Advanced Capture Technologies

Babcock-Hitachi Europe GmbHBabcock-Hitachi Europe GmbH

Manufacturers’ know how onadvanced capture technologiesManufacturers’ know how onadvanced capture technologies

- Higher efficiency towards zero emission -

02.12.2005Dr. Andreas ReidickKlaus-Dieter Rennert

[email protected][email protected]

Babcock-Hitachi Europe GmbH

Research steps on the way to the CO2-free power station

Ref: BMWi AG 4 „Zukünftige Technologien“

Efficiency

Emissions

Time

ReadyReady--forfor--thethe--market, market, COCO22--freefree

fossil power stationsfossil power stations

Demonstration

Components forCO2 operating processes

Basics of CO2 capture

Increase of efficiency


CO2 Emission of Bituminous Coal Power Stations

300

400

500

600

700

800

900

1000

1100

1200

25 30 35 40 45 50 55 60

Overall Efficiency (%)

AverageEU

Thermieultimo

Average EU2010

Thermie 700, 2 RH

CO

2Em

issi

ons

(g/k

Wh)

Reference P.S.NRWReference P.S.NRW

Ref: Thermie Forschungsprojekt 700°C-Kraftwerk

State of the Art


Incre

ase of

effic

iency

Reference Power Station NRW (550 - 600 MW)

AD 700

Altbach 2 (300 MW)Staudinger 5 (550 MW) Rostock (550 MW)

Bexbach 1 (750 MW)

CWH 3 (100 MW)

Bayer Dormagen (125 t/h)

Iskenderun (600 MW)

Torre Nord(660 MW)

Leininger (450 MW)

Amager (260 MW)

Studstrup (350 MW)

Midamerican (790 MW)

Genesee (251 MW)

Kogan Creek(750 MW)

180 220 240 260 280 300 380

700

620

600

580

560

540

Hitachi-Naka #1 (1000MW)

Tachibana Wan #2 (1050MW)

Matsuura #2 (1000MW)

Shinchi #1 (1000MW)Noshiro #1 (600MW)

Hekinan #2 (700MW)

Nanao-Ohta #1 (500MW)

Future potential

High Efficient Steam Generators

Supe

rhea

terO

utle

t Tem

pera

ture

(°C

)

Superheater Outlet Pressure (bar)

sub-critical super-critical

Lippendorf (2 x 930 MW)

Niederaußem K (1000 MW)

Boxberg (900 MW)

Neurath F/G (1100 MW)

Schkopau (2 x 400 MW)

Haramachi #2 (1000MW)


Neurath F,G (BoA2), 2x 1100 MW

• 2 x 1100 MWel / 2 x 2959 t/h

• Once-through steam generator, Benson®

• Lignite

• Steam parameters:SH: 600 °C / 272 barRH: 605 °C / 55.3 bar

• Commissioning: 2010/2011


HARAMACHI POWER STATION UNIT No. 2

Unit Capacity 1,000 MWel

Evaporation 2,890 t/h

Steam Pressure 25.9 Mpa

Steam Temperature 604 / 602 °C

Fuel Bituminous Coal

Commissioning 1998

Utility:

TOHOKU ELECTRIC POWER CO.

Japan


flue gas

s = f (allowable stress)

corrosion layer

Superheater/ Reheater Tubes

steam

tube wall

Inner Oxide layer

OuterOxide layer

steam oxydation

corrosion


Magnetite Scale in an Elbow

Spalling of outer oxide layer


Tube Internal Surface Shot Blasting Procedure

Tube

Shot Particle

Compressed Air including shot particle

material

Circumferential Blasted Nozzle

Shot Blasting Conditions (BHK Facility)

Shot Particle Material : SUS304 particle Φ 0.5 x 0.5L

Max. Blasting Pressure : 7 bar

Nozzle Movement Velocity : 100~800mm/min

Air Flow : max. 9m3/min


The effect of the shot blastingThe effect of the shot blasting

MetalMetal

Schematic

Grain boundary

Shot blasted50µm

・Step1: The crystal grains are collapsed ・Step2: Cr2O3 is formed with the result that the oxidizing velocity is very slow ・Step3: The scale growth is suppressed.

(Fe,Cr)3O4

Cr2O3

Fe3O4

Effect of Shot Blasting after 34412 Operating h Super 304 H, 586 °C Steam

Outer Scale

Inner Scale

Original MaterialMetal

50µm

Thin Cr2O3layer

Outer Scale

Inner Scale

Metal

(Fe,Cr)3O4

Fe3O4 O2-

Fe2+

Grain boundary

Schematic

and the supply of Cr to the scale is promoted.

Diffusion of Cr

The layer where the crystal grains were collapsed.Cold worked

layer


National and European Research Programs

Babcock-Hitachi EuropeSuperheaterTubing Sheets

Influence of Coldforming on CreepBehaviour of Austenitic Steels and Nickel Base Alloys

3.2003 – 2.2006VGB-

FDBR-AiFProgram

V & MHeader, PipingCriteria for Demage Evaluation in High Temperature Components of martensitic9-11 % Cr-Steels

1.2005 – 12.2007A 229

SZMFHeader, PipingOptimization of Welding Joints and Prevention of HAZ – Creep by Means of Strength Properties

7.2004 – 6. 2007A 221

V & MHeader, PipingEvaluation of Scatterband of HeatresistingMaterials Concerning Creep Behaviour withData-Mining-Methode

1.2005 – 6.2006A 198

Babcock-Hitachi EuropeHeader, PipingLongitutinal Welded PipesCompletely new heattreated P 91 and E 911

7.2002 – 12.2005A 196

Babcock-Hitachi EuropeMembrane Wall, Header, PipingVM 124.2002 – 3.2006A 180

Babcock-Hitachi EuropeSuperheaterTubingInside cladded Tubes1.2002 – 12.2004A 176

ChairmanshipSteam GeneratorComponents

MaterialPeriodProgram


Boiler SectionBabcock-Hitachi Europe

Header, Piping, Superheater

Tubing

Nickel Base Alloys,Austenitic Steels

1.1998 – 12.2004

1.2002 – 12.2006

AD700 Phase 1 AD 700 Phase 2

Alstom(Switzerland)

Header, PipingMartensitic Steels1.2005 – 12.2008COST

536

VGB

Membrane Wall, Header, Piping,

SuperheaterTubing

7CrMoVTiB10-10, P 92, HCM 12, Alloy 617, HR3C, DMV310N, Sanicro25, A7403.2005 – 3.2009COMTES

700

RWE Power/VGBHeader, Piping,

SuperheaterTubing

Nickel Base AlloysAustenitic Steels

1.1998 – 6.2005KOMET

650 I and II

Babcock-Hitach EuropeMembrane Wall, Header7CrMoVTiB10-10, P 92, VM 12, Alloy 6179.2004 – 9.2008MARCKO

700

ChairmanshipSteam GeneratorComponents

MaterialPeriodProgram

National and European Research Programs


500 °C500 °C

550 °C

580 °C580 °C 590 °C590 °C

630 °C630 °C

13CrMo4-513CrMo4-5

7CrMoVTiB10-10

HCM 12HCM 12 VM 12VM 12

Alloy 617Alloy 617

MARCKO 1

MARCKO 700

Considering the material properties :Oxidation in SteamCreep Strength


Materials for Membrane walls

Design temperatures according EN 12952


580 °C580 °C

600 °C

625 °C625 °C 635 °C635 °C

735 °C735 °C

X20CrMoVNi11-1X20CrMoVNi11-1

P 91

E 911, P 92E 911, P 92 VM 12VM 12

Alloy 617Alloy 617

MARCKO 1

MARCKO 700



Materials for Headers and Piping

735 °C735 °C

Alloy 263Alloy 263



600 °C600 °C

615 °C

635(645*) °C635(645*) °C 670 °C

770 °C770 °C

X20CrMoVNi11-1X20CrMoVNi11-1

z.B. X3CrNiMoN17-13

z.B. S 304 Hz.B. S 304 H z.B. HR3Cz.B. HR3C

Alloy 617Alloy 617

MARCKO 1 MARCKO 700

Considering the material properties :

Oxidation in Steam

High-Temperature Corrosion in Flue Gas

Creep Strength

Considering the material properties :

Oxidation in Steam

High-Temperature Corrosion in Flue Gas

Creep Strength

770 °C770 °C

Alloy 263Alloy 263

700 °C700 °C

* Bituminous coal firing systems with contents of sulphur until approx. 1 %


Materials for Reheater and Superheater Tubes

Sanicro25 under investigationSanicro25 under investigation


State of development and research need of new materials

Before the background of the requirements of the European “DGRL” and the European product standards

Chemical Composition

Physical and chemical Properties

Mechanical / Technological Properties (Short time) (Long-term)(Aging)

Creep characteristics

Fatigue properties

Rupture mechanic properties

Processing qualification deformation (cold u. warmly), Welding(Attributes HAZ and weld material, cracking hot and cold)

Evaluation of the material and construction unit characteristics(security concept)

Manufacture concept raw material

Manufactering concept, for example Welding instructions, Procedure qualifications

Order prescriptions, Quality requirements, Inspection requirements


nichterfüllt

läuft

erfüllt

DMV66 modA263Tub

ManufacturingConcept

Properties of Welding Joints and Heat Affected Zones

Creep Properties atleast 30.000 h forrupture

Creep Properties atLeast 10.000 h forrupture

Mechanical-Techno-logical Properties, incl. Aging

Physical/ChemicalProperties

ChemicalComposition

F92T/P 92Tub

SumS304,HR3C,

347Tub

DMV310,304,347Tub

San25Tub

VM 12 For

VM12 Pipe

617Forg

617Pipe

7Cr For

7Cr Tub

Materials

Requirements

Status of Investigations

available

planned

running


Planned Projects within COORETEC - Initiative

PeriodInstituteTitelNo

01.06-12.08IGZFP/BAM

Non Destructive Testability of Thick Components of Ni-base Alloys and Welding Joints

TD-1

06.06-06.10MPA Stuttgart

Strength and Deformation Behaviour of Nickel Base-Alloys Tubings, Pipings,and Forgings

DE-4

06.06-06.10MPA Stuttgart

Strength and Deformation Behaviour of 12%Cr-Steel Forgings

DE-3

01.06-12.09Tu DarmstadtProperties of Superheater Tubing Materials afterColdforming

DE-2

06.06-08.09Uni StuttgartCorrosion and Slagging Behaviour of 700°C-MaterialsDE-1


X20CrMoV121

X20CrMoV121

13CrMo44

AustenitP92

7CrMoVTiB 10 10

Ni-Basis-

MaterialsNi-Basis-

Materials

VM12

Best Available Technology for Bituminous Coal

η = 43 % η = 45 – 47 % η = 50 %262 bar / 545 °C / 562 °C 285 bar / 600 °C / 620 °C 358 bar / 700 °C / 720 °C

todaytoday 20102010 20152015


CO2 Emissions in GermanyReplacement of Bituminous Coal P.S. by BAT

CO

2ou

t of H

ard

Coa

lP.S

. (t/h

)

0

5000

10000

15000

20000

25000

2005 2010 2015 2020 2025 2030

RKW AD700

CO2 freeplants

Year

-- BituminousBituminous coalcoal --


Available technology, Lignite

today 2010today 2010η = 42 % η = > 43 %

260 bar / 554 °C / 583 °C 286.1 bar / 600 °C / 610 °C

AustenitP91

13CrMo44

E911

(P92)Super 304H

HR3C

7CrMoVTiB 10 10


CO2 Emission in GermanyReplacement of Lignite P.S. by BAT

0

5000

10000

15000

20000

25000

2005 2010 2015 2020 2025 2030

CO2 freeplants

CO

2 ou

t of L

igni

teP.

S. (t

/h)

Year

-- LigniteLignite --

BoA II /Boxberg R

Babcock-Hitachi Europe GmbHBabcock-Hitachi Europe GmbH

Dr. Andreas ReidickKlaus-Dieter Rennert

[email protected][email protected]


Reference Power Station of

North Rhine Westphalia

Reference Power Station of

North Rhine Westphalia


Target of the Concept Study

Investigation of the viability of an ultra modern power plant

remarkable reduction of emissions

economical conditions of the liberalised market


Participants

Steering Committeemanufacturers, utilities, members of ministries,

association of bituminous coal, mining union

Scientific investigations

RWI, Wuppertal-Institut,University of Essen

Manufacturers Utilities


Reference Power Plant - Boiler Concepts

550 MW * 292,5 bar * 600 / 620 °C

Cost – Comparison

Tower: 100 % Two Pass: + 3 % Horizontal fired: + 8 %


• Single unit with gross capacity of 500 - 600 MW• overall efficiency of 45 - 47%• Power consumption < 8.5 %• Steam parameters

– HP at turbine inlet 285 bar / 600 °C– RH at turbine inlet 60 bar / 620 °C

• Design coal South African• Condenser pressure approx.: 45 mbar• Cooling tower

Tower Type Boiler – “RKW Preferred Variant 600 MW”


700

750

800

850

900

45.9 46.1 46.2 46.5 47.3

Specific Cost vs. Efficiency

EUR/kWgross

Efficiency

BasedBased on 2003 on 2003

Documents

Advanced Capture Technologies