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Title: Materials for advanced ultrasupercritical steam turbines

Abstract

The U.S. Department of Energy (DOE) and the Ohio Coal Development Office (OCDO) have sponsored a project aimed at identifying, evaluating, and qualifying the materials needed for the construction of the critical components of coal-fired power plants capable of operating at much higher efficiencies than the current generation of supercritical plants. This increased efficiency is expected to be achieved principally through the use of advanced ultrasupercritical (A-USC) steam conditions. A limiting factor in this can be the materials of construction for boilers and for steam turbines. The overall project goal is to assess/develop materials technology that will enable achieving turbine throttle steam conditions of 760°C (1400°F)/35MPa (5000 psi). This final technical report covers the research completed by the General Electric Company (GE) and Electric Power Research Institute (EPRI), with support from Oak Ridge National Laboratory (ORNL) and the National Energy Technology Laboratory (NETL) – Albany Research Center, to develop the A-USC steam turbine materials technology to meet the overall project goals. Specifically, this report summarizes the industrial scale-up and materials property database development for non-welded rotors (disc forgings), buckets (blades), bolting, castings (needed for casing and valve bodies), casting weld repair, and casting to pipe welding. Additionally, the report providesmore » an engineering and economic assessment of an A-USC power plant without and with partial carbon capture and storage. This research project successfully demonstrated the materials technology at a sufficient scale and with corresponding materials property data to enable the design of an A-USC steam turbine. The key accomplishments included the development of a triple-melt and forged Haynes 282 disc for bolted rotor construction, long-term property development for Nimonic 105 for blading and bolting, successful scale-up of Haynes 282 and Nimonic 263 castings using traditional sand foundry practices, and a techno-economic study of an A-USC plant including cost estimates for an A-USC turbine which showed A-USC to be economically attractive for partial carbon and capture compared to today’s USC technology. Based on this successful materials research and a review with U.S. utility stakeholders, a new project to develop a component test facility (ComTest) including the world’s first A-USC turbine has been proposed to continue the technology development.« less

Authors:
 [1];  [1];  [1];  [1];  [1];  [1];  [1];  [1]
  1. Energy Industries Of Ohio Inc., Independence, OH (United States)
Publication Date:
Research Org.:
Energy Industries Of Ohio Inc., Independence, OH (United States)
Sponsoring Org.:
USDOE
OSTI Identifier:
1243058
DOE Contract Number:  
FE0000234
Resource Type:
Technical Report
Country of Publication:
United States
Language:
English
Subject:
36 MATERIALS SCIENCE; 32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATION

Citation Formats

Purgert, Robert, Shingledecker, John, Saha, Deepak, Thangirala, Mani, Booras, George, Powers, John, Riley, Colin, and Hendrix, Howard. Materials for advanced ultrasupercritical steam turbines. United States: N. p., 2015. Web. doi:10.2172/1243058.
Purgert, Robert, Shingledecker, John, Saha, Deepak, Thangirala, Mani, Booras, George, Powers, John, Riley, Colin, & Hendrix, Howard. Materials for advanced ultrasupercritical steam turbines. United States. https://doi.org/10.2172/1243058
Purgert, Robert, Shingledecker, John, Saha, Deepak, Thangirala, Mani, Booras, George, Powers, John, Riley, Colin, and Hendrix, Howard. 2015. "Materials for advanced ultrasupercritical steam turbines". United States. https://doi.org/10.2172/1243058. https://www.osti.gov/servlets/purl/1243058.
@article{osti_1243058,
title = {Materials for advanced ultrasupercritical steam turbines},
author = {Purgert, Robert and Shingledecker, John and Saha, Deepak and Thangirala, Mani and Booras, George and Powers, John and Riley, Colin and Hendrix, Howard},
abstractNote = {The U.S. Department of Energy (DOE) and the Ohio Coal Development Office (OCDO) have sponsored a project aimed at identifying, evaluating, and qualifying the materials needed for the construction of the critical components of coal-fired power plants capable of operating at much higher efficiencies than the current generation of supercritical plants. This increased efficiency is expected to be achieved principally through the use of advanced ultrasupercritical (A-USC) steam conditions. A limiting factor in this can be the materials of construction for boilers and for steam turbines. The overall project goal is to assess/develop materials technology that will enable achieving turbine throttle steam conditions of 760°C (1400°F)/35MPa (5000 psi). This final technical report covers the research completed by the General Electric Company (GE) and Electric Power Research Institute (EPRI), with support from Oak Ridge National Laboratory (ORNL) and the National Energy Technology Laboratory (NETL) – Albany Research Center, to develop the A-USC steam turbine materials technology to meet the overall project goals. Specifically, this report summarizes the industrial scale-up and materials property database development for non-welded rotors (disc forgings), buckets (blades), bolting, castings (needed for casing and valve bodies), casting weld repair, and casting to pipe welding. Additionally, the report provides an engineering and economic assessment of an A-USC power plant without and with partial carbon capture and storage. This research project successfully demonstrated the materials technology at a sufficient scale and with corresponding materials property data to enable the design of an A-USC steam turbine. The key accomplishments included the development of a triple-melt and forged Haynes 282 disc for bolted rotor construction, long-term property development for Nimonic 105 for blading and bolting, successful scale-up of Haynes 282 and Nimonic 263 castings using traditional sand foundry practices, and a techno-economic study of an A-USC plant including cost estimates for an A-USC turbine which showed A-USC to be economically attractive for partial carbon and capture compared to today’s USC technology. Based on this successful materials research and a review with U.S. utility stakeholders, a new project to develop a component test facility (ComTest) including the world’s first A-USC turbine has been proposed to continue the technology development.},
doi = {10.2172/1243058},
url = {https://www.osti.gov/biblio/1243058}, journal = {},
number = ,
volume = ,
place = {United States},
year = {Tue Dec 01 00:00:00 EST 2015},
month = {Tue Dec 01 00:00:00 EST 2015}
}