Materials: Steps towards 700 C power plant User Forum of the Power Plant Technology,

Transcription

1 Materials: Steps towards 700 C power plant User Forum of the Power Plant Technology, C. Stolzenberger VGB PowerTech e.v.

2 Motivation Actual high efficient Power Plants Activities towards 700 C Ultra Super Critical Coal Generation 700 C-Demonstration Power Plant Summary 24. April 2008 Power Plants - Technology in Dialogue 2

3 Efficiency Development (Hard Coal Power Station) 55% 50% Austenites (290 bar, 600 C) Nickel basis material (350 bar, > 700 C) Net Efficiency 45% 40% 35% Ferrites und Martensites (260 bar, 545 C) CCS needs Efficiency Increase 30% April 2008 Power Plants - Technology in Dialogue 3

4 Motivation Actual high efficient Power Plants Activities towards 700 C Ultra Super Critical Coal Generation 700 C-Demonstration Power Plant Summary 24. April 2008 Power Plants - Technology in Dialogue 4

5 Actual high efficient Power Plants (Hard Coal) ENEL s conversion project Torrevaldaliga Nord from oil to coal New Power Plant Total capacity 3 x 660 MW ~2000 MW Live-steam 604 C / 250 bar / 1915 t/h Reheater-steam 612 C / 56 bar / 1591 t/h Efficiency increased more than 10% 44,7% Boiler Material - Martensite: P91, P92, - Austenite: Super 304 (shot blasted) Before conversion Emissions (mg/nm3) Design values European limits - NOx SO Particulate Commercial operation end 2008/ mid 2009 / end 2009 After conversion 24. April 2008 Power Plants - Technology in Dialogue 5

6 Motivation Actual high efficient Power Plants Activities towards 700 C Ultra Super Critical Coal Generation 700 C-Demonstration Power Plant Summary 24. April 2008 Power Plants - Technology in Dialogue 6

7 700 C - Boiler Test Programme COMTES700 Component Test Facility for a 700 C Power Plant Objectives - Manufacturing, bending and welding of the components in real plant dimensions for a power plant with efficiency higher than50%, - Operational behaviour of all components especially operational testing of Ni-based alloys for tubes, pipes and valves, - Flue gas corrosion and steam oxidation behaviour of the materials and erosion effects due to sootblowing, - Operation started in summer Approximately min operation hours, end expected 2009/ April 2008 Power Plants - Technology in Dialogue 7

8 COMTES700 - Implementation into Host Boiler Host Plant - Scholven F, Germany, E.ON Net output 676 MW Live-steam 220 bar 540 C 2,250 t/h Reheater-steam 44 bar 540 C 2,044 t/h Fuel Hard coal Superheater Membrane Wall 24. April 2008 Power Plants - Technology in Dialogue 8

9 COMTES700 - Flow Diagram from Injection Safety Valve 410 C M 222 bar 610 C 705 C from SH1 Inlet Header HP-Bypass Turbine Valve 536 C 210 bar to SH4 Outlet Header Membrane Wall Mass Flow ~ 12 kg/s Superheater 410 C 44 bar to Reheater 1 Outlet Header 24. April 2008 Power Plants - Technology in Dialogue 9

10 COMTES700 - Material Concepts Membrane Wall Tube diameter 33,7 x 7,1 mm Alloy 617 P 92 Outlet HCM 12 7 CrMoVTiB 10 10/T 24 Superheater 1 & 2 Tube diameter 44,5 x 10 mm 1) 2) 44 parallel tubes 8,800 mm 13 CrMo44 43 x 48 = 2,046 mm Inlet 24. April 2008 Power Plants - Technology in Dialogue 10

11 COMTES700 - Budget, Financing & Partner Project Budget: 23.2m 3% - Know-how Access 0.7m 26% - (EC) RFCS 6.1m 67% - Emax Partners 15.6m 4% - Industrial Partners 0.8m E max Partners DONG Energy E.ON EdF Electrabel EnBW Enel PPC RWE Vattenfall Europe Vattenfall Nordic Industrial Partners Alstom BWE HPE Siemens Know-how Access EVN Evonik Energie GKM 24. April 2008 Power Plants - Technology in Dialogue 11

12 700 C - Turbine Test Programme COMTES700 - Turbine Valve Target Testing most critical components of a 700 C turboset Integration in COMTES700 and operation time > 20,000 h Evaluation of - metal temperatures - deformation and - expansion Steam Steam 24. April 2008 Power Plants - Technology in Dialogue 12

13 700 C - Material Test Programme Esbjerg Test Rig (720 C), Esbjerg, Denmark Precursor of COMTES700 and maturity test of materials Materials tested over > 30,000 h Austenite Ni-based Material - Sanicro 25 - Alloy HR3C - Alloy TP347HFG 24. April 2008 Power Plants - Technology in Dialogue 13

14 700 C - Material Test Programme MARCKO700 - Boiler Material Qualification for the 700 / 720 C Power Plant Evaluation of long-term characteristics u. operation conditions 7CrMoVTiB T/P92 12CrCoMo Alloy 617 MARCKO III - Turbine Optimized materials and material compounds behaviour for 700 / 720 C steam turbine components Development of models for the description of the thermal cyclical behaviour Analytical and numeric assessment of dissimilar weldments 24. April 2008 Power Plants - Technology in Dialogue 14

15 700 C - Material Test Programme COORETEC - Projects Fireside corrosion and steam side oxidation behaviour of materials for the 700 C power plant Characterisation of superheater materials for 700 C power plant after cold deformation Characterisation of strength and deformation of pipes and forgings made of Ni-base alloys Qualification of dissimilar weldings between 10 % Cr-steels and Ni-based alloys Fracture mechanics approaches for life time assessment of components operating in 700 C temperature regime Optimisation of non-destructive testing methods for thick walled components made of Ni-base alloys 24. April 2008 Power Plants - Technology in Dialogue 15

16 700 C - Material Test Programme AD700-1 Creep Tests Targets Creep rupture strength after 100,000 h (expected) - Sanicro 25 for 700 C 96 MPa - Inconel 740 for 750 C 107 MPa Sanicro 25 - Nimonic 263 for 750 C 89 MPa Alloy 740 Nimonic April 2008 Power Plants - Technology in Dialogue 16

17 700 C - Power Plant Feasibility Study Specification NRW 700 C Power Plant (NRW PP700) Live Steam Pressure 250/350 bar Live Steam Temperature 700 C Reheat Temperature 720 C Gross Power Demo Plant ~ 500 MW Full Scale Plant MW Fuel Demo Plant Hard Coal Full Scale Plant Hard Coal/Lignite 24. April 2008 Power Plants - Technology in Dialogue 17

18 700 C - Power Plant Feasibility Study Target (NRW PP700) Technical and economical viability of a 700 C Power Plant Defining Boundary Conditions Step by step procedure Basic Design Boiler Variants Detailed Design Boiler Turbine BoP Time Scale-Up 1,000 MW Transfer to Lignite 24. April 2008 Power Plants - Technology in Dialogue 18

19 Motivation Actual high efficient Power Plants Activities towards 700 C Ultra Super Critical Coal Generation 700 C-Demonstration Power Plant Summary 24. April 2008 Power Plants - Technology in Dialogue 19

20 700 C - Demonstration Power Plant E.ON s Project.50plus Efficiency: Capacity: 50 % LHV 500 MW br Investment: 1 bn. Location: Wilhelmshaven, E.ON, Germany until Pre-Engineering size and site Material issues, tender order, approval Erection Start-up 24. April 2008 Power Plants - Technology in Dialogue 20

21 Motivation Actual high efficient Power Plants Activities towards 700 C Ultra Super Critical Coal Generation 700 C-Demonstration Power Plant Summary 24. April 2008 Power Plants - Technology in Dialogue 21

22 Pathway to 700 C-Power Plant Year C-Power Plant 50 % C-PP Feasibility Study. Wilhelmshaven (DE) 700 C-Boiler- & Turbine Component Tests C-Material Tests C-Power Plant ~ 46 %.. Torrevaldaliga (IT), Datteln (DE), etc. 24. April 2008 Power Plants - Technology in Dialogue 22

23 Thank you for your attention! COMTES700 is funded by the Research Fund for Coal and Steel of the European Commission (project number RFC-CP-04003), European Power Plant Operators, Manufacturers and co-ordinated by VGB PowerTech e. V. 24. April 2008 Power Plants - Technology in Dialogue 23