fuel flexible gas turbines for sustainable ge energy … 2013 presentations/day-2 at pmi... · fuel...

© 2012, General Electric Company. Proprietary Information. All Rights Reserved.

GE Energy


Fuel Flexible Gas Turbines for Sustainable

Power Generation

Indian Power Stations O & M Conference • February 13-14, 2013 • NTPC, India

Dr Suresh M V J J • Regional Lead Application Engineer, GE India (Bengaluru)

Ranjith Malapaty • Engineering Technical Leader, GE Power & Water (Hyderabad)

2


© General Electric Company, 2013.

GE Proprietary Information - The information contained in this document is General Electric Company (GE) proprietary information. It is the property of GE and shall not be used, disclosed to others or reproduced without the express written consent of GE, including, but without limitation, it is not to be used in the creation. manufacture. development, or derivation of any repairs, modifications, spare parts, or configuration changes or to obtain government or regulatory approval to do so, if consent is given for reproduction in whole or in part, this notice and the notice set forth on each page of this document shall appear in any such reproduction in whole or in part. The information contained in this document may also be controlled by the US export control laws. Unauthorized export or re-export is prohibited.

GE Power & Water

3


Outline

• Introduction

• Fuel Flexibility Options Liquefied Natural Gas (LNG) Syngas Oils

• OpFlexTM Model Based Controls

• Summary

4

Introduction

5


Hydrocarbon consumption 2011 ~85% of primary energy

Hydrocarbon consumption, 2011 Million Tonnes Oil Equivalent

10,522 Total

41.2% 31.5% 27.3%

Million Tonnes Oil Equivalent, 2011

6


Fuels experience … broad range

Industry drivers for fuel flexible solutions: Diversified power generation mix (in terms of both fuel sources & suppliers)

Greater energy independence/autonomy

Efficient use of energy/emissions

LNG & Natural gas variation

8


LNG & Natural gas variation

Gas composition variation will increase as more LNG is injected into pipelines

Variation poses gas turbine operability challenges

• Auto-ignition

• Flashback

• Combustion dynamics

• Combustor lean-blowout

• Emissions compliance (NOx, CO)

Addressed by OpFlex* offerings

Constituent Min Max

Nitrogen (N2) [%] 0 0.4

Carbon-Dioxide (CO2) [%] 0 0.7

Methane (C1) [%] 85 96

Ethane (C2) [%] 3 13

Propane (C3) [%] 0 4

Iso-Butane (IC4) [%] 0 0.9

n-Butane (NC4) [%] 0 0.9

Iso-Pentane (IC5) [%] 0 0.1

n-Pentane (NC5) [%] 0 0

LHV [BTU/scf] 1045 1170

Potential NG/LNG compositional range (volume %)

Source: “Tuning on the Fly”, Turbomachinery

International, Sept/Oct 2007

1200

1250

1300

1350

1400

1450

1500

1550

Florida

California

NGC+

Mexico

EU HarmonizationSpain

France

UK

Wo

bb

e N

um

be

r

*Trademark of General Electric Company.

Syngas

10


Syngas production in an IGCC plant

42

Gasification Gas Turbine

H2 & CO

(syngas)

Partial oxidation

Solid feedstock is gasfied

MNQC Combustor

Diluent (N2, Steam)

Gas clean-up

11


Syngas to hydrogen (CO2 separation)

Gasification “Shift” Process CO2 Capture +

Compression

Gas Turbine

CO + H2O => CO2 + H2

(H2 rich syngas)

H2 & CO

(syngas)

H2

CO2

EOR or Storage

Partial oxidation

AGR & CO2 Compression Steam/Syngas Reactor

Solid feedstock is gasfied

Catalyst based Water-Gas converts CO to CO2

Acid Gas Reactor system removes CO2, which is compressed and

piped off-site

MNQC Combustor

Diluent (N2, Steam)

12


Ventilation modifications

Inlet filter house

Inlet duct & plenum

Gas fuel module

Water injection skid

Exhaust system

Controls hardware and software

Accessory module

Liquid fuel and atomizing air

Static starter

N2/Steam injection skid*

Syngas fuel skid with N2 purge

Optional air extraction skid*

Enclosure

modifications: • Piping for syngas, diluent, etc.

• Explosion proofing

• Hazardous gas detection

• Fire protection

IGCC Controls with added I/O

*Fuel and diluent skids/modules may need to be customized for specific fuel/plant configurations

Syngas turbine controls and accessories

13


MNQC for E/F Syngas Turbines

• MNQC (Multi Nozzle Quiet Combustor) – Diffusion (Not DLN)

• Same combustor architecture for 6FA, 7EA, 9E, 7F Syngas, and 9F Syngas turbines

• End cover/fuel nozzle assembly nearly identical, except for minor scaling

• Combustor liner and cap designs similar, scaled to different operating conditions

• Diluent N2 or Steam or a blend

• Air extraction available for integration with process

N2/Steam

Natural gas/ syngas

Syngas

Air extraction

Air from compressor

Liner

Flow sleeve Transition piece

Fuel nozzle

Typical modifications on 9E gas turbine for low calorific value gases

15


Biofuels field tests … ready when opportunity is right

Biodiesel • Fuel used met ASTM D-6751 & GE liquid fuel specification

• Operated from start-up to full power on a range of fuel mixtures

• Confirmed that NOx emissions were comparable to turbine running on distillate fuel

Ethanol • Successful test performed on a 6B Gas Turbine in 2008

• Commonalities with naphtha: high volatility, poor lubricity, miscible

6B Gas Turbine–standard combustor Fuel: B20 – B100 Fuel: Ethanol

7EA Gas Turbine–DLN1 combustor Fuel: B20 – B100

LM6000* SAC Fuel: B100

* LM6000 is a trademark of General Electric Company.

16


Crudes … decreasing OpEx; increasing availability

Shift to heavier oils and sour gas • Field reserves and refinery ends

• Leads to corrosion, ash deposition and

emissions concerns

• Impacts CapEx (Capital Expenditure) and OpEx (Operational Expenditure)

Technical solutions … Heavy fuel oil (HFO) availability package • 4 key attributes

− Smart cool down

− Automated water wash

− Model based control

− Open S1 nozzle

• Decreases offline time to perform water

wash (from 48 to <16 hours)

• Reduce degradation and maintain Tfire …

25% reduction in output degradation rate

• More power, better efficiency

Heavy Metal concerns:

• Preventing vanadium

corrosion

• Efficiency/

maintenance impact

Sulfur concerns:

• Acidity of oceans

environmental

standards

OpFlexTM Model Based Controls

18


OpFlexTM Model Based Controls Overview

• Direct Boundary Protection (In The Boundaries Physical Space)

• Accommodation Of Machine

Deterioration (Adaptive Model Ensures Accurate Surrogates)

• Implicitly De-Coupled Effectors (Automatic Performance Optimization)

• Robust / Flexible / Expandable (Additional Boundaries / Loops)

• Proven GT Control Technology

• Approximate Boundary Protection (Calculated Off-line to Accommodate Worst-Case Condition)

• No Explicit Accommodation Of Machine

Deterioration (New & Clean / Mean Machine Assumption)

• Coupled Effectors Prohibit Optimization (Part-Load Exhaust Temperature & Fuel Splits)

W_fuel

/ IGV

Fuel

Splits

+ _

+ _

+ _

+ _

+ _

+ _

+ _

+ _

+ _

Loop-In-

Control

Loop-In-

Control

Loop-In-

Control

IBH

ARES - Parameter

Estimation

Engine Model

16.0

27025.1

3

*394.6

95.3

3

*

*

T

SH

eP

eW

Physics-Based

Boundary Models

Lim

it S

ch

ed

uli

ng

Surrogates

Today: Indirect (Tx Space) Boundary Control

Model Based Controls : Direct (Boundary Space) Boundary Control

Iso-Therm

M

INIM

UM

Tx_req

Tx

P+I +

-

W_fuel

/ IGV

TTRF ~ Tx

Sp

lits

TTRF

Fuel

Splits

CPR

TCD

Tx Control

Curve

IBH

IGV

IBH

IGV

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Model-Reference Adaptive Control

Boundary

Transfer

Functions

Boundary

Scheduling

Logic + _

TF Tuning

Model-Based

Control Structure

(Loop Selection Logic)

Boundary Targets

Estimated Boundary

Levels Surrogates

Effectors

Errors

Commands

ARES - Parameter Estimation

Engine Model

Gas Turbine

Combustion Dynamics Measurement

Boundary Transfer Functions

20


Fuel Flexibility with OpFlexTM MBC

Model-Based Control

1st : Fuel Splits 2nd : Fuel Temperature 3rd : Load Reduction

W_fuel

/ IGV

Fuel

Splits

+_+_

+_+_

+_+_

+_+_

+_+_

+_+_

+_+_

+_+_

+_+_

Loop-In-

Control

Loop-In-

Control

Loop-In-

Control

IBH

ARES - Parameter

Estimation

Engine Model

16.0

27025.1

3

*394.6

95.3

3

*

*

T

SH

eP

eW

Physics-Based

Boundary Models

Qe

eNOxNOx

ref

ref

SHSH

TflTfl

refO

**

*)(5.9

)*(006.

%15@ 2

Lim

it S

ch

ed

uli

ng

Surrogates

Combustor Capability Unleashed

30 35 40 45 50 55 60 65

Wide-Wobbe Capability

GEI-41040

Modified Wobbe Index (MWI) (22%) (-44%)

±5%

±20%

7FA

9FA

Prioritized Dynamics Control

6

7

8

9

10

-20 0 20 40 60 80 100

Time [sec]

NO

x [p

pm

@15

%O

2]

80

90

100

110

120

Gas

Tu

rbin

e O

utp

ut

[%]

NOx

Load

(Simulated +/- 10% WI over 30sec)

Wide Wobbe

Fuel Flexibility

21


0

10

20

30

40

50

60

70

80

90

100

11:24 AM 11:38 AM 11:52 AM 12:07 PM 12:21 PM

Time

Co

mb

ust

ion

Dy

na

mic

s

Am

pli

tud

e (

% T

arg

et)

42

42

43

43

44

44

45

45

46

46

47

MW

I

Frequency 1

Frequency 2

MWI

41.5

42.0

42.5

43.0

43.5

44.0

44.5

45.0

45.5

46.0

46.5

11:24 AM 11:38 AM 11:52 AM 12:07 PM 12:21 PM

Time

MW

I

7.0

7.2

7.4

7.6

7.8

8.0

8.2

8.4

8.6

8.8

9.0

NO

x (

pp

m @

15

% O

2)

MWI

NOx • LNG terminal less than 200 km from 207FA combined-cycle power plant

• LNG storage tank originally purged with CO2 … not all CO2 removed before LNG was introduced to tank

• CO2 / LNG entered pipeline and reached site at 11:24 am

• Initial Modified Wobbe Index (MWI) value decreased 5.6% due to presence of CO2 in fuel

• MWI increased 8.7% due to LNG

• Maximum rate of change in MWI

reached 9.5%/minute

• Modular control maintained acceptable emissions and dynamics levels throughout event

Automated DLN Tuning with OpFlexTM MBC

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Summary

• Regional trends, design/operational constraints and fuel availability will continue to drive the power generation industry towards non-traditional fuels

• Gas turbines have demonstrated capability to operate on a wide variety gaseous and liquid fuels

• GE has successfully tested/operated many of these fuels and decreased OpEx and CapEx impacts to the heavy duty gas turbine … goal is for performance like it is operating on natural gas

Powering the World Responsibly

Thank You. Questions?

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