oct. 21, 2004 power generation 1 authors: schütz, kreyenberg, friede spg modern combined cycle...

Oct. 21, 2004 Power Generation 1

Authors: Schütz, Kreyenberg, Friede SPG

Modern Combined Cycle Power Plants – Improvement of a high efficient and clean technology

"Energy Efficiency in IPPC-installations" 21 and 22 October 2004

Vienna


O. Kreyenberg, H. Schütz, H. Friede Siemens PG




Agenda

Reference Power Plant Product Overview

- Steam Power Plant

- Combined Cycle Power Plant

Reference Power Plant Product Overview

- Steam Power Plant

- Combined Cycle Power Plant

Reference Power Plant Design PhilosophyReference Power Plant Design Philosophy

ReferencesReferences

Design TargetsDesign Targets

Market DriversMarket Drivers




The Market Conditions Have Changed Dramatically in the Power IndustryOver the Last 10 Years

Ma

rke

t C

on

dit

ion

s

Years

Risk Guarantee*

Price

Overall Construction Time

Efficiency

* technical warranties (NOx, et. al.), delivery time




Life Cycle Cost (LCC) Analysis

Investment costs

Financing costs

Service life

Demolition costs

Capital costs

Costs

Fuel contractconditions

Efficiency

Personnel costs

Consumables/waste

Spare parts

Maintenance

Operating costs

Fuel Costs

Parameters influencedby the supplier

Reduction of specificinvestment costs

Global sourcing

Modular design

Short delivery times

High process andcomponent efficiencies

Optimized level ofautomation

High availability

Ease of maintenance

Parameters

LiveCycleCosts




Reference Power PlantProduct Overview




Our Reference Power Plants are Focused on International Main Market Demand for IPP’s

Customized... Customized... of the shelf...of the shelf...

Multi-Shaft 50 Hz 200, 580, 800 MW 60 Hz 200, 540, 730 MW

Components, Islands Components, Islands and Turnkeyand Turnkey

Components, Islands Components, Islands and Turnkeyand Turnkey

Varioplant 300 300- 450 MW 700 500- 750 MW 900 800- 1000 MW

Coal/Oil

Gas/Oil

Single-Shaft 50 Hz 100, 290, 400 MW

Gas/Oil

60 Hz 100, 270, 365 MW




Multi-Shaft Combined Cycle Power Plant Econopac Arrangement

ECONOPAC

• Gas turbine

• Gas turbine generator

• Air intake

• Exhaust gas system

• Fuel system

• Electrical package (SFC/SEE)

• GT - Auxiliaries

• Fire protection

• Options




Multi-Shaft Combined Cycle Power Plant Power Island Arrangement

POWER ISLAND

• Econopac

• Steam turbine

• Steam turbine generator incl. SEE

• Heat recovery steam generator

• Major pumps

• Condenser

• Critical valves

• ST - Auxiliaries

• Cycle optimization

• Fuel gas pre-heater

• Options




Multi-Shaft Combined Cycle Power Plant Turnkey (Cooling Tower)

TURNKEY

• Power Island

• Fuel supply systems

• Cooling systems

• Water treatment

• Raw water system

• Waste water system

• Tanks

• Cranes/ hoists

• Buildings/ structures

• Fire protection

• Plant piping/ valves

• Plant electrical

• Further options




Multi-Shaft Combined Cycle Power Plant Turnkey with House (Cooling Tower)

TURNKEY

• Power Island

• Fuel supply systems

• Cooling systems

• Water treatment

• Raw water system

• Waste water system

• Tanks

• Cranes/ hoists

• Buildings/ structures

• Fire protection

• Plant piping/ valves

• Plant electrical

• Further options




Reference Power PlantDesign Philosophy




Evolution of Combined Cycle Power Plant Efficiency

Steam cycle

Single pressure Dual pressure Tripple pressure with reheat

Net efficiency(%)

Year of commissioning1983/84

60

58

56

54

52

50

48

461987/88 1990/91 1992/93 1994/95 1996/97 1998/99 2001

1230°C130°C110 bar550°C

1190°C200°C110 bar540°C

1160°C—100 bar520°C

1120°C—80 bar520°C

1050°C—75 bar510°C

1000°C—60 bar485°C

960°C—50 bar460°C

Fuel gas firingISO ambient conditions(15°C, 1013 mbar, 60% rel. humidity)Condenser back pressure 0.04 bar

Source: Siemens Gas Turbines

Turbine inlettemp. (ISO)

Fuel preheating

Life steampressure

Life steamtemperature

2005/06

1250°C200°C160 bar580°C

1230°C130°C125 bar565°C




0.55 mill € / MW

7.1 mill € / %-point

2.5 mill € / month


Power Output

Efficiency

Lead Time

Availability

0‘6 mill € / MW

9‘8 mill € / %-point

0‘9 mill € / month


0 0.2 0.4 0.6 0.8 1.0

0 4 6 8 10 12

0 0.5 1 1,5 2

0 1 2 3 4

Evaluation Factors (price related)(at 12% targeted Internal Rate of Return for additional investment)

Electricity Price

Fuel Price

Power Output

Efficiency

Load Regime

Boundary Conditions

37 € / MWh (escalation 1%/a)

3.9 € / GJ (escalation 1%/a)

397 MW

57.00 %

Base Load (7000hr/a)

24 22 months

185 mill €

70 / 30

35 %

20 years

Lead Time

Overall Project Costs

Debt/ equity ratio

Income Tax

Operating Period

0.55 mill € / MW




0.55 mill € / MW




0.55 mill € / MW




Power Output

Efficiency

Lead Time

Availability

0‘6 mill € / MW


0‘9 mill € / month


0 0.2 0.4 0.6 0.8 1.0

0 4 6 8 10 12

0 0.5 1 1,5 2

0 1 2 3 4

Evaluation Factors (price related)(at 12% targeted Internal Rate of Return for additional investment)

Electricity Price

Fuel Price

Power Output

Efficiency

Load Regime

Electricity Price

Fuel Price

Power Output

Efficiency

Load Regime

Boundary Conditions



397 MW

57.00 %




397 MW

57.00 %


24 22 months

185 mill €

70 / 30

35 %

20 years

24 22 months

185 mill €

70 / 30

35 %

20 years

Lead Time


Debt/ equity ratio

Income Tax

Operating Period

Lead Time


Debt/ equity ratio

Income Tax

Operating Period

Economical Evaluation Factors




Power Output, Efficiency, NOx-Emission and Cooling Air Demand versus Combustion Temperature

ElectricityCirculatingwater

Generator

Generator

Heat recovery steam generator

Cooling air 20%

Condenser

Combustion chamber

Fuel

Air intake

Ex-haustgas

102%

Electricity

Combustionair 80%

100%

Gas turbineNOX

Steam turbine

TCool.-air

2%

Tcomb.

1570°C TCombustion

TIT

GUD

NOX

1700°C

Boundary conditions:The same technology for blade cooling, combustion chamber cooling and burner.

Boundary conditions:The same technology for blade cooling, combustion chamber cooling and burner.

mKL

.




Efficiency Improvements due to Increasing the Number of Pressure Stages

600

500

400

300

200

100

0

Temperature [°C]

Exhaust gas

1-pressure process

2-pressure process

3-pressure process

Transfered heat

Temperature curves in aheat recovery steam generator

3

2

1

0

net[%-points]

1.62.1

2.8

65 bar/540 °C

80 bar/540 °C5 bar/210 °C

125 bar/565 °C29 bar/320 °C5 bar/200 °C

125 bar/565 °C28 bar/565 °C4 bar/235 °C

1-pressure 2-pressure 3-pressurewithoutreheat

3-pressurewith

reheat

Efficiency increase

54.1%




Quick Start up Increases Plant Utilisation Factor...

Time

Pla

nt

Lo

ad [

MW

]

0

50

100

150

200

250

300

350

400

Plant start-up withimproved equipment

Plant start-up withimproved equipment

≈ 40 min

GT at full load/Bypass System closed

Typical plant start-upTypical plant start-up

≈ 90 min

Start-up after 8h Shut-down




Limiting Values for Flue Gas Emissions




Relationship between turbine inlet temperature and NOx emissions

A temperature increase by 70K doubles the NOx- emissions !

0,0

0,5

1,0

1,5

2,0

2,5

1220 1230 1240 1250 1260 1270 1280 1290 1300 1310

Temperatur in °C

NO

x*




Design Targets




One the way to the Technical leadership

now tomorrow

Efficiency 58%* > 59%

TIT** 1230°C 1290°C

NOx 25 ppm 9 – 15 ppm

Details on additional measures will be presented at a VDI Symposium in Leverkusen 23./24. November 2004

* depending on cooling conditions ** turbine inlet temperature




References




Mainz-Wiesbaden, Germany Combined Cycle Power Plant V94.3A with Steam Extraction

Mainz - Wiesbaden (Germany)Concept: Multi Shaft 1+1 V94.3AOutput (nat. gas, site) : 1 x 400 MWEfficiency (nat. gas, site): >58,4 %*COD: July 2001Fuels: Natural Gas (Fuel oil Back up)

Contract: EPC TK plus 10 y. S&M

Mainz - Wiesbaden (Germany)Concept: Multi Shaft 1+1 V94.3AOutput (nat. gas, site) : 1 x 400 MWEfficiency (nat. gas, site): >58,4 %*COD: July 2001Fuels: Natural Gas (Fuel oil Back up)





Pulau Seraya, Singapore: 2 CC 1S.V94.3AThe Most Efficient Plant in SEA

Pulau Seraya (Singapore)Concept: Single Shaft 1S.V94.3AOutput (nat. gas, site) : 2x 367 MWEfficiency (nat. gas, site): >57.2 %COD: November 2002Fuels: Natural Gas (Fuel oil Back up)


Pulau Seraya (Singapore)Concept: Single Shaft 1S.V94.3AOutput (nat. gas, site) : 2x 367 MWEfficiency (nat. gas, site): >57.2 %COD: November 2002Fuels: Natural Gas (Fuel oil Back up)


oct. 21, 2004 power generation 1 authors: schütz, kreyenberg, friede spg modern combined cycle...

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