Principal Modernization Solutions for a 300 MW Power Unit to be Converted to Operate at Ultra-Supercritical Steam Parameters

This paper analyses the state of power engineering in Ukraine and the main trends in the development of the world market in the field of converting high-capacity powerful power units of thermal power plants into ultra-supercritical (USC) ones. It is shown that the energy sector of Ukraine requires special attention and the introduction of new modern technical solutions. Worldwide trends indicate that the emphasis is now on increasing the steam parameters before a turbine to ultra-supercritical ones. This allows one both to increase the efficiency of power units and to reduce thermal emissions, fighting the global environmental problem of climate warming. The implementation of this approach is proposed taking into account the realities of the Ukrainian economy and the available technical capabilities of the power engineering industry. This paper presents the results of variational computational studies of the thermal scheme of the 300 MW power unit of the K-300-23.5 turbine to be converted into a USC one. The problem was solved under the condition of maximizing the preservation of the thermal scheme, increasing the efficiency of the power unit and minimizing capital investments during the modernization of the turbine. It was chosen to preserve the regeneration system, as well as the medium-pressure (MP) and low-pressure (LP) cylinders. Considered and calculated were variants with the addition to the existing turbine of a USC cylinder and the creation of a new high-pressure cylinder (HPC) with insignificant changes in its overall characteristics. The results of computational studies showed that the most rational variant for modernizing the 300 MW turbine plant is the creation of a new HPC designed for operation at USC steam parameters as well as the addition to the IPC of a new cylinder with the purpose of increasing the reheat steam parameters while preserving the regeneration system.

Optimization of Integrated Gasification Combined-Cycle Power Plant for Polygeneration of Power and Chemicals

Efficient and flexible operation is essential for competitiveness in the energy market. However, the CO2 emissions of conventional power plants have become an increasingly significant environmental dilemma. In this study, the optimization of a steam power process of an IGCC was carried out, which improved the overall performance of the plant. CCPP with a subcritical HRSG was modelled using EBSILON Professional. The numerical results of the model were validated by measurements for three different load cases (100, 80, and 60%). The results are in agreement with the measured data, with deviations of less than 5% for each case. Based on the model validation, the model was modified for the use of syngas as feed and the integration of heat into an IGCC process. The integration was optimized with respect to the performance of the CCPP by varying the extraction points, adjusting the steam parameters of the extractions and modifying the steam cycle. For the 100% load case, a steam turbine power achieved increase of +34.2%. Finally, the optimized model was subjected to a sensitivity analysis to investigate the effects of varying the extraction mass flows on the output.

Numerical simulation of fuel staged swirl combustion in the invert furnace of boiler on advanced ultra-supercritical steam parameters

The paper considers the schemes of Kuznetsky lean coal combustion for the M-shaped boiler. With such a boiler profile, it is possible to significantly reduce the length of main steamlines, which is especially important for the advanced ultra-supercritical parameters of the superheated steam. The furnace in this boiler unit is performed downward (invert). In this work, the aerodynamics of 6 combustion schemes was simulated by means of computational fluid dynamics. All considered schemes were designed on the basis of direct-flow burners and nozzles. For the most aerodynamically reasonable scheme the thermal processes in the boiler furnace firing Kuznetsky lean coal have been simulated by means of computational hydrodynamics. The simulation results showed a high efficiency of fuel burnout: loss due to unburned combustible equaled 0.1%, carbon-in-ash loss equaled 0.8%. Carbon monoxide concentration at the furnace outlet in conversion to excess air equal α = 1.4 amounted 226 mg/m3, the nitrogen oxides concentration in the flue gases (in conversion to normal conditions) equaled 424 mg/m3. It is appropriate to use the results obtained in this research in the development of new solid fuels combustion schemes.

FACTOR ANALYSIS OF THE THERMAL SCHEME OF CHP WITH SUPER CRITICAL STEAM CYCLE ON THE BASIS OF EXERGY METHOD

The most promising direction of CHP modernization is the introduction of power units on supercritical steam parameters. Increasing steam parameters is one of the most effective ways to increase the efficiency of a CHP plant. Thus, the development of the concept of thermal schemes turbines for supercritical steam parameters, taking into account the characteristics of their operation at the existing CHP Ukraine is an actual scientific problem. The solution to this problem will make it possible to replace or modernize the power generating equipment that has exhausted its resource with modern power units that meet world economic and environmental standards. The method of exergy analysis is adapted to the study of thermal schemes of CHP plants with supercritical steam cycle. As an example of application of a method the exergy analysis of the power plant working on the one-stage thermal scheme is carried out. Within the framework of the proposed method, a thermodynamic and topology-exergetic model of the power plant is created. Based on the topology-exergetic model the indicators of thermodynamic efficiency of the power plant operating on supercritical parameters of steam are determined. It is proposed to apply the theory of experiment planning in exergy analysis of the thermal circuit of a CHP. With the involvement of this theory, a multifactor numerical experiment was conducted to determine the impact on the exergetic efficiency of the thermal scheme of CHP of the main determining variable factors, such as adiabatic and thermal efficiency of the plant, as well as the operating parameters. The generalized equation of functional interrelation of exergetic efficiency of system and exergetic efficiency of elements of thermal scheme of CHP is received. The proposed equation can be used as a tool for further training of neural networks and their application both in the design and in the diagnosis of energy efficiency of CHP. According to the results of the factor analysis, a rather high conservatism of the considered one-stage scheme of CHP to the change of the varied parameters was revealed. This indicates the presence of more rigid structural links between the elements, which is generally a positive aspect of the reconstruction.

Thermal Characterization of a Steam Turbine Casing Including Measuring of Adiabatic Wall Temperatures Using Proprietary Sensors

Modern steam turbines must increasingly be designed for flexible operation. However an increasing amount of cold starts and load changes have a massive impact on fatigue resistance of the material. So the monitoring of thermal parameters of the casing is significant for checking thermally induced stresses and furthermore lifetime calculation. Additionally the measurement data is helpful for CFD validation reasons. This paper presents a new proprietary developed sensor setup and measurement results. The sensors are flush mounted into a steam turbine at different axial and circumferential locations in the recirculation area between the intermediate and the lower pressure turbine. Hence it is possible to detect temperatures, temperature gradients and heat flux in the part of the wall near the fluid. Moreover the field of temperature within the sensor can be modulated by powering an installed heater. So the adiabatic wall temperature can be identified. For measuring the temperature gradient, seven equidistant spaced thermocouples were used in difference circuit. Therefore two different types of thermocouples were applied. Both types have better transfer characteristics compared to a thermocouple of type K. High amplification enables monitoring of small differences in temperature. The temperature measures an integrated resistor thermometer. The sensors are applied on a real 12 MW industrial steam turbine with maximal live steam parameters of 400 °C and 30 bar. The measurements show various operation points and load changes.

INCREASING THE EFFICIENCY OF COMBINED PRODUCTION HEAT AND ELECTRICITY

The main directions of increasing the efficiency of combined production of electric and heat energy are considered, associated with the improvement of power generating equipment, regime and circuit changes in heat supply systems while ensuring heat load. For many years, centralized heat supply based on combined heat and power generation has been successfully developing in Russia, which is a very attractive energy and nature saving technology. Its use makes it possible to save about 20 million tons of fuel annually, which is about 14% of the total volume of fuel consumed in Russia for the needs of heat supply. More than 50% of electricity is generated at CHPPs in Russia, and the efficiency of fuel use at them reaches about 70–75%. Such areas include the use of steam and gas technologies (CCGT units and gas turbine superstructures of equipment of operating CHPPs) and GTU-CHPPs, increasing the initial steam parameters at CHPPs, superstructure of hot water boilers with gas turbine units, improvement and modernization of existing turbine equipment and CHPP schemes, as well as rejection of peak boilers in favor of peak boilers at CHPPs, transition to a lower temperature schedule and a change in the structure of heat supply systems. The main advantages of these areas and the problems associated with their implementation are presented. The conditions of possible and expedient application of some directions are considered. It is shown that, in many respects, the choice of certain technical solutions, despite the energy efficiency, is determined by the conditions of the regional heat and electric energy markets.

DEVELOPMENT OF CONCEPTUAL TECHNICAL SOLUTIONS AND METHODS OF THEIR IMPLEMENTATION DURING THE DESIGN OF A DUST COAL STEAM GENERATOR OF SUPER-SUPER CRITICAL PARAMETERS OF STEAM 28 MPa / 600 °С / 600 °C FOR 300 MW ENERGY UNIT. PART 2

In the second part of the work, using the mathematical model described in first unit, a direct-flow pulverized coal boiler with supercritical steam parameters of 28 MPa /600 °C /600 °C was calculated for a 300 MW power unit at loads of 50–70 %. It is shown that: a) the temperature of contaminated screens 1234 °С in the active combustion zone, where 92 % of the initial fuel burns out, is lower than the temperature of slagging beginning (1268 °С) of ДГ-100 coal, which indicates the slag-free operation of the screens of the lower radiation part (LRP) b) over the entire range of the boiler load change of 50–100 %, the temperature at the exit from the active combustion zone will be higher than the minimum permissible temperature of 1250 °C, below which the flame is attenuated; c) upon transition to 50 % load, the temperature of gases at the outlet from the active combustion zone decreases from 1506 °C to 1342 °C, as a result of which the specific thermal stress of the LRP screens decreases by 1.469 times, while the feed water consumption at the inlet of the boiler falls by 2 times, which leads to an increase in the temperature of the LRP steam, the middle and upper radiation parts, screens of the ceiling and rotating chamber; d) to reduce the thermal stratification of the inlet stage of the secondary steam superheater (ППП1), and as a consequence, the pipe wall temperature, it is necessary to divide the ППП1 surface into two packets, installing an intermediate mixing manifold between them with full steam mixing. Bibl. 5, Fig. 13, Tab. 3.

A mathematical model of the double-pipe system with TBCs application

Following Rankine’s cycle efficiency, steam with ever-higher parameters is used to improve the efficiency of advanced ultra-supercritical power plants. The high steam parameters require the use of expensive high-alloy steels. Therefore, design concepts with reduced investment costs are more and more popular. In the power industry, the use of thermal barrier coatings to protect components exposed to high temperatures is becoming ever more common. The innovative concept is a double-pipe system with a thermal barrier that provides insulation for the primary pipe, in which ultra-supercritical steam flows. On the outside, the pipe is cooled by lower performance steam. The following paper presents a two-dimensional mathematical model of the proposed solution. A set of heat transfer equations allows the determination of the temperature field in the steady and transient-state operation of such a system. The numerical model is compared with the CFD one. The temperature gradient in the inner pipe wall with and without coating was determined. In addition, the response of the wall temperature to the step-change of the steam temperature was investigated. The paper shows that the use of TBCs allows reducing high-alloy steels and improving the handling properties of thick-walled components.