CCT Pre-Engineering Study for a 700 deg C high efficient PC-Power Plant

Transcription

1 CCT 2009 Fourth International Conference on Clean Coal technologies May 2009 Pre-Engineering Study for a 700 deg C high efficient PC-Power Plant 1

2 Step by Step Power Plant Development VGB E max - Initiative Enhancement of Efficiency Ecological compatible Cost effective and Reliable Long term Option Reference Power Plant Component Test Facility COMTES700 Demo-Plant 700 C of CO 2 -Separation and -Storage 600/620 C 700 C time R&D Programme: EU: Thermie, AD 700, FP 6, FP 7 DE: KOMET 650, COORETEC, e. a. 2

3 Funding Project Coordination Steering Committee E.ON Energie AG (DE), Electricité de France (FR), Electrabel European Generation (BE), EnBW Kraftwerke AG (DE), EVN AG (AS), DONG Energy Generation (DK), RWE Power AG (DE), STEAG AG (DE), Vattenfall Europe Mining & Generation AG & Co. KG (DE), Vattenfall A/S Nordic Generation (DK) & Funds of State North Rhine-Westphalia & EU (ERDF) Working Groups (60 GEN.- Experts) Overall Plant Layout Kjaer, DONG Boiler Island Götte, RWE Turbine Island Viennot, EdF CO 2 Capture Tschaffon, RWE Overall Plant Design and BoP Concept Master Cycle Basic Boiler Design Membran Wall Arr. Detailed Boiler Design Material and Manufacturing Issues HP Turbine IP Turbine Turbine Scale-up Contractor Material Interferences Boiler Scale Boiler & Plant Design Transfer to Lignite 3

4 Steering Committee E.ON Energie AG (DE), Electricité de France (FR), Electrabel European Generation (BE), EnBW Kraftwerke AG (DE), EVN AG (AS), DONG Energy Generation (DK), RWE Power AG (DE), STEAG AG (DE), Vattenfall Europe Mining & Generation AG & Co. KG (DE), Vattenfall A/S Nordic Generation (DK) & Funds of State North Rhine-Westphalia & EU (ERDF) E.ON Engineering Overall Plant Layout Kjaer, DONG Boiler Island Götte, RWE Turbine Island Viennot, EdF CO 2 Capture Tschaffon, RWE Overall Plant Design and BoP Concept Master Cycle Basic Boiler Design Membran Wall Arr. Detailed Boiler Design Material and Manufacturing Issues Material Interferences Boiler Scale HP Turbine IP Turbine Turbine Scale-up Boiler & Plant Design Transfer to Lignite 4

5 Steering Committee E.ON Energie AG (DE), Electricité de France (FR), Electrabel European Generation (BE), EnBW Kraftwerke AG (DE), EVN AG (AS), DONG Energy Generation (DK), RWE Power AG (DE), STEAG AG (DE), Vattenfall Europe Mining & Generation AG & Co. KG (DE), Vattenfall A/S Nordic Generation (DK) & Funds of State North Rhine-Westphalia & EU (ERDF) Overall Plant Layout Kjaer, DONG Overall Plant Design and BoP Concept Master Cycle DONG Energy Boiler Island Götte, RWE Basic Boiler Design Membran Wall Arr. Detailed Boiler Design Material and Manufacturing Issues Material Interferences Boiler Scale Turbine Island Viennot, EdF HP Turbine IP Turbine Turbine Scale-up CO 2 Capture Tschaffon, RWE Boiler & Plant Design Transfer to Lignite 5

6 Steering Committee E.ON Energie AG (DE), Electricité de France (FR), Electrabel European Generation (BE), EnBW Kraftwerke AG (DE), EVN AG (AS), DONG Energy Generation (DK), RWE Power AG Alstom Power Systems Burmeister & Wain Hitachi Power Europe (DE), STEAG AG (DE), Vattenfall Europe Mining & Generation AG & Co. KG (DE), Vattenfall A/S Nordic Generation (DK) & Funds of State North Rhine-Westphalia & EU (ERDF) Overall Plant Layout Kjaer, DONG Boiler Island Götte, RWE Turbine Island Viennot, EdF CO 2 Capture Tschaffon, RWE Overall Plant Design and BoP Concept Master Cycle Basic Boiler Design Membran Wall Arr. Detailed Boiler Design Material and Manufacturing Issues HP Turbine IP Turbine Turbine Scale-up Material Interferences Boiler Scale Boiler & Plant Design Transfer to Lignite 6

7 Different Boiler Variants - Basic Engineering Phase Alstom Power Boiler High Pressure Cycle (350 /705 /720) Hitachi Power Europe Interm. Pressure Cycle (250 /705 /720) Burmeister & Wain Master Cycle (350 /705 /720) 7

8 -31.4% % p= 85 bar t= 443 C t s = 299 C p= 17 bar t= 234 C t s = 203 C 8

9 High Pressure Cycle 365 bar / 705 C 71 bar / 720 C Interm. Pressure Cycle 260 bar / 705 C 66 bar / 720 C Master Cycle 365 bar/702 C 111 bar/720 C 25 bar/720 C 9

10 14m x 14m 34,6 m 15m x 15m 42 m 13m x 13m 47 m 10

11 Cycle Calculation Efficiency net efficiency regarding for 705/720 C different regarding live different steam live and steam reheat and reheat pressures 550 net efficiency [%] 50,4-50,6 50,2-50, ,2 49, ,6-49,8 49,4-49,6 49,2-49, ,2 48, ,6-48,8 48,4-48,6 48,2-48, ,2 47, ,6-47,8 47,4-47,6 500 Live Steam Pressure LS-pressure [bar] RH-pressure [bar] RH Steam Pressures 11

12 Cycle Calculation Net efficiency depending on feed-water temperature and reheating pressure net efficiency for 705/720 C and 365 bar regarding different reheat pressures and boiler inlet temperatures 100 net efficiency [%] 50,1-50, ,1 49, ,8-49,9 49,7-49,8 49,6-49,7 49,5-49,6 49,4-49,5 49,3-49,4 49,2-49, RH Pressure RH-pressure [bar] boiler inlet temperature [ C] Boiler Inlet Temperature 12

13 Measures for Efficiency Enhancement 13

14 Intermediate Pressure Cycle (260 bar/ 705 C / 720 C) η < 49 % 14

15 Master Cycle (365 bar/ 702 C / 720 C /720 C) η > 50 % 15

16 High Pressure Cycle (365 bar/ 705 C / 720 C) η > 50 % 16

17 Steering Committee E.ON Energie AG (DE), Electricité de France (FR), Electrabel European Generation (BE), EnBW Kraftwerke AG (DE), EVN AG (AS), DONG Energy Generation (DK), RWE Power AG (DE), STEAG AG (DE), Vattenfall Europe Mining & Generation AG & Co. KG (DE), Vattenfall A/S Nordic Generation (DK) & Funds of State North Rhine-Westphalia & EU (ERDF) Overall Plant Layout Kjaer, DONG Overall Plant Design and BoP Concept Master Cycle Boiler Island Götte, RWE Basic Boiler Design Membran Wall Arr. Detailed Boiler Design Material and Manufacturing Issues Material Interferences Boiler Scale-up Turbine Island Viennot, EdF Call for Tender (HPC) HP Turbine IP Turbine Turbine Scale-up CO 2 Capture Tschaffon, RWE Boiler & Plant Design Transfer to Lignite 17

18 Steering Committee E.ON Energie AG (DE), Electricité de France (FR), Electrabel European Generation (BE), EnBW Kraftwerke AG (DE), EVN AG (AS), DONG Energy Generation (DK), RWE Power AG (DE), STEAG AG (DE), Vattenfall Europe Mining & Generation AG & Co. KG (DE), Vattenfall A/S Nordic Generation (DK) & Funds of State North Rhine-Westphalia & EU (ERDF) Overall Plant Layout Kjaer, DONG Overall Plant Design and BoP Concept Master Cycle Boiler Island Götte, RWE Basic Boiler Design Membran Wall Arr. Detailed Boiler Design Material and Manufacturing Issues Material Interferences Boiler Scale-up Turbine Island Viennot, EdF Alstom Power Systems HP Turbine IP Turbine Turbine Scale-up CO 2 Capture Tschaffon, RWE Boiler & Plant Design Transfer to Lignite 18

19 Basic Design 500 MW Detail Design 500 MW 19

20 Design 1000 MW Design 500 MW 20

21 Material Concept 700 C Boiler Heating Surface 13 CrMo CrMo 910 T91 S 304 B SB HR3C Alloy 617 m HR3C Sanicro 25 Alloy 617 m RH1 SH3 Header ECO: WB36 (in/out) RH1: 13 CrMo 45 (in) Alloy 617 m (out) SD 3: Alloy 617 m (in/out) Alloy 617 m RH2 RH 2: Alloy 617 m (in/out) Alloy 740 Sanicro 25 SH4 SH 2 PL SH 4: Alloy 617 m Alloy 263 SH 2: P 92 Alloy 617 m (in) (out) (in) (out) 21

22 Example Temperature Distribution 22

23 Example Stress Distribution 23

24 Example Insulation 24

25 Example Insulation 25

26 Example Pipe Routing to Turbine 26

27 Steam Turbine Technology Development Alstom Power Generation Siemens Power Generation 27

28 Steering Committee E.ON Energie AG (DE), Electricité de France (FR), Electrabel European Generation (BE), EnBW Kraftwerke AG (DE), EVN AG (AS), DONG Energy Generation (DK), RWE Power AG (DE), STEAG AG (DE), Vattenfall Europe Mining & Generation AG & Co. KG (DE), Vattenfall A/S Nordic Generation (DK) & Funds of State North Rhine-Westphalia & EU (ERDF) Overall Plant Layout Kjaer, DONG Overall Plant Design and BoP Concept Master Cycle Boiler Island Götte, RWE Basic Boiler Design Membran Wall Arr. Detailed Boiler Design Material and Manufacturing Issues Material Interferences Boiler Scale-up Boiler & Plant Design Transfer to Lignite Siemens Power Generation Turbine Island Viennot, EdF HP Turbine IP Turbine Turbine Scale-up CO 2 Capture Tschaffon, RWE 28

29 Steering Committee E.ON Energie AG (DE), Electricité de France (FR), Electrabel European Generation (BE), EnBW Kraftwerke AG (DE), EVN AG (AS), DONG Energy Generation (DK), RWE Power AG (DE), STEAG AG (DE), Vattenfall Europe Mining & Generation AG & Co. KG (DE), Vattenfall A/S Nordic Generation (DK) & Funds of State North Rhine-Westphalia & EU (ERDF) Overall Plant Layout Kjaer, DONG Boiler Island Götte, RWE Turbine Island Viennot, EdF CO 2 Capture Tschaffon, RWE Overall Plant Design and BoP Concept Master Cycle Basic Boiler Design Membran Wall Arr. Detailed Boiler Design Material and Manufacturing Issues Material Interferences Boiler Scale-up Boiler & Plant Design Transfer to Lignite HP Turbine New WP IP Turbine Turbine Scale-up Qualification Alloy 740 Q. thick Wall Alloy 617 Q. cent. casted Alloy

30 HP- Turbine Design Cooling Steam 330 bar / 550 C Live Steam 350 bar / 700 C Exhaust Steam 75 bar 30

31 Ongoing Material Qualification Projects Manufacturing of test melts of unqualified materials Determination of the material characteristics Investigation of the manufacturing procedures Preparation of green bodies Preparation of pilot components Testing of pilot components Creation of material engineering standards 31

32 HP- and IP- Valve Development Quelle: Siemens 32

33 HP- Valve Development (AD 700-2) 33

34 Development Alloy 617 Centrifugal Casted Pipe Schmidt + Clemens GmbH + Co.KG Edelstahlwerk Kaiserau Lindlar 34

35 Average Worldwide CO 2 -Emissions per kwh 30% 1.116/g CO 2 /kwh 480 g Coal/kWh 38% Efficiency*) CO2-Emissionens Fuel Consumption EU 881 g CO 2 /kwh 379 g Coal/kWh State-of-the-art Technology 45% 743 g CO 2 /kwh 320 g Coal/kWh Steam power plant 700 C-Technology rd. 50% 669 g CO 2 /kwh 288 g Coal/kWh CCS- Technology But: Efficiency loss 7-12% points CO 2 - Reduction -21% - 33% -40% -90% Time VGB PowerTech e.v. *) Average data for hard coal fired power plants 35

36 First 700 C Demonstration Project Fuel: Hard Coal Capacity: 550 MW Efficiency: > 50 % Start up: 2015 Location: Wilhelmshaven Source: E.ON 36

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