Advances in Power Boilers

Description

Advances in Power Boilers is the second volume in the JSME Series on Thermal and Nuclear Power Generation. The volume provides the fundamentals of thermal power generation by firstly analysing different fuel options for thermal power generation and then also by tracing the development process of power boilers in about 300 years. The design principles and methodologies as well as the construction, operation and control of power boilers are explained in detail together with practical data making this a valuable guide for post-graduate students, researchers, engineers and regulators developing knowledge and skill of thermal power generation systems. Combining their wealth of experience and knowledge, the author team presents recent advanced technologies to the reader to enable them to further research and development in various systems, notably combined cycles, USC and A-USC, as well as PFBC and IGCC. The most recent best practices for material development for advanced power system as well as future scope of this important field of technology are clearly presented, and environment, maintenance, regulations and standards are considered throughout. The inclusion of photographs and drawings make this a unique reference for all those working and researching in the thermal engineering fields. The book is directed to professional engineers, researchers and post-graduate students of thermal engineering in industrial and academic field, as well as plant operators and regulators. Title-page_2021_Advances-in-Power-Boilers Advances in Power Boilers Copyright_2021_Advances-in-Power-Boilers Copyright Contents_2021_Advances-in-Power-Boilers Contents List-of-contributors_2021_Advances-in-Power-Boilers List of contributors About-the-editors_2021_Advances-in-Power-Boilers About the editors Preface-of-JSME-Series-in-Thermal-and-Nuclear-Powe_2021_Advances-in-Power-Bo Preface of JSME Series in Thermal and Nuclear Power Generation Preface-to-Volume-2--Advances-in-Power-Boilers_2021_Advances-in-Power-Boiler Preface to Volume 2: Advances in Power Boilers 1---Fossil-fuels-combustion-and-environmental-is_2021_Advances-in-Power-Boil 1 Fossil fuels combustion and environmental issues Chapter outline 1.1 Introduction 1.2 Overview and properties of coal, oil, and gas 1.2.1 Coal 1.2.1.1 Formation 1.2.1.2 Classification 1.2.1.3 Properties 1.2.2 Oil 1.2.3 Gas 1.2.3.1 World natural gas supply and demand outlook 1.2.3.2 Changes in global LNG transactions 1.2.3.3 Changes in global natural gas sale prices 1.3 Combustion of fuels 1.3.1 Coal 1.3.1.1 Fundamentals of combustion 1.3.1.1.1 Combustion process 1.3.1.1.2 Combustion air and flue gas 1.3.1.2 Combustion systems 1.3.1.3 Combustion characteristics 1.3.1.3.1 Combustion efficiency 1.3.1.3.2 NOx formation 1.3.2 Oil 1.3.3 Gas 1.3.3.1 Natural gas–fired combustion 1.3.3.2 Blast furnace gas–fired combustion 1.3.3.3 Biogas-fired combustion 1.3.3.4 Alternative fuel gas–fired combustion 1.4 Emission-induced environmental issues and protection 1.4.1 Flue gas treatment technology 1.4.1.1 Dust collection technology 1.4.1.2 De-NOx technology 1.4.1.3 Flue gas desulfurization technology 1.4.1.4 Combined technologies to reduce NOx and SOx emissions 1.4.1.5 Mercury emission control technology 1.4.2 Wastewater treatment 1.4.2.1 Boron 1.4.2.2 Selenium 1.5 Remarks Nomenclature Notations Greek letters Subscripts References 2---Introduction-to-boilers_2021_Advances-in-Power-Boilers 2 Introduction to boilers Chapter Outline 2.1 Start of steam application to pumping water 2.2 Dawn of steam power 2.3 Classification of boilers 2.4 History of boiler development 2.4.1 Cylindrical boiler development 2.4.2 Development in water tube boiler 2.4.3 Once-through boiler 2.4.4 Summary of boiler development 2.5 Historical development of power generation boilers in Japan 2.6 Similarity law in boiler furnace and other various important issues References 3---General-planning-of-thermal-power-plant_2021_Advances-in-Power-Boilers 3 General planning of thermal power plant Chapter Outline 3.1 Overview of steam power plant 3.2 Concept of general planning and factors to be considered 3.3 Principal concept for high-performance plant 3.3.1 Site location 3.3.2 Fuel 3.3.3 Type of boiler 3.3.4 Unit capacity 3.3.5 Steam condition 3.4 Reheat cycle and regenerative cycle 3.4.1 Steam pressure 3.4.2 Steam temperature 3.4.3 Condenser vacuum 3.4.4 Regenerative cycle 3.4.5 Reheat cycle 3.4.6 Example of heat balance 3.4.7 Feedwater temperature 3.5 Enthalpy–pressure diagram along steam generating tube 3.6 Legal regulations in Japan References 4---Power-boiler-design_2021_Advances-in-Power-Boilers 4 Power boiler design Chapter Outline 4.1 Heat transfer in boiler 4.1.1 Radiation 4.1.2 Conduction 4.1.3 Convection 4.1.4 Heat transfer in boiler 4.1.4.1 Furnace 4.1.4.2 Computational fluid dynamics 4.1.4.3 Heat transfer for heating surface (superheater, reheater, economizer) in the flue gas pass 4.2 Boiler gas side performance for furnace design 4.2.1 Principles of boiler furnace design 4.2.1.1 Required space for complete combustion: H2–H4 4.2.1.2 Control ash adhesion to furnace wall: FD×FW, H4 4.2.2 Boiler components 4.2.2.1 Furnace wall, passage sidewall, and 2ry pass wall tubes and roof tubes 4.2.2.1.1 Structure 4.2.2.1.2 Fluid circuits 4.2.2.1.3 Water separator and water separator drain tank 4.2.2.2 Superheaters 4.2.2.2.1 Primary superheater 4.2.2.2.2 Secondary superheater 4.2.2.2.3 Tertiary superheater 4.2.2.3 Reheaters 4.2.2.3.1 Primary reheater 4.2.2.3.2 Secondary reheater 4.2.2.4 Material for final superheater, main steam pipe, final reheater, hot reheat pipe 4.2.2.5 Desuperheaters 4.2.2.6 Economizer 4.2.2.7 Boiler supports 4.2.2.8 Casing and insulation 4.2.3 Membrane wall 4.2.4 Pulverized coal combustion 4.2.4.1 Combustion 4.2.4.2 Firing system 4.2.4.2.1 Circular corner firing system 4.2.4.2.2 Wall firing 4.2.4.3 Pulverizer performance 4.2.4.4 Slagging and fouling 4.2.4.4.1 Slagging 4.2.4.4.2 Fouling 4.2.4.4.3 Coal ash characterization 4.2.4.5 Corrosion and erosion 4.2.4.5.1 Corrosion 4.2.4.5.2 Erosion 4.2.5 Fluidized bed combustion 4.2.5.1 Principle of fluidized bed combustion 4.2.5.2 Bubbling fluidized bed boiler 4.2.5.3 Circulating fluidized-bed boiler 4.2.6 Stoker combustion 4.2.6.1 History of stoker combustion 4.2.6.2 Characteristics of waste as a fuel 4.2.6.3 Basic configuration of stoker-type incinerators and the waste combustion process 4.2.6.4 Stoker-type combustion incineration configuration 4.2.6.4.1 Waste feeder 4.2.6.4.2 Stoker 4.2.6.4.3 Incinerator types 4.2.6.4.4 Measures for increased durability 4.2.6.5 Combustion control technology for stoker-type combustion incinerators 4.2.6.6 Recent stoker combustion technology 4.2.7 DeNOx, deSOx process, gas cleaning 4.2.7.1 NOx reduction (selective catalytic reduction) 4.2.7.1.1 History and basic technique 4.2.7.1.2 Technology lineup 4.2.7.1.2.1 Examples of selective catalytic reduction system application 4.2.7.1.2.2 High-performance/low-SO2 oxidation catalyst 4.2.7.1.2.3 Mercury oxidation catalyst 4.2.7.1.2.4 Recycling of catalyst 4.2.7.1.2.5 High-performance catalyst in case of high NO2 ratio 4.2.7.1.2.6 High-temperature selective catalytic reduction catalyst 4.2.7.1.2.7 Low-SO2 oxidation catalyst for low-quality solid fuel 4.2.7.2 SOx reduction (wet flue gas desulfurization) 4.2.7.2.1 History and basic technique 4.2.7.2.2 Technology lineup 4.2.7.2.2.1 Limestone–gypsum wet desulfurization equipment for bituminous/subbituminous coal-fired boilers 4.2.7.2.2.2 Limestone–gypsum wet desulfurization equipment for lignite-fired boilers 4.2.7.2.2.3 Limestone–gypsum wet desulfurization equipment for heavy oil-fired boilers 4.2.7.2.2.4 Seawater desulfurization equipment 4.2.7.3 PM reduction (electrostatic precipitator) 4.2.7.3.1 History and basic technique 4.2.7.3.2 Technology lineup 4.2.7.3.2.1 Dry-type electrostatic precipitator 4.2.7.3.2.2 Moving electrode electrostatic precipitator 4.2.7.3.2.3 Wet-type electrostatic precipitator 4.3 Water circulation design 4.3.1 Water circulation system principle 4.3.2 Submerged cylindrical type 4.3.3 Water tube type 4.3.3.1 Cooling principle in water tube 4.3.3.1.1 Heat flux consideration 4.3.3.1.2 Heat transfer consideration 4.3.3.1.3 Hydrodynamic consideration 4.3.3.2 Stability of mass velocity against heat absorption deviation 4.3.3.2.1 Natural circulation characteristic 4.3.3.2.2 Forced circulation characteristic 4.3.4 Steam drum 4.3.4.1 Reasons for better separation performance 4.3.4.2 Separation principles 4.3.4.2.1 Suppression of water carryover to steam 4.3.4.2.2 Suppress steam carryunder to water 4.3.5 Once-through boiler 4.3.5.1 Subcritical pressure once-through boiler 4.3.5.2 Supercritical pressure once-through boiler 4.3.5.2.1 Heat transfer consideration 4.3.5.2.2 Hydrodynamic consideration 4.3.6 Supercritical sliding pressure operation once-through boiler 4.3.6.1 Merit and effectiveness of supercritical sliding pressure operation 4.3.6.2 Heat transfer and hydrodynamic consideration 4.3.6.2.1 Heat transfer consideration 4.3.6.2.2 Hydrodynamic consideration 4.3.6.2.2.1 Pressure drop in single-phase flow region 4.3.6.2.2.2 Pressure drop in two-phase flow region 4.3.6.2.3 Other aspects to be considered 4.3.6.2.3.1 Inclined tube critical heat flux 4.3.6.2.3.2 Hydrodynamic behavior in downward flow of stem–water mixture 4.3.6.3 Flow stability 4.4 Deposition, erosion and corrosion, and water treatment 4.4.1 Importance of water quality control in thermal power plants 4.4.2 History of water treatment methods for thermal power plants 4.4.3 New technologies regarding water treatment for thermal power plants 4.4.3.1 Measures against flow-accelerated corrosion 4.4.3.2 Measures against powdered-scale deposition in oxygenated treatment operation in once-through boiler 4.4.4 Remarks References 5---Construction--operation--and-control-of-power_2021_Advances-in-Power-Boi 5 Construction, operation, and control of power boiler Chapter outline 5.1 Construction of coal-fired boiler 5.1.1 Introduction 5.1.2 Advanced construction method/simultaneous construction method 5.1.3 Floor block erection method/floor unit construction method 5.1.4 Hyper core structure construction method 5.1.5 Top girder and pressure parts integrated block jack-up method 5.1.6 Module construction method 5.1.6.1 Coil module for boiler pressure parts method 5.1.6.2 Boiler split module method 5.1.6.3 Zone module construction method 5.1.6.3.1 Side, front, and rear zone 5.1.6.3.2 Mill zone 5.1.6.3.3 Bunker zone 5.1.6.3.4 Eco hopper zone 5.1.6.3.5 Selective catalytic reduction and air heater zone 5.1.6.3.6 Furnace upper zone 5.1.6.3.7 Furnace lower zone 5.1.6.3.8 Secondary pass zone 5.2 Operation and control of power boiler 5.2.1 Dynamic behavior of power boiler and control system 5.2.1.1 Dynamic characteristics of drum boiler 5.2.1.1.1 Step increase in fuel flow rate 5.2.1.1.2 Step increase in feedwater flow rate 5.2.1.1.3 Step change in governing valve opening position 5.2.1.1.4 Step increase in spray water flow rate 5.2.1.2 Dynamic characteristics of once-through boiler 5.2.1.2.1 Step increase in fuel flow rate 5.2.1.2.2 Step increase in feedwater flow rate 5.2.1.2.3 Step increase in spray water flow rate 5.2.2 Boiler control system 5.2.2.1 Drum boiler 5.2.2.1.1 Automatic combustion control 5.2.2.1.1.1 Steam pressure control (boiler master control) 5.2.2.1.1.2 Air–fuel ratio control at low–excess air ratio 5.2.2.1.2 Feedwater control 5.2.2.1.3 Steam temperature control 5.2.2.1.3.1 Main steam temperature control 5.2.2.1.3.2 Reheat steam temperature control 5.2.2.2 Control of once-through boiler 5.2.2.2.1 Main steam temperature control 5.2.2.2.2 Recirculation flow control system in the once-through boiler 5.2.2.2.2.1 Recirculation operation zone 5.2.2.2.2.2 Once-through operation zone 5.2.2.3 Other boiler control 5.2.2.3.1 Unit output command control 5.2.2.3.1.1 Unit output signal 5.2.2.3.1.2 Automatic frequency control 5.2.2.3.1.3 Turbine master control 5.2.2.3.1.4 Boiler master control 5.2.2.3.2 Feedwater flow control 5.2.2.3.3 Water–fuel ratio control 5.2.2.3.3.1 Fuel flow control 5.2.2.3.3.2 Air–fuel ratio control 5.2.2.3.3.3 Airflow control 5.2.2.3.3.4 Furnace pressure control 5.2.2.4 Latest boiler steam temperature control 5.2.3 Boiler start-up and shut-down operation 5.2.3.1 Boiler start-up 5.2.3.1.1 Boiler cold cleanup 5.2.3.1.1.1 Boiler water filling 5.2.3.1.1.2 Boiler cold cleanup blow 5.2.3.1.1.3 Boiler cold cleanup circulation 5.2.3.1.2 Boiler light-off preparation 5.2.3.1.2.1 Feedwater system 5.2.3.1.2.2 Air and flue gas system and furnace purge 5.2.3.1.2.3 Fuel system 5.2.3.1.2.4 Master fuel trip reset 5.2.3.1.2.5 Others 5.2.3.1.3 Boiler light-off 5.2.3.1.4 Boiler hot cleanup 5.2.3.1.5 Boiler pressure and temperature rise 5.2.3.1.5.1 Limit target at start-up 5.2.3.1.5.2 Adjustment of fuel flow 5.2.3.1.5.3 Feedwater flow and storage tank level control 5.2.3.1.5.4 Operation of drain valve and star-up bypass valve 5.2.3.1.5.5 Temperature rise/pressure rise completed 5.2.3.1.6 Turbine start-up, acceleration, and synchronization preparation 5.2.3.1.7 Synchronization/load up (I) 5.2.3.1.8 Load up (II) 5.2.3.1.9 Load up (III) 5.2.3.2 Boiler shutdown 5.2.3.2.1 Normal shutdown 5.2.3.2.2 Shut-down mode after desynchronization 5.2.3.2.2.1 Boiler hot banking shutdown 5.2.3.2.2.2 Boiler forced cooling shutdown 5.2.4 Partial load operation/sliding pressure (variable pressure) operation 5.2.4.1 Partial load operation of sliding pressure once-through boiler 5.2.4.2 Challenges of sliding pressure operation 5.2.5 Remarks Nomenclature References 6---Gas-turbine-combined-cycle_2021_Advances-in-Power-Boilers 6 Gas turbine combined cycle Chapter Outline 6.1 Gas turbine combined cycle power generation 6.1.1 Overall feature of combined cycle plant 6.1.2 Thermodynamic principle of gas turbine combined cycle power plant 6.1.2.1 Steam power generation 6.1.2.2 Gas turbine power generation 6.1.2.3 Gas turbine combined cycle power generation 6.1.3 Types of gas turbine combined cycle power plant 6.1.3.1 Classification by cycle configuration 6.1.3.1.1 Heat recovery combined cycle 6.1.3.1.2 Full fired heat recovery combined cycle 6.1.3.1.3 Supplementary fired heat recovery combined cycle 6.1.3.2 Classification by shaft configuration 6.1.3.2.1 Multishaft combined cycle 6.1.3.2.2 Single-shaft combined cycle 6.1.4 Features of gas turbine combined cycle power plant 6.1.4.1 Advantage of gas turbine combined cycle power plant 6.1.4.2 Disadvantage of gas turbine combined cycle power plant 6.1.5 Heat recovery steam generator 6.1.5.1 Feature of heat recovery steam generator 6.1.5.2 Technical trend of heat recovery steam generator 6.1.5.2.1 Optimization for water and steam system 6.1.5.2.2 High steam temperature condition 6.1.5.2.3 Supplementary firing heat recovery steam generator 6.1.5.2.4 Selective catalytic reduction system 6.1.5.2.5 Construction method of heat recovery steam generator 6.1.5.3 Example of heat recovery steam generator 6.1.5.4 Remarks 6.2 Pressurized fluidized-bed combustion boiler 6.3 Integrated coal-gasification combined cycle 6.3.1 Overview of integrated coal-gasification combined cycle development in the world 6.3.2 Gas turbine combined cycle system 6.3.3 Benefits of integrated coal-gasification combined cycle 6.3.4 Environmental advantage 6.3.5 Development history of air-blown integrated coal-gasification combined cycle 6.3.6 Development history of oxygen-blown integrated coal-gasification combined cycle 6.3.7 Gasifier facilities 6.3.7.1 Coal pulverizing and feeding system 6.3.7.2 Coal pulverizer 6.3.7.3 Pulverized coal feeding system 6.3.8 Gasifier 6.3.8.1 Air-blown gasifier 6.3.8.2 Oxygen-blown gasifier 6.3.9 Char recycle system 6.3.9.1 Char cyclone 6.3.9.2 Porous filter 6.3.10 Gas clean-up system 6.3.10.1 COS hydrolysis and scrubbing/washing section 6.3.10.2 H2S absorber/stripper section 6.3.11 Combined cycle system 6.3.11.1 Gas turbine 6.3.11.2 Heat recovery steam generator 6.3.11.3 Steam turbine References 7---Ultrasupercritical-and-advanced-ultrasupercriti_2021_Advances-in-Power-B 7 Ultrasupercritical and advanced ultrasupercritical power plants Chapter outline 7.1 Introduction 7.2 Efficiency improvement 7.2.1 Pragmatic approach in thermodynamic point of view 7.2.1.1 Elevating steam condition 7.2.1.2 Double-reheat cycle 7.2.2 Definition of thermal power plant efficiency 7.2.2.1 Higher or lower heating value base efficiency 7.2.2.2 Gross efficiency or net efficiency 7.2.2.3 Other factors to be considered 7.3 History of elevating steam condition in the world 7.4 Development programs for ultrasupercritical and advanced ultrasupercritical power plants in the world 7.4.1 Development program of ultrasupercritical power plants in Japan 7.4.2 Development program of advanced ultrasupercritical power plants in Japan 7.4.2.1 Development system and sequence 7.4.2.2 Material development for advanced ultrasupercritical power boilers 7.5 Aspects of metallurgy and stress analysis 7.5.1 Creep-rupture properties 7.5.1.1 Development of creep strength–enhanced ferritic steel 7.5.1.2 Revised allowable stress and its account 7.5.1.3 Management for creep strength–enhanced ferritic steel 7.5.1.3.1 Quality improvement 7.5.1.3.2 Enhancement of heat-affected zone 7.5.1.3.3 Life prediction 7.5.1.3.4 Analysis in multiaxial stress field 7.5.1.3.5 Nondestructive testing and examination 7.5.2 Corrosion resistance properties 7.6 Concluding remarks References 8---Examples-of-thermal-power-station_2021_Advances-in-Power-Boilers 8 Examples of thermal power station Chapter outline 8.1 Tachibana-Wan Thermal Power Station Unit No. 2 (ultrasupercritical, sliding pressure, once-through boiler) 8.1.1 Development of advanced steam condition boilers 8.1.2 Main design features of the boiler 8.1.2.1 Use of high-strength materials 8.1.2.2 Combustion system 8.1.3 Construction 8.1.3.1 Side span module for steel frame structure zone 8.1.3.2 Coil module for pressure parts zone 8.1.3.2.1 Pendant convection pass sidewall area 8.1.3.2.2 Reheater area 8.1.3.2.3 Superheater area 8.1.3.3 Wind box module for pressure zone 8.1.4 Achievements in the commissioning 8.1.5 Remarks 8.2 Himeji No. 2 Power Plant (gas turbine combined-cycle plant) 8.2.1 Outline of the plant 8.2.1.1 Description 8.2.1.2 Main characteristics 8.2.1.2.1 High plant efficiency 8.2.1.2.2 Environment protection 8.2.1.2.3 Excellent operational characteristics 8.2.1.3 Plant-rated performance and equipment specification 8.2.1.3.1 Plant-rated performance 8.2.1.3.2 Equipment specification 8.2.2 Characteristics of the main component 8.2.2.1 Gas turbine 8.2.2.2 Steam turbine 8.2.2.3 Heat-recovery steam generator 8.2.2.4 Turbine cooling air cooler and fuel gas heater 8.2.3 Test operation performance 8.2.4 Remarks 8.3 Karita PFBC plant 8.4 Nakoso and Osaki Integrated Coal Gasification Combined Cycle (IGCC) Plants 8.4.1 Nakoso 250MW air-blown IGCC demonstration plant 8.4.1.1 Construction 8.4.1.2 Jack-up construction method for gasifier pressure vessels 8.4.1.3 Advanced installation method 8.4.1.4 Operation 8.4.1.5 Fukushima IGCC project (Nakoso, Hirono) 8.4.2 EAGLE project and Osaki CoolGen project (oxygen-blown IGCC) 8.4.2.1 EAGLE project 8.4.2.1.1 EAGLE—step 1 (1998 to March 2007) 8.4.2.1.2 EAGLE—step 2 (April 2007 to March 2010) 8.4.2.1.3 EAGLE—step 3 (April 2010 to June 2014) 8.4.2.2 Osaki CoolGen project 8.5 Incineration firing by circulating fluidized bed References 9---Boiler-explosion-and-inspection_2021_Advances-in-Power-Boilers 9 Boiler explosion and inspection Chapter Outline 9.1 Historical trend of boiler explosions 9.2 Legislative framework 9.3 Development in boiler code and inspection organization in the United States and Germany 9.4 Historical development of boiler regulation in Japan 9.5 Outline of current inspection of power boiler 9.5.1 Nondestructive inspection technology for thermal power plants 9.5.1.1 Boiler damage and nondestructive inspection technologies 9.5.1.2 Outline of various nondestructive inspection technologies 9.5.1.2.1 Cable-less inner ultrasonic testing system 9.5.1.2.2 Corrosion thinning part inspection technique by tube-inserted eddy current testing 9.5.1.2.3 Surface defect detection technology by pencil eddy current testing 9.5.1.2.4 Creep damage detection technique by phased-array ultrasonic testing 9.5.1.2.5 Thickness-monitoring technique by thin film ultrasonic testing 9.5.2 Boiler inspection technology by drones 9.5.2.1 Characteristics of inspection drones 9.5.2.1.1 Wheeled bumper mounted drone 9.5.2.1.2 Spherical bumper mounted drone 9.5.2.2 Customer advantages References 10---Future-perspective-and-remarks_2021_Advances-in-Power-Boilers 10 Future perspective and remarks Chapter Outline 10.1 Introduction 10.2 Situation of thermal power generation 10.2.1 Efforts by major nations to reduce greenhouse gas emissions 10.2.2 Efforts by Japan to reduce greenhouse gas emissions 10.3 Next-generation thermal power generation technology for a decarbonized society (∼2030) 10.3.1 Future outlook for next-generation, high-efficiency technology 10.3.2 Outlook for developing carbon dioxide capture, utilization, and storage and hydrogen power generation technology 10.4 Future outlook for thermal power generation (2030∼) 10.5 Conclusion References Index_2021_Advances-in-Power-Boilers Index