NextGenPower
Encyclopedia
NextGenPower is a unique integrated project which aims to demonstrate new alloys and coatings in boiler, turbine and interconnecting pipework. The concept of NextGenPower is to perform innovative demonstrations that will significantly contribute to the EU target to increase the efficiency in existing and new build pulverized coal power plants.
(CCS) is envisaged to be the main transition technology to comply with the CO2 reduction targets set by the European Commission
. However, CCS has the drawback that the electrical efficiency of the coal-fired power plant will drop significantly. The efficiency loss caused by CCS in coal-fired power plants will range from 4 to 12% points, depending on the CCS technology chosen.
To overcome this drawback, one has to increase the plant efficiency or the share of biomass
co-firing. Both options are limited due to the quality of the current available coatings and materials. Live steam temperatures well in excess of 700°C are necessary to compensate the efficiency loss caused by CCS and to achieve a net efficiency of 45%.
NextGenPower aims to develop and demonstrate coatings and materials that can be applied in ultra-supercritical (in excess of 700˚C) conditions.
, COMTES, EON 50plus) where the first commercial steam turbine will enter service without prior operation in a test loop. Following alloy selection, full-scale steam turbine casings and rotor forgings will be manufactured and materials properties demonstrated through implementation of a mechanical testing programme. Full-scale demonstration of the welding technology and the NDE capability required for welded rotor and casing manufacture will also be carried out.
Background
Carbon Capture and StorageCarbon capture and storage
Carbon capture and storage , alternatively referred to as carbon capture and sequestration, is a technology to prevent large quantities of from being released into the atmosphere from the use of fossil fuel in power generation and other industries. It is often regarded as a means of mitigating...
(CCS) is envisaged to be the main transition technology to comply with the CO2 reduction targets set by the European Commission
European Commission
The European Commission is the executive body of the European Union. The body is responsible for proposing legislation, implementing decisions, upholding the Union's treaties and the general day-to-day running of the Union....
. However, CCS has the drawback that the electrical efficiency of the coal-fired power plant will drop significantly. The efficiency loss caused by CCS in coal-fired power plants will range from 4 to 12% points, depending on the CCS technology chosen.
To overcome this drawback, one has to increase the plant efficiency or the share of biomass
Biomass
Biomass, as a renewable energy source, is biological material from living, or recently living organisms. As an energy source, biomass can either be used directly, or converted into other energy products such as biofuel....
co-firing. Both options are limited due to the quality of the current available coatings and materials. Live steam temperatures well in excess of 700°C are necessary to compensate the efficiency loss caused by CCS and to achieve a net efficiency of 45%.
NextGenPower aims to develop and demonstrate coatings and materials that can be applied in ultra-supercritical (in excess of 700˚C) conditions.
Summary
The NextGenPower project was due to start on 1 May 2010 and have a duration of 48 months. The budget is €10.3million, with an EU contribution making up €6million of the budget.Objectives
The following scientific and technological objectives have been defined for NextGenPower, leading to the following project activities:- Demonstrating the application of precipitation hardened NickelNickelNickel is a chemical element with the chemical symbol Ni and atomic number 28. It is a silvery-white lustrous metal with a slight golden tinge. Nickel belongs to the transition metals and is hard and ductile...
-alloys for pulverized coal-fired boilerPulverized coal-fired boilerA pulverized coal-fired boiler is an industrial or utility boiler that generates thermal energy by burning pulverized coal that is blown into the firebox....
s having allowable levels of creep and fatigue evolving from high temperatures envisaged with USC - Demonstrating the application of cost-effective fireside coatings, compatible with affordable and available tube alloys, for coal-fired boilers capable of withstanding the corrosive conditions envisaged with USC and the environment of biomass co-firing under different conditions
- Demonstrating the application of cost-effective steam side coatings/protective layers to extend the life of boiler tube and interconnecting pipe work, and to facilitate the use of cheaper alternative materials without compromising component life or reliability
- Demonstrating the application of Ni-alloys for interconnecting pipe work between boiler and steam turbineSteam turbineA steam turbine is a mechanical device that extracts thermal energy from pressurized steam, and converts it into rotary motion. Its modern manifestation was invented by Sir Charles Parsons in 1884....
withstanding high temperatures envisaged with USC and to explore alternative design options to allow for the use of cheaper, more available materials than Ni-alloys - Demonstrating the capability to cast, forgeForgingForging is a manufacturing process involving the shaping of metal using localized compressive forces. Forging is often classified according to the temperature at which it is performed: '"cold," "warm," or "hot" forging. Forged parts can range in weight from less than a kilogram to 580 metric tons...
and weldWeldingWelding is a fabrication or sculptural process that joins materials, usually metals or thermoplastics, by causing coalescence. This is often done by melting the workpieces and adding a filler material to form a pool of molten material that cools to become a strong joint, with pressure sometimes...
Ni-alloys for critical steam turbine components
Sub-projects
There are also four sub-projects which will be focused on throughout the course of the NextGenPower project.Sub Project 1 – boiler
NextGenPower aims at overcoming fireside corrosion and steamside oxidation in high temperature parts through the application of suitable coatings. The main goal for Sub Project 1 is to demonstrate the benefits and limitations of materials and coatings for the fireside under biomass co-firing conditions as well as for the boiler and main steam pipework under USC and current steam conditions.Sub Project 2 - steam turbine
The main goals for Sub Project 2 are to select the best candidate alloys for the HP and ID steam turbines operating at high steam temperatures (≥720˚C). A number of nickel-base alloys have been developed whose properties have been proven at the laboratory scale and for small-scale components. The main uncertainty in the application of these alloys for steam turbine applications is the ability to manufacture, weld and inspect large components. The performance in service presents a much smaller risk since there is confidence that the mechanical behaviour can be modelled on the basis of the material properties. This philosophy follows the approach applied in the development, demonstration and exploitation of materials technology for 700-720˚C steam turbines in other projects (AD700AD700
The AD700 Technology initiative began in the early 1990s with the idea of developing a range of advance materials that would permit the raising of main and reheat steam temperatures in Pulverized Fuel boilers up to 700°C and beyond.-Key features and benefits:...
, COMTES, EON 50plus) where the first commercial steam turbine will enter service without prior operation in a test loop. Following alloy selection, full-scale steam turbine casings and rotor forgings will be manufactured and materials properties demonstrated through implementation of a mechanical testing programme. Full-scale demonstration of the welding technology and the NDE capability required for welded rotor and casing manufacture will also be carried out.
Sub Project 3 – integration
Sub Project 3 provides a framework for the testing and demonstration work in the overall project. It will review the expected operating parameters required for NGP plants, with and without CO2 capture technologies, and with and without biomass co-firing. The aim is to evaluate a series of NextGenPower plants with CCS systems in terms of their power generation efficiencies and CO2 emissions per unit of electricity generated.Sub Project 4 – dissemination
The main goal for Sub Project 4 is to ensure that the generic results and results from topical activities are actively disseminated. It promotes results and approaches and encourages the duplication in other, thereby contributing to EU objectives of the CO2 reduction, efficiency improvement and security of energy supply. Another objective is to facilitate the sharing of policies, approaches and knowledge between the participants.Participants
- Aubert & Duval
- Cranfield UniversityCranfield UniversityCranfield University is a British postgraduate university based on two campuses, with a research-oriented focus. The main campus is at Cranfield, Bedfordshire and the second is the Defence Academy of the United Kingdom based at Shrivenham, Oxfordshire. The main campus is unique in the United...
- Doosan BabcockDoosan BabcockDoosan Babcock, is part of Doosan Power Systems Ltd a UK-based subsidiary of Doosan Heavy Industries & Construction. DPS is a power sector utility boiler OEM and after market services company, offering specialist services and technologies to clients in the nuclear power generation, fossil-fired...
- E.onE.ONE.ON AG, marketed with an interpunct as E•ON, is the holding company of the world's largest investor-owned energy service provider based in Düsseldorf, Germany. The name comes from the Greek word aeon which means eternity....
- Goodwin Steel Castings LtdGoodwin Steel Castings LtdGoodwin Steel Castings Limited is a heavy engineering firm located in Stoke on Trent, Staffordshire, England. The company specialises in the production of large, bespoke, machined steel castings.-History:...
- Kema
- Monitor Coatings
- Saarschmiede
- Skoda Power
- TUDDarmstadt University of TechnologyThe Technische Universität Darmstadt, abbreviated TU Darmstadt, is a university in the city of Darmstadt, Germany...
- VTT Technical Research Centre of FinlandVTT Technical Research Centre of FinlandVTT Technical Research Centre of Finland is largest multidisciplinary research organisation in Northern Europe. It provides high-end technology solutions and innovation services...
- VUZ