fuel flexible gas turbines for sustainable ge energy … 2013 presentations/day-2 at pmi... · fuel...
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© 2012, General Electric Company. Proprietary Information. All Rights Reserved.
GE Energy
© 2013, General Electric Company. Proprietary Information. All Rights Reserved.
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)
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© 2013, General Electric Company. Proprietary Information. All Rights Reserved.
© 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
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© 2013, General Electric Company. Proprietary Information. All Rights Reserved.
Outline
• Introduction
• Fuel Flexibility Options Liquefied Natural Gas (LNG) Syngas Oils
• OpFlexTM Model Based Controls
• Summary
4
Introduction
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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
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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
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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
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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
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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)
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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
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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
Oils
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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.
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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
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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
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© 2013, General Electric Company. Proprietary Information. All Rights Reserved.
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
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© 2013, General Electric Company. Proprietary Information. All Rights Reserved.
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?