Andrea Burrato, GE Oil and Gas: A Development and applications of ORegen™ Waste Heat Recovery...
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Transcript of Andrea Burrato, GE Oil and Gas: A Development and applications of ORegen™ Waste Heat Recovery...
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GE Oil Gas ORegenTM Presentation for
Australian Gas Turbine Conference
Andrea Burrato
ORegenTM Product Leader
Brisbane October 30th, 2013
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2GE Confidential & Proprietary Information
GE © 2013 – All Rights Reserved
GE in Australia & New Zealand ...
GE in Australia1896 - infrastructure for Brisbane’s tramway 1906 - installed the electric motors in the
Pyrmont Bridge at Darling Harbour – still operating
GE Businesses in the region today:• GE Aviation • GE Capital• GE Healthcare • GE Lighting• GE Energy Management • GE Mining• GE Power and Water • GE Transportation
• GE Oil & Gas
Employing 6,000+ people across Australia & New Zealand
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3© 2013 General Electric Company
Serving the Oil&Gas industry … from extraction, to transportation, to end use
Liquefaction of Natural Gas
(LNG)
Drilling
PressureControl
Artificiallift Offshore
Refinery & Petrochemical
PowerGeneration
Gas Storage & Pipeline Compression and Inspection
Cutting edge technology & services solutionsacross the value chain
Drilling & SurfaceMeasurement & Control
Subsea Equipment & Services
TurbomachineryEquipment & Services
DownholeTechnology
Gas MonetizationOffshore
Subsea Compression
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The ANZ O&G Story
• Active since the first LNG train was installed on the North West Shelf in the mid-1980s
• GE Oil & Gas is currently
engaged in 100% of LNG Developments in Australia
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5GE Confidential & Proprietary Information
GE © 2013 – All Rights Reserved
Investing to deliver technology, service and develop skills …
500 people supporting customers across the oil & gas value chain
Jandakot / Perth• Regional Hub• Skills Development Centre• SubSea Systems• Asia Engineering Centre• GT & Compressor Service Centre• LNG Field Service Centre
Brisbane• Pressure Controls
Adelaide• Pressure Controls• SubSea Systems
Sydney & Christchurch• Measurement & Control
5© GE Oil & Gas 2013. All Rights Reserved
Unauthorized Reproduction Prohibited
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ORegenTM
for Waste Heat Recovery
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7GE Confidential & Proprietary Information
GE © 2013 – All Rights Reserved
ORegenTM
What is ORegenTM
GE designed Organic Rankine Cycle system to recover waste heat energy from Gas Turbines exhaust (or similar waste heat sources) and produce electricity without using water or additional fuel or emissions
Developed for powergen application … mechanical drive also a possible applications
ORegenTM References
17MW system sold in Canada
17MW x 3 systems sold in China on 3 pipeline stations
17MW system sold in Brunei on a powergen station
17MW system sold in Thailand on a pipeline station
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Case study ORegenTM benefits
3 GTs connected to 1 ORegen2 units running – 1 stand by
Net Output ~14 MWeProduced Power ~119 GWhr per year Saved gas ~1,160 Tj per year
... equivalento to ~38k tons/y CO2 cut
First system sold in Canada in a pipeline application
Plant overall efficiency up to 50%
14 MW of recovered power / +9 points efficiency
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Why waste heat recovery?
Air
• GT simple cycle efficiency: 25-40%
• Oil & Gas GT mainly in simple cycle
• Global trends: - CO2 reduction legislation
- Increased efficiency- Increased power demand
ORegenTM
+ = Up to 17MW of power recoveryon sinlge skid
Wa
ste
he
at
* ORegen is a trademark of Nuovo Pignone Spa and is available in selected markets
• Electricity production … sell back to grid
• Help comply with emissions regulations
• Increase plant efficiency
Simple cycle GT
Exhaust Gas
Fuel
Waste heat
Gas Turbine
77% of O&G installed GT are in simple cycle
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Organic Rankine Cycle is a thermodynamic cycle basedon the Rankine classic cycle using an organic working fluid
GE Research Centre selected Cyclo-Pentane as working fluid
The ORC concept
Entropy [kJ/(kg°C)]
ORC cycle T-S diagram
50
100
150
200
250
-3 -2.5 -2 -1.5 -1
Te
mp
era
ture
[°C
]
T dew T bubble T cycle @ min p T cycle @ max p
Heaters
ExpanderRecuperatorCondenserPump
Regenerator
Expansion
Condenser
Pump
Regenerator
Pre-heater
Vaporizer
Super-heater
Cyclo-Pentane C5H10
characteristics:
• Boiling point 49.3°C
• Freezing point -94 °C
• Molecular Weight 70.1
• Auto-ignition point 361°C
(Max C5 temp below auto-ignition point)
• Appearance: clear, colorless liquid
• No corrosion risk on plant equipment
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ORegenTM plant schematic & scope of supply
Gas Turbine
Typical scope of supply includes:
• Diathermic oil system
• Organic C5 fluid system
• Vaporizer & heat exchangers
• Turboexpander genset
• Condenser
• C5 and oil pumps
GT exhaust
CONDENSER
HEAT EXCHANGERS
OIL HEATER
Fan
C5 Pump
Cyclopentane loop
Diathermic Oil loop
Generator
Expander
Hot Oil Pump
RECUPERATOR
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17 MW Turboexpander
1 common lube oil system
4-pole synchronous generator
gearbox
Oudoor installation
with thermo-acoustic insulation
LxWxH: 13x4x5.5m
TEX designed for Zone 2
Configuration on skids:
• Ease transportation
• Installation cost reduction
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Turboexpander(5-17 MW family)
2 stage variable IGVs
16-blade wheels (17-4PH)
5000 rpm shaft
10000 rpm shaft
1500/1800 rpm shaft
Double DGS +
standstill ring
4.8 expansion ratio
6.5 expansion ratio
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ORegen™ Typical LayoutGT exhaust stack
Exhaust diverter (only interface with GT)
GT exhaust stack(with ORegen installed)
Control cab
DiathermalOil piping
Waste Heat
Oil heater
Turbo-Expander Generator
C5 condenser
Cyclo-pentane island
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15GE Confidential & Proprietary Information
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ORegenTM configurationsParallel Oil
WHRU
#1
ORCCondenser
WHRU
n
GT#1
GT#n
GT#1 WHRU
ORC#1Condenser #1
ORC#2Condenser #2
Direct
Multi cycles Parallel Gas
To be defined as typical arrangement
To be scaled up / down from a standard design
To be selected case by case. depending from the site conditions and project requirements
WHRU ORCCondenser
GT#1
WHRU ORCCondenserGT#1
- - - - - -
GT#n
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GT Model GT Power
(KW)
Exhaust Flow
(Kg/sec)
Exhaust Temp
( C)
GT Efficiency
(%)
ORC Output
(MWe)
System Efficiency
(%)
GE10 (2X config) 11 250 47.5 482 31.4% 8.4 43.1%
PGT25 (*) 23 261 68.9 525 37.7% 6.9 48.9%
PGT25+ (*) 31 364 84.3 500 41.1% 7.9 51.5%
PGT25+ G4 (*) 33 973 89.0 510 41.1% 8.6 51.5%
MS5001 (*) 26 830 125.2 483 28.4% 11.3 40.4%
MS6001B (*) 43 530 145.0 544 33.3% 15.6 45.2%
MS7001E (*) 87 300 302.0 535 33.1% 31.1 44.9%
LM6000 (**) 43 397 125.6 454 41.7% 9.7 51.1%
LMS100 (**) 100 700 216.8 423 43.8% 15.7 50.8%
MS5002B (*) 26 100 121.6 491 28.8% 10.8 40.7%
MS5002C (*) 28 340 124.3 517 28.8% 12.4 41.4%
MS5002D (*) 32 580 141.4 509 29.4% 13.8 41.9%
MS5002E (*) 32 000 101.0 510 36.2% 9.8 47.2%
Reference data @ISO Conditions. 100% GT Turbine load
(*) Values at gas turbine shaft
(**) Values at generator terminals
ORegenTM output
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17GE Confidential & Proprietary Information
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ORegenTM CC Traditional (2 pressure levels)
Output Net 100 % 115 %
Efficiency [kWe/kWt] 23% 26%
CAPEX - Bottom Cycle 100 % 125 %
CAPEX - Water Treatment Not Required Required
OPEX - Maintenance 100 % 6000 %
OPEX - Human Attendance Not RequiredRequired
(subject to local regulation )
Installation Time 100% 120%
Plant Layout 1600 sqm 2000 sqm
Reliability (TEX vs. ST) 98% 98%
Availability (maintenance plan)Boroscope 24k hrs
Major overhaul 48k hrs
Minor overhaul 24k hrs
Major overhaul 48k hrs
ORegenTM vs Steam Combined Cycle
Note
• High level comparison between solution with same design standards• Estimation done for single WHR plant installed after a GT running at full load with 85kg/sec @ 500C exhaust gas
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ORegenTM main component list
OIL SYSTEM
•Waste Heat Recovery Unit
•GT exhaust ducts modifications
(ducts, diverter & bypass stack)
•Hot Oil Expansion Vessel
•Hot Oil Circulation Pumps
•Piping system
CYCLO-PENTANE SYSTEM
•C5 Circulation Pumps
•Shell & Tube Heat Exchangers
(recuperator, pre-heater, vaporizer, superheater)
•Turboexpander Generator
•Air or Water Condenser
•Plant & TEX Control System
•Auxiliaries
•Piping System
WHRU ORegenCondenser
Skidded solution to minimize installation work
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ORegen™ plant key cycle features
Designed for Unmanned operation
No need for 24/7 on-site presence of certified operators
Turndown capabilities
Best solution for GT partial load operation … @50% GT load still 80% of power recovered
Highly reliable gas Expander as main unit
No blow down
Negligible organic fluid consumption
No water requirement
No water system treatment required
Efficiency
Up to 13 points
C5 Bottom pressure
Above atmospheric pressure, High Safety (No O2
ingestion)
C5 Top pressure
Below fluid critical pressure (No supercritical operation), Best Power Recovery
Thermal Oil
Great operability Range –35° ... +330°C
Condenser sized to handle uncondensable
Compact footprint, C5 condensing above atmosphere
Specific CO2
Decrease by 40%
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Condenser
BCL
Exchanger
Inlet pressure
Discharge pressure
ORegen for Mechanical Drive application
Waste heat
Flow Capability Increase
Flow Capability Increase
• Waste energy used to drive an additional compressor through an ORegen cycle
• New compressor in parallel with existing ones
Increase NG flow capability using GT waste heat
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Mini ORC - 2.0 MW size
• Modular approach 2 MW size
• Minimum waste heat temp 220°C
• Different cycle parameters
• Applicable to small to medium size waste heat sources
• Optimized solution for small GT &low grade waste heat sources
Complementing ORegen for 0.5 2 MW size
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Case study
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Ambient data
• Average Temp 25 °C
• Elevation 0 m a.s.l. (P=1.01 bar)
• Relative Humidity 60%
Note - ORegenTM designed on average air temp of 25.0°C
Case study - Base data
#2 LM6000 Turbines installed and running
LM6000 waste heat characteristics
• Exhaust Flow 115 kg/s
• Exhaust Temp 456 °C
• Air Temp 25 °C (for air condenser design)
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Case study - Solution
#2 LM6000 connected to #1 ORegen in parallel oil configurationn
#1 ORegen required
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Case study - Output
Expected performance
ORegenTM Gross Power MW ~17.0
ORegenTM Net Power MW ~14.7
Net Produced Power (*) MWhr/year ~124,000
Reduced CO2 emissions (**) Tons/year ~65,000
Fuel savings (***) GJ/year ~1,150,000
(*) 8500 running hours per year
(**) generated in 1 year by a 40% efficiency gas turbine to produce the same power
(***) fuel saved by switching off 1 GT considering increasing fuel consumption on running units
#1 ORegen requiredORegenCondenser
WHRU #1 LM6000 #1
WHRU #2LM6000 #2
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ORegenTM
Produce up to 17MW electric power with no additional fuel by recovering heat from GT exhaust
• Efficiency improvement 20% … CO2 footprint 20% • Carbon credits … singular enabler • Cyclo-pentane as working fluid in a closed loop … no water!
26GE Proprietary Information
GE © 2011 – All Rights Reserved
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Thank you