Technology Adaptation In Power Generationgas turbine technology • CO 2/H 2O working fluid in the...

Penn State March 2013 © Siemens AG 2012. All rights reserved

Technology Adaptation In Power Generation

Evolution of the Gas Turbine

Bruce Rising Siemens Energy, Inc.


US Power Generation—Today

The US power infrastructure is in the process of evolving from one that is substantially based on thermal (Rankine) energy conversion §  Approximately 500,000 MWe of thermal power

§  330,000 MWe based on coal §  We have retired some 70,000 MW of thermal plants since 1970 §  Over 1,100 units, averaging 44 years of service, and 77 MWe capacity §  Expect to retire at least this amount in the next few years.

§  250,000 MWe of combined (Brayton + Rankine) cycle systems §  125,000 MWe of Brayton cycle (peaking units) §  100,000 MWe of Nuclear (Rankine cycle) units §  4 additional units under construction, and some being retired

§  50,000+ MWe of Wind Expect that the gas turbine (Brayton) cycle will be the mainstay for much of future energy developments


BACKGROUND ON THE DEVELOPMENT


Expansion of the US Power Infrastructure

1970 CAA

1990 CAA

NYC Blackout NE Blackout

FGD Retrofit Era

1977 CAA

Rankine Era Brayton Era

PURPA Fuel Use Act

PUHCA PUHCA Repeal

Global Economic

Depression


Generation by Fuel Type-through 2012

Primarily Rankine cycles

Combination of Rankine and Brayton Cycles


67,259 MWe Coal 54,865 MWe Coal

200,985 MWe Coal 17,791 MWe Coal


TECHNICAL DEVELOPMENTS


Large Frame Gas Turbine (+250 MW)


Evolution in Turbine Design


COMPRESSOR CHALLENGES

Component Development Compressor

§  Increased mass flow §  Increased efficiency requirements §  Increased pressure ratio §  Cost

Compressor CFD Results

COMPRESSOR SOLUTIONS

Compressor Rear Stage Test Rig

§  New Compressor design, decreased stages §  Lower production cost §  3-D blading for improved efficiency §  Highly loaded airfoils


•  Eliminate use of water injection for NOx control

•  Reaching lower NOx emission levels than possible with diluents

•  Increased efficiency

•  Increased parts life

DLN Combustor


Premixed combustion system designs are the de facto standard in much of the world. They are primarily optimized to function with natural gas (some smaller industrial units can function with liquid distillate fuels). But natural gas is the default fuel design for the bulk of systems placed into practice. DLN combustors require a narrow range of fuel quality specifications (i.e. quantities of methane, ethane, and propane, in the fuel supply). Nominally, this is controlled by a pipeline tariff.

Premixed Combustor Design-a 30 year design evolution


Combustion System Design


TURBINE CHALLENGES

Component Development Turbine

§  High firing temperatures exceed material limits

§  Increased mass flow §  Multi-fuel capability requirement §  Physical component size (blade height)

TURBINE SOLUTIONS

§  Aerodynamics § Advanced 2D & 3D CFD Modeling § High Turning, Highly Loaded Airfoils § End Wall Contouring development § Exhaust diffuser development § Sealing Technology

§  Heat Transfer § Advanced cooling row 1 blade, novel

cooling of row 4 blade, advanced film cooling patterns

§  Component Design § Manufacturing of novel component

concepts § Blade root design optimization through

software tool development

CFD Analysis

Advanced Vane


A single vane airfoil Turbine Wheel with all blade airfoils

Power Turbine-High Temperature Energy Conversion


Heat Transfer-Blade Cooling


Material Evolution on the Steam Cycle


Killingholme, 2 x 450 MW

Didcot “B” 1&2, 710 MW + 702 MW

Mainz-Wiesbaden, > 400 MW

1996 1992

Irsching 4 incl. SGT5-8000H, > 530 MW

2008/2011 2001

> 58% net efficiency

> 60% net efficiency

56% net efficiency

52%

net efficiency

Continuous development of gas turbine and

combined cycle technology

Evolution of Combined Cycle Power Plants


Conceptual design looks like this…

T&D-relays, switchgear

Heat transfer materials-corrosion

Plume drift

Acoustics/noise

NOx, CO, NH3, PM2.5

Acoustics/noise

Acoustics/noise

NOx, CO, NH3, PM2.5

Material Stress

Material Stress

Piping design

Engine controls, diagnostics and monitoring

Plume model

Gas quality Lube systems

Grid interconnection

SFC for fast-start

Gas pipeline supply

Steam Turbine

Gas Turbine


It finally looks like this…


WHAT ELSE?


E-2

E-3

E-4

E-5

E-6

P-4

§ The area occupied by the carbon capture and compression equipment can be a significant portion of the total plant layout.

§  In 1990: Estimated CAPEX was $60,000/tpd of CO2 capture on a 200 tpd gas fired plant

§  In 1999: Estimated OPEX for a 1,000 tpd Recovery on a coal-fired unit was $18.70/ton

…and if CO2 has to be captured…


CO2 Capture: Process Chemistry

CO2 extraction (recovery) is energy intensive, and requires unique solvent chemistry tailored to the application

CO2 extraction is more efficient at high pressure, where physical solvents are more effective.

At low pressure, i.e. conditions at a typical power plant exhaust stack, only chemical solvents are used

Granulated slag

Cooling screen

Pressur. water

Quenchwater

inlet

overflowWater

Gas outlet

Cooling jacket

Oxygen, SteamFuel

Pressur. wateroutlet

Burner

Gas separation technologies are key to limiting GHG emissions Gas separation of oxygen, CO2, nitrogen, hydrogen and ammonia


Potential Game Changers?

•  Adaptation of existing steam and gas turbine technology

•  CO2/H2O working fluid in the power turbine section

•  Isolation of CO2 –no solvents

•  Enhanced carbon capture

•  Adaptable for CO2 use in EOR

•  First demonstration will using a modified Siemens SGT-900 gas turbine in an EOR application

•  Multiple product streams: Electricity, H2O, and CO2

•  Innovation similar to Oxy-Fuel

•  Oxygen delivered to fuel via a metal oxide

•  CO2/H2O exits as one stream; N2 exits the other

•  High thermodynamic efficiencies possible

•  40-45%, including CO2 extraction

•  But a long development cycle; no commercial units or full scale demonstrations yet

§  582 MWenet

§  ~65% carbon capture (~3 M tons of CO2/year)

§  Siemens scope includes:

§  Two SGT6-5000F gas turbine generators

§  Primary Fuel: High H2 Syngas

§  Backup/Startup fuel: Natural gas

§  Capability to extract air for integration, air-blown gasifier

Mississippi Power Plant Ratcliffe IGCC Project

Spring 2013

Oxy-Fuel

Chemical Looping

• H2O+CO2

• O2+N2

• Fuel (CH4)

• N2

MeO MeO

Me Me


Innovative Technology Announcements

Recent DOE Awards in new energy conversion technologies Oxy-Fuel

•  Siemens •  Gas Technology Institute* •  Pratt & Whitney Rocketdyne* •  Unity Power Alliance/MIT*

Chemical Looping •  Alstom Power* •  Babcock & Wilcox* •  University of Kentucky

Research Foundation* Source: http://www.fe.doe.gov/news/techlines/2012/PrintVersion_1_44848_44848.html?print

(*)Announced 26 July 2012

200

874

0 6

456

34 0

100 200 300 400 500 600 700 800 900

1000

Chemical Looping

Superconducting Power


Summary

Power generation technical innovation has evolved rapidly in the last few decades. The US has moved relatively quickly into a period where advanced cycles like the Brayton cycle now dominate new project developments. •  Required evolution of new design methodologies and materials, notably the expanded role of adapting to extreme temperatures (heat transfer) •  Required new computation methods to design highly specialized features in the gas flow path (Improved compressor performance and compressor maps, turbine performance) •  Yielded new combustion system designs that reduce water consumption using premixed combustion to meet restrictive environmental requirements. •  Also, it brought along new tools for advanced diagnostics-real time monitoring of highly stressed components; predictive monitoring methods to mitigate component failure. •  This technology (gas turbine) is probably the only core technology capable of achieving compliance with tough environmental regulations—air, water, soil, hazardous, etc.

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