syngas turbine technology

GE Energy

Syngas Turbine Technology

2010

1990

2000

2x7F Syngas Coal IGCC (USA)

3x9E Refinery (Europe)

3x9E Steel Mill (Europe)

1x7FA IGCC (USA)

2x6F Syngas Refinery (Asia)

2x6FA Refinery (USA)

1x7FA IGCC (USA)

2 SYNGAS TURBINE TECHNOLOGY

GE turbines for syngas and low-Btu fuel

applications are operating at locations

around the world with more than one

million hours of total operation.

This vast experience covers operations

employing GE and other gasification

technologies, and a variety of fuels

including high- and low-sulfur coals and

petroleum coke. GE offers an unparalleled

edge in providing customers with well-

proven and experienced combined-cycle

technology for syngas applications.

Turbine Innovation Realized

GE Turbines On Low-Btu Fuels

2x9E Steel Mill (Asia)

Sources for generating power are becoming more varied, and more stringent emission requirements are fueling a need

for flexible solutions to meet growing energy demand. At GE, we’re developing solutions today that are flexible enough to

integrate into your diverse portfolio of power generating options, helping you to profitably guide the industry—and your

community—into the future.

As a leader in combined-cycle gas turbine technology, GE has invested its time, resources and expertise to develop a

range of efficient, reliable gas turbines to help energy providers meet these new challenges. GE’s versatile gas turbines

can operate on a variety of low-Btu fuels, in a wide variety of power applications, including hydrogen, low-rank steel

industry furnace gases, light distillates, heavy residuals from refining and syngas. Our solutions can help customers

enhance fuel utilization, reducing fuel costs and improving revenues.

Fuel Flexible Solutions

Many utilities look towards abundant supplies of relatively low-cost coal for power generation. Increasingly the use

of coal—and the emissions and carbon burning it produces—is coming under scrutiny, and many power generators

are turning to integrated gasification combined-cycle (IGCC) technology.

At the front end of IGCC is gasification, which takes a carbon-based fuel source such as coal, refinery residuals

or biomass, and under high heat and pressure, converts it into a synthesis gas (or syngas) comprised of H2 and

CO. Impurities and carbon can be removed easily and economically from the syngas stream on a pre-combustion

basis—leaving a hydrogen-rich fuel—before it is burned to create electricity.

Carbon capture technologies, which have been in commercial operation for many years, offer the ability to

efficiently and cost effectively remove carbon from syngas for permanent storage or use in enhanced oil recovery

before burning the fuel. The resulting gas is essentially a carbon-free, high hydrogen fuel available for combustion

within a combined-cycle power plant. GE’s syngas power turbines offer a powerful, reliable solution that can

operate on the high hydrogen fuels resulting from this carbon separation.

While today’s GE syngas turbines have been used

successfully on fuels with up to 50% hydrogen, we

continue to advance the capabilities of the next

generation of gas turbines for high hydrogen fuels.

We’re working on breakthroughs that will deliver cleaner,

efficient technologies to customers who may capture

carbon for storage.

Syngas Gas Power Generation in a Carbon Constrained World

SYNGAS TURBINE TECHNOLOGY 3

Our syngas turbine platforms are built upon GE’s extensive experience and rigorous engineering processes. Advances in

technology will deliver high efficiency and reliability. Among these advances is the Multi Nozzle Quiet Combustion (MNQC).

One of the key challenges of hydrogen fuel is the high flame speed. The MNQC, a diffusion flame-based system that is

free of the sensitivities to flame speed and combustion instability (combustion dynamics) that are inherent to lean pre-mix

combustion systems was developed to address this challenge.

GE’s MNQC system has been designed to run on low-Btu fuels and is capable

of operating on many varieties of syngas, including high H2 fuels. It is built for

high efficiency and offers superior benefits for customers operating in base load

applications. This combustor is also capable of operating on natural gas for

start-up and shut-down operations, and can operate at base load on natural

gas for extended periods of time if syngas is not available.

With MNQC technology, GE can offer a similar combustor configuration for

several turbine products using syngas and high hydrogen fuels, all based upon

a combustion system design that has been in use since the 1990s, and can

operate with un-shifted and shifted (hydrogen-rich) syngas.

Syngas Turbine Fuel Applications

9E

6FA

7EA

7F

9F

FUEL HEATING VALUE

LOWAir IGCC Syngas

Blast Furnace Gas

MEDIUMO2 IGCC Syngas

GTL Off-gas

HIGHHigh H2 for CCSHigh H2 for EOR

Challenges Met, Innovation Attained


Notes:

(1) Conventional gasification fuel, without CO2 capture.

(2) Performance at ISO conditions.

(3) No integration with process. Steam turbine and generator product fit TBD. Assumes multishaft configuration.

Gas Turbines for Syngas Applications

7EA

6FA

9E

7F

9F256 MW 285 MW

187 MW 232 MW

126 MW 140 MW

77 MW 92 MW

85 MW 85 MW SIMPLE CYCLE OUTPUT (MW)

NATURAL GAS

SYNGAS

Gas Turbines for IGCC Syngas Applications1

Gas Turbines Combined-Cycle

Model Nominal Syngas Power Rating2 Model Nominal Syngas Output Power3

6B 46 MW (50/60 Hz) 106B 70 MW (50/60 Hz)

7EA 80 MW (60 Hz) 107EA 120 MW (60 Hz)

9E 140 MW (50 Hz) 109E 210 MW (50 Hz)

6FA 92 MW (50/60 Hz) 106FA 140 MW (50/60 Hz)

7F Syngas 232 MW (60 Hz) 207F Syngas 710 MW (60 Hz)

9F Syngas 286 MW (50 Hz) 209F Syngas 880 MW (50 Hz)


GE’s portfolio of syngas capable turbines, includes units for both 50 Hz and 60 Hz segments, simple-cycle

configurations with output ranging from 46–300 MW, and combined-cycle configurations with output ranging

from 70–880 MW, depending on fuel and site specific conditions.

6B…Reliable and rugged 50/60 Hz powerThis rugged and reliable gas turbine, a popular choice for mid-range power generation service, has a well-documented availability of 94.6%

and 99% reliability. With over 1,100 units worldwide, the dependable 6B features low capital investment and low maintenance costs. It

has accumulated over 60 million operating hours in a wide range of applications—including simple-cycle, heat recovery, combined-cycle,

and mechanical drive. Introduced in 1978, many upgrades are available to improve the performance of earlier versions, including rotor life

extension and combustion system retrofits that can deliver 5 ppm NOx when operating on natural gas. With its lengthy industrial experience

and high reliability, the 6B is an excellent fit for industrial and oil and gas applications, providing horsepower and high exhaust energy. The

6B has long operating experience on a variety of medium- or low-BTU fuels, including syngas produced from oil and steel mill gasses.

7EA…Proven performance for 60 Hz applicationsThe size of the versatile 7EA gas turbine enables flexibility in plant layout and fast, low-cost additions of incremental power. With high

reliability and availability, this unit provides strong efficiency performance in simple-cycle and combined-cycle applications—and is ideally

suited for power generation, industrial, mechanical drive, and cogeneration applications. 7E/EA units have accumulated millions of hours

of operation using crude and residual oils, and were featured in the first large scale IGCC demonstration plant at Coolwater that operated

in the mid 1980s.

9E…Flexible and adaptable performance for 50 Hz applicationsSince its introduction in 1978, GE’s 9E gas turbine fleet of 430+ units has accumulated over 22 million hours of utility and industrial

service—often in arduous climates ranging from desert heat and tropical humidity to arctic cold. Capable of operating on a variety of

medium- or low-BTU fuels, including syngas produced from oil and steel mill gasses, the 9E is a quick power solution also well suited for

IGCC or mechanical drive applications. This reliable, low first-cost machine has a compact design that provides flexibility in plant layout and

easy addition of incremental power when phased capacity expansion is required.

6FA (50/60 Hz)…Advanced technology mid-sized combined-cycle and cogenerationWith over 2.5+ million operating hours and more than 110 units installed or on order, the 6FA gas turbine is a good fit for local power for

industrial complexes. It delivers high efficiency and high availability, and provides the operating flexibility needed for harsh environments. A

direct down-scaling of the proven 7FA, the 6FA is rated at 85–95 MW when operating with syngas. Four 6FAs have been operating syngas

at two refinery cogeneration plants since the early 2000s.

7F Syngas…Large baseload syngas performance for 60 HzBuilding on GE’s F-class syngas experience, the 7F Syngas turbine was developed specifically for syngas operation. The configuration of

the 7F Syngas turbine combines materials with known syngas compatibility and turbine components designed for the increased mass flow

in syngas applications. These elements allow the 7F Syngas turbine to generate 232 MW on dry syngas at ISO conditions. This turbine—like

GE’s other syngas turbines—is capable of operating on syngas and on high hydrogen (carbon captured) fuels. The first two units shipped to

Duke Energy’s Edwardsport IGCC plant in 2010.

9F Syngas…Advanced turbine technology for 50 Hz applicationsThe latest addition to GE’s syngas turbine portfolio is the 9F Syngas turbine. This unit, based on the 9FA, building on the world’s most

experienced fleet of highly efficient 50 Hz large units. The 9F Syngas turbine can be arranged in a single-shaft or multi-shaft configuration

that combines one or two gas turbines with a single steam turbine. This turbine is capable of operating on syngas (non-carbon captured)

or a high hydrogen fuel (carbon capture).

GE Syngas Turbine Solutions


Gasification technology combined with GE’s syngas turbines is an effective way to use refinery residuals and generate N2,

H2, steam and power in a petrochemical complex.

GE deploys its advanced gas turbine technology to deliver greater performance levels than ever before, offering

customers gas turbine solutions with a wide range of fuel and process integration flexibility. Based on its significant gas

turbine and syngas experience, GE is pleased to offer solutions that deliver high efficiency and reliability for advanced

IGCC and cogeneration plants.

Refinery Residuals for Cogeneration


Developing an IGCC plant or gasifier in a petrochemical complex is a capital-intensive project, so delivering results is important.

Seamlessly integrating the gasification and power islands will help enable operators of IGCC and cogeneration plants to derive

return on their investment. Our syngas turbines provide air extraction (air from the gas turbine compressor) to the process

plant, allowing for a reduction in the number of compressors required to supply air to gasifier, air separation unit, or other

plant-level process, delivering value to the operators.

Plant Integration

Syngas or high H2

N2 from Air Separation Unit for dilution

Process heat for fuel heating

High P, T Air to reduce compressor loads

GE offers expertise in the integration of the syngas turbine, including:

•Steam-sideintegration

•Nitrogenreturn

•Fullsteamandairintegration, including air extraction and nitrogen return

GE Energy provides innovative, technology-based products and service solutions across the full spectrum of the energy

industry and is committed to investing in a cleaner, smarter, and more efficient future. To put GE’s proven syngas turbine

technology to work for you, contact your local GE representative or visit http://www.ge-energy.com

GE Delivers


Flexibility of GE Syngas Turbine TechnologyGE leads the world in the application of its heavy duty gas turbines to gasification combined-cycle gas projects. Our

success with low- and medium-Btu fuel gases is a consequence of extensive full-scale laboratory testing on various fuels

for nearly 24 years at GE’s combustion laboratory in Schenectady, New York, and, since 2002, testing at the combustion

development laboratory in Greenville, South Carolina.

In these facilities, we develop and validate system components

and the impacts of impact of various characteristics on

performance of a combustion system. At our Greenville

test facility, for example, we are able to validate the 7F

syngas turbine combustion system, testing it at full pressure,

temperature and flows. The facility also has the capability

to blend a variety of syngas-like fuels. We can also test the

turbine on start-up fuel (natural gas) at full speed, no load

conditions. Typical test campaigns examine combustion full

and part load performance, including combustion dynamics,

emissions and exit profile. In addition, thermocouples, strain

gauges and thermal paint – combined with advanced

computational fluid dynamics and finite element analysis –

allow full durability validation of the system. Combustion lab

testing has evaluated performance over a range of fuel space

and load points. Results from these tests have confirmed that

the system will be able to meet customers’ performance goals.

syngas turbine technology

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steel mill

deliver high

7f syngas

9f syngas

including

syngas turbine

high hydrogen

air separation