New Generation Strategy

Ultra-Supercritical
Technology
Presented by:
Tim Riordan, Manager
New Generation Design & Eng.

APP Site Visit

October 30 November 4, 2006

AGENDA
Power Plant Steam Cycle (Rankin Cycle)
History of Supercritical Units
Ultra-supercritical (USC) Overview
AEP Ultra-supercritical Design
Steam Generator Design
Turbine/Generator Design
Efficiency and Emissions Comparison

Typical Heat Balance

SCR NOx control added

to meet NOx SIP Call.
Additional NOx control
greater than 85%

FGDS to reduce SO2 by

greater than 90%

Bag filter to remove Particulate

Low NOx Burners.

NOx reduction
greater than 50 %

The Basic Heat Cycle

Critical Point 3208psi/705F

Sub-Critical Steam Cycles : Water boiling to steam
with pressures below critical point
Super-Critical Steam Cycles: Water to steam without
boiling. Pressure above critical point
Ultra-Supercritical Steam Cycles: Steam temperatures
above 1100 F as defined by Electric Power Research
Institute (EPRI)

Gaining Efficiency
Higher Pressure and Temperature

Critical Point

The Evolution Continues

Comparison
Ultra Supercritical
Supercritical

Temperature

1960 Vintage
Subcritical Reheat

Early 20th Century Vintage

Subcritical Non-Reheat

1940 Vintage Subcritical

Non-Reheat

Entropy

History of Supercritical Units

First Supercritical Unit: AEP Philo Unit 6
Initial Operation Date: 1957 (49 years ago)
125 MW
Steam Conditions: 4500psi/1150F/1050F/1000F
(double-reheat)

World-wide Over 200 units

Typical steam pressures: 3350 to 4200 psi
Typical steam temperatures: 1000 to 1050F
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Generating Technology:
Ultra-Supercritical (USC) Pulverized Coal Plants
What is USC Technology?
Defined by EPRI as Rankin Cycle steam temperatures
above 1100F
Limited to ASME code approved metallurgy for pressure
part design
Higher temperatures increase cycle efficiency
USC technology is most efficient cycle available for selected
fuels (sub-bituminous coal)
Higher efficiency = Less emissions
IGCC is limited for sub-bituminous coal applications

Generating Technology:
Ultra-Supercritical (USC) Pulverized Coal Plants

An ultra-supercritical (USC) steam generation unit operates at

supercritical pressure (typically 3500 psi or higher) and at
steam temperatures above 1100 oF (593 oC).
For comparison, a conventional supercritical unit operates
at steam temperatures of 1000-1050 oF (538-566 oC).
Modern chrome and nickel-based super alloys in the steam
generator, steam turbine, and piping systems can
withstand prolonged exposure to this high temperature
steam.
By operating at elevated steam temperatures, the turbine
cycle is more efficient. This reduces fuel (coal) consumption,
and thereby reduces emissions.
USC technology is compatible with all types of coal.
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Steam Generator Cross Section

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AEP USC Steam Generator Design Conditions

Pulverized Coal-fired Benson Cycle, Spiral-wound Boiler

PRB Coal
Main Steam: 3675 psi/1115 F
Reheat Steam: 1130 F

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USC Impact on Steam Generator

High Temperature Oxidation

Internal oxidation of boiler tubing above 1050 oF
Exfoliation of oxide layers leads to tube pluggage and
could damage turbine blading.
SA-213-T91 material not used in heat transfer zone
Approaching limits of dissimilar metal weld (DMW) designs
DMW Design Limit = 1150 oF

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Steam Generator Materials of Construction

SSH Outlet Bank: SA-213-347 HFG Stainless Steel

RH Outlet Bank: SA-213-347 HFG Stainless Steel
Superheater Headers : SA-335 P92
Other alloys typical of previous supercritical designs

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Steam Turbine/Generator
Current Turbine Design for AEP USC Unit:
Four-casing, 3600 RPM, Tandem Compound, Single
Reheat
Single-flow High-pressure (HP) turbine section
Double-flow Intermediate-pressure (IP) turbine section
Two (2) Double-flow Low-pressure (LP) turbine sections
Designed for full arc, sliding pressure operation
Improved Efficiency
Minimize Component Thermal Fatigue Damage

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Steam Turbine/Generator
Generator Design for AEP USC Unit:
Two-Pole, Three-Phase Synchronous Machine
840 MVA Rating
Direct Hydrogen cooled field and stator core
Direct water cooled stator windings

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USC Impact on Turbine

Higher operating temperatures call for improved materials of
construction:
Most important components:
Forgings (rotors)
Castings (casings)
Piping
Material Requirements to handle USC operating conditions:
High creep rupture strength
Resistance against embrittlement
Low oxidation growth and no loosening of oxidation layer
Ease in manufacturing and availability
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Turbine Materials of Construction

Main Steam and Reheat Steam Piping: SA-335-P92

Main Steam Valve Casing: 9Cr (CB2)
HP Inner Shell: 9Cr (CB2)
HP Rotor: 9Cr (FB2)
HP Rotating Blading Inlet Stages: Nimonic (Ni80TiAl)
Nickel-based alloy
Superior to steel alloys at temperatures above 1050 oF

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Efficiency and CO2 Emissions Comparison

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Emission Comparison
Sub-Bituminous Coal

Emission Ultra SC
3800psi/1100F/1100F

Supercritical

IGCC

Subcritical

3500psi/1000F/1000F

2X1 7FB GT Dry Feed

2400psi/1000F/1000F

SO2

0.91 lb/MWh

0.97 lb/MWh

0.55 lb/MWh

0.99 lb/MWh

NOx

0.64 lb/MWh

0.68 lb/MWh

0.65 lb/MWh

0.70 lb/MWh

PM-10

0.14 lb/MWh

0.15 lb/MWh

0.09 lb/MWh

0.15 lb/MWh

CO2

0.97 T/MWh

1.03 T/MWh

0.99 T/MWh

1.06 T/MWh

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Conclusion
Ultra-supercritical Pulverized Coal Technology
Higher Temperatures = Better Efficiency
Better Efficiency = Less Emissions and Less Carbon Dioxide
Metallurgy Currently Available for Temperatures above 1100F
Equipment Suppliers Can Guarantee Performance and
Reliability

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