Outline of the 2 x 1,000 MW USC (Ultra Super Critical) Boiler Technology for Malaysia Project

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1 Outline of the 2 x 1,000 MW USC (Ultra Super Critical) Boiler Technology for Malaysia Project Yuta Oka, Shinichi Takano, Kazuhiro Nagamine IHI Corporation JAPAN Power-Gen Asia 2015, BANGKOK, THAILAND, 1-3 September 2015 Track 3: Power Plant Technologies Session 3: Coal Fired Power Plants Technology

2 Abstract Outline of the 2 x 1,000 MW USC (Ultra Super Critical) In recent years, ultra super critical (USC) / super critical steam (SC) technology has become mandatory in ensuring reliable CO 2 emission reduction and considerably high economic efficiency in the world. From the viewpoint of the energy security and the effective utilization of coal resources, Sub-Bituminous Coal Single Fired Boilers are in high demand, although sub-bituminous coal has properties that makes it harder to handle than bituminous coal including: a lower heating value, higher moisture, higher slagging and fouling properties, and so on. In 2014, in Malaysia where electricity demand is steadily growing, IHI was contracted to supply a 2x1,000MW USC Power Plant with Sub-Bituminous Coal Single Fired boiler which plans to start the commercial operation in IHI is responsible for the boiler supply with coal firing system and boiler plant as the EPC Leader for the overall project. Here, IHI introduces the outline of the 2x1,000MW USC Boiler for the Malaysia project, with steam capacity of 3,025t/h, main/reheat steam temperature of 603/612 C, main steam pressure of 27.9 MPa(g). Various kinds of Sub-Bituminous / Bituminous Coals imported from Indonesia, Russia, South Africa, and Australia are applied to the Boilers as the design coal. Firstly we will introduce the project outline and the features of IHI s USC Boiler with the highest steam condition to reach the high plant efficiency and its background technology including the IHI Coal Firing System, IHI Low NOx Wide Range Burner (IHI-WR Burner) and the IHI Coal Pulverizer (IHI-VS Pulverizer). Secondly, the design concept of the IHI USC Boiler applied to this project is introduced by comparing it with IHI s other referenced USC boilers, Sub-Bituminous Coal Single Fired Boilers in USA. Finally we explain about the plant performance, plant efficiency, economical performance, and environmental benefits, especially CO 2 emissions. 2

3 1. Introduction Coal is an abundant energy source, widely distributed throughout the world, with a considerable amount of recoverable reserves. Furthermore its price is also stable when compared with other fossil fuels. For these reasons, coal-fired power plants will continue to play an important role in power generation worldwide. On the other hand, since coal exhausts more CO 2 per unit of electricity generation than other generating energies such as nuclear, renewable energy and other fossil fuels, efforts are being made to reduce this amount. Also, from an economical viewpoint and considering the supply capability of coal resources, the power plants that can make use of the low-rank coals are highly desirable. Under this situation, the ultra super critical (USC) / super critical steam (SC) technology is recently getting mandatory for the newly installation or replacement project of the coal fired power plants in the world to minimize the CO 2 emission. The sub-bituminous coal single fired boiler is then demanded at the many projects planned in all over the world. IHI has rich experiences designing, fabricating, installing and commissioning USC and SC boilers to the power industrial markets in Japan and around the world. IHI successfully supplied three sub-bituminous coal single firing boilers in the USA from 2009 to 2013 and they are operating stably after COD (refer to Table-1). IHI s boiler in the USA was awarded for its high reliability and availability by the Client and praised as one of top innovative coal fired plant by the trade magazine, POWER. In addition to these achievements, IHI has signed on the Engineering, Procurement and Construction (EPC) Contract of the Jimah East Power Project (hereafter JEP ) which have 2 x 1,000MW net output, ultra super critical steam condition and a sub-bituminous coal single fired boiler. Table-1 IHI s Track Record of 100% Sub-bituminous Coal Firing Boiler in USA Name Output (Net) Steam Condition A Plant 900 MW Super Critical B Plant 665 MW Sub-critical C Plant 660 MW Sub-critical Boiler Type COD Coal Once Through, Variable Pressure, Reheat Type Natural Circulation, Variable Pressure, Reheat Type Natural Circulation, Variable Pressure, Reheat Type Sub-bituminous Coal (PRB Coal) 3

4 2. Project Outline 2.1 General The JEP site is located in the Negeri Sembilan State, on the west coast of the Malay Peninsula and approx. 50 km south of Kuala Lumpur. It is newly and independently constructed beside the existing sub-critical coal fired power plant, Jimah 2x700MW (refer to Fig-1). The plant capacity is 2 x 1,000 MW (net) and the main fuel is sub-bituminous coals. IHI has a lot of experience in the supply and construction of coal fired power plants in Malaysia. 9 units of boiler plants were installed and further two units will be added (refer to Table-2). Jimah East Power 2 x1,000mw Existing Jimah PP Site Location of Jimah East Power Table-2 IHI Boilers in Malaysia Name Type Output Fuel COD S.S.A.A Power Station Phase 2 S.S.A.A Power Station Phase 3 Natural Circulation, Single Drum, Reheat Type Ditto Fig-1 Site Location & Photo (Dec. 2014) 2 x 300MW (Gross) 2 x 500MW (Gross) Coal, Oil, Gas Coal, Gas , 1989 Tanjung Bin Ditto 3 x 700MW (Net) Coal 2006, 2007 Jimah Ditto 2 x 700MW (Net) Coal 2009 Jimah East Power Ultra Super Critical, Once Through, Variable Pressure, Reheat Type 2 x 1,000MW (Net) Coal

5 2.2 Project Organization The project owner is Jimah East Power Sdn. Bhd. which is a Special Purpose Company for this project. The EPC Contractor is IHI-TOSHIBA-HYUNDAI Consortium and IHI is the commercial and technical leader of that EPC consortium. The scope of the Consortium is full turnkey including marine & civil works, and IHI is to provide the USC boiler and its auxiliaries including construction and commissioning work. The project organization chart is shown in Fig-2. The boiler and its auxiliaries are IHI s scope of supply. 2.3 Project Schedule The project schedule is shown in Fig-3. The boiler construction work period up to the COD is 29 months. CODs of Unit-1 / Unit-2 are set to middle of 2019 and end of 2019 respectively. Currently the reclamation work is proceeding at the site. Jimah East Power Sdn. Bhd. Toshiba Corporation Turbine and Auxiliary Reclamation and Off-shore Civil Work IHI Corporation EPC Consortium Leader Boiler and Auxiliary Fig-2 Project Organization Hyundai Engineering Hyundai E&C BOP On-shore Civil Work Architectural Work Commencement Unit 1 Boiler Construction Start Initial Firing 29 Months COD Unit Fig-3 Project Schedule 5

6 3. Introduction of IHI USC Boiler Outline of the 2 x 1,000 MW USC (Ultra Super Critical) 3.1 General Specifications The specification of the USC boiler for JEP is shown in Table-3. Fig-4 and 5 show the general arrangement of the boiler. The main steam flow at BMCR (Boiler Maximum Continuous Ratio) condition is 3,025 t/h. The steam condition is 27.9 MPa(g), 603 C for the main steam and 612 C for the reheat steam at the boiler outlet. It is designed to utilize 100% sub-bituminous coal. Table-3 Boiler Specification for JEP Item Unit Specification Output (BMCR) MW Gross 1,096MW Boiler Type Ultra Super Critical (USC) Condition, Stationary Once-through Variable Pressure Reheat (SOVR) Type Pulverized Coal Boiler, Outdoor Service SH Outlet t/h 3,025 Steam Flow RH Outlet t/h 2,427 Steam Condition (BMCR) Steam Temp. SH Outlet C 603 RH Outlet C 612 SH Outlet MPa(g) 27.9 Steam Press. RH Outlet MPa(g) 4.7 Feed Water Temp. ECO inlet C 303 Firing Type Opposed Firing (Wall Firing) Draft Type Balanced Draft Minimum Operating Load (Coal Firing) % 30 Main Fuel Coal (Sub-bituminous and Bituminous) 6

7 Furnace Exit (Location of FEGT) Fig-4 General Arrangement of the Boiler Fig-5 3D Model of the Boiler Plant 7

8 3.2 USC Boiler Technology We have applied our proven USC boiler technology to JEP based on our many years of experience in Japan and worldwide. The features of our USC boiler are as follows Wall Firing System Wall firing (Opposed firing) system has been applied which has the advantages of high combustion efficiency, good distribution of the flue gas flow and temperature at furnace outlet, and good flame stability Helical Tube Furnace Wall For the boiler furnace (wall panels), IHI applied the helical wounded tube furnace wall to ensure sufficient steam/water mass flow in order to avoid over heating of the tubes and to provide even heat absorption on each tube path. The difference of heat absorption between tubes is greatly reduced compared to a vertical tube furnace wall arrangement. The helical tube furnace wall does not require inlet orifices, unlike a vertical tube designed furnace wall, to adjust the steam/water flow at each tube path. Also, the smooth tube is applied to the furnace wall whereas that the rifled tube have to be applied to the vertical tube designed furnace wall Parallel Pass Design IHI has applied the parallel pass design on the heat recovery area (HRA) of the boiler. The gas pass is separated to the superheater pass and the reheater pass. The reheater temperature is controlled by the control damper located at the parallel pass outlet, controlling the flue gas amount of the superheater pass and the reheater pass. The reheat steam temperature can be controlled without both reheater spray and gas recirculation fan. It contributes to enhancing the cycle efficiency and reducing maintenance costs Material Selection for Pressure Parts To provide stable and reliable operation under the high steam temperatures above 600 C, we have applied ASME Code Case 2328 (Super304) and SA213MT91 to high temperature heating part of the superheater and the reheater tubes. For the furnace wall we have applied SA213MT12 as shown in Table-5. Through a lot of the past experiences in the other projects, IHI has designed and selected well-proven materials to enhance the higher reliability of the plant operation. Fig-6 shows the typical material selections for IHI s super critical boilers. 8

9 Table-5 Major applied material for heating parts Heating Parts Designed Material (Typical) Furnace Wall SA213MT12 Primary Superheater SA213MT12 Secondary Superheater SA213MT91 / Code Case 2328 Final Superheater Code Case 2328 Primary Reheater SA213MT22 / SA213MT91 Secondary (Final) Reheater Code Case 2328 Applied Range for JEP Turbine Inlet Steam Temperature [ C] ECO SA178C / SA210C Furnace SA213T2 / SA213T12 Separator / Separator Drain Tank SBV62 / SA302C Final SH (Heated Tubes) SA213T91 CC2328 (Super304) Final SH (Unheated Tubes) SA213T91 Final SH Outlet Header SA335P22 SA335P91 Main Steam Pipe SA335P22 SA335P91 Final RH (Heated Tubes) SA213T91 CC2328 (Super304) Final RH (Unheated Tubes) SA213T22 SA213T91 Final RH Outlet Header SA cl.2 / SA335P22 SA335P91 Hot Reheat Pipe SA cl.2 / SA335P22 SA335P91 Low Cr Alloy (Ferristic Steel) 9 Cr Alloy (Ferristic Steel) Austentic Steel Fig-6 Typical Material Selection for IHI Super Critical Boiler 3.3 Coal Firing System Coal pulverizers and burners are designed and fabricated by IHI. 6 sets of IHI-VS 25 coal pulverizers are installed per unit. 1 set is for stand-by and 100% Load can be achieved by 5 sets of pulverizers. The pulverizer is the vertical spindle type as shown in Fig-7 and selected to be able to pulverize all range of design coals. A total of 36 sets of IHI Low NOx Wide Range dual flow burners (IHI-WR burners) are installed per unit. The boiler has 6 rows (front side 3 rows / rear side 3 rows) of burners and 6 sets of burners are arranged per row. This IHI-WR burner has a unique concept jointly developed by Shikoku Electric Power CO., Inc., Central Research Institute of Electric Power Industry and IHI to realize both low NOx and wide unit load range operation with stable combustion. As shown in Fig-8, the burner has a ring in the outer sleeve for adjusting the concentration distribution of pulverized coal. This makes stable combustion high potential in stable flame even at the low-load operation. 9

10 Coal Feed Pipe Grinding Roller Grinding Table Air Port Raw Coal Distributer Classifier Reject Chute Roller Pressurize Unit Scraper Fig-7 IHI-VS Pulverizer Fig-8 IHI-WR Burner 4. Design concept for the Sub-bituminous Coal Firing 4.1 Design Coal Property The range of the design coal property is shown in Table-6. The boiler is designed to ensure both of the single coal firing and blended coal firing within this range. Table-7 shows the coal property of the performance coal. Fig-9 is the plot of the design coal on the ASTM coal rank chart. The design coals are widely distributed at the range of bituminous coal and sub-bituminous coal. The performance coal is ranked as Sub-bituminous coal B. We also confirmed that the low rank side coals are distributed at almost the same range of IHI s experienced coals in the USA project. IHI can then design the boiler to realize highly stable and reliable operation under firing these coals by reflecting our reference boilers in USA. In the next section, the design concept for sub-bituminous coal firing is explained. Table-6 Coal Range of the Design Coal Unit Max Min Gross Calorific Value kcal/kg (a.r.) 5,700 4,375 Total Moisture % (a.r.) 38 - Ash % (a.r.) 25 - Total Sulfur % (a.r.) Volatile Matter % (a.r.) - 22 HGI Ash Fusion Temp. (IDT) Reducing, C - 1,000 10

11 Table-7 Coal Property of the Performance Coal Proximate Analysis Ultimate Analysis Outline of the 2 x 1,000 MW USC (Ultra Super Critical) Unit Value Total Moisture % (a.r.) Inherent Moisture % (a.d.b.) Fixed Carbon % (a.d.b.) Volatile Matter % (a.d.b.) Ash % (a.d.b.) 1.50 Carbon % (a.r.) Hydrogen % (a.r.) 3.56 Nitrogen % (a.r.) 0.65 Sulfur % (a.r.) 0.07 Oxygen % (a.r.) Total Moisture % (a.r.) Ash % (a.r.) 1.30 Gross Calorific Value kcal/kg (a.r.) 5,000 : Design Coal for JEP - Straight Burn Coal D i C l f USA j t (f f ) Fig-9 Plot on the ASTM Coal Rank 11

12 4.2 Design Consideration to Sub-bituminous Coal Outline of the 2 x 1,000 MW USC (Ultra Super Critical) Characteristics of Sub-bituminous Coal Generally speaking, sub-bituminous coals have the characteristics shown in Table-8. To prevent any problems caused by such characteristics of sub-bituminous coal, the boiler and auxiliaries have to be designed and operated properly. Because of high volatility, the coal firing system has to be operated properly to eliminate coal accumulation inside of the pulverizer or other parts to avoid catching fire. And, because of characteristics of low calorific value and high moisture content, larger capacity pulverizers and regenerative gas air heater have to be designed compared to the bituminous coal firing boiler. High slagging and fouling potential resulting from the ash characteristics of sub-bituminous coal is the biggest area of concern when designing the sub-bituminous coal firing boiler. Serious slagging and/or fouling will cause reduced heat absorption in the furnace and HRA portion of the boiler. The design consideration against high slagging/fouling potential of sub-bituminous coal is also described in Table-8 below. Table-8 Characteristics of sub-bituminous coal and required design/operation consideration Characteristics Major Concern Countermeasure High Volatility - Pulverizer explosion - Proper operation sequence to eliminate coal - Fire around coal firing system such as burner, accumulation such as clearing and purge operation at the time of Pulverizer trip pulverizer and coal bunkers. - Proper arrangement of protection system such as inert and detection system Low Calorific Value - Capacity of coal firing system - Selection of adequate size pulverizer and regenerative gas air heater. High Moisture - Capacity of hot air High Slagging Potential High Fouling Potential system to dry out coal - Severe slagging at furnace wall and heating element inside furnace - Severe fouling at heating element in heat recovery area - Larger boiler furnace sizing - Lowering furnace exit gas temperature - Burner throat design to minimize the ash deposition - Optimum sootblower for furnace - Wider tube pitch of heating element - Wider tube pitch of heating element - Optimum sootblower arrangement at the heat recovery area - Applying bare-type economizer Design Consideration to High Slagging/Fouling Potential We have to design the boiler to prevent severe slagging and fouling and also have countermeasures to remove slagging and fouling. In the interest of preventing severe slagging and fouling, the furnace heat release rate and furnace exit gas temperature, heating tube arrangement are taken into consideration when reflecting the reference boilers firing Sub-bituminous coals. For the removal of slagging and fouling ash, the 12

13 installation of optimal sootblowers and their adequate arrangement must be carefully considered and designed. The following shows the design of the JEP boiler, with our experiences of sub-bituminous coal single firing boilers in the USA (refer to Table-10). (1) Furnace Sizing (Heat Release Ratio) The furnace size is designed to obtain appropriate furnace heat release rate. In general, the furnace for sub-bituminous coal single firing shall be designed 10~ 15% larger than that of bituminous coal firing to prevent the slagging (refer to Fig-10). Based on the coal property of JEP design coal, the larger furnace size has been applied to realize lower furnace heat release rate and it has been fed back from our experienced USA project as shown in Fig-11. (2) Furnace Sizing (Furnace Exit Gas Temperature) Considering lowest ash fusion temperature among the design coals, the furnace size and the arrangement of the Secondary SH and the Final SH at furnace upper part has been determined to realize the furnace exit gas temperature (FEGT, at the location of Fig-4) lower than limitation. The limitation of FEGT has been set in consideration of the 20 C margin from the ash fusion temperature. (3) Sootblower for Furnace Water sootblower has been applied to the JEP (according to the experienced USA boilers) whereas steam wall deslagger is applied to lower slagging potential condition. Cleaning area and timing by the water sootblower is controlled based on the heat flux value monitored by the sensors on the furnace wall. (4) Less Castable Burner Throat The burner throat is one of the trigger points of ash deposition. IHI has developed the Less Castable type burner throat, well-bending the furnace wall tubes with less castable arrangement. This type of burner throat has been fully applied to JEP boiler. Please refer to Fig-12. (5) Tube Panel Pitch of Superheater and Reheater To prevent slag bridging between panels of heating panels and ash accumulation onto the horizontal tubes at the heat recovery area, wider tube pitch is designed, as shown in Table-9. (6) Sootblower Arrangement To remove the accumulated ash on the heating elements, an appropriate number of the sootblowers arranged at proper locations are required. JEP have 42 sets of sootblowers (excluding economizer sootblowers) as shown in Fig-13 and it is 13

14 more than USA projects. Two rows ( double ) of sootblowers are arranged at the primary reheater and primary superheater area. (7) Economizer The bare tube type economizer has been applied to the sub-bituminous coal firing boiler to prevent the ash piling and/or accumulation on it. Economizer sootblowers are also arranged around the economizer. Sub-bituminous Coal Firing Large Bituminous Coal Firing Base Fig-10 Coal Type and Furnace Size : Bituminous Coal Firing : Sub bituminous Coal Firing Fig-11 Furnace Plan Area / Volume Heat Release Rate 14

15 Less Castable Burner Throat (after modification) No remarkable ash adherent Normal Burner Throat (before modification) Ash adherent Ash adherent Castable CL of Burner CL of Burner Furnace Inside Furnace Inside Normal Burner Throat Fig-12 Comparison of Burner Throat Less Castable Burner Throat Table-9 Comparison of Tube Pitch (Panel Pitch), [mm] Sec. SH Final SH Sec. RH Pri.RH Pri.SH JEP 2, / /165 A Plant 2, N/A 220/ /165 B Plant 1, /378 N/A 283.5/ / C Plant 1, /378 N/A 283.5/ / Tube Pitch (Panel Pitch) Base Tube Pitch (Panel Pitch) Wider Tube Pitch 15

16 : Location of Sootblower Fig-13 Arrangement of Sootblowers Table-10 Comparison of Boiler Design JEP A Plant B Plant C Plant Bituminous Coal Firing Boiler (Typical) Coal Type Sub-bituminous Sub-bituminous Sub-bituminous Sub-bituminous Bituminous Furnace Large Large Large Large Base Sizing Type of Furnace Sootblower Type of Burner Throat Tube Pitch (Panel Pitch) Number of Sootblower Economizer Tube Economizer Sootblower Water Sootblower Less Castable Type Water Sootblower Water Sootblower Water Sootblower Wall Deslagger Normal Type Normal Type Normal Type Normal Type Wide Wide Wide Wide Base 42 sets (More than base) More than base More than base More than base Base Bare Type Bare Type Bare Type Bare Type Finned Type Applied Applied Applied Applied NOT applied 16

17 5. Performance of the Plant 5.1 Plant Efficiency By applying USC steam condition, the plant heat rate has been drastically improved compared with the sub-critical coal fired power plants which are commonly operated in Malaysia. The guaranteed net plant heat rate for JEP is improved more than 6% (relative) from the reference plant of sub-critical coal fired power plant in Malaysia as shown in Fig-14. This improvement corresponds to the reduction of more than 10 million tons of coal consumption for two units (considering 25 years operation) and approximately 700 million USD of fuel cost (based on 70 USD/t). 5.2 Flue Gas Emission Flue gas emissions comply with the regulations of Malaysia as shown in Table-11. The value of NOx can be achieved without SCR system. CO 2 emission is approximately 0.84 t-co 2 /MWh (at 100% Load, Performance Coal). CO 2 emission has been reduced, as well as the plant net heat rate improvement. Fig-14 Net Heat Rate of the Plant Table-11 Flue gas emission (6% O 2 dry, 0 C and 1atm) Unit Limitation of Emission Level Total prticles emission at ESP outlet mg/nm 3 50 SO2 emission at stack outlet mg/nm NOx emission at stack outlet mg/nm CO emission at stack outlet mg/nm Mercury at stack outlet mg/nm PCDD/PCDF at stack outlet ng TEQ/Nm HCl at stack outlet mg/nm HF at stack outlet mg/nm

18 6. Conclusion Outline of the 2 x 1,000 MW USC (Ultra Super Critical) This paper has presented the outline of the Jimah East Power Project and feature of IHI s USC boiler. The design concept and the expected performance of the boiler plant with the sub-bituminous coal single firing were also introduced. The boiler plant is well-designed to achieve both USC steam condition and stable operation firing sub-bituminous coal. Now the project is ongoing and the plant will start commercial operation in IHI is pleased to provide a state-of-the-art and highly reliable coal fired power plant. It will contribute to stable electrical power supply and further economic growth in Malaysia and also global energy issue. 18

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