters can be a natural circulation or a forced (assisted) circulation circulation.

Steam Conditions
Todays supercritical coal fired power plants permits efficiencies that exceed 45%, depending on cooling conditions. Options to increase the efficiency above 50 % in ultra-supercritical power plants rely on elevated supercritical steam conditions as well as on improved process and component quality. Steam conditions up to 30 l MPa/600C/620C are achieved using steels with 12 % chromium content. Up to 31.5 MPa/620C/620C is achieved using Austenite, which is a proven, but expensive material. Nickel-based alloys, e.g. Inconel, would Nickel based permit 35 MPa/700C/720C, yielding efficiencies up to 48%. 720C,

1-2: 2-3: 3-4:

HP Turbine Expansion Reheat IP + LP Turbine Expansion

4-5: 5-6: 6-1:

Condenser Feedwater heating and pumping Boiler

Fig-2. Supercritical Rankine Cycle

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International Journal of Mechanical Engineering and Technology (IJMET), ISSN 0976 6340(Print), ISSN 0976 6359(Online) Volume 3, Issue 2, May-August (2012), IAEME

BOILER LOAD CONDITIONS Boiler Maximum Continuous Rating (BMCR): Boiler Maximum Continuous Rating (BMCR)
is the maximum rating specified for the boiler. This corresponds to 109.94% of Turbine maximum continuous rating. Turbine Maximum Continuous Rating (TMCR): Turbine Maximum Continuous Rating (TMCR) is the basis of steam generator output and is equal to the turbine generator maximum guaranteed rating.

Constant Pressure Operation

Above 90% TMCR, the main steam pressure remains constant at the rated value, condition, while the load is controlled by throttling main steam flow with the designated partial arc control valve. Below 30% TMCR, the main steam pressure remains constant at the minimum. The minimum constant pr. is 92 bar. The start-up and re-circulation system is designed to provide the necessary mass flow for adequate cooling of the evaporator during start-up and low load operation. A minimum of 30% of TMCR flow is maintained up to a boiler load of 30% TMCR. In this re-circulation system, the feedwater flows through the boiler feedwater line to the economizer, to the evaporator and then to the water separator. From the separator the recirculated water returns through the Boiler Recirculation Pump to the boiler feedwater line, where it is mixed with feedwater.

BFP

Economizer

Water Wall BCP

Separator

Superheater

Fig- 4 Once through operation of supercritical boiler

Division Superheater

Platen Superheater

Final Superheater

HP TBN

Water separator

HP BPV

Reheater

IP

t
Evaporator BCP Deaerator

LP

Condenser

Economizer

COP HP HTR BFP LP BPV LP HTR Fig-3 Cycle of supercritical power plant

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International Journal of Mechanical Engineering and Technology (IJMET), ISSN 0976 6340(Print), ISSN 0976 6359(Online) Volume 3, Issue 2, May-August (2012), IAEME

Performance of supercritical boiler: 1. Efficiency calculation of boiler:

There are two methods to calculate the efficiency of boiler. That is, Heat loss method and heat inputoutput method. To calculate the efficiency of boiler correctly we use heat loss method. b
=

(1 L ) X 100 [%] H f + Ba

.......................................1

Where, H f : Higher heating value of fuel [J/kg] Ba : Total heat credit [J/kg]

Heat Loss Items of Boiler

(a) Dry Gas Loss (b) Heat Loss of Water Contents Caused by Hydrogen Combustion in Fuel (c) Heat Loss of Unburned Carbon (d) Water Loss in Fuel (e) Water Loss in Combustion Air (f) Radiation Loss (g) Unaccounted Losses

Heat Distribution of Boiler

(a) Economizer The heat absorption rate in economizer of subcritical boiler is twice more than that of supercritical boiler.

Heat Absorption Rate in Economiser

12000 10000 8000 6000 4000 2000 0 0 20 40 60 subcritical

Load

80

100 supercritical

120

(b) Furnace (Radiation) The radiation heat absorption of subcritical boiler in furnace is less than that of supercritical boiler at every load.

Radiation Absorption Rate in Furnace

14000 12000 10000 8000 6000 4000 2000 0 0 20 40 60

Load 80

100

120

subcritical

supercritical

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International Journal of Mechanical Engineering and Technology (IJMET), ISSN 0976 6340(Print), ISSN 0976 6359(Online) Volume 3, Issue 2, May-August (2012), IAEME
(c) Furnace (Convection) The convection heat absorption of supercritical boiler in furnace is twice more than that of subcritical boiler.

12000 10000 8000 6000 4000 2000 0 0

Convective Heat Absorption Rate in Furnace

20

40

60 Load 80 100 subcritical supercritical

120

(d) Primary Superheater The heat absorption rate in primary superheater of supercritical boiler is twice more than that of subcritical boiler.

Heat Absorption Rate in primary superheater

30000 25000 20000 15000 10000 5000 0 0 20 40 60 Load 80 100 subcritical supercritical 120

(e) Secondary superheater The heat absorption rate in secondary superheater of subcritical boiler is 3 times more than that of supercritical boiler.

Heat Absorption Rate in secondary superheater

140,000 120,000 100,000 80,000 60,000 40,000 20,000 0 0 20 40 60 subcritical

Load

80 supercritical

100

120

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International Journal of Mechanical Engineering and Technology (IJMET), ISSN 0976 6340(Print), ISSN 0976 6359(Online) Volume 3, Issue 2, May-August (2012), IAEME
(f) Final Superheater The heat absorption rate in final superheater of subcritical boiler is approximately the same that of supercritical boiler.

15000 10000 5000 0 0 20

Heat Absorption Rate in Final superheater

40

60 Load subcritical

80 100 supercritical

120

(g) Primary Reheater The heat absorption rate in primary reheater of subcritical boiler is 10 times more than that of supercritical boiler.

120,000 100,000 80,000 60,000 40,000 20,000 0 0

Heat Absorption Rate in Primary Reheater

20

40

60 subcritical

Load

80 supercritical

100

120

(h) Final Reheater The heat absorption rate in final reheater of subcritical boiler is much more than that of supercritical boiler.

30,000 25,000 20,000 15,000 10,000 5,000 0 0 20

Heat Absorption Rate in Final Reheater

40

60 subcritical

Load

80 supercritical

100

120

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International Journal of Mechanical Engineering and Technology (IJMET), ISSN 0976 6340(Print), ISSN 0976 6359(Online) Volume 3, Issue 2, May-August (2012), IAEME
(i) Air Preheater The heat absorption rate in air preheater of subcritical boiler is much more than that of supercritical boiler.

2,000 1,500 1,000 500 0 0 20

Heat Absorption in Air preheater

40

60 subcritical

Load

80 100 supercritical

120

(j) Heat Absorption Rate of Each Part in Boiler The heat absorption rate in water wall of supercritical boiler is approximately twice more than that of subcritical boiler. The heat absorption rate in economizer of subcritical boiler is approximately 4 times more than that of supercritical boiler.

Boiler Heat Absorption Rate (%)

60 40 20 0 Economiser Waterwall subcritical Superheater supercritical Reheater

Efficiency of Boiler
The boiler efficiency of supercritical boiler is a little lower than that of subcritical boiler.

100 80 60 40 20 0 Subcritical

Boiler Efficiency (%)

Boiler Efficiency

Total Loss

Supercritical

CONCLUSIONS Analysis shows that higher output can be obtained with high temperature steam at supercritical pressure comparing with the output of subcritical units operating with same steam flow rates. Thermal efficiency of supercritical plant is high as well as emission is also reduced due to higher efficiency. Performance of supercritical boiler is calculated by different graphical representation and it is compared to subcritical boilers curves. The increased pressure also increases cycle efficiency and, although this effect is a second-order effect compared with the effect of temperature, it can still make 428

International Journal of Mechanical Engineering and Technology (IJMET), ISSN 0976 6340(Print), ISSN 0976 6359(Online) Volume 3, Issue 2, May-August (2012), IAEME an important contribution to increasing overall plant efficiency. However Supercritical boilers operate in a higher pressure and temperature zone as compared to subcritical boilers leading to increased thermal efficiencies. REFERENCES 1. Bejan A., Tsatsaronis, G., and Moran A., 1996, Thermal Design and Optimization, Wiley, New York. 2. Kotas T.J., 1985, The Exergy method of Thermal Power analysis, Butterworth. 3. Nag P.K., Power plant engineering, 2nd Ed., Tata Mc Graw Hill, New York, 1995. 4. Dr. gupta A.V.S., second low analysis of super critical cycle. 5. Viswanathan, R., 2001, Boiler materials for ultra supercritical coal power plants, USC Materials quarterly report, EPRI Inc., Oct-Dec 2001. 6. Kiameh, P. (2002), Power Generation Handbook, McGraw-Hill Handbooks. 7. Rajput, R.K. (2001), Thermal Engineering, Laxmi, New Delhi. 8. Babcock & Wilcox power generation groups technical papers.

Appendix: select data Table 1

Operating condition
BMCR
Steam flow superheater kg/hr Steam flow reheaters kg/hr 0 Steam temp. superheater c 0 Steam temp. reheaters c 0 Reheat entering temp. c Reheat entering pressure bar 0 Feed water temperature c Boiler efficiency % 2225,000 1741,820 540 568 299 45.39 289.64 86.28

SH control point 50% TMCR

963,760 836,410 540 568 289 22.15 244.34 86.85

Table 2

performance
load Steam flow superheater kg/hr Steam flow reheaters kg/hr 0 Superheater outlet temp. c Superheater outlet press. bar 0 Reheat inlet temp. c 0 Reheat otlet temp. c Reheat inlet pressure bar Reheat oulet pressure bar Reheat pressure drop. bar 0 Feed water temperature c Fuel fired kg/hr Efficiency % BMCR 2225,000 1,741,820 540 250 299 568 46.37 44.71 1.65 289.64 471800 86.28 TMCR 2,023,750 1,678,370 540 248.48 296 568 44.80 43.21 1.58 286.23 438100 86.29 429 80%TMCR 1,572,470 1,328,960 540 232.35 281 568 35.49 34.21 1.27 270.35 354900 86.69 60%TMCR 1,158,410 996,950 540 174.92 286 568 26.56 25.56 1.0 254.09 272400 86.88

International Journal of Mechanical Engineering and Technology (IJMET), ISSN 0976 6340(Print), ISSN 0976 6359(Online) Volume 3, Issue 2, May-August (2012), IAEME

Table 3

performance
load Steam flow superheater kg/hr Steam flow reheaters kg/hr 0 Superheater outlet temp. c Superheater outlet press. bar 0 Reheat inlet temp. c 0 Reheat otlet temp. c Reheat inlet pressure bar Reheat oulet pressure bar Reheat pressure drop. bar 0 Feed water temperature c Fuel fired kg/hr Efficiency % 50% TMCR 963,760 836410 540 147.30 289 568 22.15 21.29 .86 244.34 231100 86.85 30% TMCR 596,100 517200 540 91.0 294 540 13.33 12.77 .55 219 147300 86.24 Both HPH out 1,839,500 1,784,200 540 246.98 309 568 48.52 46.86 1.66 196.15 463100 87.31

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