Building on History …the Next Generation of Technology€¢ 7FB gas turbine • Integrated...
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Transcript of Building on History …the Next Generation of Technology€¢ 7FB gas turbine • Integrated...
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Copyright 2009 General Electric Company. All Rights Reserved. This material may not be copied or distributed in whole or in part, without prior written permission of the copyright owner.
Building on HistoryBuilding on History……the Next the Next
Generation of TechnologyGeneration of Technology
Joseph R. ZuikerJoseph R. Zuiker
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Copyright 2009 General Electric Company. All Rights Reserved. This material may not be copied or distributed in whole or in part, without prior written permission of the copyright owner.
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500
1000
1500
2000
GasificationTech
CombustionTurbine
Both
Inst
alle
d B
ase
(MW
)
GE’s gasification historyAn industrial gasification leader
• Gasification leader since 1948
• First coal gasification plant in 1978
• As of Oct 2009:
–67 operating plants
–130+ Gasifiers
• Short mechanical completion time ~36 m
An IGCC leader
• Cool water 1984-1989
• TECO-Polk 1996+
• Duke Energy Edwardsport 2012
• 3GW complete; 1GW underway
Dahua successful start-upSep 27, 2009
Design/Const.
GE IGCC Experience
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Copyright 2009 General Electric Company. All Rights Reserved. This material may not be copied or distributed in whole or in part, without prior written permission of the copyright owner.
Houston, TX – process & product design; IGCC experience & integration; R&D; services; operability
Bangalore, India – process design; R&D
Shanghai, China – materials characterization; R&D; services; component localization
IrvineIrvineHoustonHouston
ShanghaiShanghaiBangaloreBangalore NiskayunaNiskayuna WarsawWarsaw
Gasification: a diverse global team
Niskayuna, NY – R&D; validation
Irvine, CA – gasification modeling & experimental experts
Warsaw, Poland – reliability and maintenance analysis
Schenectady, NY/ Salem, VA –controls; simulation
Greenville, SC – design, adv materials, power block (IGCC)
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Copyright 2009 General Electric Company. All Rights Reserved. This material may not be copied or distributed in whole or in part, without prior written permission of the copyright owner.
Today:Duke Energy Edwardsport• Detailed design nearing completion
• Major components arriving
• On-site fabrication initiated
Next Steps:
• 50Hz system level enhancements• Carbon capture detailed design• Posimetric feed integration
IGCC plant solution
2005:A concept
2006:Focused R&D programs:• Improved RSC
• Improved feed injectors
• Longer life refractory
• 7FB gas turbine
• Integrated controls
system
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Copyright 2009 General Electric Company. All Rights Reserved. This material may not be copied or distributed in whole or in part, without prior written permission of the copyright owner.
Today:Duke Energy Edwardsport• Detailed design nearing completion
• Major components arriving
• On-site fabrication initiated
Next Steps:
• 50Hz system level enhancements• Carbon capture detailed design• Posimetric feed integration
IGCC plant solution
2005:A concept
2006:Focused R&D programs:• Improved RSC
• Improved feed injectors
• Longer life refractory
• 7FB gas turbine
• Integrated controls
system
6
Copyright 2009 General Electric Company. All Rights Reserved. This material may not be copied or distributed in whole or in part, without prior written permission of the copyright owner.
Today:• Detailed design complete
• External components at site
• Fabrication in process
• Internals at site 1Q 2010
Next Steps:• Structured options for 50Hz/
polygen applications
Radiant syngas cooler
2007:• Lessons learned
• Detailed analysis
• Improved design methods
• Availability & performance
improvements
• 30% better performance;
30% lower cost; higher
reliability versus TECO
configuration
2005:A concept
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Copyright 2009 General Electric Company. All Rights Reserved. This material may not be copied or distributed in whole or in part, without prior written permission of the copyright owner.
Today:• Stage testing in process• Simulators in operation• Operability scenario reviews
• Design validation
Next Steps:• OTS delivery
Integrated controls and simulation
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Design Validation
Model PC Operator & Engr. PCsMark VIe Emulator PCs
Model PC Operator & Engr. PCsMark VIeI/O Bridge
Engineering NPI and Design
Stage Test – Control Hardware in the Loop
Concurrent Model and System Development
Validate System Design & Operability
Quick Transition to Simulated I/O
Validate System Controls &
Operability
Phase
1Phase 2
Phase
3
Model PC Operator & Engr. PCsMark VIe Emulator PCs
Operator & Engr. PCsMark VIe
On-Site Commissioning Support
On-Site Training/Engineering Simulator
Transition to Plant I/O
Concurrent use of Simulation
during commissioning
Actual logic & displays - not Emulated
Validate Actual control and system
changes prior to implementation
Field Equipment
2006:NPI Project
2008:Detailed Validation Plan
• Table top testing
• Stage testing
• Field validation
• Operator training simulator
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Copyright 2009 General Electric Company. All Rights Reserved. This material may not be copied or distributed in whole or in part, without prior written permission of the copyright owner.
Drop tube furnace
2007:• Detailed Design
initiated
2006:A concept• Gasification
kinematics
• Fouling validation
Today:• Construction complete• Commissioning initiated
• Testing commences early 2010
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Copyright 2009 General Electric Company. All Rights Reserved. This material may not be copied or distributed in whole or in part, without prior written permission of the copyright owner.
Posimetric feed system
2008:• System level validation
strategy• Research partnership
with University of Wyoming
2005:Need defined
2007:Technology down-select and acquisition
Today:• Pump validation: CA, TX
• System validation: Shanghai
• HPG-ATC site selected: Cheyenne
Next Steps:• Scale-up validation
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Copyright 2009 General Electric Company. All Rights Reserved. This material may not be copied or distributed in whole or in part, without prior written permission of the copyright owner.
Licensing enhancements:large quench gasifier
2007:Concept
2008:• Entrainment modeling/validation
• Feed injector modeling and test
Today:• Improved conversion
• Improved quench
configuration
Next steps:• Scale-up validation
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Copyright 2009 General Electric Company. All Rights Reserved. This material may not be copied or distributed in whole or in part, without prior written permission of the copyright owner.
Summary
• 60 years of success in gasification operation and innovation
• 25 years of IGCC experience
• Significant investments in design methods; tools; and validation facilities
• 19 months from first fire of Edwardsport IGCC facility
• Investing in next generation industrial and power gasification technology