technologies for next generation turbine systems for next generation turbine ... trent lm 6000 pd lm...
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Technologies for NextGeneration Turbine
Systems
Turbine Power Systems Conference andCondition Monitoring Workshop
February 25-27, 2002Galveston, Texas
Alfonso (Al) Wei
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Combined Cycle Performanceat
Simple Cycle Cost andFlexibility
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Approach to “economically viable” NGT
Low 50’s % eff’y. Large development; highrecuperator durability risk; difficult to control.
Wet I.C. Wet Recuperated (WIWR)
SpiralRecuperator
Inlet
Modified Trent Engine
IntercoolerHumidifier
RecuperatorHumidifier
WaterRecovery
UnitWater Tank
~
Low 50’s % eff’y. Largebut lower risk
development (integrationof known technologies);
slight compromise inperformance vs. WIWR.
Super Steam Injection
Exhaust
Inlet
Water Tank
OTSG
~
WaterRecoveryUnit
Modified Trent Engine
Low 40’s % eff’y. Higher PR & tempto improve - risky technologies; very
difficult fuel flexible DLE.
High P.R. Simple Cycle
52 MWIndustrial
Trent
ICR
Mid 40’s % eff’y Only small additionalimprovements in efficiency possible.
25 MWWR-21
Less development butcompromised performance;complicated arrangement;increased unit cost.
Parallel Shaft WIWR
WetRecuperated
RB211 + 501-KPower Section
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R-R NGT Concept #1 -Wet Intercooled Wet Recuperated
Exhaust
Spiral Recuperator
Inlet
Modified TrentEngine
IntercoolerHumidifier
RecuperatorHumidifier
WaterRecovery
UnitWaterTank
~Power: 50-80 MWe
Elect’l Efficiency: >50%
Turnkey Price: $400-450/kW
Emissions: <10 ppm NOx<10 ppm CO
Start-up Time: <15 min
Water System: Closed loop
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R-R NGT Concept #2 - Super Steam Injection
Power: 50-80 MWe
Elect’l Efficiency: >50%
Turnkey Price: $400-450/kW
Emissions: <10 ppm NOx<10 ppm CO
Start-up Time: <15 min
Water System: Closed loop
Exhaust
HRSG
Inlet
LPT IPT
HPTHPC IPC
Modified R-RTrent Engine
WaterRecovery
Unit
Water Tank
~
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1 Generator Skid 2 Gas Turbine Skid 3 GTG Auxiliary
Module 4 Control Room
Similar Plant Layouts
9 Water Recovery Sys10 Once Thru Steam Generator11 Fin Fan Cooler
5 High VoltageModule
6 Utility Tie 7 Gas Compressor 8 Water Recovery
Tank
12 Demin waterstorage
13 Polishing Unit14 Demin Unit15 Make up water
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R-R’s NGT - Comparison to Current Products
GE LM6000
PD (DLE)
R-R Trent DLE
GE Fr6FA
GELM6000 Sprint
R-RNGT#1-SI (Super Stm
Inj)
R-RNGT#2-WIWR
(Wet IntrCool / Wet Recup)
GELM6000
C.C.
R-RTrent C.C.
GEFr6FAC.C.
GEFr7EAC.C.
Power (MW) 43.1 51.2 70.1 47.3 50-80 50-80 56.4 66 107.4 130.2
Efficiency (%) 41.4% 41.6% 34.2% 41.4% >50% >50% 52.5% 54.3% 53.2% 50.2%
Turbogenerator Price ($/kW) $366 $303 $285 $298
Turnkey Price ($/kW) ~ $560 ~$500 ~$480
~$430(no water
recov)
$400-450 (incl water
recov)
$400-450 (incl water
recov)$658 $650 $730 $514
Flexibility High High High High High - High - Med/Lo Med/Lo Low Low
Simple Cycle Combined CycleWet Cycle
R-R’s NGT Solution:
• ~ 25% improvement in efficiency of simple cycle machines
• ~ 30% improvement in capital cost ($/kW) of combined cycle plants
• Maintains operational flexibility of simple cycle machines
Source: Gas Turbine World Handbook
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R-R’s NGT Concept Meets The DOE Goals
Determine the feasibility of developing flexible gas turbine systems with a greaterthan 30 MW power rating. Compared to 1999 state-of-the-art systems, theproposed systems shall include:
– 15% or higher improvement in net system efficiency;
– improvement in turndown ratios;
– 15% or higher reduction in COE;
– improved service life;
– reduction of emissions (carbon and NOx);
– 15% or higher reduction in operations & maintenance costs;
– 15% or higher reduction in and capital costs;
– increased flexibility (min. 400 starts/year);
– improvement in RAM; and
– capability to use multiple fuels.
R-R’s NGT
√√√
√√
Achievable
Achievable
Achievable
Achievable
Achievable
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The Market Opportunity Appears to Exist
0
100
200
300
400
500
600
700
1988 1989 1990 1991 1992 1993 1994 1995 1996 1997 1998 1999 2000
Uni
ts O
rder
ed
180 MW & above
120 - 180 MW
60 - 120 MW60 MW & above
30 - 60 MW
Source: Diesel & Gas Turbine Worldwide Annual Power Gen Survey
NGT
}
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Customer Survey: R-R Solution Seems AppropriateDistributed Generation Growth?
Yes
No
Peaking Market Growth? Continued Growth -Same Rate
Continued Growth -Reduced Rate
No Growth
Don't Know
Future Mid-Merit Market?
AgreeDisagreeDon't Know
Market Perceived for R-R's NGT?
Yes
No
70-80 MW Size?
SatisfactoryToo LargeToo small
How Fast Should Start Time Be?
<10 Min10-15 min15-20 min20-30 min>30 min
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R-R’s NGT - Economic Benefits to Operators
IRR Comparison - Spot Market TradingExample
-20
-10
0
10
20
30
40
50
60
70
80
90
100
110
New England PJM Calif ornia UK Pool
Inte
rnal
Rat
e o
f R
etu
rn (
%
Trent
LM 6000 PD
LM 6000 ES
6FA
7EA
NGT 1
NGT 2
COE Comparison - Mid-Merit OperationNGT vs. Simple Cycle Machines
2
3
4
5
6
7
8
9
Bas e c as e Sc en ar io 1 Sc en ar io 3 Sc en ar io 4
CO
E (c
ents
/kW
h)
Trent LM 600 0 PD LM 600 0 ES 6FA 7EA NGT 1 NGT 2
Scenario 1High gas price(2 x base case)
Scenario 3Gas price 1.5 xbase case, CO2tax in later years
Scenario 4Low longer-termgas prices, highCO2 taxation
Base caseReference Case inEIA Annual EnergyOutlook - 2001
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Public Benefits of R-R’s NGT
• Assuming 34 NGT units (2550 MWs) per year installed in U.S.:
– CO2 Emissions - Cumulative 15 Year Savings• Compared to Simple Cycle GT, 150 million tonnes savings
• Compared to Coal Plant, 630 million tonnes savings
• $3B savings in CO2 trading credits (assumed @ $20/tonne) cf simple cycle GT
• $12.6B savings in CO2 trading credits (assumed @ $20/tonne) cf coal plant
– Fuel (natural gas) Consumption - Cumulative 15 Year Savings• Compared to Simple Cycle GT, 2.6 trillion cubic feet savings
• $8.3B fuel cost savings compared to Simple Cycle GT
• $2.1 billion/yr potential export sales from 2006 (assumed 54 units/yr)
• Lower risk approach allows earlier availability to market
• Flexible characteristics allow for viable and efficient operations even inchanging market conditions
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Summary
• R-R’s NGT concepts have been approached from an “economic viability” perspective:
– Leveraging available hardware and technologies to lower risk, investment, and time tomarket; and
– Applying these in innovative ways to develop a solution that will provide customers withimproved return on investment (ensure deployment) while providing extensive publicbenefits.
• R-R’s NGT concepts (Wet Intercooled/Wet Recuperated; Super Steam Injection):
– Meet DOE NGT goals;
– Seem to be appropriate for the future marketplace;
– Provide substantial economic benefits to operators; and
– Provide substantial public benefits.
• R-R is encouraged by the results of this study. However, the significant technical &market risks and the large investments required make launching an NGT product verydifficult in today’s business environment.