U.S. Program for Advanced Ultrasupercritical (A-USC) Coal Fired Power Plants Dr. Jeffrey Phillips Senior Program Manager, Advanced Generation McIlvaine Company Hot Topic Webcast: Next Generation of Coal Combustion Technologies March 24, 2011
Definitions Nomenclature Conditions Net Plant Efficiency Net Plant Heat Rate (HHV) Subcritical 2400 psig (16.5 MPa) 1050ºF/1050ºF (565ºC/565ºC) 35% 9751 Btu/kWh Supercritical (SC) >3600 psig (24.8 MPa) 1050ºF/1075ºF (565ºC/585ºC) 38% 8981 Btu/kWh Ultrasupercritical (USC) >3600 psig (24.8 MPa) 1100ºF/1150ºF (593ºC/621ºC) and above >42% 8126 Btu/kWh Advanced UltraSupercritical (A-USC) 5000 psig (34.5 MPa) 1250ºF (677ºC) and above >45% 7757 Btu/kWh 2
Temperature, Degrees F Temperature, Degrees C Materials for A-USC Coal Power Plants U.S. Department of Energy (DOE) and Ohio Funded Project 1500 1400 1300 1200 1100 1000 900 800 700 600 500 400 Eddystone 1 Philo 6 1900 10 20 30 40 50 60 70 80 90 2000 10 Year Maximum Steam Turbine Inlet Temperature History 750 700 650 600 550 500 450 400 350 300 250 200 During 1 st 60 years of the 20 th century, steam turbine temperatures rose from 500 F to 1200 F Thermal efficiency rose from 4% to 40% (HHV) Eddystone experienced several materials issues Derated from 1200 F to 1135 F No improvements for 50 years! Provides 20% lower CO 2 emissions than existing fleet average 3
Heat Rate Improvement Technologies 4
Acknowledgements: U.S. DOE / Ohio Coal Development Office (OCDO) A-USC Steam Boiler and Turbine Consortia Federal State National Laboratory Non Profit For Profit Cost Sharing Consortium 5
Primary Technical Goals of the U.S. A-USC Materials Program Materials Technology Evaluation Focus on nickel-based alloys Development of fabrication and joining technology for new alloys Unique Conditions for U.S. Program Considerations Higher temperatures than European Program (760 C versus 700 C) means additional alloys are being evaluated Corrosion resistance for U.S. coals Data for ASME code acceptance of new materials Phase II Boiler work includes Oxycombustion 6
Stress (MPa) Stress (ksi) ksi = 1000 psi Materials Limit the Current Technology 500 300 CCA617 Average Temperature for Rupture in 100,000 hours ( o F) 1100 1200 1300 1400 Std. 617 Inconel 740 Haynes 282 Nickel-Based Alloys Age Hardenable = A-USC 760 C (1400 F) 70 50 30 100 80 60 40 9-12Cr Creep-Strength Steels = USC Enhanced Ferritic 620 C Steels (1150 F) (Gr. 91, 92, 122) Solid Soln = A-USC Advanced Austenitic ~700 C (1300 F) Alloys (Super 304H, 347HFG, NF709, etc.) 550 600 650 700 750 800 Average Temperature for Rupture in 100,000 hours ( o C) Haynes 230 10 8 6 Minimum Desired Strength at Application Temperature 7
U.S. DOE OCDO Advanced USC Project Accomplishments over the past 10 years Fabrication Processes General design studies show favorable economics Welding Technology Developments Steam-Side Oxidation HP Turbine Concept Fireside Corrosion (High-Sulfur Coal & In-Plant Testing) 8
Successes: Air-cooled Probes Cleaned surface of an air-cooled probe exposed for 2 years in a coal-fired boiler at A-USC temperatures Inconel 740 shows lower wastage than a high-chromium cladding (50/50), a 23% Cr wrought alloy (HR6W), and weld overlays (WO) 9
Successes: Welding Technology Today: Repeatable 3 (75-mm) thick Inconel 740 welds without cracking Original Inconel 740 weld trials (Liquation cracking in heat affected zone) Consortium Research Consortium research has demonstrated revolutionary progress in nickel-based alloy welding 10
A-USC Research & Development (R&D) Current Boiler & Turbine Materials R&D Effect of oxycombustion on materials Improved weld/weldment performance Code approval of new alloys Long-term high-temperature material property databases Production of larger forgings Scale-up and repair of nickel-based castings Air, Low O 2, High O 2 April 7 Workshop in Washington, DC Hotel Monaco Events on EPRI.com for more information 11
Timelines of Advanced USC Development 2011 2012 2013 2014 2015 2016 2017 2018 2019 2020 2021 2022 2023 2024 2025 Current Materials Development Program R&D Build Last Lap Component Test Facility Design Build Operate Supplier Development Build Test Pieces A-USC 600 MW Demonstration Plant >1300 F Demo Plant Design Permit Build Operate Design Permit Build Operate Other R&D Provides 5 Years of Commercial-scale Experience by 2025 12
Together Shaping the Future of Electricity 13