Plant Design

The world’s first supercritical pulverized coal–fired low mass flux vertical tube Benson boiler is Jinzhushan 3, located in the Hunan Province of the People’s Republic of China. The 600-MW Babcock & Wilcox Power Generation Group Inc. once-through boiler burns Chinese anthracite using downshot pulverized coal (PC) technology. Part 1 of this three-part article presented a summary of the project design features. Part 2 discussed the boiler technology. This third and final part reviews the plant’s performance test results.

While the war on coal is working to reduce coal generation and consumption and associated carbon dioxide emissions in the United States, many world economies are looking toward coal for future generation needs. China, India, Russia, and Germany, to name a few, are building coal-fired power plants.

This synopsis of today’s most interesting research related to power generation gives you a glimpse of what’s possibly coming to your plant in the not-so-distance future. Research under way today will surely determine how power plants are designed, operated, and maintained for many years to come.

Insulation and lagging are key to saving energy in a typical steam plant, and plant operators would be well advised to pay close attention to energy losses in their insulation and lagging systems.

The world’s first supercritical pulverized coal–fired low mass flux vertical tube Benson boiler is Jinzhushan 3, located in Hunan Province of the People’s Republic of China. The 600-MW Babcock & Wilcox Power Generation Group Inc. once-through boiler burns Chinese anthracite using downshot pulverized coal (PC) technology. Part 2 of this three-part article discusses the boiler technology. The third and final part will review the plant’s performance test results.

Dominion Virginia Power plans to convert its oldest coal-fired power plant, the 227-MW Bremo Power Station near Bremo Bluff, Va., to natural gas, the company announced earlier this month. The two-unit plant would be the ninth in its fleet to be closed or converted to alternative fuels.

The world’s first supercritical pulverized coal–fired low mass flux vertical tube Benson boiler is Jinzhushan 3, located in the Hunan Province of the People’s Republic of China. The 600-MW Babcock & Wilcox Power Generation Group Inc. once-through boiler burns Chinese anthracite using downshot pulverized coal (PC) technology. Part 1 of this three-part article provides a project summary and overview. The other two parts will look at technology features of the unique boiler design and plant performance test results.

Advanced ultrasupercritical (A-USC) is a term used to designate a coal-fired power plant design with the inlet steam temperature to the turbine at 700C to 760C. In the first two parts of this three-part report, we introduced the A-USC boiler and the metallurgical advancements required for the A-USC boiler to operate at such high temperatures. This final report explores the A-USC boiler’s unique design challenges.

Coal combustion products often can be recycled into a variety of construction and building materials. However, first you must be able to retrieve the wet ash from a holding pond before the ash can be dried and sold.

Advanced ultrasupercritical (A-USC) is a term used to designate a coal-fired power plant design with the inlet steam temperature to the turbine at 700C to 760C. In Part I of this three-part report, we introduced the A-USC boiler. In this segment, we look at the metallurgical advancements required for the A-USC boiler to operate at such high temperatures. The final report will explore the A-USC boiler’s unique design challenges.

Trying to assess the potential for coal-to-gas switching in today’s environment is something of an art form. Suppose for a moment that one were able to devise an economic model that truly replicates real-world generation dispatch for plant operators. A model is only as good as the inputs that go into it, and, let’s face it, future natural gas prices are a critical component.

Advanced ultrasupercritical (A-USC) is a term used to designate a coal-fired power plant design with the inlet steam temperature to the turbine at 700C to 760C. In Part I of a three-part report, we introduce the A-USC boiler. Future reports will discuss the metallurgical and boiler design challenges.

Creating a landfill to hold dry boiler ash is a challenging proposition these days. There’s more to the project than you might imagine, as you’ll learn from this article about the development of a typical new ash landfill.

A Romanian lignite-fired power station wanted to minimize the operating cost of the flue gas desulfurization (FGD) system by placing the booster fans in the "wet position," between the wet FGD scrubber and the wet stack, where they would consume significantly less power. A number of combined environmental effects must be considered in this design.

When sootblower operation frequency is too high, a plant risks losing power generation from tube leaks; but when sootblower frequency is too low, there is a risk of boiler pluggage. Intelligent sootblowing finds the right balance between tube erosion and plant economic operation.

Several states have already instituted mercury emission limits in expectation of tightening mercury emission rules that will require reductions of up to 91%. Coal-fired plants searching for an economical way to meet the new limits may need to look no further than replacing their baghouse filter elements.

Pulverizers prepare the raw fuel by grinding it to a desired fineness and mixing it with the just the right amount of air before sending the mixture to boiler burners for combustion. In Part I of this three-part report, we examined the essentials of pulverizer design and performance.  In the second part, we discuss the importance of fuel fineness. In the final article, we will discuss the importance of air and fuel measurement.

Utilizing engineering ingenuity and today’s developing computational fluid dynamics tools, a new classifier design is now available that significantly improves fineness from pulverizers without the heavy costs associated with dynamic classification or any downsides on pulverizer capacities, maintenance, and parasitic power.  Instead, operational flexibility and improved emission control options are enhanced.

The regenerative air heater on a typical steam generator usually accounts for over 10% of a coal-fired plant’s thermal efficiency. A poorly performing air heater will cause an increase in the gas outlet temperature, often reducing the electrostatic precipitator collection efficiency and baghouse reliability. Recent design innovations enable restoration of this lost performance.

Pulverizers prepare raw fuel by grinding it to a desired fineness and mixing it with the just the right amount of air before sending the mixture to boiler burners for combustion. In Part I of three parts, we’ll examine the essentials of pulverizer capacity, what should be done after a coal pulverizer fire or other incident, and how to tune up pulverizer performance. In future articles we’ll discuss measuring pulverizer performance and performance optimization.

Why should utilities consider converting existing coal-fired plants to burn gas? We explore the rationale for fuel switching, some of the options available for the conversion of coal-fired units, technical considerations related to conversion, and some of the financial considerations that will impact the final decision.

Utilities struggling to meet renewable portfolio standards requirements have studied the conversion of existing coal-fired boilers to burn biomass. The results of those studies have been mixed, although test burns continue; the results of one such test are included. Overall, the market is tending toward smaller biomass projects, and the low price of natural gas is perhaps the biggest reason utility-scale projects are now few and far between.

The international policy framework regulating the emissions of greenhouse gases from industrial and utility boilers is in flux. Meanwhile, most boiler owners are evaluating potential strategies for when, not if, more stringent emissions reduction regulations are put in place. One of the most attractive compliance options is the cofiring of biomass in existing coal-fired boilers.

Duke Energy and Progress Energy announced January 10 that they are combining to create the nation’s biggest electric utility. The $13.7 billion deal is likely to draw tough scrutiny from federal and state regulators—and some protests from big power buyers—given the companies’ overwhelming market dominance in North Carolina and more modest operational overlap in South Carolina.

Ringing what may be the death knell for the $3.5 billion Taylorville IGCC project, the Illinois Senate voted 33-18 in early January against authorizing construction of a coal gasification and power generating plant proposed in the state by Tenaska.

Energy efficient and environmentally responsible dry bottom ash technologies will soon be required by regulation. Progressive companies will bring their plants into compliance early because it’s a good business strategy. Here are your compliance options.

Boiler insulation practices have moved from using a single layer to a double layer of the same total thickness in recent years. However, this dual-layer trend has a downside: higher installation costs and the opportunity for contractors to cut corners when installing insulation. It’s time to return to using single-layer insulation on power boilers.

Every power engineer must have a firm grasp of the rudiments of how fuel is processed to produce electricity in a power generation facility. With this article, we begin a series of Power 101 tutorials that present these fundamentals in a clear and concise way. First up are the essentials of recovering heat from flue gas.

In a move that could cost the state’s electricity generators an estimated $8.5 billion, New York regulators [have] issued a draft policy that would require the installment of closed-loop cooling systems at two dozen large power plants in the state, including oil, coal, nuclear and natural gas generators, to reduce fish kills and other harmful effects to wildlife in the water bodies that supply the plants’ cooling water.

The loading and discharge of conveyor belts is the area where many, if not most, of the problems in solids conveying occur. Fortunately, a new technology provides chutes to accomplish conveyor loading and discharge without blockages while minimizing the dust generated: engineered-flow transfer chutes.