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Title: Boiler materials for ultra supercritical coal power plants

Abstract

The U.S. Department of Energy (DOE) and the Ohio Coal Development Office (OCDO) have undertaken a project aimed at identifying, evaluating, and qualifying the materials needed for the construction of the critical components of coal-fired boilers capable of operating at much higher efficiencies than current generation of supercritical plants. This increased efficiency is expected to be achieved principally through the use of advanced ultrasupercritical (A-USC) steam conditions up to 760°C (1400°F) and 35 MPa (5000 psi). A limiting factor to achieving these higher temperatures and pressures for future A-USC plants are the materials of construction. The goal of this project is to assess/develop materials technology to build and operate an A-USC boiler capable of delivering steam with conditions up to 760°C (1400°F)/35 MPa (5000 psi). The project has successfully met this goal through a focused long-term public-private consortium partnership. The project was based on an R&D plan developed by the Electric Power Research Institute (EPRI) and an industry consortium that supplemented the recommendations of several DOE workshops on the subject of advanced materials. In view of the variety of skills and expertise required for the successful completion of the proposed work, a consortium led by the Energy Industries of Ohiomore » (EIO) with cost-sharing participation of all the major domestic boiler manufacturers, ALSTOM Power (Alstom), Babcock and Wilcox Power Generation Group, Inc. (B&W), Foster Wheeler (FW), and Riley Power, Inc. (Riley), technical management by EPRI and research conducted by Oak Ridge National Laboratory (ORNL) has been developed. The project has clearly identified and tested materials that can withstand 760°C (1400°F) steam conditions and can also make a 700°C (1300°F) plant more economically attractive. In this project, the maximum temperature capabilities of these and other available high-temperature alloys have been assessed to provide a basis for materials selection and application under a range of conditions prevailing in the boiler. A major effort involving eight tasks was completed in Phase 1. In a subsequent Phase 2 extension, the earlier defined tasks were extended to finish and enhance the Phase 1 activities. This extension included efforts in improved weld/weldment performance, development of longer-term material property databases, additional field (in-plant) corrosion testing, improved understanding of long-term oxidation kinetics and exfoliation, cyclic operation, and fabrication methods for waterwalls. In addition, preliminary work was undertaken to model an oxyfuel boiler to define local environments expected to occur and to study corrosion behavior of alloys under these conditions. This final technical report provides a comprehensive summary of all the work undertaken by the consortium and the research findings from all eight (8) technical tasks including A-USC boiler design and economics (Task 1), long-term materials properties (Task 2), steam- side oxidation (Task 3), Fireside Corrosion (Task 4), Welding (Task 5), Fabricability (Task 6), Coatings (Task 7), and Design Data and Rules (Task 8).« less

Authors:
 [1];  [2];  [3];  [3];  [4];  [4];  [5];  [6];  [6];  [7]
  1. Energy Industries of Ohio, Independence, OH (United States)
  2. Electric Power Research Inst., Palo Alto, CA (United States)
  3. Alstom Power Inc., Windsor, CT (Untied States)
  4. The Babcock & Wilcox Company, Baberton, OH (United States)
  5. Riley Power Inc., Worchester, WA (United States)
  6. Foster Wheeler North America Corp., Hampton, NJ (United States)
  7. Oak Ridge National Lab. (ORNL), Oak Ridge, TN (United States)
Publication Date:
Research Org.:
Energy Industries of Ohio, Independence, OH (United States)
Sponsoring Org.:
USDOE Office of Fossil Energy (FE)
Contributing Org.:
Electric Power Research Inst., Palo Alto, CA (United States); Alstom Power Inc., Windsor, CT (United States); The Babcock & Wilcox Company, Barberton, OH (United States); Riley Power Inc., Worchester, MA (United States); Foster Wheeler North America Corp., Hampton, NJ (United States); Oak Ridge National Lab., Oak Ridge, TN (United States)
OSTI Identifier:
1346714
Report Number(s):
DOE-EIO-EPRI-01NT41175
CDO-D-05-02(A)
DOE Contract Number:  
FG26-01NT41175
Resource Type:
Technical Report
Country of Publication:
United States
Language:
English
Subject:
20 FOSSIL-FUELED POWER PLANTS; 01 COAL, LIGNITE, AND PEAT; 32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATION; 36 MATERIALS SCIENCE; ultrasupercritical; boiler; turbine; waterwalls; casings; castings; rotors; blades; high temperature materials; air quality control system; post combustion CO2 capture; exfoliation; oxyfuel; fireside corrosion; welding; fabricability; coating; steamside oxidation; A-USC

Citation Formats

Purgert, Robert, Shingledecker, John, Pschirer, James, Ganta, Reddy, Weitzel, Paul, Sarver, Jeff, Vitalis, Brian, Gagliano, Michael, Stanko, Greg, and Tortorelli, Peter. Boiler materials for ultra supercritical coal power plants. United States: N. p., 2015. Web. doi:10.2172/1346714.
Purgert, Robert, Shingledecker, John, Pschirer, James, Ganta, Reddy, Weitzel, Paul, Sarver, Jeff, Vitalis, Brian, Gagliano, Michael, Stanko, Greg, & Tortorelli, Peter. Boiler materials for ultra supercritical coal power plants. United States. doi:10.2172/1346714.
Purgert, Robert, Shingledecker, John, Pschirer, James, Ganta, Reddy, Weitzel, Paul, Sarver, Jeff, Vitalis, Brian, Gagliano, Michael, Stanko, Greg, and Tortorelli, Peter. Tue . "Boiler materials for ultra supercritical coal power plants". United States. doi:10.2172/1346714. https://www.osti.gov/servlets/purl/1346714.
@article{osti_1346714,
title = {Boiler materials for ultra supercritical coal power plants},
author = {Purgert, Robert and Shingledecker, John and Pschirer, James and Ganta, Reddy and Weitzel, Paul and Sarver, Jeff and Vitalis, Brian and Gagliano, Michael and Stanko, Greg and Tortorelli, Peter},
abstractNote = {The U.S. Department of Energy (DOE) and the Ohio Coal Development Office (OCDO) have undertaken a project aimed at identifying, evaluating, and qualifying the materials needed for the construction of the critical components of coal-fired boilers capable of operating at much higher efficiencies than current generation of supercritical plants. This increased efficiency is expected to be achieved principally through the use of advanced ultrasupercritical (A-USC) steam conditions up to 760°C (1400°F) and 35 MPa (5000 psi). A limiting factor to achieving these higher temperatures and pressures for future A-USC plants are the materials of construction. The goal of this project is to assess/develop materials technology to build and operate an A-USC boiler capable of delivering steam with conditions up to 760°C (1400°F)/35 MPa (5000 psi). The project has successfully met this goal through a focused long-term public-private consortium partnership. The project was based on an R&D plan developed by the Electric Power Research Institute (EPRI) and an industry consortium that supplemented the recommendations of several DOE workshops on the subject of advanced materials. In view of the variety of skills and expertise required for the successful completion of the proposed work, a consortium led by the Energy Industries of Ohio (EIO) with cost-sharing participation of all the major domestic boiler manufacturers, ALSTOM Power (Alstom), Babcock and Wilcox Power Generation Group, Inc. (B&W), Foster Wheeler (FW), and Riley Power, Inc. (Riley), technical management by EPRI and research conducted by Oak Ridge National Laboratory (ORNL) has been developed. The project has clearly identified and tested materials that can withstand 760°C (1400°F) steam conditions and can also make a 700°C (1300°F) plant more economically attractive. In this project, the maximum temperature capabilities of these and other available high-temperature alloys have been assessed to provide a basis for materials selection and application under a range of conditions prevailing in the boiler. A major effort involving eight tasks was completed in Phase 1. In a subsequent Phase 2 extension, the earlier defined tasks were extended to finish and enhance the Phase 1 activities. This extension included efforts in improved weld/weldment performance, development of longer-term material property databases, additional field (in-plant) corrosion testing, improved understanding of long-term oxidation kinetics and exfoliation, cyclic operation, and fabrication methods for waterwalls. In addition, preliminary work was undertaken to model an oxyfuel boiler to define local environments expected to occur and to study corrosion behavior of alloys under these conditions. This final technical report provides a comprehensive summary of all the work undertaken by the consortium and the research findings from all eight (8) technical tasks including A-USC boiler design and economics (Task 1), long-term materials properties (Task 2), steam- side oxidation (Task 3), Fireside Corrosion (Task 4), Welding (Task 5), Fabricability (Task 6), Coatings (Task 7), and Design Data and Rules (Task 8).},
doi = {10.2172/1346714},
journal = {},
number = ,
volume = ,
place = {United States},
year = {Tue Dec 29 00:00:00 EST 2015},
month = {Tue Dec 29 00:00:00 EST 2015}
}

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