Simulation of low-load operation for a 350 MW supercritical unit

Currently, there is a scarcity of studies exploring the safe operating parameters for coal-fired power units at loads below 30%.To accurately understand the operating characteristics of coal-fired units under low load conditions, and to provide a design basis for flexibility modifications, a simulation model coupled with boiler and turbine was established, which includes the flue gas and air system, steam and water system, steam turbine, and steam extraction heat recovery system, and the iterative calculation strategy for low load conditions was proposed. The simulation calculation was performed on a 350 MW supercritical coal-fired unit, with the model results showing a high degree of alignment with the unit’s design and operational parameters. Under the condition of 269MW, the maximum calculation error between the model’s predicted exit flue gas temperature of the air preheater and the actual operational results was 8.84%. This discrepancy was due to a sudden increase in the operating flue gas temperature, which may be associated with a blockage in the air preheater. And the simulation results under low load conditions indicate that when the unit load is below 20%, the furnace total airflow is controlled to no less than 30% of the airflow at Maximum Continuous Rating (BMCR) and the minimum feedwater flow rate can be reduced to 20% of that in Turbine Heat Acceptance (THA) load, and the unit switches to wet state operation around 20% load. As the unit load decreases, the coal consumption rate for power generation and steam turbine heat consumption rate both increase significantly. The coal consumption rate for power generation at 30% load is increased by 13.3% compared to BMCR load, and it is increased by 32.5% at 15% load which is operated in wet state. Under low load conditions, the coal consumption rate of the unit can be reduced by decreasing the oxygen content in the flue gas, reducing the minimum feedwater flow rate, and implementing boiler water recirculation.