Super Critical Details

Ultra Super Critical Pressure Coal Fired Boiler
- State of the Art Technology Applications -
Yoshio Shimogori
BABCOCK-HITACHI K.K. 1
1. Improvement of Steam Conditions
2. Improvement of Material and

Manufacturing Technology
3. 1000MW Hitachi-Naka No.1
4. Next-Generation USC Boiler
Fig.1 What is Super Critical
Super Critical means no distinction
between water and steam
3,500
600
3,000 Steam(Gas) 500
2,500
Temp.(oC )
Enthalpy＊(kJ/kg)
Critical (22.06MPa)
2,000 400
Mix. Of Steam & Water
1,500
Saturated line 300
1,000
Water 200
Sub-Critical Super Critical
500
100
10 20 30
* Thermodynamic quantity Pressure(MPa)
Fig.2 Ultra Super Critical (USC) Technology
Purpose High Plant Efficiency

High Efficiency Coal Utilization
Low Emission (CO2 etc.)
USC Condition
USC Super Critical Critical Point
Over SC Condition of Water
Example 24.1MPa/ 22.06MPa/
25.0MPa/ 538℃ or 566℃ 374℃
600℃/600℃
* Steam Condition shows Turbine inlet
Fig.3 Steam Conditions of Coal Fired Boiler Improvement by BHK
Hitachinaka No.1 (1000MW)

Tachibanawan No.2 (1050MW)
Haramachi No.2 (1000MW)
Matsuura No.2 (1000MW)
Nanao-Ohta No.1 (500MW) 25.0MPa/600/610oC
24.5MPa/600/600oC
Shinchi No.1 (1000MW)
Noshiro No.1 (600MW) 24.1MPa/593/593oC Canada (495MW)
Hekinan No.2 (700MW) USA (870MW)
24.1MPa/566/593oC
Matsuura No.1 (1000MW)
Takehara No.3 (700MW) Ultra Super Critical
24.1MPa/538/566oC Super Critical
1985 1990 1995 2000 2005 2010

Year
Fig.4 Improvement of Plant Efficiency
45 Sub critical Super critical USC

Gross Plant efficiency (%) HHV base
44
43
42
41
40
16.6MPa 16.6MPa 24.1MPa 24.1MPa 24.1MPa 24.1MPa 24.5MPa
538/538OC 538/566OC 538/566OC 566/566OC 566/593OC 593/593OC 600/600OC
Table 1 Boiler Type and Furnace Construction
NC Boiler (Vertical Type) Benson Boiler(Spiral Type)
Steam Feed
Water
DRUM
Furnace
Construction
Down Comer
Feed Water
Operating Pressure Sub-Critical Sub-Critical to Supercritical Region
(Constant or Sliding) (Sliding Pressure)
Applicable Steam Pressure Subcritical Supercritical & Subcritical
Through Furnace Enclosure Tubes
Temperature Uniformity Better Much Better
Mass Flow Rate Approx. 13% 100%
Sliding Pressure Operation ? YES YES (Wide Range)
Allowable Min. Load (%) 15 25 - 35 (OT Mode)
15 (Circ. Mode)
Load Change Rate Base Higher
Start-up Time (min.) (Hot start) 120 – 150 with TB By-pass 120 – 150 with TB By-pass
Furnace Enclosure Construction Vertical Spiral
Tube O/D (mm) 57.0 - 63.5 31.8 - 38.1
Max. Unit Capacity in Operation 600 MW 1,050 MW
Notes NC:Natural Circulation OT:Once-Through Circ.:Circulation O/D:Outside Diameter
Fig.5 Boiler Types Supplied by BHK Group
BENSON BENSON
NC UP (Two Pass Type) (Tower Type)
Boiler type
Capacity (MW) 50 ~ 600 350 ~ 1000 75 ~ 1050 ~ 930
Pressure Subcritical, Subcritical, Subcritical,

Subcritical Supercritical Supercritical Supercritical
Steam temp. (oC) Up to 571 Up to 571 Up to 613 Up to 580
Coal combustion PCF PCF PCF (Opposed, Tangential),

method (Opposed)(Opposed) Slag tap
Coal kind Bituminous, Sub-bituminous Bituminous, Sub-bituminous,

Lignite, Anthracite
Notes NC:Natural Circulation UP : Universal Pressure
Supplied by BBPS (Babcock Borsig Power Systems)
Fig.6 Wide Range of Coal Qualities Fired
80 Lignite
Volatile Matter (dry ash free), %
70
Sub Bituminous
60 BItuminous
50
40
30
20
10 Anthracite
0
0 10 20 30 40
Net calorific value, MJ/kg

Fig.7 Development Progress of Ferritic CrMo Steel Pipes
Creep Rupture Strength (600oC/105h)

30 - 40MPa 60MPa 100MPa 140MPa
2.25Cr1Mo 2.25Cr1.6WVNb
SA335P22 SA335P23
(HCM2S)
9Cr1Mo 9Cr2Mo
SA335P9 JIS:STPA27
(HCM9M)
9Cr1MoVNb 9Cr0.5Mo1.8WVNb
SA335P91 SA335P92
(Mod.9Cr1Mo) (NF616)
12Cr1MoV 12Cr1Mo1WVNb 11Cr0.4Mo2WCuVNb

X20CrMoV121 JIS:SUS410J2TP SA335P122
(HCM12) (HCM12A)
:Conventional
:Advanced
Fig.8 Allowable Stresses of Ferritic CrMo Steel Pipes
150
Allowable stress (MPa) SA335P91

(9%Cr)
SA335P92
100
(9%Cr)
SA335P23 SA335P122
(2.25%Cr) (11%Cr)
50
SA335P22
(2.25%Cr)
0
500 550 600 650 700
Temperature (oC)
Fig.9 Development Progress of Austenitic Stainless Steel Tube
Creep Rupture Strength (650oC/105h)
55 - 60MPa 90MPa 110 - 120MPa
18Cr8Ni 18Cr10NiTi 18Cr10NiNbTi

SA213TP304H SA213TP321H JIS:SUS321J1HTB
(Tempaloy A-1)
18Cr10NiNb 18Cr9Ni3CuNbN
SA213TP347H SA213-UNS30432
(SUPER304H)
21Cr32NiTiAl 20Cr25Ni1.5MoNbTi
Alloy800H JIS:SUS310J2TB
(NF709)
25Cr20Ni 25Cr20NiNbN
JIS:SUS310TB SA213TP310HCbN
(HR3C)
: Conventional
: Advanced
Fig.10 Allowable Stresses Advanced Stainless Steel Tubes
150
SA213TP310HCbN
(25%Cr:HR3C)
Allowable stress (MPa)
SA213UNS S304 32
100 (18%Cr:Super 304H )
JIS:SUS310J2TB
(20%Cr:NF709)
50
JIS:SUS321J1TB
(18%Cr:Tempaloy A1)
SA213TP321H
0 (18%Cr)
550 600 650 700 750
Temperature (oC)
SA213UNS30332
SUS310J2TB
SA335P92 SA335P122
SA213TP310HCbN Fig.12 Macro Structures of

Narrow Gap TIG Weld
Fig.11 Macro Structures of

TIG Weld of Tube Materials
Fig.13 Steam Oxide Scale of Stainless Steel Tubes
Inner scale thickness (micro m)

50
Time:1,000h
40
SA213UNS S304 32 JIS:SUS310J2TB
(18%Cr:Super 304H) (20%Cr:NF709)
30
SA213TP347HFG
(18%Cr:Fine Grain)
20
A213TP310HCbN
(25%Cr:HR3C)
10 Shotblasted
A213UNS S304 32
0 (18%Cr:Super 304H)
550 600 650 700 750 800
Temperature (oC)
Fig.14 Improvement Trend of Hitachi NR Series Burners
Guide sleeve
Flame Stabilizing
Guide sleeve Space Creator
Ring＋Baffle Plate
Air register Flame Stabilizing Flame Stabilizing
Ring Ring
Swirler
Spin Vane P.C. Concentrator P.C. Concentrator
Dual Burner NR Burner NR2 Burner NR3 Burner

Delayed Combustion Rapid ignition(In Flame NOx Reduction)
Coal property
300 ppm(100%)
Fuel Ratio : 2.2
400 Nitrogen : 1.8%
Two Stage Combustion
NOx (6%O2,ppm)
175 ppm(60%)
300 150 ppm(50%) 125 ppm(40%)
200 （100 ppm(33%)）

Dual Burner
(Conventional)
100 NR Burner NR2 Burner NR3 Burner
Coal property
Fuel Ratio：1.8
0
1980 1985 1990 1995 2000 Nitrogen:1.5%
Two Stage Combustion

Fig.15 Side View of Hitachi-Naka No.1 Boiler
Secondary Superheater Tertiary Superheater
Steam Separator
Reheater
Primary Superheater
Economizer
Coal
Bunker
NO Ports
Burners
DeNOx
Coal Feeders System
Air Heaters
Mills Boiler Circulation Forced Draft Primary Air

Pump Fans Fans
Table 2 Main Specification of Hitachi-Naka No.1
Generator Output 1000 MW

Babcock Hitachi Supercritical Sliding
Boiler Type Pressure Operation Benson Boiler
MCR Steam Pressure Main 24.5 MPa(g)
Steam Main 600 oC

Temperature Reheat 600 oC
Economiser Inlet Feedwater Temp. 286.9 oC

Combustion System Pulverised Coal Fired
Draught System Balanced Draught System
Main Water Fuel Ratio Control and
Steam Temperature Staged Spray Attemperation
Control System Reheat Parallel Gas Dampering and
Spray Attemperation
Fig.15’ Side View of Hitachi-Naka No.1 Boiler
High strength material

SA335P122, SUPER304H
Optimized heating
surface arrangement
Parallel gas damper with

Spiral wall with
adequate heating surface
opposed firing
Fig.16 Steam and Water Temperature
30%ECR 50%ECR 75%ECR 100%ECR
650
Superheater Outlet
600
Steam and Water Temperature (oC) 550 Reheater Outlet
500
450
Superheater Inlet
400
350
Reheater Inlet
Economizer Outlet
300
Economizer Inlet
250
200
0 1000 2000 3000
Main Steam Flow (t/h）
Fig.17 Reheater Outlet Steam Temperature during Load Change
100% Load Demand

650
Damper opening degree
3%/min (Reheater side)
50%
Reheater outlet
steam temperature
550
(oC) 0 30min. 0 30min.
Previous Design Hitachi-Naka No.1
with Gas Recirculation without Gas Recirculation
Fig.18 Combustion Test Results at 100% Load
100%ECR
8
Unburned Carbon in Ash (%)
Coal A Coal B Coal

6 Target Point Country Indonesia Australia
Fuel Ratio (-) 1.00 1.99
4 Ash(dry%) 9.3 7.4
B Coal
N(dry%) 1.3 1.8
2
A Coal Fixed Carbon
0 Fuel Ratio =
100 120 140 160 180 200 Volatile Matter
NOx at Boiler Outlet (ppm 6%O2)
Fig.19 Flame of Hitachi NR 3 Burner at Minimum Load
Flame of Hitachi NR3

Burning B Coal at Minimum Load

Fig.20 Target Steam Conditions of Next-Generation USC Developing Project
USA/VISION21 EU/THERMIE
Main Steam Temperature (oC)
AD700
750 ’98-’13
700
Germany/MARCKO DE2
’99-’03
650
Target for
Existing next generation
600
USC Boiler USC Boiler
550 Sub-Critical
Boiler
15 20 25 30 35
Main Steam Pressure (MPa)
Fig.21 Creep Rupture Strength for Material of Next Generation USC
Creep Rupture Strength (105hr,N/mm2 ) Alloy617 (52Ni22Cr)

200 HR6W (40Ni23Cr)
NF709 (25Ni20Cr)
SA335P122(11Cr2W0.4Mo)
150
Pipe Tube
100
50
0
600 650 700 750 800 850
Temperature (oC)
Summary
Coal fired USC technology is established up to

600ooC class steam condition
Improvement of material and manufacturing
technology for boiler tubes and pipes increases
steam conditions
600ooC class USC Boiler , Hitachi-Naka unit No.1,
starts commercial operation with advance
technology such as low NOx, high combustion
efficiency and steam temperature control.
Investigation for next Generation USC 700ooC
class is started.
Feature of Supercritical Sliding Pressure Operation
Main Steam Press. (Mpa )

SLIDING PRESSURE OPERATION
30
Unit output control method by sliding pressure is as 25
follows. 20
15
By the sliding pressure in proportion to the generator
10
output, steam quantity at turbine inlet can be
changed at a constant volume flow while keeping 5
governing valve open. 0
0 20 40 60 80 100
Turbine Load (%)
improvement degradation
Relative comparison of
A smaller governing valve loss enables improvement 5
Thermodynamic loss by
of high pressure turbine internal efficiency : A 4 falling in pressure
3 A
Heat Rate (%)

Decrease of feed water pump throughput : B 2
1
Boiler reheat steam temperature can be maintained
0 B
at higher level because of higher temperature in 1
high pressure turbine exhaust steam : C 2 C
3 0 20 40 60 80 100
In comparison to constant pressure operations, a sliding Turbine Load (%)
type enables much improvement in plant efficiency
under partial load operations. Improvement of Turbine Heat Rate
due to Sliding Pressure Operation
High Efficiency Coal Utilizations
(HHV) PFBC : Pressurized Fluidized Bed Combustion From : NEDO FORUM 2002
IGFC : Integrated Coal Gasification Fuel Coal
55 Combined Cycle
IGCC : Integrated Coal Gasification Combined Cycle
IGCC/IFGC
USC : Ultra Super Critical
Net Plant Efficiency (%)
50
Hyper Coal
Next Generation USC
30MPa 700/700oC
PFBC
45
Pulverized Coal Pulverized Coal

Bed Fluidized
40
USC USC Coal Gasification
24.1MPa 24.5MPa 30.6MPa Hyper Coal
538/538oC 600/600oC 630/630oC
1980 1990 2000 2010 2020 2030


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Ultra Super Critical Pressure Coal Fired Boiler

- State of the Art Technology Applications -

2. Improvement of Material and

3. 1000MW Hitachi-Naka No.1

4. Next-Generation USC Boiler

3,000 Steam(Gas) 500

Purpose High Plant Efficiency

* Steam Condition shows Turbine inlet

Hitachinaka No.1 (1000MW)

24.1MPa/538/566oC Super Critical

1985 1990 1995 2000 2005 2010

45 Sub critical Super critical USC

Capacity (MW) 50 ~ 600 350 ~ 1000 75 ~ 1050 ~ 930

Pressure Subcritical, Subcritical, Subcritical,

Steam temp. (oC) Up to 571 Up to 571 Up to 613 Up to 580

Coal combustion PCF PCF PCF (Opposed, Tangential),

Coal kind Bituminous, Sub-bituminous Bituminous, Sub-bituminous,

Supplied by BBPS (Babcock Borsig Power Systems)

2. Improvement of Material and

3. 1000MW Hitachi-Naka No.1

4. Next-Generation USC Boiler

Creep Rupture Strength (600oC/105h)

12Cr1MoV 12Cr1Mo1WVNb 11Cr0.4Mo2WCuVNb

Allowable stress (MPa) SA335P91

Creep Rupture Strength (650oC/105h)

55 - 60MPa 90MPa 110 - 120MPa

18Cr8Ni 18Cr10NiTi 18Cr10NiNbTi

SA213TP310HCbN Fig.12 Macro Structures of

Fig.11 Macro Structures of

Inner scale thickness (micro m)

Dual Burner NR Burner NR2 Burner NR3 Burner

200 （100 ppm(33%)）

2. Improvement of Material and

3. 1000MW Hitachi-Naka No.1

4. Next-Generation USC Boiler

Secondary Superheater Tertiary Superheater

Mills Boiler Circulation Forced Draft Primary Air

Generator Output 1000 MW

MCR Steam Pressure Main 24.5 MPa(g)

Steam Main 600 oC

Economiser Inlet Feedwater Temp. 286.9 oC

High strength material

Parallel gas damper with

30%ECR 50%ECR 75%ECR 100%ECR

Steam and Water Temperature (oC) 550 Reheater Outlet

Main Steam Flow (t/h）

100% Load Demand

Coal A Coal B Coal

NOx at Boiler Outlet (ppm 6%O2)

Flame of Hitachi NR3

2. Improvement of Material and

3. 1000MW Hitachi-Naka No.1

4. Next-Generation USC Boiler

Main Steam Pressure (MPa)

Creep Rupture Strength (105hr,N/mm2 ) Alloy617 (52Ni22Cr)

Coal fired USC technology is established up to

Main Steam Press. (Mpa )

Heat Rate (%)

Pulverized Coal Pulverized Coal

1980 1990 2000 2010 2020 2030

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