LEADING THE INDUSTRY

IN SUPERCRITICAL
BOILER TECHNOLOGY
 HIGH-EFFICIENCY
SUPERCRITICAL TECHNOLOGY

Alstom is a global leader in the world of power generation, setting the Alstom pioneered supercritical steam generation and today leads
benchmark for clean, innovative technologies to create customer value. the industry in supercritical boiler technology. We have directly
supplied more than 80,000 MWe of supercritical boilers world-
We supply major equipment in 25% of the installed base worldwide.
wide. In addition weve trained and licensed other companies to
And weve developed an unmatched level of expertise in steam
install an additional 72,000 MWe of Alstom supercritical boiler
generation and fuel combustion technology, having supplied more
technology. Globally, we have unmatched experience in tailoring
than 400 GWe of boilers around the world.
boiler designs to fuel properties.
Our boilers convert fuel into steam for the generation of electricity
cleanly, cost-effectively, reliably. As the No 1 supplier of boilers
worldwide, we can meet your project requirements today and in the
future with the design, manufacture and supply of state-of-the-art
systems and equipment.
FOR CLEAN POWER TODAY!

Why Alstom Advanced

Supercritical?

Superior environmental
Leading Through Technology enables the capture
performance
of CO2 emissions
Today, our advanced high-efficiency pulverized coal supercritical
from fossil fuels, Highest unit efficiency
boilers offer plant owners many benefits. The technologys higher
including pulverized
steam temperature and pressure parameters deliver the most Operating flexibility
coal boilers. Known
economical way to improve plant efficiency and operating
as oxy-fuel firing, Design tailored to fuel choice
flexibility, achieve fuel cost savings, and reduce emissions for each
this technology is
kWh of electricity generated. Alstoms Advanced Supercritical Fuel cost savings
being tested in a 30
technology reduces all emissions, including CO2.
MWth pilot at the
In fact, an efficiency improvement of 1 percentage point equals
Schwarze Pumpe
2%-3% less CO2 emitted.
Power Station in Germany. Oxy-fuel firing is especially promising
Alstom is also driving the development and deployment of the for CO2 -free supercritical generation in the near term.
next generation of clean coal combustion technologies. We are
In addition to our own R&D activities, we participate in a
investing in the future of clean power across 22 development
number of public development projects and partnerships,
centers and 13 laboratories around the world with the express
including those sponsored by the European Union and the US
goal of minimizing environmental impact. One Alstom combustion
Department of Energy, as well as nearly all joint boiler materials
technology currently in the pilot plant demonstration phase
development programs.
 THE SUPERCRITICAL
DIFFERENCE

Once-through supercritical technology offers important benefits Increased Efficiency and Lower Emission Levels
to plant owners, including:
Plants that employ todays generation of Alstom supercritical
Increased efficiency boilers can operate at cycle efficiencies in excess of 42-45% HHV
Lower emissions levels (44-47% LHV). As efficiency is increased, less fuel is consumed per
Lower operating costs kilowatt-hour (kWh) with a corresponding decrease in emissions
Greater operating flexibility per kWh. Because these units do not have thick-walled steam
drums, their start-up times are quicker, further enhancing
These benefits are possible because of the higher steam pressures
efficiency and plant economics. We continue to develop increasingly
and temperatures which are a hallmark of the technology.
efficient supercritical cycles for improved efficiency. Alstoms current
technology development will lead to our prototype ultra-supercritical
plant, operating at 1290 F (700 C) / 5075 psi (350 bar).
Understanding Supercritical Technology
Water/steam circulation systems are divided into two main
classifications: once-through, in which the water and steam Lower Operating Costs
generated in the furnace waterwalls passes through only once;
Lower fuel consumption is a direct consequence of higher
and drum-type boilers, in which water/steam separation occurs,
efficiencies. Fuel costs are a power plants largest operating cost
and water is recycled back to the waterwalls.
item. Because the capital cost of supercritical plants is close to
Supercritical conditions occur when the boiler pressure increases those of subcritical plants, overall life cycle costs are often reduced.
above the critical pressure of 3,208 psi / 221.2 bar. Above this
point, two phase mixtures of water and steam cease to exist, and
Heat Rate Improvement vs.
are replaced by a single supercritical fluid. This eliminates the need
Steam Conditions (Single Reheat)
for water/steam separation in drums during operation, and allows
a simpler separator to be employed during start-up conditions.

Faster Start-up Time with Once-Through Design

 Efficiency Improvement with Increasing Steam Conditions

5075/1350/1400
5075/1290/1330 350/730/760
350/700/720
4050/1110/1150
280/600/620 R&D ongoing
R&D ongoing USA
USC Materials
psi/OF/OF Consortium & EC
(bar/OC/OC) 3900/1075/1110 AD 700 project
270/580/600 (Ni-base)
3500/1000/1050 Market
2400/1000/1000 240/540/565 intro. by
Efficiency Increase

167/540/540 Japan
and
Mature technology Europe
CONTINUED ADVANCEMENTS
SUPERCRITICAL DOE USC Matl.
SUBCRITICAL DOE Steam Turbine Matl.
AD 700 project
COMTES 700

1960 1980 2000 2010 2020

Steam Conditions Material Improvement Milestones Today

Greater Operational Flexibility Unlike drum boilers, once- Sliding Pressure Operation
through units do not have a for Once-Through Boilers
Todays market realities demand that units are not only designed
fixed evaporative point: the
for baseload operation, but are capable of cycling and/or two-shift
final evaporation occurs in the
operation. Units must be designed for rapid response times.
furnace wall systems with steam
Alstom once-through supercritical boilers have the ability to
that is leaving the furnace
respond and adjust to changes in load demand while maintaining
walls being superheated to a
tight control of steam temperatures.
certain degree. Since the
Alstoms supercritical boilers operate in the sliding pressure evaporation point is not fixed,
mode, where pressure is reduced with load. This allows the heat duties can be shifted
maintenance of relatively constant first-stage turbine temperature, between the furnace and the
reducing the thermal stress on components as the unit is cycled. superheaters, allowing for
Less stress translates into less maintenance and higher availability. adjustment to changing
slagging and fouling 1. Constant pressure operation
Todays generation of supercritical boilers boast high availabilities, 2. Modified sliding pressure operation
comparable to those of subcritical units, as well as improved plant conditions caused by 3. Pure sliding pressure operation
efficiency at lower loads. changing fuel properties.
 ADVANCED
BOILER DESIGNS

Alstom technologies deliver realistic solutions for reliable clean

coal generation now. Our advanced supercritical boiler designs are
at the heart of todays state-of-the art plants, meeting the diverse
requirements of projects all over the globe and firing the full
range of international coals.

With Alstoms supercritical boiler design advantages, coal is

clean, economical and secure.

1 x 750 MWe, US
Furnace Wall Designs
In todays market, two designs dominate for once-through units:
the spiral furnace tube arrangement and the vertical tube arrangement.
Design choice is governed by furnace size and customer preference
there are advantages to both, depending on project drivers.
The furnace walls are exposed to the greatest heat flux of all
heat-absorbing surfaces. This is because of the intense radiant
heat from the fireball.
Spiral Configuration
Benefits from averaging of lateral heat absorption variation
(each tube forms a part of each furnace wall)
Simplified inlet header arrangement
Large number of operating units
Use of smooth bore tubing throughout
entire furnace wall system
No individual tube orifices
For any given furnace size, the spiral wall unit in which the tube is
wrapped around the unit has fewer tubes than the vertical wall unit.
The vertical waterwall design uses internal ribbing in the tubes to
improve heat transfer. The vertical wall option is available for larger
units where lower perimeter-to-furnace plan area ratios result in
higher fluid flow per tube. The vertically oriented tubes are
self-supporting within the wall, allowing a simpler
support system. In fact, the relative simplicity of a
vertical wall furnace can result in significant
construction cost savings.
Vertical Configuration
Simpler windbox openings
Simpler furnace water wall support system
Elimination of intermediate furnace wall transition header
Less costly to construct
Easier to identify and repair
tubes leaks
Lower water wall system pressure
drop thereby reducing required feed
pump power
ADVANCED
BOILER DESIGNS

2 x 800 MWe, South Korea

Tower and Two-Pass Designs Two-pass is a shorter design which incorporates vertical heating
surface in the radiant section of the furnace, and horizontal
Alstom provides tower and two-pass boiler designs, both of
surface in a parallel backpass. The selection of boiler configuration
which are widespread in power generation applications. In a tower
is project specific, with consideration given to fuel ash
design, all heating surfaces are horizontal and drainable, and
characteristics, site restrictions, and customer preference.
generally in a single vertical configuration within the furnace
bounding walls.

Nominal 900 MWe

Tower Boiler Arrangement Two-Pass, Pendant Arrangement

Niederaussem Unit K, Germany Houshi Units 5-7, China

1 x 1000 MWe 3 x 600 MWe
Tower Design Two-Pass Design
 Waterwall Tubes SH Outlet Header

Advanced Materials Several boiler materials with improved mechanical properties

have been developed recently, and new materials still in the R&D
High temperature materials enable the steam conditions and
stages will enable higher ultra-supercritical steam cycles than are
corresponding thermal efficiency of advanced supercritical
today commercially available. Most materials development is
steam cycles. Ideally, materials used in steam generator pressure
being conducted under national or internationally coordinated
parts combine high temperature strength with reasonable
programs. Alstom participates in nearly all cooperative materials
resistance to oxidation. In addition, the workability of the
development programs, including the AD 700 / COMTES 700
materials and corrosion behavior are important attributes.
program funded by the European Commission, and the US
The increase of steam conditions primarily affects the waterwalls, Ultra-Supercritical Materials Consortium sponsored by the
final superheater and reheater tubing, and the thick-walled US Department of Energy.
components, mainly the high pressure outlet headers and piping
to the turbine. Classes of materials include conventional and
advanced ferritic steel, austenitic steel, and nickel alloys.

Material Development Stages and Related Steam Parameter Limits

Membrane Wall Tubes SH Outlet Header

Future
Options
T92 Nickel Alloy Nickel Alloy
Nickel Alloy

Austenitic NF 12,
9-12% SAVE 12, VM12
Cr-Steels
Current
7 CrMo VTiB 10 10 Austenitic E 911, P 92, P 122
HCM 2S

X 20 X 20
CrMoV 121 CrMoV 121

Past
13 CrMo 4 4 Austenitic P 91

Bar SHO 260 270 290 300 350 260 270 290 300 350 260 270 290 300 350
0
C - SH Temp 550 580 600 630 700 550 580 600 630 700 550 580 600 630 700
0
C - RH Temp 570 600 620 650 720 570 600 620 650 720 570 600 620 650 720
 A WORLD OF
SUCCESS STORIES

Recent References BELCHATOW POLAND

Alstom Advanced Supercritical Boiler Technology
1 x 833 MWe
Lignite
Owner: BOT Elektrownia
BEIJIANG CHINA Belchatow SA
Commercial operation: 2010
2 x 1000 MWe
Highest efficiency level of
Chinese Bituminous
any brown coal-fired plant
Owner: Tianjian Guotou Jinning
in the country
Power Generation Ltd.
Commercial operation: 2010

Most advanced steam

conditions for China IATAN 2 US

1 x 920 MWe
Powder River Basin coal
Owner: Kansas City Power
COMANCHE 3 US & Light
Commercial operation: 2010
1 x 814 MWe
Features advanced vertical
Powder River Basin coal
wall construction
Owner: Xcel Energy
Commercial operation: 2009

Will achieve one of the

lowest NOx levels in US
NEURATH F & G GERMANY

2 x 1100 MWe
Lignite
Owner: RWE Power AG
Commercial operation: 2010

CO2, SO2, NOx and dust

emissions reduced by 31%
compared to existing
lignite-fired plants
 1954: Earliest Extant Supercritical Generating Unit in the World

Alstom laid the foundation for todays Advanced Supercritical fleet at

Philadelphia Electric Companys Eddystone Unit 1 (US). Eddystone
pushed the technology for steam generating electric plants, pioneering
substantial increases in steam pressure, steam temperature and unit
size. At the time of start up, the 394 MWe Eddystone 1 was
the most efficient plant in the United States. It is still operating
at advanced steam conditions.

Initial steam cycle: 5293 psig, 1200/1050/1050 F

365 bar, 649/566/566 C

Current steam cycle: 5200 psig, 1130/1030/1030 F

359 bar, 610/554/554 C

NING HAI CHINA PEE DEE US

2 x 1000 MWe 1 x 640 MWe

Range of Chinese coals Eastern Bituminous
Owner: Zhejiang Guohua Zheneng Owner: Santee Cooper
Power Generation Co. Commercial operation: 2011
Commercial operation: 2009
Designed to fire up to
Another addition to Chinas 30% petcoke
highest-efficiency fleet

WAI GAO QIAO PHASE II CHINA YONGHUNG SOUTH KOREA

2 x 900 MWe 2 x 800 MWe

Range of Chinese coals International coal
Owner: Shanghai Municipal Owner: KEPCO
Electric Company Commercial operation: 2004
Commercial operation:
First units based on the new
2003-2004
800 MWe Korean Standard
Design replicated in Wai Gao Thermal Power Plant
Qiao Phase III 2 x 1000 MWe,
scheduled to enter commercial
operation in 2008
 FIRING SYSTEMS

Alstom is a global leader in supplying firing systems for utility

boilers. Our firing systems burn a wide range of fuels, reduce
emissions levels and retain excellent levels of availability
and reliability.

Primary classes of utility-scale firing systems include suspension

firing and fluidized bed combustion.

In suspension firing, the fuel is either finely ground (for solid

fuels), atomized (for liquid fuels), or fired as a gas that quickly
burns as it mixes with combustion air and passes through the
furnace. Fuel is not recirculated in suspension firing as it is in
fluidized bed combustion.

State of the Art. Proven. Innovative.

Taean, one of the 20 x 500 MWe sliding pressure supercritical units using Alstom 2 x 800 MWe efficient and highly reliable supercritical steam generation since
technology in Korea. Since 1995, this unit has operated in daily two-shift operation 1996 at the Schwarze Pumpe Station in Germany.
with high reliability.
 Alstom An Industry Leader

Alstom introduced tangential firing

systems to the power generation
Tangential Supercritical CFB For Maximum Fuel Flexibility
industry. Today, Alstoms family of
Firing and Efficiency
advanced low NOx tangential firing
Alstoms preeminent systems leads the industry in Alstom has led the power industry in scaling-up utility-class CFB
suspension firing reduced emissions. boilers from 50 MWe to 600 MWe. Now customers can benefit
system is tangential from our expertise in both supercritical and CFB technology
(corner) firing, with Alstoms commercial designs for 400-600 MWe supercritical
with a track record of reliable performance, efficient combustion, CFB units. This premier technology application combines the
and very low nitrogen oxide emissions. improved efficiency of advanced supercritical steam cycles with
the unparalleled fuel flexibility of CFBs. Based on rational design
With tangential firing, a stable fireball is formed in the center of innovations in larger size boilers, including 6 cyclones and higher
the furnace over the entire operating range. Heat absorption steam parameters, Alstoms supercritical CFB technology is
profiles are more predictable. As boiler load changes, corresponding another step in bringing our customers added value, improving
fuel elevations are deployed. Tangential firing has the additional the overall environmental performance of coal-fired plants, and
advantage of a stable flame pattern with any combination of reducing global CO2 emissions.
fuel elevations in service. Unbalances are minimized, and the
predictable lateral heat absorption profiles allow a more
conservative design of furnace wall circuits. Supercritical CFB Boiler Design

Alstoms family of TFS

2000 firing systems
employs both horizontal
and vertical staging of combustion air to produce ultra-low NOx
emissions. The latest addition to this product line is the TFS-XP
system, delivering enhanced performance to owners of new
pulverized coal units. Vortex control improvements to this design
result in better gas mixing, lower combustible gaseous emissions,
and uniform furnace outlet energy.

Circulating Fluidized Bed

Alstoms most popular fluidized bed combustion system is the
Circulating Fluid Bed (CFB). Used especially for more difficult to
burn fuels, CFBs also reduce NOx emissions because of their
lower combustion temperatures. Longer residence time of fuel in
the boiler is key unburned fuel is captured and recirculated for
further combustion. The addition of a sorbent (generally limestone)
also allows SO2 capture within the boiler for reduced SO2
emissions without post-combustion capture.
 MORE SOLUTIONS
FOR CLEAN POWER
Alstom has the expertise and experience to make todays energy
production as clean and efficient as it can be. We are a world-
leading provider of integrated environmental solutions for power,
petrochemical and industrial plants including ways to improve
the performance and lifespan of your existing units.
In addition to high-efficiency boilers, Alstom's supercritical plant
offering includes supercritical turbines, mills, air heaters and post-
combustion equipment. Alstoms in-furnace and post-combustion
technologies can help meet todays strictest requirements for NOx,
SOx, VOCs, mercury, CO and particulates. And our integrated
boiler/backend designs will optimize your units sizing and
performance criteria, all with the lowest installed and operating costs.
Renewable targets? Alstoms experts in biomass co-firing can
reduce your carbon footprint and help your bottom-line.
Alstoms unparalleled breadth of product offering in Air Quality
Control (AQS) systems and Energy Recovery systems means we
can meet your toughest project requirements. With the largest
installed base in the world for air preheaters and coal pulverizers,
our customers benefit from superior performance, increased
efficiencies, and reliable service. And with more than 70 years
of experience in customizing AQS systems for new and existing
plants, you can depend on Alstom to deliver sustainable,
high-quality solutions at a competitive cost and performance ratio.
1 x 1000 MWe, Germany
For further information,
please contact one of our
Regional Offices or e-mail
Boiler.Marketing@power.alstom.com

Western Europe/South America/

Africa/Middle East
Sales Region
Tel: +33 (0)1 46 29 16 32
Fax: +33 (0)1 46 29 16 70

Central and Eastern Europe/India

Sales Region
Tel: +49 711 917 1269
Fax: +49 711 917 1222

Tel: +91 124 4221 100

Fax: +91 124 4221 660

Asia Pacific
Sales Region
Tel: +33 (0)1 46 29 15 85
Fax: +33 (0)1 46 29 16 70

North America/Mexico/
Central America/Caribbean
Sales Region
Tel: +1 860 285 2348
Fax: +1 860 285 4172

Ref: PWER/BPROB/BOILERTECHNO/eng/BUBB/
12.07/US/3329 ALSTOM 2007. Alstom, the
Alstom logo and any alternative version thereof
are trademarks and service marks of Alstom.
The other names mentioned, registered or not,
are the property of their respective companies.
Please note: The information in this brochure is
of a general nature, and may not be applicable for
use in any specific application. Reprinted 2007.

www.power.alstom.com