ADANI POWER MAHARASHTRA LIMITED

5 X 660MW
SUPER CRITICAL UNIT
OPERATION EXPERIENCES

Presented by
BHASKARPRASAD
What is Supercritical Technology ?
 The critical point in steam water cycle
is nothing but the thermodynamic
state where there is no clear
distinction between the Water and
Steam phase in the Rankine Cycle

 Water reaches to this state at a

pressure above 22.1 Mpa.

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Rankine Cycle Supercritical

4
 Diff. Between Subcritical &
Supercritical units

 Major changes are boiler area, water

chemistry and steam turbine metallurgy.
 Subcritical Unit
 The power plant Rankine cycle operating
pressure below 18 MPa in the evaporator part
of the boiler

 Cycle medium is non homogeneous mixture of

water and steam in the boiler. The boiler cycle
is known as subcritical.
 The steam needs to be separated from water,
using steam drum.
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Controlled Circulation V/s Once Through System
 Supercritical Boiler
 Features
There are two design features utilized in boiler water
wall design for once through supercritical boilers

The spiral tube furnace arrangement:

 The modern supercritical once through furnace water wall
are exposed to the higher heat flux of all heat absorbing
surface
 Intense radiant heat from the furnace firing zone or fireball.
 Spiral tube wall design (wrapped around the unit) helps to
increase the adequate mass flow of steam/water mixture
through each tube
 Mass flow improves heat transfer between the tube metal
and the fluid inside, so the tube metal is sufficiently cooled
despite of the high heat flux.
 Boiler pressure parts weight is lower than the subcritical
boiler

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8
 Supercritical Boiler
The vertical Features
tube furnace arrangement:

 The vertical tube designs are used for larger units with
internal ribbed tube to enhance heat transfer.

 Suitable for making high-pressure boiler to improve the

efficiency by preventing the forming of steel film

 Improved materials helps the maximum steam cycle

performance at the furnace wall exit, superheated and
reheated outlets tubes

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 •Generate swirl flow
•Centrifugal action
RIBBED TUBES •Result water force towards the wall
•Expensive --- Slight increase in P
LTRH Emergency DSH
Inlet HDR

LTRH
Outlet HDR
Micro flow
DSH
FRH
Inlet HDR

FRH
Outlet HDR
 Eco HDR or Eco
Eco Eco Header Hanger (F&R)
Inlet Eco Header Hanger
Under LTSH Under LTSH
Header Under Outlet
LTRH Band

Vertical Transition Water

Storage Walls & Spiral
Separators Intermediate wall
Tank & Upper Water
Header & Walls lower
BCP Header walls header

Back pass extended Butterfly panel

side walls
Back pass
Roof I/H Back pass Back pass side walls &
F&R Wall O HDR Upper HDR

FSH Platen LTSH Divisional

Wall, Spacer Divisional
SH I/O Upper I/H
I/O tube & Lower
HDR HDR
HDR
 571°C,
569° 254 Bar 492°C,
C, FUR ROOF
I/L HDR ECO HGR O/L
HDR

HRH
LINE MS
LINE411 411°
°C, C,
SEPARATOR

S FINAL
FINAL SH

T DIV PANELS SH
RH LTRH

PLATEN

O SH

R
A VERTIC
G G AL WW
ECO

329°C,
JUNCTION

45Ksc
HDR
LPT IPT
HPT E
C
O
N ECONOMISER
D
E
N
S
E
R
T
ECO I/L
A
LPT N
ir al
K Sp ter
wa lls
wa
FEED WATER
BWRP
292°C,
FUR LOWER HDR
FRS
 PF FIRING OPTIONS - COMPARISON

BURNER

FIRE
BALL

BURNER

Tangential Corner Fired Unit Theoratical Arrangement

 Benefits of Supercritical
Unit
 Supercritical technology provides electricity generation at lower
operating fuel cost (15-20 % reduction)

 Higher unit cycle efficiency (40-44%)

 Superior environmental Performance (15 -20 % CO2 reduction)

 Operating flexibility – Sliding pressure capability without loss of

cycle efficiency

 Increased availability, reliability, fuel flexibility and faster load

response capability

 Lower water losses because no continuous blow down.

 Reduced auxiliary power consumption

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 Environmental Benefits
 Reduced carbon dioxide (CO2) and
other greenhouse gas (GHG)
emissions by 25 %, Provides carbon
credit mainly due to less fuel
consumption.

 Emissions may be reduced by using

fuel through efficient generating
electricity within the Rankine cycle.

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 Boiler equipment
 The capacity for APML project is 5x660MW. The
boiler was designed and manufactured by
Shanghai Boiler Works Limited. It is the full
suspended Π—type, once-through boiler with
the supercritical pressure, primary
intermediate reheating, single furnace
balanced ventilation, semi-enclosed
arrangement, dry bottom, all-steel framework.
 The model is SG-2111/25.4 － M986.
 2111-Steam flow in TPH.
 25.4-Steam operating pressure in Mpa.
 M986-Boiler serial number.
 Super heater :16080m2
 Re heater :24402m2
 WW high temp :41290m2
 WW intermediate:30054m2
 WW low temp :13095m2
sum :84439m2
 Storage tanks & separators : 25.5m3
 Water wall : 67m3
 Economizer : 138m3
 Super Heaters : 221m3
 Re Heaters : 370m3
Sum : 824m3
 Boiler
 The boiler start system is equipped
with water circulating pump.
 The steam separation takes place
inside separator at initial condition.
 Two separators for start-up and one
separator water storage tank are
engineered for each boiler.
 The separators and the water storage
tanks are set up on upper part of the
boiler front vertically.
 Boiler
 The main steam temperature is
controlled by water coal ratio and
spray desuperheater.
 The normal reheater steam
temperature is controlled by
dampers in second pass.
 RH Spray desuperheating devices are
provided for normal & emergency .
 Boiler
 Pulverizing system uses cold primary fan
positive pressure direct blowing system. Eight
HP1103 intermediate-speed bowl coal mills,
Six mills in operation and Two on standby
under TMCR & seven service, one standby
under BMCR, are provided. Each coal mill is
consistent with a layer of burner.
 The system has two axial forced primary draft
fans with moving blade pitch adjustment and
two centrifugal seal air fans.
 110-Bowl Dia.
 3-No of rollers.
 PERFORMANCE DATA
FUEL DATA

Gross as Received 3927 kcal/kg

Total Moisture 10 %
Ash Content 37 %
Volatile Matter 27.6 %
Fixed Carbon 25.4 %
Boiler Efficiency 87.19 % (GCV Basis)
 Boiler
 The boiler draft fan system is
equipped with two axial forced
draft fans with moving blade
pitch adjustment, two axial
Induced draft fans and two tri-
sector rotary air preheaters.
 ESP
 The ESP is equipped with double
pass, 10 X 4,10 X 4 Two sets
fields.
 ESP having total 80 X 2 =160
hoppers.
 Electrostatic
precipitator （ efficiency≥99.80 ）
 Boiler
 Boiler deslagging system adopts
Bottom ash clinker grinder. The
wet process is adopted as the
slurry removal method.
 Ash system adopts a dense
phase pneumatic conveying
system with positive pressure
for ash handling.
 Unit-operation
 The Turbine can be run with a
fixed pressure OR sliding
pressure mode.
 When the boiler is running with
low load or starting, sliding
pressure is recommended to
obtain a higher economic
efficiency.
 Boiler specification
NO. Item Specification Unit
1 model SG2111/25.4 － M986
2 mode once-through boiler with supercritical pressure
3 Superheated steam flow 2111 t/h
4 Superheater outlet pressure 25.4 MPa
5 Superheater outlet temperature 569 ℃
6 Reheated steam flow 1749.1 t/h
7 Reheater inlet pressure 4.73 MPa
8 Reheater outlet pressure 4.49 MPa
9 Reheater inlet temperature 324 ℃
10 Reheater outlet temperature 569 ℃
Feedwater pressure 28.8 MPa.g
11 Feedwater temperature 280 ℃
12 Separator’s steam temperature 421 ℃

Air preheater’s outlet air temperature, uncorrected 153.3 ℃

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After correcting 147.2 ℃
14 Calculating thermal efficiency of boiler 87.19% （ BMCR ）
15 Guarantee thermal efficiency of boiler 87.2% （ BRL ）

Cold primary fan positive pressure direct blowing

16 Pulverizing type
system

Corner-mounted tangential circle combustion , dry

17 Burner type
ash extraction

18 Draft type balanced ventilation

19 Design fuel Indian coal

20 Check fuel Indian coal

100% BMCR Coal consumption (Design) 390.37
21 t/h

100% BMCR Coal consumption (Worst)

466.90 t/h

100% BMCR Coal consumption (Best Coal)

337.80 t/h

22 Fuel oil for startup and ignition light diesel oil and heavy diesel oil

Ratio of coal and water, secondary spray

23 Superheated steam temperature adjustment
desuperheating

Burner Tilt controlling, Rear flue gas damper,

24 Reheated steam temperature adjustment
primary spray desuperheating
 Important parameters to
control:

1. Water / coal ratio – 7:1

2. OHDR- 20 to 30

3. Maintaining Pressure at SH and RH

- 25.4 & 4.45

4. Effect of Excess air

5. Water Chemistry

6. Tube metal temperatures

Difference in Operation
1. Boiler initial filling.
2. BCP filling and operation
3. Pressure and Temp rise rate w.r.t Metal temps.
4. Change in Boiler operation phases in Unit
operation
(Wet to Dry state, Subcritical once through to
super critical once through)
5. Boiler tube failures - identification
6. Chemistry parameters – methods of chemical
treatment
7. Unit startup and Shutdown(dry to wet opn)
8. Additional Protections for Boiler