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#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)
BR#1630
Orimulsion at Dalhousie
Orimulsion, the fourth fossil fuel, has gained increasing acceptance as an economically viable fuel for power generation. The first full-scale demonstration commenced almost ten years ago. A number of power plant boilers have been converted in Japan, Canada, the United Kingdom, and Denmark, with more conversions planned. Early conversion experience is discussed, along with specific attention to the SO2 reduction system at the Dalhousie plant in New Brunswick, Canada. (345K)
BR#1627
Numerical Simulation Models for a Modern Boiler Design
Numerical simulation models have become an increasingly important design and analysis tool for boiler components and auxiliary equipment. Mature numerical simulation programs with affordable high speed desktop workstation computers have resulted in an ever expanding list of numerical applications. General capabilities accommodate any combination of fossil fuel combustion (coal, oil, and natural gas), non-reacting flows with energy exchange, or isothermal flow problems. Model complexity can be tailored to specific areas of interest. The goal of these numerical simulations is to improve the design of a new or existing boiler component by optimizing the flow distribution. This paper discusses (1) results from several typical applications to new, existing, and retrofit equipment, (2) the influence on product design and development with the advent of numerical simulation results, and (3) existing numerical limitations and future numerical capabilities. (233K)
BR#1615
Comparative Evaluation of Cogeneration Cycle Alternatives
Competition from deregulation is driving utilities and consumers to seek out alternate means to reduce the cost of electricity. The utility industry is expected to shift generation away from the traditional central station philosophy to dispersed generation with the formerly wasted heat to be recovered and used for industrial steam or to heat commercial buildings.[1] Some experts suggest that the dispersed generation will take the form of cogeneration by locating thermal electric generators with heat recovery steam generators alongside the thermal host. Coincidentally, there are a large number of existing boilers that can serve as waste heat receivers if properly modified. This could result in substantial capital savings, further reducing the cost of the dispersed electrical generation. Repowering cold windbox industrial boilers compliments and reinforces the dispersed generation philosophy. This paper will compare the economic and technical advantages of repowering existing small industrial boilers with conventional engine/gas turbine driven generator sets. Operating advantages in steam generation reliability and flexibility will be presented.(95K)
BR#1612
Advanced Sensors and Control Requirements for Multi-Burner Pulverized Coal-Fired Boilers
As the 21st century begins, it is anticipated that the U.S. will require new generating plants to meet the growing demand for electricity and to replace aging plants approaching the end of their useful life. For coal to be the fuel of choice, new coal-fired plants will have to be extremely clean, efficient and economical. Advances in emission control techniques resulting in reduced costs and auxiliary power requirements combined with significant efficiency gains from steam turbine and cycle design clearly show that pulverized coal technology can be competitive in both cost and performance. B&W, under contract to the U.S. Department of Energy (DOE), is leading a team in the development of an advanced generating plant in DOE’s Combustion 2000 program entitled "Engineering Development of Advanced Coal-Fired Low Emission Boiler System" (LEBS). This program combines advanced environmental control technologies capable of achieving emissions of SOx, NOx and particulate far below current New Source Performance Standards (NSPS) with an advanced boiler equipped with improved combustion and heat transfer subsystems for net plant efficiencies exceeding 40%.(146K)
BR#1603
Numerical Flow Modeling of Power Plant Windboxes
Numerical flow modeling has become an increasingly important design and analysis tool for improving the air distribution to power plant burners. Uniform air distribution allows the burners to perform as designed to achieve the lowest possible emissions and best fuel burn-out. Modifications can be made internal to the existing windbox to improve the burner-to-burner and burner peripheral air distributions. These modifications can include turning vanes, flow splitters, perforated plate, and burner shrouding. Numerical modeling allows the analysis of design trade-offs between adding flow resistance, fan power, and windbox modification construction cost. Numerical modeling has advantages over physical modeling in that actual geometric scales and air temperatures are used. Advantages over a field data based study include the ability to quickly and cheaply analyze a variety of design options without actually modifying the windbox, and the availability of significantly more data with which to interpret the results. Costs to perform a numerical study are generally one-half to one-third of the cost to perform a physical flow model and can be one-fourth of the cost to perform a field study. The continued development of affordable, high speed, large memory workstations and reliable, commercially available computational fluid dynamics (CFD) software allows practical analyses of power plant windboxes. This paper discusses (1) the impact of air distribution on burner performance, (2) the methodology used to perform numerical flow modeling of power plant windboxes, and (3) the results from several windbox analyses including available post-modification observations. (224K)
BR#1588
Development and Application of a Dynamic Simulation Model for a Drum Type Boiler with Turbine Bypass System
Dynamic simulation models using powerful personal digital computers are a very cost-effective tool for studying the operating characteristics of power plants to improve the design and control strategy to meet stringent operational requirements. The required operating modes of large fossil-fueled generating plants call for continued operation after load rejection, and rapid, frequent and reliable unit start-ups to achieve flexible and economic production of electricity. This paper discusses the development of a dynamic simulation model and its application in the study and design of a new control philosophy and turbine bypass system to meet the operational requirements. (130K)
