The following technical papers can be downloaded in portable document format (PDF) or can be ordered free of charge for delivery to you via mail.
BR#1852
Steam Generator for Advanced Ultra-Supercritical Power Plants 700 to 760C
Advanced ultra-supercritical (A-USC) is a term used to designate a coal-fired power plant design with the inlet steam temperature to the turbine at 700 to 760C (1292 to 1400F). Average metal temperatures of the final superheater and final reheater could run even higher. Nickel-based alloy materials are thus required. Increasing the efficiency to improve the economics of electric power generation and to achieve lower levelized cost of electricity (LCOE) has been a long sought after goal. Efficiency improvement is also a means for reducing the emission of carbon dioxide (CO2) and the cost of capture, as well as a means to reduce fuel consumption costs. Industry support associations and private companies working to advance steam generator design technology have established programs for materials development of nickel-based alloys needed for use above these higher temperatures. Ultimately, the economic viability of A-USC power plants is predicated on the comparable lower LCOE with carbon capture and sequestration (CCS) using either oxy-combustion or post-combustion capture.
BR#1849
Successful Operation of Jinzhushan 3, the World's First PC-Fired Low Mass Flux Vertical Tube Supercritical Boiler
June 2009 marked the initial coal-fired operation of the world's first supercritical pulverized coal-fired low mass flux vertical tube Benson boiler. Jinzhushan 3, located in Hunan Province in the People's Republic of China, is a 600 MW B&W PGG VTUP™ once-through boiler with vertical tube furnace construction designed to burn Chinese anthracite using downshot pulverized coal technology. The boiler was supplied by Babcock & Wilcox Beijing Company, Ltd. (BWBC) under license from B&W PGG. This paper reviews the development history of supercritical, once-through steam generator technology and product advancements. Downshot pulverized coal combustion technology is used to efficiently utilize low volatile anthracite coal that is difficult to burn conventionally. The unique design features of the downshot combustion system are reviewed as well as the adaptation of this technology to the VTUP design.
MS#14
Natural Gas Conversions of Existing Coal-fired Boilers
Electric utilities are always searching for ways to minimize costs, improve availability and reduce emissions. Recent changes in the price of natural gas have made that fuel economically attractive, with the added benefit of reduced emissions of SO2, NOx and CO2. For those utilities with existing coal-fired units, conversion from coal firing to natural gas firing might be an option worth considering. This paper considers the rationale for fuel switching, some of the options available for conversion of coal-fired units, technical considerations related to conversion, and some of the financial considerations that will impact the final decision.
BR#1827
Elimination of Fissures in Thick Section Inconel® Alloy 740 Welds
Inconel® alloy 740 has been identified as a prime candidate for the severe operating conditions of ultrasupercritical (USC) boilers. Compared to other candidate alloys it exhibits the highest stress rupture strength and corrosion resistance at projected operating steam temperatures approaching 1400F (760C). Extensive studies were executed to characterize its weldability using typical boiler shop welding equipment and practices. The alloy was originally found to be susceptible to heat affected zone microfissuring in sections greater than one inch (25 mm) thickness. This paper describes successful recent efforts to eliminate this microfissuring through modification of the base and weld filler metal chemistries.
BR#1790
New Progress of Weston 4 Supercritical Project in Wisconsin
Weston 4 is a coal-fired 590 MW B&W spiral wound universal pressure (SWUP™) installation in Rothschild, Wisconsin. This paper discusses the Weston Unit 4 project, a brief history of supercritical units in the U.S., and looks at future trends in high temperature and pressure supercritical units.
BR#1789
Indonesian Coal-Fired Power Project Recovers After Five-Year Delay
After a five-year project suspension, the 1320 MW Tanjung Jati B Power Station achieved commercial operation in the fall of 2006. Tanjung Jati B features two 660 MW (net) pulverized-coal-fired boilers, electrostatic precipitators, wet flue gas desulfurization (FGD) systems and coal and ash handling systems provided by B&W. This paper summarizes the project and the issues faced during the delay.
BR#1750
New Opportunities for Economically Improving the Performance and Emissions of Coal-Fired Power Stations
This paper inspects the economic impact of installing environmental equipment and simultaneously upgrading an operating coal-fired power plant, as a way to ameliorate the financial cost of the environmental improvements.
BR#1736
Coal Ash Corrosion Resistant Materials Testing Program: Evaluation of First Section Removed, November 2001
The "Coal Ash Corrosion Resistant Materials Testing Program" is being conducted by B&W, the U.S. Department of Energy and the Ohio Coal Development Office at Reliant Energy's Niles plant in Niles, Ohio, to provide full-scale, in situ testing of recently developed boiler superheater materials. This paper describes the program; its importance; the design, fabrication, installation and operation of the test system; materials utilized; experience to date; and results of the evaluation of the first section.
BR#1735
Steam Oxidation Testing of Candidate Ultrasupercritical Boiler Materials
This paper discusses B&W's role as a consortium member of the U.S. Department of Energy / Ohio Coal Development Office "Boiler Materials for Ultrasupercritical Coal Power Plants" program. Through this program, steamside oxidation testing of candidate materials for ultrasupercritical boilers will be performed on ferritic and austenitic materials at temperatures ranging from 650°C (1202°F) to 900°C (1652°F). (177K)
BR#1724
Completing a 550 MW Pulverized-Coal-Fired Utility Project on an Accelerated Schedule
In February 1999, a natural gas explosion destroyed a 500MW coal-fired utility boiler at KCPL's Hawthorn Generating Station. The loss of this critical base-load unit left KCPL with a difficult decision - replace the coal-fired boiler, or convert to gas-fired combined cycle. Ultimately, KCPL decided to replace the destroyed steam generator with another coal-fired unit, and repower the existing turbine/generator equipment. By August, 1999 the utility, Burns & McDonnell and B&W had a plan in place to build a new, 550MW pulverized-coal-fired facility and have it producing power and revenue by June 2001. This paper describes the project execution plan and team approach for the boiler island, environmental equipment and balance of plant with concentration on the accelerated schedule.(1027K)
BR#1723
Vertical Tube, Variable Pressure Furnace for Supercritical Steam Boilers
The U. S. Department of Energy (DOE) is developing highly efficient, low-emission, and low-cost power generation technology with industry participation for future power plants. As part of the DOE advanced combustion program, B&W/MTI will be testing a system that emulates a vertical tube, variable pressure furnace designed for supercritical boilers. Two types of supercritical boiler furnace designs are in use today, both requiring high mass flow per tube for cooling. One operates at a constant fluid pressure in the furnace and utilizes vertical tubes, and the other allows the fluid pressure to vary with changing loads and utilizes a spiral furnace design. The constant pressure furnace design has been used primarily in the U.S. while the variable pressure design has been dominant in Europe. In this paper, design features of the optimized multi-lead ribbed tube and the test plan are presented. (1765K)
BR#1658
B&W Supercritical (Once Through) Boiler Technology
This paper provides an overview of B&W's Once Through Boiler Technology. This review includes its history, beginning with the world’s first ultra-supercritical steam system, which began operation at the American Electric Power (AEP) Philo Station in 1957. The features of this boiler style, which is designed for base load and load cycling operation, are discussed, as are the requirements for daily start/stop and variable pressure operation. (975K)
