Preliminary Agenda 040511 - EPRImydocs.epri.com/docs/publicmeetingmaterials/1104/7GNN4VBV5D6/E... · Agenda Workshop on the US Dept of Energy/Ohio Coal Development Office Advanced

Agenda

Workshop on the US Dept of Energy/Ohio Coal Development Office Advanced Materials for Ultrasupercritical Power Plants Projects

April 7th, 2011 Hotel Monaco

Washington, DC 20004 Athens Room

Thursday, April 7th Time Topic Presenter 7:00 a.m. Breakfast 8:30 a.m. Department of Energy (DOE) Welcome

Ohio Coal Development Office Welcome Vic Der, DOE R. Purgert, EIO

9:00 a.m. Keynote Address J. Wheeldon, EPRI 9:30 a.m. Discussion 10:00 a.m. Break 10:20 a.m. A-USC Boiler Design & Operation I. Perrin, ALSTOM 10:40 a.m. A-USC Steam Turbine Materials & Design R. Schwant, General Electric 11:00 a.m. Boiler Fabrication & Welding Successes J. Tanzosh, B&W 11:20 a.m. In-Plant Fireside Corrosion Testing H. Hack, Foster Wheeler 11:40 a.m. US Manufacturing Capacity R. Purgert, EIO 12:00 p.m. Lunch 1:00 p.m. A-USC Technology Readiness D. Koza, Bechtel 1:20 p.m. Path Forward J. Phillips, EPRI 1:40 p.m. Feedback and Survey J. Phillips, EPRI 2:40 p.m. Adjourn

“Opening the Door to the Coal Power Plant of Tomorrow”

J. ShingledeckerSenior Project Manager, EPRI Fossil Materials & Repair Program

EPRI Workshop on the US Department of Energy Ohio Coal Development Office Advanced Materials for Ultrasupercritical Power PlantsApril 7, 2011 Hotel Monaco, Washington, D.C.

2© 2011 Electric Power Research Institute, Inc. All rights reserved.

Acknowledgements: U.S. Department of Energy (US DOE) / Ohio Coal Development Office (OCDO) A-USC Steam Boiler and Turbine Consortia

Federal – State – National LaboratoryNon Profit – For Profit

Cost Sharing Consortium

Federal – State – National LaboratoryNon Profit – For Profit



Agenda

Adjourn2:40 p.m.J. Phillips, EPRIFeedback and Survey1:40 p.m.J. Phillips, EPRI•Path Forward1:20 p.m.D. Koza, BechtelA-USC Technology Readiness1:00 p.m.

Lunch12:00 p.m.R. Purgert, EIOUS Manufacturing Capacity11:40 a.m.H. Hack, Foster WheelerIn-Plant Fireside Corrosion Testing 11:20 a.m.J. Tanzosh, B&WBoiler Fabrication & Welding Successes11:00 a.m.R. Schwant, General ElectricA-USC Steam Turbine Materials & Design10:40 a.m.I. Perrin, ALSTOMA-USC Boiler Design & Operation10:20 a.m.

Break10:00 a.m.Discussion9:30 a.m.

J. Wheeldon, EPRIKeynote Address9:00 a.m.

Vic Der, DOER. Purgert, EIO

Department of Energy (DOE) Welcome Ohio Coal Development Office Welcome

8:30 a.m.Breakfast7:00 a.m.


Housekeeping & Goals

• Safety• Fact booklet (EPRI Report 1022770)• Introductions• Meeting Goals

1. What reservations or concerns would you have about using this technology in a commercial power plant?

2. What aspects of this technology still need to be proven before it is ready for use in a commercial power plant?

3. What is the best way to test this technology to show that it is ready for use in a commercial power plant?

4. Would you or one of your colleagues be willing to serve on an advisory panel to the research consortium as we plan the next stage of this project?


Together…Shaping the Future of Electricity

11

-Ohio 501(c)3 Non Profit

-Address Energy Supply & Demand Efficiency

-Focus on Baseload Producers/Intensive users

-Foster CollaborationsFoster CollaborationsFederal, State, University, National Federal, State, University, National Laboratories & Private IndustryLaboratories & Private Industry

Welcomewww.energyinohio.org

Federal State National Laboratory Non Profit For Profit


Ohio Coal Ohio Coal DevelopmentDevelopment

OfficeOffice

$50 Mil Project

Consortium of All U.S. Boiler and Turbine Manufacturers and EPRI

Success Story for Resource Leveraging: ~15% Ohio Coal Development Office~20% Team Members~65% U.S. DOE (NETL)+ Oak Ridge National Laboratory

Ohio involved as a major user and producer of energy (6th in U.S., 4th forIndustrial); to insure high sulfur eastern coal included

Advanced UltraSuperCritical Materials Advanced UltraSuperCritical Materials for Coal Fired Power Generationfor Coal Fired Power Generation

Project OversightProject Oversight

Program Management– EIO is Administrative Lead and Prime Contractor– EPRI is Technical Lead Organization– Industry Members are Task Leaders– ORNL and NETL-ARL for Metallurgical Support

Program Technical Steering Committee oversees technical aspects via Quarterly MeetingsProgram Management Oversight Committee exists for high level Business/Administrative Decisions

Consortium ModelConsortium Model

Based Upon:Based Upon:–– Memo of Understanding amongst membersMemo of Understanding amongst members–– Formal Agreement for IP Sharing/Patent RightsFormal Agreement for IP Sharing/Patent Rights–– Defined Reporting Formats and integrationDefined Reporting Formats and integration–– Established Communication Protocols Established Communication Protocols –– A refined Budget integration process for team w/A refined Budget integration process for team w/

Differing Fiscal YearsDiffering Fiscal YearsDiffering Accounting Regulations (profit/non)Differing Accounting Regulations (profit/non)Differing Invoice formatsDiffering Invoice formats

Year 9 of Successful 1Year 9 of Successful 1stst Time Ever ApproachTime Ever Approach

Progress to Date Progress to Date and Goals and Benefitsand Goals and Benefits

Initial Phase I efforts were completed per budget (offset Initial Phase I efforts were completed per budget (offset increases for test materials with other savings)increases for test materials with other savings)Project Phase II completion is scheduled for 2013 Project Phase II completion is scheduled for 2013 (managed thru interruptions due to budget issues)(managed thru interruptions due to budget issues)Phase III (Last Lap) will likely end consortium activities Phase III (Last Lap) will likely end consortium activities due to U.S. antidue to U.S. anti--trust considerationstrust considerations–– Proprietary Phase would follow for commercializationProprietary Phase would follow for commercialization

Promotes economic expansion by providing the U.S. with Promotes economic expansion by providing the U.S. with an environmentally responsible energy resourcean environmentally responsible energy resourceProvides an opportunity for transitioning U.S. industrial Provides an opportunity for transitioning U.S. industrial capabilities into advanced energy supplierscapabilities into advanced energy suppliers

© 2011 Electric Power Research Institute, Inc. All rights reserved.

Introduction to Advanced Ultra-Supercritical Workshop

John Wheeldon ([email protected])EPRI Generation Technical Executive

Washington DC, April 7, 2011


What Do We Hope to Achieve Today?

• Identify the economic benefits offered by advanced ultra-supercritical (A-USC) PC units with steam temperatures of 1300 to 1400°F– Could also be a circulating fluidized-bed combustor– Both technologies could be air-fired or oxy-fired.

• Relate the success of the DOE Boiler and Steam Turbine MaterialsProgram in identifying and characterizing materials for use at these temperatures.

• Gain support from the utility industry in transitioning the program from materials research to technology deployment– Form an Advanced Generation Advisory Panel.• Identify what is needed to commercialize A-USC technology– Establish basis on which to advance demonstration project– Identify what else is needed to proceed.


Advances in PC Power Plant Technology

(*) Values based on Illinois #6: heating value 11,000 Btu/lb with 3.2% sulfur, without CCS

Year 1921 2010 2025

Net output , MW 40 750 750Efficiency, % (HHV) (*) 24 38 up to 50Main steam temperature, °F 611 1,050 up to 1,400Main steam pressure, psia 315 3,515 up to 5,015SO2, lb/MWh 84 1.1 0.07NOx, lb/MWh 9.1 0.6 0.07CO2, lb/MWh 2,850 1,840 As low as 1,400

DOE A-USC Materials Program established to identify enhanced boiler and steam turbine materials to raise generating efficiency


Coal with Carbon Capture and Storage Essential if Electricity to Remain Affordable

• Coal-fired power plant technology must re-invent itself to remain amajor provider of electricity– Driven by need to reduce CO2 emissions.

• Analysis by EPRI and the International Energy Agency concludes that such re-invention is essential if CO2 reduction is to be achieved while maintaining affordable electricity.

• Over reliance on natural gas will place price pressure on power andnatural gas– Consumer adversely affected by cost increase in two energy sources.• Recent history emphasizes that fuel diversity is a vital component in

keeping power prices low.

“Prism/MERGE Analyses: 2009 Update”, EPRI Report 1019563, issued July 2009


EPRI’s MERGE-Prism Analysis: 2009U.S. Power Production Deployment

2030 COE +50% (*)2030 COE +90% (*)

2050 COE +210% (*) 2050 COE +80% (*)

(*) Relative to 2007


Re-Inventing and Demonstrating Coal-Fired Power Plant Technology

• Dual development approach– Raise steam towards 1400°F

to increase generating efficiency and reduce CO2/MWh: less CO2 tocapture, transport, and store.

– Add cost-effective CO2capture and storage (CCS) technologies when available

• PRISM-MERGE analysis indicates that US will not require significant amounts of new coal-fired generation until 2025– The interim period allows for technologies to be demonstrated and be

commercially available by that time.


45%+ Generating Efficiency, the “No-Regrets”Approach

• If 1400°F technology was available 10 years ago and used on all coal plants brought on-line in the US between 2006 and 2012 ( 21GW), 16 million tonnes CO2 peryear would be avoided starting in 2013– Avoided cost below $20/tonne

• How long will it be before the US will have 16 million tonnes CO2/yravoided via CO2 Capture and Storage projects?

Will we have similar regrets in 2025 or will we make A-USC happen?

0

50,000,000

100,000,000

150,000,000

200,000,000

250,000,000

300,000,000

350,000,000

2006

2008

2010

2012

2014

2016

2018

2020

2022

2024

2026

2028

2030

Cum

ulat

ive

CO

2 Avo

ided

(ton

nes)

16 million tonnes/yr


When CO2 Capture Included, Higher Generating Efficiency Lowers Levelized Cost-of-Electricity

Capture only. Transportation and storage costs also reduced by improved efficiency

Based on current post-combustion capture (PCC) technology with KS-1.

Oxy-combustion projected to be similar.

Relative COE will fall as technologies improve. ARPA-E investigating next

generation CCS.


Why Care About New Coal Power Plant Technology?

• In US construction of new coal power plants has slowed greatly– Plants being retired in response to tighter environmental controls.

• While market for new coal power not favorable now, the past few years have shown how volatile the outlook for power generation can be– Is it wise to put all eggs in the natural gas basket?– Gas price is volatile: if all new generation is natural gas fired,

electricity prices will fluctuate correspondingly– Gas is a fossil fuel and emits CO2: eventually CCS will be applied to

NGCC.• Advanced coal-fired USC technology will help stabilize electricity prices

and keep them affordable, but if it is to be available in 2025 need to work on it today.

Fuel diversity continues to have value in stabilizing cost of electricity


Timeline: Why Action is Required Now

(1) NRG 60-MW slipstream on Parish #5, AEP 235-MW slipstream on Mountaineer

(2) Could include improved solvents , membranes, and ARPA-E technologies

(3) Ameren 200-MW repowering Meredosia #4

Engage now to ensure continuity of program and to prepare for demonstration


EPRI Study of 1290°F Advanced USC PC: Design Basis

• 750-MW A-USC PC fired with sub-bituminous coal with air as oxidant– Vertical-tube boiler, two-pass arrangement, regenerative air heater – Steam conditions 5100 psia/1290°F/1330°F, based on conditions

included in European AD700 Materials Program.• CaBr2 injection, opposed wall-fired LNB with overfire air, SCR, ESP (with

provision for brominated activated carbon injection if required), wet FGD– NOX & SO2 = 0.03 lb/MBtu, PM (f plus c) = 0.02 lb/MBtu, 90%

mercury capture.• WorleyParsons designed balance-of-plant and environmental controls,

Doosan Babcock designed the boiler, and Siemens provided steam turbine design data.

• Presentation concentrates on results of study– Additional details presented in Notes Section.

Cost data are in mid-2007 dollars and not adjusted for recent price increases


Performance Summary of Four PC Designs Fired with Sub-Bituminous Coal

Subcritical Supercritical 1100°F USC 1290°F A-USC

Main stream, °F/psia 1005/2600 1080/3800 1120/4000 1290/5100

Net efficiency, % (HHV) 36.5 38.5 39.2 43.4

Net heat rate, Btu/kWh (HHV) 9370 8880 8720 7880Coal flow lb/hr 840,600 797,000 782,700 707,000Flue gas, ACFM 2,107,000 2,016,000 1,982,000 1,791,000

Make-up water, gpm 4,260 3,750 3,650 3,300

NOX & SO2, lb/MWh 0.280 0.266 0.261 0.236

CO2, lb/MWh from plant 1980 1880 1840 1660

CO2, lb/MWh from mining and transportation (*) 146 139 136 123

(*) Values based on life-cycle assessment model prepared by Carnegie Mellon University

CO2 emissions per MWh from 1290°F A-USC unit are 16.2% lower than emissions from state-of-the art subcritical unit


Economic Summary of Four PC Designs Fired with Sub-Bituminous Coal

Technology Sub SCPC 1100°FUSC

1290°FA-USC

Fuel Cost, $/MBtu (HHV) 1.80 1.80 1.80 1.80TPC,$/kW 1,780 1,800 1,840 1,990Fixed O&M, $/kW-yr 48.5 49.1 50.3 54.3Var. O&M, $/MWh 1.57 1.47 1.43 1.33Efficiency, % (HHV) 36.5 38.5 39.2 43.4Capital, $/MWh 28.9 29.3 29.9 32.3O&M, $/MWh 8.1 8.1 8.2 8.6Fuel, $/MWh 16.9 16.0 15.7 14.2LCOE, $/MWh (1) 53.9 53.3 53.8 55.1Dispatch cost, $/MWh (2) 18.5 17.5 17.1 15.5

A-USC LCOE $1.8/MWh higher than SC PC but dispatch cost $2.0/MWh lower

(1) Basis presented in Notes Section (2) Fuel + Variable O&M


Effect of CO2 Adder and Higher Cost of Sub-Bituminous Coal

Technology Sub SC PC 1100°FUSC

1290°FA-USC

Fuel Cost, $/MBtu (HHV) 1.80 1.80 1.80 1.80LCOE, $/MWh 53.9 53.3 53.8 55.1Dispatch cost, $/MWh 18.5 17.5 17.1 15.5

CO2 adder, $/MWh (1) 24.8 23.5 23.0 20.8LCOE, $/MWh 78.7 76.8 76.8 75.9

Dispatch cost, $/MWh 43.2 41.0 40.1 36.3

Fuel Cost, $/MBtu (HHV) 3.60 3.60 3.60 3.60LCOE, $/MWh (2) 70.7 69.3 69.5 69.3Dispatch cost, $/MWh (2) 35.4 33.5 32.8 29.7

Economic benefit of A-USC enhanced by both CO2 adder and higher fuel cost

(1) $25/ton of CO2 (2) No CO2 adder only fuel cost


Coal Plants Dispatch Ahead of NGCC Plants with or without CCS

(1) Coal $1.80 MBtu, gas $5.00/MBtu (2) Average CF in 2008 (3) $25/ton CO2

• Lower dispatch cost for coal results in low capacity factors for NGCC– COE for NGCC at lower capacity factor higher than that of coal plant– This is part of why coal with CCS is essential in keeping electricity affordable.

Capacity factor, %

LCOE, $/MWh Dispatch cost, $/MWh

+ CO2 adder (3) + CO2 adder (3)1290°F A-USC PC (1) 85 55.1 75.9 15.5 36.32 x 7FB NGCC (1) 85 51.0 (*) 61.6 38.3 48.92 x 7FB NGCC 40 (2) 69.2 (**) 80.9 42.1 53.8

With 90% PCC (similar results for oxy)

1290°F A-USC PC (1) 85 87.9 90.8 19.6 22.52 x 7FB NGCC (1) 85 68.5 69.8 46.7 48.02 x 7FB NGCC 40 (2) 97.6 99.0 51.2 52.6

For natural gas at $10.00/MBtu COE increases to (*) $87.6 /MWh and (**) $109.5/MWh


Avoided Cost of CO2

Technology Sub SC PC 1100°FUSC

1290°FA-USC

LCOE, $/MWh 53.9 53.3 53.8 55.1CO2, lb/MWh from plant 1980 1880 1840 1660CO2 avoided cost, $/ton

Relative to SC PC Base 25.0 14.5

NETL and EPRI studies show current CCS technologies have CO2avoided costs of ~$50 to 70/ton

Technology SC PC 1350°FA-USC

LCOE, $/MWh 63.2 64.3CO2, lb/MWh from plant 1760 1560

CO2 avoided cost, $/tonRelative to SC PC Base 11.0

EPRI study, PRB coal

DOE-NETL study, Illinois #6


Advanced USC Power Plants & Uncertainty

• High natural gas prices – sitting pretty.• Low natural gas prices – still good, coal plant with lowest dispatch cost.• CO2 restrictions – coal plant with lowest dispatch cost.• No CO2 restrictions – no regrets, lowest dispatch cost, investment utilized.• High construction & materials costs – not good news.• Low construction & materials costs – good news.• High power demand – sitting pretty.• Low power demand – coal plant with lowest dispatch cost.

Provided capital cost can be controlled, A-USC looks good under a variety of scenarios


Comment on Capital Cost Estimate from EPRI Study

• Total Plant Cost for 1290°F A-USC is 11% higher than for SC unit but potential to halve the difference.

• In 2007 cost of Alloy 617 varied from $12.60/lb to $23.10/lb; $17.80/lb used in study. Cost is lower than that today!

• Vendors estimated installation cost of the high-nickel alloy, high-energy piping to be 3 times greater than for SC PC units and general fabrication costs to be 2 times greater– Factors will come down with installation and fabrication experience.

TPC, $M1290°F A-USC PC 1,494SC PC 1,348Delta 146

Demonstration project will be first-of-a-kind and differential cost will be higher: need Government support to cover this differential


Improvements to EPRI Thermodynamic and Economic Performance Estimates

• Possible measures to raise base efficiency from 43.4 percent– Back-end heat recovery can raise efficiency by 1% point to 44.4%

• Recovered water may be of benefit as well as reducing water usage in FGD: CCS increases water usage

– Double reheat can raise efficiency by 0.7% point to 44.1%• Less effective than at lower steam temperatures and reduced

temperature driving forces result in large heat transfer bundle– Raising steam conditions to 5015 psia/1350°F/1400°F raises efficiency by

1.2 % points to 44.6%: US DOE Materials Program objective• Lower capital cost by locating A-USC plant at a retired power station– For example one 500-MW A-USC unit with 45 % efficiency will have 40 %

lower CO2 emissions than 3 x 160 MW units with 32 % efficiency.

Potential to raise efficiency to over 46% for PRB (over 48% for bituminous), but still need to determine cost effectiveness of measures proposed


Efficiency Gains with CCS Incorporated

• 1100°F Series USC loses 7.7 efficiency points once CCS incorporated.

• By going to 1300 – 1400°F A-USC conditions, plus select other improvements this loss can be more than recovered– Economic evaluation to

determine most cost-effective A-USC temperature of steam,1300 –1400°F

• Net efficiency improvements will be enhanced by CCS improvements.

(1) Back-end heat recovery (2) Double reheat

(3) 1350°F with back-end heat recovery and double reheat


What You Will Hear from the Materials Program


“Last-Lap” Proposal

• Need to develop the supply chain to provide the materials and components to build an A-USC power plant.

• Need to build and operate an A-USC demonstration plant 350+ MW to be in service by 2020 to meet anticipated commercial demand in 2025.

• First-of-kind with higher cost and higher risk: –Need industry-government partnership to cover differential cost

compared to conventional unit–What measures does the industry need to see completed to limit risk?

• A test facility testing materials and components in an operating boiler for ~15,000 hours to prove materials in commercial setting.

• Or would you be prepared to proceed directly to demonstration?

Cannot proceed to demonstration phase without participation of the end user in defining the necessary course of action


Together…Shaping the Future of Electricity


Supplemental Slides


Design Basis for 1290°F A-USC Study

• NOX leaving furnace = ~150 mg/Nm3 (0.15 lb/MBtu), SCR efficiency = 80% to achieve ~30 mg/Nm3 (0.03 lb/MBtu)

• SO2 capture efficiency = 96%• Steam conditions 349 bar/680°C/700°C (5100 psia/1256°F/1292°F)• Some cost-cutting measures based on European experience – Single back-end flue gas train

• Induced draft fan reliability does not adversely impact plant availability• Four mill trains without spare– 85% load on three trains


Design Basis for 1290°F A-USC Study (cont’d)

• Plant laid out to accommodate second unit and to minimize run of high-energy piping

• Designed to maximize efficiency–Boiler efficiency = 87.2%; air heater exit temperature = 249°F (121°C)–Five LP feedwater heaters and three HP feedwater heaters• Single-flow HP stage, double-flow IP stage, three double-flow LP stages– Isentropic efficiencies = 90%, 94.2%, and 88.6%, respectively– Individual casings and sliding pressure control over load range


• Design prepared with CO2 capture in mind– Motor-driven feed pump to preserve steam for use in capture plant

• In Europe, motors are available at required size at lower cost than turbine drive

• Shaft drive off turbine would be more cost-effective and is being investigated

• Full-flow tubular air heater considered, but preliminary assessment found it not to be cost-effective– ~80% of air leakage is from primary air flow, so smaller tubular air

heater may be cost-effective (still to be evaluated)• Reduced leakage lowers size of back-end equipment, including CO2

absorber and forced draft fan

Design Basis for 1290°F A-USC Study (cont’d)


Background for COE Table

• Source: Engineering and Economic Evaluation of 1300F Series Ultra-Supercritical Pulverized Coal Power Plants: Phase 1. EPRI Report 1015699, Palo Alto, CA: September 2008.

• Note this study used information from Siemens based on designs for 50 Hz machines. As 60 Hz operation imposes more stress on rotating components the study elected to reduce steam temperatures by 40°F to achieve strength requirements. DOE Materials Program will overcome this limitation so the temperature has been raised up to 1290°F and the efficiency increased by 0.7% points.

• Footnotes:1. Mid-2007 dollars, 30-year book life, carrying charge = 0.121,

capacity factor = 85%, no CO2 emissions cost2. Dispatch cost = fuel cost + variable O&M


Effect of Coal Type on 1290°F A-USC Power Plant Performance

Location Kenosha, Wisconsin (3) Texas (2)Fuel PRB Ill #6 Pitts #8 Lignite LigniteFuel Cost, $/MBtu (HHV) 1.8 1.9 2.6 1.0 1.0

TPC,$/kW 1,990 1,950 1,840 2,380 1,840Fixed O&M, $/kW-yr 54.3 56.2 53.4 52.8 49.6Var. O&M, $/MWh 1.33 2.66 1.52 4.37 4.37Efficiency, % (HHV) 43.4 44.2 45.4 41.3 41.3Capital, $/MWh 32.3 31.7 29.9 38.7 29.9O&M, $/MWh 8.6 10.2 8.7 11.5 11.0Fuel, $/MWh 14.2 14.7 19.6 8.3 8.3LCOE, $/MWh (1) 55.1 56.6 58.2 58.4 49.2Dispatch cost, $/MWh (1) 15.5 17.3 21.1 12.7 12.7

(1) See notes on separate slide (2) Mine mouth location

(3) Lignite not available in Wisconsin but data provided for comparison

A-USC Boiler Conceptual Design“What is the same and what is different about this

technology?”

7 April 2011

Ian J. Perrin

© ALSTOM 2011. All rights reserved. Information contained in this document is indicative only. No representation or warranty is given or should be relied on that it is complete or correct or will apply to any particular project. This will depend on the technical and commercial circumstances. It is provided without liability and is subject to change without notice. Reproduction, use or disclosure to third parties, without express written authority, is strictly prohibited.

A-USC Boiler Conceptual Design - IJP - 7 Apr 2011 - P 2

Agenda

Introduction

What is the same?

What is different?

Design Challenges

Next steps



Why A-USC?

• The use of advanced materials for increased steam conditions is an attractive strategy…

- Evolutionary technology• We have been doing this for a while!• A-USC technology familiar to power industry

- Complemented by other efficiency improvements• Steam turbine efficiency• Flue gas heat recovery• Double reheat• Other plant improvements

- Compatible with CO2 capture• Oxy-firing• Post combustion capture

Oxy – PC Power Plant Concept



Agenda

Introduction

What is the same?

What is different?

Design Challenges

Next steps



What is the same? – Boiler Concept

• Boiler arrangement and systems remain the same- Two-pass or tower- Wall or tangential firing- Evaporator concept

• Builds on validated know-how- ASME Code- Design standards- Manufacturing methods- Operating experience

• Back to the future!©

ALS

TOM

200

9©

ALS

TOM

200

9

1350F (730C), 5000 psi (350bar)



©A

LSTO

M 2

009

©A

LSTO

M 2

009

1100F (600oC), 3800psi (258bar) 1350F (730oC), 5000psi (350bar)

What is the same? – Boiler Concept

SH

ECON

RHRH

SH



What is the same? – Boiler Concept• Why are we jumping from 1100F (600C) to 1350F (730C)?

- Because of the jump in material strength and corrosion resistance associated with the move from ferritic and stainless steels to nickel based alloys enables the step.

Temperature Capabilty of Materials

CS

T1 T11T12 T22

T23T91

T92TP304H

TP316H

TP347HS304H

TP310HCbN

IN617H230

IN740H282

400

450

500

550

600

650

700

750

800

Tubing Material (ASME Designation)

Tem

pera

ture

(C) _

Ferritic Steels

Austenitic Steels

NickelAlloy

Approximate temperature capability based on typical stress for boiler tubing.

1000F/1050F Cycle

1100F Cycle

1300F Cycle



What is the same? – Flexibility

• Size- Scalable technology

• 350MW to >1000MW

• Operational- Base load- Cycling- Sliding pressure operation

• Fuels- Burn existing range of fuels

Illustration of sliding pressure operation showing avoidance of steaming in economizer, transition to sub-critical low load operation, and constant SH / RH outlet temperature across the load range.



What is the same? – Emissions Control

• Conventional emissions control equipment- In-furnace (NOx)- SCR (NOx)- Scrubber (SOx)- ESP (Particulate)- Mercury

• CO2 capture options- Oxy-firing- Post combustion capture

Move to A-USC will maintain environmental emissions control and can employ oxy-firing or post combustion CO2 capture



Agenda

Introduction

What is the same?

What is different?

Design Challenges

Next steps



What is different? – Sizes

• Higher efficiency decreases size of some balance of plant equipment for same MW

- In moving from 1100F (600C) to 1350F (730C)- 8% reduction in flue gas weight

- Auxiliary systems (mills, fans) decrease in size and power consumption.

- Less flue gas to treat decreases size of emissions control equipment



What is different? – Alloys

• More tubing- Gas temperatures remain the same but increased

steam temperatures require more tubing to capture the heat.

• In moving from 1100F (600C) to 1350F (730C)- 35% more superheater- 200% more reheater

• Higher alloys- Higher temperatures require

nickel-based alloys• Specialized welding• Specialized heat treatment

©A

LSTO

M 2

009

©A

LSTO

M 2

009



Superheater Material Distribution

Progression to higher cycle efficiency achieved with greater nickel alloy use

0

200

400

600

800

1000

1200

600/258 700/350 730/350

Cycle Parameters T/P - C/Bar

Wei

ght -

Ton

neIN740

A617

H230

S304H

TP347H

T92

T91

T22



Reheater Material Distribution

Reheater impacted by lower temperature difference between flue gas and steam

0

500

1000

1500

2000

2500

600/258 700/350 730/350


Wei

ght -

Ton

ne

IN740

H230

HR6W

S304H

TP347H

HR3C

T92

T91

T122

T23

T22

T12



Furnace Wall Material Distribution

Furnace walls employ higher strength steels for high-efficiency cycles

0

200

400

600

800

1000

600 / 258 700 / 350 730 / 350


Wei

ght -

Ton

ne T92T23T12210C



Economizer Material Distribution

Economizer impacted by change in feedwater temperature

0

500

1000

1500

2000

600 / 258 700 / 350 730 / 350


Wei

ght -

Ton

ne

210C



Agenda

Introduction

What is the same?

What is different?

Design Challenges

Next steps



Design Challenges – Material Selection• The key design challenges relate to material selection

- Properties: Strength, corrosion resistance, …- Fabrication: Bending, welding, …

• Design of boiler and selection of steam conditions will ultimately be driven by economic considerations.- Same materials for 1300F (700C) and 1400F (760C)

• More nickel-alloys for higher steam temperatures.

• Optimization opportunities exist…- Cycle pressure and temperature- Arrangement

• Material transitions• Piping sizes and paths



Design Challenges – Material Validation

2: Material Properties

3: Steamside Oxidation

4: Fireside Corrosion

5: Welding

6: Fabricability

7: Coatings

1: Conceptual Design

8: Design Data & Rules (including Code interface)



Design Challenges – Material Validation

• Steam Loops- Demonstrate fabrication and installation- Gather data on fireside corrosion and steam-side oxidation



Test Evaporator Panel Test Superheater

HP Header Piping

European COMTES 700Components Test Facility

011 664p



Agenda

Introduction

What is the same?

What is different?

Design Challenges

Next steps



Next Steps

• Complete ASME Code approval for key alloys- IN740, H282, …

• Design concepts- Finalize design based on latest data- Take advantage of Code updates

• Supply chain development- Validate production of full scale components

• Design for demonstration plant- Fully develop boiler design

• Build and operate demonstration plant- Fabricate, erect, commission and operate

www.alstom.com/power

Image of a Turbine

Advanced UltrasupercriticalSteam Turbine

GE Energy

Topics

Steam Cycle & Configuration

Mechanical Design

Producibility

GE Proprietary Information 24/7/2011

Steam Cycle OptimizationSteam Turbine Cycle Parameterso Power Output Desired

o Inlet Steam Conditions

o Double vs. Single Reheat

o Heater Selection, Feed Water Temperature, Feed Pump Drive, Reheat& Crossover Pressure Optimization, Process Extraction Requirements

Accommodations for Remainder of PlantCOE Depends on More Than Just the Turbine

oBoiler, Condenser/Cooling, Balance of PlantoWith/Without Carbon Capture System

Optimum Turbine Design ConsidersPlant Size, Efficiency Goals and Cost Target


Steam Turbine Inlet Conditions

ST Heat Rate Improvement Vs. Steam Conditions

0

8

16

2400 2800 3200 3600 4000 4400 4800

Main Steam Pressure (psia)

ST H

eat R

ate

Impr

ovem

nt -

%

1000F / 1000F

1100F / 1100F

1200F / 1200F

1250F / 1300F

1350F / 1400F

Value Story Will Drive Selection of Inlet Conditions

Steam Cycle Considerations

High Superheat from IP Extractionso BOP Cost and Cycle Affects

o Master Cycle, De superheating

Feedpump Power / Typeo Motor or Turbine Driven

o Integration with FW Heaters

Optimization of LP Inlet Conditionso Impact on Low Pressure Turbine Materials

o Setting IP Expansion Requires Tradeoffs

Design & Cycle Tradeoffs Will Be Determined WhenTurbine Size, Efficiency Goals and Cost Target are Determined

Mechanical DesignBuckets/Nozzles/Rotors in the High TemperatureRegion: Similar to Gas Turbineo Individual wheels

o Multi wall casings

Fatigue Duty Much Less Severe Than Gas Turbineo Less severe/fewer load transients

o Longer component lives vs GT

Traditional Safety Factors Achievable

Reliability Should Be Comparable to Other Large Turbines


Cycles

Strain

Advanced UltrasupercriticalSteam Turbine


•Multi- Wall Construction•Directed Superalloy Usage•Operability Comparable to Other Large Turbines

Producibility

Designing Turbines with SuperalloysIs Not New

Design & Manufacturing ExperienceAircraft Engine: 60+ years

Industrial Gas Turbine: 40+ yearsGE Proprietary Information

GE Proprietary Information4/7/2011

Proven Rotor Technology

• Gas Turbine NickelBased Components AreAlready Larger thanRequirements forAdvanced 1000MWSteam Turbine

• Supply Chain WellEstablished

• Over 5000 Large DisksProduced

GE Proprietary InformationGE Proprietary Information

4/7/2011

89”Diameter

Buckets Are Not a New Challenge1960’s Superalloy Buckets Modern Buckets

Over 1,000,000 Superalloy Blades MadeGE Proprietary Information


Two Paths to Large Castings• Sand Casting ProcessDevelopment– Promising NETL resultsare being scaled up thisyear

• Established PowderMetallurgy Technology– PM parts up to 12,000pounds are produced forGas Turbines

PM Image


4/7/2011

Alloys Have Been Demonstrated

• Alloys 740, 282, 105

• Formable

• Castable

• Weldable

• MetallurgyUnderstood

• Properties Measured

1400F Material Properties= Properties of Materials

Used at Lower Temperature


4/7/2011

LCF for PA & OA Candidate Alloys(R = 0 & -1.0)

0.10

1.00

10.00

100 1,000 10,000 100,000 1,000,000

Cycles to Initiation (Ni)

Tota

l Stra

in R

ange

(%)

Nimonic 105 - 1400F

Haynes 282 - 1400F

Udimet 720 - 1382F

Alloy 617 - 1382F

LCF for PA & OA Candidate Alloys(R = 0 & -1.0)

0.10

1.00

10.00

100 1,000 10,000 100,000 1,000,000

Cycles to Initiation (Ni)

Tota

l Stra

in R

ange

(%)

Nimonic 105 - 1400F

Haynes 282 - 1400F

Udimet 720 - 1382F

Alloy 617 - 1382F

Temperature (F)

0 200 400 600 800 1000 1200 1400 1600

UTS

(ksi

)

0

50

100

150

200

250

Haynes 282 SAUdimet 720Li HTNimonic 105 APNimoniic 105 HT

Temperature (F)

0 200 400 600 800 1000 1200 1400 1600

UTS

(ksi

)

0

50

100

150

200

250

Haynes 282 SAUdimet 720Li HTNimonic 105 APNimoniic 105 HT

Forging Flow Stress

Creep RuptureLow Cycle Fatigue

Dendrite Arm Spacing

Tensile Strength

Deformation Mechanisms

Where Do We Stand?• AUSC is the Turbine of the Future

– More to be done, but no show stoppers

• Designs Can Be Configured Over a Wide Power Range– Highly favorable steam cycles

• Can Leverage Critical Rotating Mechanical Design From VerySuccessful Gas and Aircraft Turbines– Most popular gas turbine and aircraft engine technology in the world

• Operability & Reliability Will Be Similar to Other Large Turbines– But need demo to validate

• Will Accommodate Oxycombustion and Carbon Sequestration

AUSC Technology is Poised for Full Scale Demonstration


Significant EnergyChallenges Are JustAround the Corner…

Help Us Create thePower Plant You Needto Meet These Challenges


.1

A USC Manufacturing and WeldingResearch and Development

Learning to Fabricate New Materials for the Next Generation

of Ultra High Efficiency Coal Fired Power Plants

J M Tanzosh Mgr Materials Technology

April 7, 2011 Washington DC

.2

U.S. DOE/OCDO: AU.S. DOE/OCDO: A--USC Steam BoilerUSC Steam BoilerConsortium Phase I & IIConsortium Phase I & II

2: Material Properties

3: Steamside Oxidation

4: Fireside Corrosion

5: Welding6: Fabricability

7: Coatings

8: Design Data & Rules

1: Conceptual Design

Develop the materials technology to fabricate and operate a A-USC Steam Boiler with Steam Parameter up to 760°C

.3

.4

TASK 5 Methodology of Weldability Studies

• Verify weldability in thin and thick section

• Develop welding procedures (processes/parameters/weldmetals)

• Extensive preliminary testing (microscopy, hardness)

• Assess creep strength and mechanical properties of theweldment

• Qualify ASME Section IX

.5

Task 5 Weldability ResultsWelding of small diameter tubes of all candidate alloys successfulAll but Alloy 740 can be welded with SMAW as well as GTAW or GMAW;work continues on 740 under NSF project

.6

Task 5 Weldability Results

Butt welding processes using thick section products qualifiedCCA 617:

• SAW using matching filler.• SMAW using matching filler

Haynes 230:• Pulsed GMAW using matching filler.

Alloy 740:• Hot wire GTAW using matching filler• Took several iterations

.7

• Solid solution strengthened alloy candidate for tubing and for headers

• Currently being examined in depth in European A USC program. Cracks inEuropean COMTES demonstration.

• Alloy 617 is ASME Code approved

• Three processes evaluated:

GTAW, SMAW, SAW

• Two filler metals examined:

INCONEL 117 and CCA 617

PWHT will be required – 1650F

CCA 617 filler metal

and SAW/GTAW processes

qualified to ASME Section IX

CCA617

.8

Haynes 230

• Solid solution strengthened alloy candidate for tubing and for headers

• Haynes 230 is ASME Code approved

• Tube and thick section plate (3” thick) examined

• Four processes evaluated: GTAW, SMAW, GMAW, SAW

• Successful welds with GTAW, GMAW

and SMAW. SAW abandoned due

to microfissuring

• All three qualified to ASME Section IX

3” Thick

Haynes 230W Filler Metal,

GMAW

.9

Inconel Alloy 740• Best available alloy for combination of steamside oxidation and fireside

corrosion resistance, and creep strength

• This gamma prime strengthened alloy is a candidate for tubing, headers andmain steam piping

• First thick section welds on 3” plate made to original chemistry were prone tomicrofissuring

• Consortium of Research and Industrial partners pulled together

Edison Welding Institute

Oak Ridge National Laboratory

Special Metals

Babcock & Wilcox

• Modified and optimized the 740 chemistry for thick section weldingapplication without compromising strength

.10

Inconel Alloy740•Demonstrated weldability in thick sections, in the aged condition

•With two filler materials (matching 740 and Haynes 282) •Using Hot-wire GTAW and GMAW

•Code case submitted early 2011 – with data generated within the consortium•Includes PWHT of 1400 – 1500F for 4 hrs

3” thick,Haynes 282 FillerHot Wire GTAW

.11

Stress Relaxation Screening TestAllows simultaneous testing

several material conditions ata given temperature:• Stress relieved• As welded• Effect of filler metal• Stress

Capable of inducing the same SRCfailure mechanism observed inservice

Will be used to optimize PWHTprocedures

.12

Tube to Tube Dissimilar Metal Welds• Tube material combinations welded successfully

• Also focused on ferritic to austenitic DMWs

• The implementation of higher strength ferritic materials (i.e. Grade 91/92) andhigher strength austenitic materials (Super 304H, 310HCbN) could exacerbateDMW cracking problem

• A new filler material, EPRI P87, wasdeveloped that promises toeliminate the classic failuremechanism along the fusion line ofthe ferritic material

• EPRI P87 was evaluated in 16different high strength materialcombinations and qualified to ASMESection IX

.13

Task 6 Fabricability

Tube cold U bend trials up to 35% strain successfully completed forall USC project alloys

(740, 230, CCA617, S304H, HR6W, & SAVE12)

Hot bending trials successful

Machining trials successful

Tube swaging trials successful

Controlled cold strain/recrystallization/precipitation studiescompleted for all USC project alloys

.14

.15

.16

Conclusions• Have gained the know how for construction and repair of

materials used at steam conditions between 1100 and 1400°F.• The weldability of a number of promising alloys has been

established – especially with the essential nickel base alloys.

• The highest strength nickel base alloys have been evaluated withcommon welding processes, and qualified to ASME Section IX.

• Two nickel base material alloys, 617 and 230, are already Codeapproved. Alloy 740 Code Case submitted in 2011 with requiredweldment data.

• Fabrication trials have been successfully completed with all thealloys and manufacturability demonstrated.

Advanced –Ultrasupercritical Boiler Materials

Fireside Corrosion Testing

Foster Wheeler

April 2011

Confidential2

Why is Fireside Corrosion Important?

Some coals are corrosive

Fireside corrosion was a factor in derating Eddystone

Good database for traditional alloys (Cr-Mo, 304H, 347H)

Need to develop a database for high-strength alloys required for A-USC conditions

How do we do it?

Confidential3

Fireside Corrosion Testing: Three Step Approach

Laboratory testing ($)Simulated flue gas and synthetic deposits under isothermal conditions

Screening tool

Air cooled corrosion probes ($$)Boiler environment – actual flue gas and deposits and a thermal gradient

Minimal impact on unit operation

Steam loop testing ($$$)Realistic operating scenarios (flue gas on OD, steam on ID)

Confidential4

Laboratory Tests

30 materials (monolithic, overlays, coatings)

~480 coupons

Three simulated coal ash conditions

Pittsburgh #8

Illinois #6

Eagle Butte (PRB)

Waterwall and SH/RH conditions

Eight temperatures: 850 F - 1600 F (455 C - 870 C)

Confidential5

A-USC SH/RH Materials

CSEF (23, 92, ABE, Save 12, HCM12A)

Austenitic stainless steel (304, 214, 347HFG, S304H, HR3C, Save 25)

Fe-Ni-Cr alloys (800HT, HR120, 353MA)

Ni-based alloys (HR6W, 45TM, 214, 602CA)

Ni-based superalloys (230, 740, N263, 617)

Overlays (622, 52, 72, 50-50LC)

Coatings (FeCr, SiCr, AlCr)

Confidential6

Lab Corrosion Test Results

Someperformed

well

Others notso well

Confidential7

Lab Corrosion Test Results

0

5

10

15

20

25

30

Tota

l Met

al W

asta

ge (i

n m

ils/1

000

hour

s)

Material (Arranged in Order of Increasing Cr Content)

1200°F

1300°F

1400°F

Confidential8

Air-Cooled Probes

Three units

Three different coals

15 materials (monolithic, overlays and coatings)

~5,000 – >15,000 hours of exposure

Variable temperatures: 1000 F – 1525 F (540 C –715 C)

Confidential9

Typical Installation Location~2200°F

Confidential10

Air Cooled Probes – As Fabricated

Retraction mechanism

Cooling air supply line

Corrosion specimens

Probe

Confidential11

Air Cooled Probes – Installed

Confidential12

Air Cooled Probes – Retracted

Confidential13

Air Cooled Probes - Evaluation

Site #1Zone 1

Site #1Zone 2

Site #2Zone 1

Site #2Zone 2

Someperformed well

Others not so well

Confidential14

Two units (one complete, one in progress)

13 materials Monolithic

Overlays

Thermal spray

~10,000 hrs of exposure

Variable temperatures~1025 F – 1475 F (~550 C – 800 C)

Steam Loop Testing

Confidential15

Steam Loop Fabrication

Confidential16

Steam Loop Testing

Confidential17

Steam Loop Evaluation

Someperformed

well

Others not so well

Confidential18

Three-step approach Comprehensive test program designed to generate real, reliable corrosion data

Corrosion rates are dependent on coal typeSeveral materials exhibited acceptable corrosion behavior over a wide range of temperatures expected for A-USC for a variety of coalsWeld overlay materials may be required for relatively aggressive coal types

Summary and Conclusions

11

U.S.U.S.ManufacturingManufacturingCapacity and Capacity and

Opportunities for Opportunities for an Advanced an Advanced

Energy Supplier Energy Supplier BaseBase

www.energyinohio.orgwww.energyinohio.org

22

Pulverized Coal CCS technologyPulverized Coal CCS technologyefficiency emissions efficiency emissions

Consortium of All U.S. Boiler and Consortium of All U.S. Boiler and Turbine Manufacturers and EPRITurbine Manufacturers and EPRIIdentified New Materials and Identified New Materials and new uses for othersnew uses for othersRecognize that Supply Chain is Recognize that Supply Chain is the key for commercializationthe key for commercialization

EIO is Prime Contractor for $50M AdvancedEIO is Prime Contractor for $50M Advanced--UltraSuperCritical Materials ProgramUltraSuperCritical Materials Program

33

National Compact Fusion National Compact Fusion Stellerator ProgramStellerator Program

EIO charged withprototyping and providing large, high strength Nuclear CastingsStaff experienced for working with Nuclear supplier industry, Nat’l Labs and Producers

BackgroundBackground

Both Programs involved locating suppliersBoth Programs involved locating suppliersFound Castings, Forgings, and Extrusions are Found Castings, Forgings, and Extrusions are THETHE ““pinch pointspinch points””Found Supplier Base is limited and saturated Found Supplier Base is limited and saturated Found Supplier Base for Coal/Nuclear OverlapsFound Supplier Base for Coal/Nuclear OverlapsFound Supplier Availability will impact the rate Found Supplier Availability will impact the rate for introducing both Clean Coal and Nuclear for introducing both Clean Coal and Nuclear SystemsSystems

44

55

66

Opportunity for Developing a U.S.Opportunity for Developing a U.S.Advanced Energy (AE) Supplier BaseAdvanced Energy (AE) Supplier Base

Needs are traditional Ohio/Midwest/U.S. productsNeeds are traditional Ohio/Midwest/U.S. productsEIO has direct relationships with the energy intensive EIO has direct relationships with the energy intensive industries that would produce the needed components industries that would produce the needed components Knowledge that their current markets are decliningKnowledge that their current markets are decliningKnowledge that they are looking for new marketsKnowledge that they are looking for new marketsKnowledge that they are capable of transition into AE marketsKnowledge that they are capable of transition into AE markets–– ButBut…….They don.They don’’t know of Advanced Energy opportunitiest know of Advanced Energy opportunities–– AndAnd…….Power Gen potential customers don.Power Gen potential customers don’’t know of themt know of them

Need to connect the dots! Need to connect the dots!

1. Define the “real needs envelope” of components for Fossil and Nuclear Industries

2. Survey and Screen Existing Capability -Shuttered plants w/ restart ability-Current operating plants

3. Establish a Web based Supplier Catalogue4. Provide a conduit for OEM/Supplier interaction5. Assist Industrial transition for re-tooling, training, etc.

88

Program Goal and Outcome

The AThe A--USC Opportunity USC Opportunity

The A-USC program needs to demonstrate components made of high nickel alloys

Some of the selected alloys have never been produced as energy components

Know of U.S. firms who are willing to develop the production processes needed to make demo components

Would give U.S. suppliers the lead when commercialized

99

1010

A-USC Supplier Needs are Extensive

11111111

Supplier Hubs and Clusters for A-USC will need to be developed

1212

SummarySummary

U.S.U.S. HASHAS a Supplier Base for Baseload Energy componentsa Supplier Base for Baseload Energy componentsButBut……Many donMany don’’t know of opportunities or customer needst know of opportunities or customer needsEIOEIO’’s direct contact for Pilot has been successfuls direct contact for Pilot has been successfulSupport of FirstEnergy (FE) has been key to credibilitySupport of FirstEnergy (FE) has been key to credibilityThe AThe A--USC ComTes would provide a USC ComTes would provide a ““head starthead start””opportunity to U.S. firms for working in new nickel alloysopportunity to U.S. firms for working in new nickel alloysA-USC Demonstration project could form a new industrial base for commercial projects in US and beyondWith consequent high potential for job growth and retention With consequent high potential for job growth and retention in vital U.S. industriesin vital U.S. industries

Advanced USC TechnologyReadiness Report Prepared

forEPRI

by Bechtel Power Corporation

© Bechtel 2011. All rights reserved. 1

Presented byDon Koza

Sr. Technical SpecialistBechtel Power Corporation

2© Bechtel 2011. All rights reserved.

A-USC PC TECHNOLOGY VISIONIncrease coal-fired generating up to 50% efficiency which results in:

• Decrease consumption of coal

• Decrease emissions

• Reduce overall operation costs

Increasing steam temperatures to 1300 to 1400°F would not pose a disproportionately large risk to deployer

Alloys for this service required to be ready for demonstration within 4-5 years


A-USC PC TECHNOLOGY VISIONRelative effects of temperature and pressure

8600

8700

8800

8900

9000

9100

9200

9300

3500 4000 4500 5000

Throttle Pressure, psia

1.82

%1.

56 %

1.50

%

NPH

R, B

TU/k

Wh

HH

VImproved Net Plant Heat Rate

0.68 % 0.53 % 0.35 %

1000F/1000F

1050F/1050F

1100F/1100F

1150F/1150F

Temp.Temp.


INDUSTRY READINESS STUDY OBJECTIVESChallenge is to show that the technology

• Does not pose a disproportionately large risk to a deployer

• Topic areas include:

Boiler & stream turbine design

Material availability and fabrication procedures

Operational characteristics, including availability and turndown

Reliability and maintainability, including maintenance requirements


PARTICIPATING INDUSTRY VENDORSVendors included in this study:•Alstom Power – Boiler and Steam Turbine•Babcock & Wilcox – Boiler•Hitachi Power Systems – Boiler and Steam Turbine•Mitsubishi Heavy Industries – Boiler and Steam Turbine

No intent to discuss proprietary or confidential information and report does not compare vendor technologiesSurvey based on questions developed by EPRI and CoalFleet members with support from Bechtel


STEAM TURBINE VENDORS’ READINESS

Temperature and pressure expected• Most development efforts have been for the 50Hz Market (60 Hz temperatures may be slightly lower)

• Current commercial temperature limit is approximately 650°C (1200°F) with a target limit in the near term of 700°C (1300°F) and above

• Consensus among suppliers that pressure above 270 bara (3900 psia) will provide limited turbine efficiency benefit


STEAM TURBINE VENDORS’ READINESSReheat cycle configuration:• Double reheat technically feasible but not economic

– Long expensive piping between the boiler and steam turbine– Additional boiler heat transfer surface area– Additional turbine complexity

• Steam extraction for post-combustion CO2 capture is an additional consideration. Not affected by oxy-combustion

Preferred material properties:• Materials operating at high temperatures should:

Achieve a balance between strength and hot-workabilityHave sufficiently higher creep strength for the conditionsHave capability to maintain properties at 600-760°C, cycling modeHave matching thermal expansion coefficients to reduce leakages

• Materials are available and being qualified by DOE Program


Turbine installation and operational requirements –similar to conventional turbine.

May have two stage HP turbine to limit use of high-nickel alloys Start up time longer because of higher temperature but load following not expected to be affectedBFW extractions similar but final BFW temperature higher

Repairs of casings will require specialized welding and blading will likely have to be sent off-siteValve designs available but must use castable materialsVendors recognize need to achieve same availability as conventional turbines – committed to this objective

May take some field improvements to achieve this, hence need fordemonstration project

STEAM TURBINE VENDORS’ READINESS


STEAM TURBINE MATERIAL STATUS

AvailableIn Use Allvac 718PlusBolts

AvailableIn UseInconel 718Bolts

AvailableIn UseNimonic 263Casings/Valve Chests

AvailableIn UseWaspaloyBolts

AvailableIn Use Nimonic 115Bolts

AvailableIn UseNimonic 105Bolts

AvailableIn UseInconel 718Casings/Valve Chests

AvailableIn UseInconel 623Casings/Valve Chests

In TrialsIn TrialsFENIX 700Rotors

AvailableIn Use12CrMoVCbNNozzle Boxes

AvailabilityDate

QualificationStatus

MaterialDesignation

Components

Some of Proposed Steam Turbine-Related Materials


SUMMARY OF STEAM TURBINE VENDOR READINESS

Vendors actively working on A-USC designsBasic design and operation similar to conventional turbines

Materials characterization at advanced stage but still some work to complete

Some large forgings produced in support of rotor development

Involvement of power industry (potential customers) and developing a demonstration project and will accelerate these activities and the development of commercial designs

Starting design and manufacturing process by 2016/17 considered feasible


BOILER VENDORS’ READINESS FOR A-USCPC SERVICE

Temperatures and Pressures ExpectedUp to 1400F and pressures in range 4000 to 5000 psia

Preferred Material PropertiesSimilar to those for steam turbine but also need to be resistant to fire-side and steam-side corrosion because of higher metal temperatures

Fuels Suitable for FiringAll coals should be able to be used, possibly avoiding very high sulfur coals until after learnings from demonstration plant


A-USC BOILER DESIGN CONSIDERATIONSFurnace designs similar to conventional units

FEGT same as conventional unit

Convection pass and pendant SH would be larger due to lower temperature differentials

Handling larger, more, and heavier heat transfer circuits will increase construction timesDissimilar welds to be made in shop so more modular construction

Design codes in place, biggest difference is materialsVendors engaged in materials programs and report characterization and welding requirements at advanced stageVendors report materials with excellent fire-side and tube-side corrosion performance.


A-USC BOILER DESIGN CONSIDERATIONSPressure Relief valve designs are available but need to be made from castable materials

More development required to provide materials in this form

Branch ConnectionsBranch intersection welds may require enhanced design rules due to failures in the HAZ when operating in the creep range

BFPsHigher pressure designs are already available

BFW treatment, FWHs, and condenser designs are unaffected


ADDITIONAL BOILER CONSIDERATIONSRepairs will require specialized procedures requiring additional training to achieve required skills

Maintenance costs will be higher; demonstration project will provide good indication of increase

Vendors recognize need to achieve same availability as conventional boilers and are committed to this objective

May take some field improvements to achieve this, hence need for demonstration project

Startup and Load ChangesLow load likely set by environmental controls: sliding pressure down to ~30-40% MCR, depending upon inclusion of economizer bypassStart up times longer but at same rate as conventional unitRate of load change for load following the same


ADDITIONAL BOILER CONSIDERATIONS

Compared to conventional units, the main difference of A-USC is the materials used.All vendors are engaged in programs that are nearing completion to qualify materials


SUMMARY OF PROPOSED A-USC BOILER MATERIALS

Ready NowASME QualifiedP91, P92 Furnace Headers/Piping and Low

Temperature SH/RH Headers/Piping

Ready NowASME QualifiedT91, T92Low Temperature SH/RH Tubes

Ready NowASME QualifiedP11, P12, P22, P23, P24Headers/Piping

Ready NowASME QualifiedT11, T12, T22, T23, T24, Furnace Tubes

Ready NowASME Code Case 2328-1Super 304/304HSH/RH Tubes

TBDCode Case Data being DevelopedSanicro 25SH/RH Tubes

2012 EarliestCode Case in ProcessInconel 740SH Tubes, Headers/Piping(**)

TBDPendingInconel 700Tubing/Headers/Piping

Ready NowASME QualifiedInconel 617Tubing/Headers/Piping

TBDCode Case in ProcessHR6WHeaders/Piping

Ready NowASME QualifiedHR3C (310 HCbN)SH/RH Tubes, Headers/Piping

Ready NowCode Case Data being DevelopedHaynes 282SH Tubes

Ready NowCode Case Data being DevelopedHaynes 263Headers/Piping(*)

Ready NowASME QualifiedHaynes 230 CC2063SH Tubes

Ready NowASME Qualified347HFGSH/RH Tubes

Availability DateQualification StatusMaterial DesignationComponents

(*) Has been produced in piping form for demonstration only (**) Has not been produced in piping form to date


Key codes associated with PC Fired USC Plants:• ASME, Section I, Power Boilers

• ASME, Section II, Materials

• ASME, Section V, Nondestructive Examination

• ASME, Section IX, Welding and Brazing Qualifications

• ASME B16.5, Pipe Flanges and Flanged Fittings

• ASME B16.34, Valves-Threaded, Flanged, and Welding End

• ASME B31.1, Power Piping

Code cases• Code case for alloy UNS N06617 (Inconel 617) is 2439 (approval

2/14/2003)

• Code case for alloy UNS 06230 (Haynes 230) is 2063-6 (approval 10/2/2008)

CODES AND STANDARDS IN PLACE


SUMMARY OF BOILER VENDORS’READINESS

Similar to turbine vendors but a little further along in development

Basic design and operation similar to conventional boilersStarting design and manufacturing process by 2016/17 considered feasible

Materials characterization at advanced stage but still some work to completeInvolvement of power industry (potential customers) and developing a demonstration project and will accelerate these activities and the development of commercial designs


PATH FORWARD FOR A-USC PC APPLICATION

Design and materials qualification for boiler and steam turbine are well advanced

Vendors have been working in this area for some years and majority of work is completeA-USC material development is a remarkable success

All vendors said a customer would oil the wheels of A-USC development

Demonstration plant essential to progressOperationally, US power industry is already familiar with the technology on which an A-USC power plant is based

Bechtel’s view, based on this survey and knowledge of DOE Program, is that technology is approaching stage that demonstration is feasible

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First Name Last Name Email Address Company Title Address City St Zip Phone

Robin Bedilion [email protected] Power Research Institute (EPRI) Engineer 2312 E 54th Ln Spokane WA 99223-9121 650-855-2225

David Berger [email protected] PPL Generation, LLC Senior Engineer 2 N 9th St Allentown PA 18101-1139 610-774-5161Rick Bingham [email protected] MPR Associates, Inc. Senior Engineer 320 King St Alexandria VA 22314-3272 703-519-0442

Robert Burbage [email protected] Valley Authority (TVA) Project Manager 1101 Market St Chattanooga TN 37402-2801 423-751-7044

Vito Cedro III [email protected] National Energy Technology Laboratory

General Engineer/Project Manager

626 Cochrans Mill Rd Pittsburgh PA 15236 412-386-7406

Stephen [email protected] GenOn Energy, Inc.

Manager, Engineering

8301 Professional Pl landover MD 20785 301-955-9018

Kipp [email protected]

Mowrey Meezan Coddington Cloud LLP Partner 6830 Elm St McLean VA 22101 703-760-0750

Regis [email protected]

DOE National Energy Technology Laboratory

1000 Independence Ave Washington DC 20585

Daniel Cornell [email protected] GE Energy (USA), LLC Principal Engineer 1 River Rd Schenectady NY 12345-6000 518-385-5853

Stuart Dalton [email protected] Power Research Institute (EPRI) Director, Generation 3420 Hillview Ave Palo Alto CA 94304-1338 650-855-2467

John [email protected] Special Metals Corporation

Mgr., Product & Process Dev. 3200 Riverside Dr Huntington WV 25705-1764 304-526-5634

Vic Der Unavailable U.S. Dept. of EnergyDirector, Clean Energy Systems Unavailable Unavailable

Unavailable Unavailable Unavailable

Thomas [email protected] GE Infrastructure Energy Principal Engineer 1 River Rd Schenectady NY 12345-6000 518-385-0742

Francis [email protected] Progress Energy, Inc.

412 S Wilmington St Raleigh NC 27601-1849 919-546-3999

Michael [email protected] Foster Wheeler

Development Engineer

12 Peach Tree Hill Rd Livingston NJ 07039-5704 973-535-2322

Horst Hack [email protected] Wheeler Power Systems, Inc. Director of R&D

12 Peach Tree Hill Rd Livingston NJ 07039-5704 973-535-2200

Workshop on the DOE/OCDO for Ultrasupercritical Steam Conditions Power PlantsHotel Monaco

Washington, DC April 7, 2011

Page 1 of 4




Howard Hendrix [email protected] Power Research Institute (EPRI)

Senior Project Manager

1300 W Wt Harris Blvd Charlotte NC 28262-8550 980-213-7433

Gordon [email protected]


Materials Research Engineer

1450 Queen Ave SW Albany OR 97321-2152 541-967-5874

John Holt UnavailableNational Rural Electric Cooperative Assn.

Senior Manager, Generation and Fuel Unavailable Unavailable


Charles Jones [email protected] The Shaw Group, Inc. Senior Director Charlotte NC 704 3316237

Amir Khaksari [email protected] Natural Resources, Inc. Senior Analyst 999 Corporate Blvd

Linthicum Heights MD 21090 410-689-7912

Ehsan Khan [email protected] U.S. Dept. of EnergySenior Technical Advisor

Independence Ave SW Washington DC 20585-0002 202-586-4785

Hassan Khan [email protected] Electric Power Service Corp. Engineer 1 Riverside Plz Columbus OH 43215-2355 614-716-1769

Veronika Kohler Unavailable National Mining AssociationInternational Policy Analyst Unavailable Unavailable


Donald Koza Unavailable Bechtel Power Corporation Principal Engineer Unavailable UnavailableUnavailable Unavailable Unavailable

Ned Leonard [email protected]

American Coalition for Clean Coal Electricity (ACCCE)

Vice President - Program Services

333 John Carlyle St Ste 530 Alexandria VA 22314 703-302-1206

John Marion Unavailable ALSTOM Power, Inc. V.P., Technology Unavailable Unavailable Unavail Unavailable Unavailable

Riley Moore [email protected]

Tri-State Generation & Transmission Association, Inc.

Sr. Engineer, Generation 1100 W 116th Ave Denver CO 80234-2814 303/254-3350

Steve Moorman [email protected] Babcock & Wilcox Co.Mgr. Business Development

20 S Van Buren Ave Barberton OH 44203-3585 612-670-8261

Russell Noble [email protected] Southern CompanyManager, Power Generation R&D 600 18th St N Birmingham AL 35203-2206 205-257-7232

John Novak [email protected] Power Research Institute (EPRI)

Exec. Dir., Sect Fed & Indust Ac

2000 L St NW Ste 805 Washington DC 20036-4913 202-293-6180

Page 2 of 4




Ian [email protected] ALSTOM (Switzerland) Ltd. Manager, MSE 2000 Day Hill Rd Windsor CT 06095-1580 860/285-3413

Jeff Phillips [email protected] Power Research Institute (EPRI) Program Manager


Robert Purgert [email protected] Energy Industries of Ohio President Park Center One Independence OH 44131-6914 216-643-2952Kalyan Raman Unavailable Unavailable Unavailable Unavail Unavailable Unavailable

Patricia [email protected]


626 Cochrans Mill Rd Pittsburgh PA 15236 412-386-5882

John Repasky [email protected] Products & Chemicals, Inc.

Separation Technology

7201 Hamilton Blvd Allentown PA 18195-1501 610-481-5653

Robert Romanosky [email protected] National Energy Technology Laboratory

Technology Manager

c/o Energy & Envir. Solutions, LLC Morgantown WV 26505 304-285-4721

Robin Schwant [email protected] GE Energy (USA), LLCMgr., Low Temp Materials Dev. Eng. 1 River Rd Schenectady NY 12345-6000 518-385-7357

Elizabeth [email protected]

FirstEnergy Service Company

Mgr., Energy Supply Technologies 76 S Main St Akron OH 44308-1890 330-761-4481

John Shingledecker [email protected] Power Research Institute (EPRI)

Senior Project Manager


Richard Smith [email protected] Ameren Services Co.Manager, Research & Development One Ameren Plaza Saint Louis MO 63103-3085 314-554-3531

William Stevens [email protected]. Environmental Protection Agency

Senior Advisor - Power Technology

1200 Pennsylvania Ave NW Washington DC 20460-0001 202-343-9642

James Tanzosh [email protected] Babcock & Wilcox Co.Mgr., Materials Technology

20 S Van Buren Ave Barberton OH 44203-3585 330-860-1448

Peter Tortorelli [email protected] UT Battelle, LLCDeputy Division Director, Materials PO BOX 2008 Oak Ridge TN 37831-2008 865-574-5119

Brett Tossey [email protected] DNV Columbus, Inc. Sr. Engineer 5777 Frantz Rd Dublin OH 43017614-761-1214 6938

Jason Tyll [email protected] Alliant TechsystemsDept. Director, Advanced Programs 77 Raynor Ave Ronkonkoma NY 11779

631-737-6100 178

Page 3 of 4




Brian [email protected] Riley Power, Inc.

Mgr., Project Engineering 5 Neponset St Worcester MA 01606-2714 508-854-4015

Paul Weitzel [email protected] Babcock & Wilcox Co. Tech. Consultant20 S Van Buren Ave Barberton OH 44203-3585 330-860-1655

John Wheeldon [email protected] Power Research Institute (EPRI) Technical Executive

c/o NCCC, PO Box 1069 Wilsonville AL 35186-1069 205-670-5857

Page 4 of 4

:

Workshop on the US DOE/OCDO Advanced Materials for USC Power Plants Projects

Discussion Topics/Question Raised by Utility Attendees During the Meeting (Wall

Notes)

Repairs & Welding The Program has expended considerable effort in studying the weldability of all of the candidate materials. Welding processes and procedures have been defined, and significant weld metal and weldment testing performed. Some of the advanced nickel based alloys require more careful welding or special processes (e.g. no stick welding), but post-weld heat-treatment (PWHT) is generally less exacting compared to creep strength enhanced ferritic steels. Work is also ongoing to look specifically at repair of materials subjected to long term ageing in service. Work to date supports that no major, unforeseen difficulties should be encountered.

Capability to retrofit with CCS – included in Consortium’s R&D programs? Yes. In fact,

Phase II of the Program is specifically looking at the ability of the A-USC to adopt CCS through oxyfiring. Details of heat integration and plant arrangement have not been explored in detail for post-combustion capture, but the requirement is no different than that for today’s supercritical cycles with retrofit CCS. For either case (oxy or post- capture), the economy of the plant is significantly enhanced when based on A-USC, taking into account the reduction in amount of CO2 and correlating reduced cost of capture and sequestration.

What is the boiler design methodology – Design by analysis? The design methodology is

very similar to conventional supercritical boilers (ASME Section I). Presently, Section I of the ASME Code does not mandate nor restrict the use of design by analysis. Although we are using state-of-the-art materials, we are using the same basic levels of conservatism to derive allowable stress values as for conventional boiler materials, therefore the conventional boiler design rules are still applicable. It should be noted that all boiler OEMs supplement the ASME design rules with analysis to refine design of boiler parts design; thus analysis has been used for years to supplement SC and USC boiler design and in the future for A-USC designs.

Impact/Potential for jobs & exports The technology could be deployed anywhere in the world (we know other countries have research projects: EU, Japan, China, India) so if we can demonstrate the technology first we may have export opportunities. If we are not first to demonstrate then it is likely that technology will be imported to the US at the cost of US jobs. The greatest potential for increased jobs in the US probably comes from the material supply side. The major new alloys are all US company based, and the increased demand for these materials in the very large quantities required for boiler construction will be a very strong job creator.

Revisit code rules for high temperature regime We do not envisage any particular need to

revisit code rules for the high temperature regime because we are using the alloys at the same

:

fractions of their strength as we do for conventional alloys. There are however some specific requirements for Ni-based alloys regarding welding/fabrication to properly account for their unique properties. Revisions to ASME Section I PG-19 and specific fabrication/welding rules written into the applicable code cases are two examples of ways the consortium has addressed A-USC in the codes already.

Nickel-alloy stop valve needs to be tested Component production through supply chain

development is an important part of the future work recommended by the Consortium to DOE. One aspect of this work is to verify large castings (and/or alternative manufacturing routes) for a number of the candidate alloys. Work is already ongoing within the A-USC steam turbine research for production, welding, and repair of the main steam stop valve casing.

Need to update economic analysis The consortium, EPRI, and DOE-NETL have all

conducted independent economic analyses for A-USC technology at different times resulting in differing construction costs and cost of electricity estimates. These paper studies have all shown a number of economic advantages for the technology, especially in light of a future with a penalty for CO2 emissions. The consortium agrees that a more detailed pre-FEED study with an Architect Engineering (AE) firm would provide greater accuracy to these paper studies and could identify any remaining gaps to making the technology commercially available.

Would like fabrication to be less onerous than P91/92 Overall, many of the candidate

nickel-based alloys are much less sensitive than P91/92. Moreover, welding of nickel alloys does not create complicated weld heat affected zones with low strength regions. P91/92 has proven to be a challenge to the utility industry because fabricators/manufacturers have been remiss in strictly following the rules. EPRI studies have shown that the great majority of problems are due to improper welding or heat treatment control. The newest and strongest of the alloys considered for A-USC plants, being nickel-based for the most part, do require a special level of control compared to traditional austenitic stainless steel grades. However, they are more tolerant and have a wider processing/operating window and are not as sensitive to mistreatment as P91/92. A learning curve is to be expected with the nickel alloys but not as steep and onerous as that suffered with P91/92.

Need to understand degradation mechanisms & NDE techniques to detect them

Degradation mechanisms are relatively well understood from long experience with nickel alloys in other products/industries. There are no critical transformation temperatures and major phase changes such as we experience in P91/92 so the degradation is predictable. As part of the consortium research, long term creep testing and ageing of these alloys has been studied and follows the known metallurgical principles. NDE research has only been studied as part of the consortium for steam turbine components, but NDE of nickel-based alloys is routinely done in other industries. The NDE techniques are available, most of which are the same as those used on conventional boiler materials. For steam turbines, the same NDE techniques in use today on nickel-based gas turbine discs/wheels will be used and are well established.

:

Slagging characteristics & soot-blowing requirements known? The science of slag fusion is well known and existing rules can be extended to the higher temperature metal surfaces that will be experienced in the outlet sections of the A-USC boiler. Slagging is not a function of the material, but higher surface metal temperatures could result in somewhat different deposition characteristics. This will be taken account during design, based on fuel characteristics, to ensure surfaces are below ash melting temperatures and that sufficient space and sootblowing is provided to avoid fouling.

S/U & S/D Cycling flexibility/capability? – This is anticipated to be very similar to today’s

USC sliding pressure plants in terms of ramp rates and times.. The plant can be designed for flexible operation with the only difference being a slight increase in the overall time to reach full temperature due to the higher steam temperatures over today’s USC plant. Some consortium research suggests turndown may actually improve for an A-USC oxyfuel boiler compared to an air fired boiler since there is more flexibility in gas recirculation.

Master Cycle (Tuning Turbine) impact considered? – Various cycle options, including

Mastery Cycle, are being considered in the overall steam cycle optimization. A pre-FEED study could assist in addressing this type of arrangement.

Turndown ratio & part-load heat rates – The boiler and turbine will be able to operate down

to roughly 30% load. Heat rates at this condition will be a function of the overall cycle and configuration but are anticipated to be very similar to today’s USC plants.

International cooperation? To date, each international group (nation) involved in A-USC

development has worked independently, and have shared general technological accomplishments through a series of international conferences, the last of which was held last fall. DOE has been in communication with several countries regarding the potential for more cooperative efforts in the future. It is believed that China and India have both announced plans to demonstrate A-USC boiler technology. The extent of cooperation needs to be defined by DOE.

Compare Int’l design codes The common international design codes have slight differences

in approach on some of the details but they all fundamentally control the design of components by limiting the primary stress at design conditions to be within the material strength limits, with some factor of safety. Therefore, since the approaches are quite similar then the materials of interest (nickel-based alloys) will be included with all the design codes and boiler manufacturers will offer products to any of the international codes (ASME, EN, and ultimately IBR or GB).

Guarantee 10 year overhaul cycle for steam turbine? –Based on the use of advanced

materials, maintenance interval recommendations are expected to be similar to modern USC units.

:

ST design life: 200,000 hrs minimum adequate? Feasible? – Critical component lives are expected to be comparable to modern USC units.

Need adequate warning of end-of-life of ST components – Extensive experience with high

temperature alloys in gas turbine applications provides a solid foundation for prediction of the end of life.

Safety of working around 1400 °F equipment. What are insulation requirements The

higher metal temperatures in the boiler penthouse and external piping will require more substantial insulation, but this is not considered difficult to address as other industries have handled higher temperatures and we can draw on their successful experience.

Cold Start-Up (S/U) time versus conventional ST’s – Cold start-up times will be similar for

current sliding pressure SC/USC boilers. Turbine cold start-up times are not generally more limiting than the balance of plant for current 600C USC applications. Determination of A-USC turbine start-up time will require further study based on A-USC boiler start-up curves in a pre-FEED study.

Applicable to CFBs? Could demo be CFB if host wanted it? A-USC technology is

theoretically applicable to CFBs, but CFBs have the inherent limitation of maximum gas temperature that can be achieved in the combustion zone. The very high steam temperatures demanded of the A-USC require more and very efficient capture of heat. While CFBs are candidates for both A-USC and oxyfuel CFBs, they have not been included in the work scope of the Program to date and a pulverized coal (PC) boiler would most likely be a favored option for demonstration.

Exfoliation & SPE of S.T. components The boiler program has extensively tested and

characterized oxidation behavior of new and existing alloys. The oxidation rate of nickel-based alloys at A-USC conditions is much less than traditional stainless steels. Surface modification has also been studied and characterized to minimize oxide exfoliation in the stainless steel in order to avoid tube plugging. The industry experience with austenitic stainless steels in USC applications suggest SPE turbine damage is less severe than SPE caused by traditionally ferritic steel materials.

Uncertainty over coal-fired power plant regulations is large barrier Uncertainty of

regulations and laws has been a challenge to utilities both in operation and planning of their assets, and will probably remain so for the foreseeable future. However, efficiency is always a ‘least regret’ strategy because burning less coal for the same MegaWatts reduces the dispatch cost and reduces the amount of emissions to clean or sequester (in the future). Reducing the specific fuel consumption and all emissions by 40% from the average installed base (and an even greater savings over the plants ready for retirement), while using the main domestic energy resource, should be promoted as a strong selling point for permitting A-USC plants.

:

Need to share important learning’s from program to suppliers The Program recognizes the importance or transferring welding and manufacturing technology to the ultimate users of the technology, and we are committed to developing the guidelines and procedures necessary to fabricate, erect, and repair these new materials.

Share Annotated Bibliography of reports & papers – The Consortium FACT book (EPRI

Report 1022770 – download for free from www.epri.com) provides a large number of open literature publication references on a range of topics from materials and welding to economics.

2nd bearing of ST will be operating at higher T. – Standard design methods and features are

applied that control rotor temperatures at oil seals and journal bearings to acceptable levels based on past successful experience.

How much time will be required for inspection of demo plant? Fundamentally, the A-USC

steam boiler is designed and constructed in the same manner as today’s USC boilers with a handful of new materials. Inspection protocols utilized by the utility to manage their current fleet will be used in the same manner. If an A-USC component test facility was constructed, operated, and removed from an existing boiler, post mortem examination would take 6 months to 1 year.

Piping of steam from boiler to ST: rolled & welded? If so how do you guarantee it will

not fail? What will be weld strength reduction factor? Piping will be extruded (seamless) pipe. The Consortium has spent considerable effort testing weldment and weld metal strength to allow for the determination of a safe and reliable weld strength reduction factors that could be included in design, and these will be included in the design rules adopted by ASME. There is some strength reduction associated with welds in nickel-alloy components but this is basically associated with weaker weld metal and therefore is less complex to understand and account for in design if required. If a full A-USC plant engineering & design study were conducted, the cost-benefit of multiple pipes versus a single pipe could be examined.

Boiler code approval Aspects of upgraded design rules have been previously covered.

Some alloys are already approved (IN617, H230), others are in process at the time of this writing (IN740), and others need more data (H282). The approval process for these new alloys is the same as for conventional boiler materials because they have very similar behavior (just at higher temperatures) and we are using them with the same safety margins as with conventional boiler materials.

Competition vs. sharing knowledge - How to avoid 2199 code case (T23) experience A

number of the Consortium members had been involved in finding and resolving the T23 issues so we are very familiar with it. That instance was due to an uncommunicative alloy supplier that was not forthcoming with some critically important material alloying and processing information. In the case of the new alloys involved with the A-USC, we have had excellent and nearly constant communication and cooperation with the alloy manufacturers involved and have also learned from the T23 case to be ever vigilant to obtain all important material

information. Pre-competitive knowledge (e.g. basic material data) is shared among the consortium partners. This is the advantage of doing collaborative research and development – a wider range of properties and issues can be explored than any one organization can manage. Also, it is the boiler manufacturers (the “users”) who are doing the work, rather than the material developers, which inherently leads to a different perspective on what is tested and what confidence is gained.

Transfer of technology to those that fabricate and install the new materials (e.g. P91) The information generated in the program is owned by DOE, who has every incentive to distribute this sort of information to boiler owner/operators. The fact that all four major boiler OEMs in the US were involved in developing the technology also assures an equal access to the information. Suppliers will require some training and experience. Also, key requirements would be reflected in specifications to suppliers.

Impact on availability guarantees needed on availability The overall goal of the research is

to develop the materials technology to build and operate a boiler and steam turbine at A-USC conditions. On this basis, availability will be very similar to today’s USC plants.

Operability – Since the overall design of the boiler has not changed significantly, the

operability will be very similar to today’s USC plants.

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Documents

Preliminary Agenda 040511 - EPRImydocs.epri.com/docs/publicmeetingmaterials/1104/7GNN4VBV5D6/E... · Agenda Workshop on the US Dept of Energy/Ohio Coal Development Office Advanced