ge adgt application chp-cogen-cc

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GE LM Aero GT Applications GE SOA, Korea July 2014 Tomas Hertzell / Global Technical Solutions July 9, 2014

GE Proprietary Information—Class III (Confidential) Export Controlled—U.S. Government approval is required prior to export from the U.S., re-export from a third country, or release to a foreign national wherever located.

General introduction

Aeroderivative Gas Turbines

Where are they used

What types of applications

Operating schemes

3

GE Proprietary Information – Subject to restrictions on front cover

Aeroderivatives … where are they used?

Utility Pipeline Alaska

Floating production vessels

LM6000

Independent power producer

District heating Denmark

Mobile power

Ireland 3xTM2500

Platform 538 Package

Operational flexibility, high efficiency, superb reliability, fast

installations GE Proprietary Information – Subject to restrictions on front cover

11%

11%

17%

17%

28%

16%16%

16%

36%

24%

8%

A wide range of applications

LM6000 +830 units in operation

LM2500 +1500 units in operation

LMS100 46 units in operation

(55 units ordered)

Cogeneration

Land Base PG

Land Base MD

Lease / Other

Platform MD + PG

Dispatch Peaking

Dispatch Mid Merit

Dispatch Base Load

System Stability

Merchant Peaking

Repower

Simple Cycle

Combined Cycle

Cogeneration

65% 20%

15%

Worldwide


Wide Range of Operating Schemes LM units reporting to ORAP® for 12 month period ending March 2013

No. of units

Avg hours

Avg starts

LM6000 206 3052 132 Source: ORAP® ; All rights reserved: SPS®

Hours operated in prior 12 months

Sta

rts

in p

rio

r 1

2 m

on

ths

Continuous base-load

Seasonal base-load

Mid-merit , quick dispatch,

load-following

Peaking Daily dispatch base-load

1 3 5 8 12 hours per start

30

100


0

160

320

480

640

0 2196 4392 6588 8784

LM2500

LM6000

LMS100

Dispatch – 2009 data

ORAP® report for 12 month period ending Jan 2010

Model

No. of units

Avg hours

Avg starts

LM2500 135 5014 37

LM6000 257 2945 106

LMS100 11 1308 175

Source: ORAP® ; All rights reserved: SPS®

Hours operated in prior 12 months

Sta

rts

in p

rio

r 1

2 m

on

ths

540 starts 3237 hours

382 starts 6862 hours

Continuous base-load

Seasonal base-load

Mid-merit, quick dispatch, load-following

Peaking Daily dispatch base-load


Peak load, grid support and wind firming

Redefining the meaning of “True” flexibility…

• Fast starts … zero to 100% in 10 minutes, 5 min. option available

• Fast response … 50 MW per minute ramp-up

• Pro boost … reserved power when need it , under frequency support

• High part load efficiency +36% @ 50% load

• Multiple daily starts … no maintenance penalties

• Wide range of fuels … CoG, flare gases , naphtha, biofuels

• Zero water capable with DLE • High availability … 12 days in 50k hours


System dynamics driving higher peak demand

10

Addition of wind generation:

Net Load Duration Curve becomes more steep

Wind generation has small (but not zero)

impact on peak load

Wind generation has major impact on low and minimum

load conditions

Hours of Operation / Year

Sys

tem

Lo

ad

Base Load

Generation

Mid-Merit

Generation

Peaking

Generation

Mid-Merit

Generation

Base Load

Generation

System Load without wind

Net System Load with wind

Peaking

Generation

Gas GT

Gas CCGT

Clean Coal

Flexible Generation Portfolio is key to successful integration of wind and other renewables


Renewable energy demands flexibility

11

400 Wind - 100 LMS

(One represenative week of good wind operation)

-200.0

-100.0

0.0

100.0

200.0

300.0

400.0

500.0

1 13 25 37 49 61 73 85 97 109 121 133 145 157

Hour

MW

Actual Wind

LMS power

Production beyondforecast

Missed production

Forecast Wind(unbiased)

NW Miller 2/7/2007 Energy Consulting


• Multiple starts per day

• High partial load efficiency

• Fast ramp rate

Customer 3

0

20

40

60

80

100

120

8/4/08

14:24

8/4/08

19:12

8/5/08

0:00

8/5/08

4:48

8/5/08

9:36

8/5/08

14:24

8/5/08

19:12

8/6/08

0:00

Po

we

r (M

W)

Customer 3

0

20

40

60

80

100

120

8/4/08

14:24

8/4/08

19:12

8/5/08

0:00

8/5/08

4:48

8/5/08

9:36

8/5/08

14:24

8/5/08

19:12

8/6/08

0:00

Po

we

r (M

W)

Features of flexibility Supporting evolving energy demands

% P

art

Lo

ad

% P

art

Lo

ad

%

Pa

rt L

oa

d


Maximizing renewable energy utilization In the plains of Kansas, the wind changes constantly and suddenly. Weststar Energy’s Emporia fossil power plant supports 1.2 GW of wind power with four GE LM6000 gas turbines to firm renewable power. The LM6000 is capable of fast response and daily start-stop cycling, which keeps emissions and operational costs to a minimum.


Firming the US grid …

The US grid has over 500 LM6000 connected to the grid. GE’s Aero technology offers fast response, capable of load following, while sustaining high efficiency in simple cycle.


Off-grid power generation

World-class reliability & availability dependable power when needed, anywhere

Remote power off grid solutions…

3x LM6000, Cement Plant

Obajana, Nigeria

3x LM6000, Newcrest Mines

Telfer, Australia


Cogeneration

Cogeneration applications

• Industrial process steam supply • GT + HRSG for direct steam supply

• District heating • Direct steam or hot water generation

• Combined cycle with district heating STG

• District cooling, absorption chillers • Exhaust gas fired

• Via steam generation

• Trigeneration (district heating/cooling)

• Cogeneration combined cycle

18


Aero gas turbines offer a wide range of electric vs. thermal energy solutions

System

Flexibility Each system can

operate over a defined range of

thermal and electrical loads

Condensers, duct firing and turn-down are ways to match the desired loads


GT + HRSG for process steam supply

• For stable electric/steam loads, select GT rating to closely match steam demand

• For fluctuating loads, GT should preferably be rated to below steam demand, with balance steam via supplementary firing

• Supplementary firing improves overall cogeneration efficiency

• System decouples electric / steam production to allow plant to

simultaneously match both requirements – particularly important

when steam and electric demands are independent of each other

20


Heat & Power for Ferrero chocolates

In the City of Alba, Italy, GE LM6000

cogeneration technology is providing

enough power and heat energy to the

Ferrero factory to manufacture 1,000 tons

of chocolate per day, while providing

electricity and district heating to the city.


Kuala Lumpur, KLIA 2 x LM2500

Osaka, Kansai 2 x LM2500

Paris, Charles de Gaulle 1 x LM6000

London, Heathrow 1 x LM1600

New York, JFK 2 x LM6000

Toronto, Pearson 2 x LM6000 + 2 x LM6000

San Francisco 1 x LM2500

Major airports with GT Cogen facilities

ñ

ñ ñ ñ

ñ ñ

ñ


Toronto Airport Cogeneration plant Using supplementary firing

The OTSG is capable of extremely fast startups and is

typically able to supply full steam loads within 60 minutes.

The OTSG can start from a dry condition, so there is no requirement to slowly heat the water contained within the drum.

The fast startup of the OTSG allows both the gas turbine

to reach full load and the SCR to achieve its minimum operating temperature very quickly.

Gas Turbine

Model

Output

(MW)

Fuel type

Exhaust

Mass Flow

(tons/hr)

Exhaust Gas

Temp.

(ºC)

Firing

Temp.

(ºC)

Feedwater

Temp.

(ºC)

LM6000 2 x 43 Nat. Gas 462 456 581 53.3

HP Steam

Flow

(tons/hr)

HP Steam

Pressure

(bar)

HP Steam

Temp.

(ºC)

LP Steam

Flow

(tons/hr)

LP Steam

Pressure

(bar)

LP Steam

Temp(ºC)

HRSG Surface

Area

(m2)

81.1 52.4 373 5.2 12.3 203 22,851


District heating /cooling / Tri-generation

• Similar to industrial cogen – but with low temperature heat consumption for improved heat recovery

• In case of cogen system, all exhaust steam from STG is normally used for district heating, i.e. no heat rejection to atmosphere for excellent cogeneration efficiency

24


Technical specifications (ISO Conditions): Principal Data Electrical Production, net 102 MW District Heating Production, net 82 MW Electrical efficiency 50.5 % Overall efficiency 89.2 % Gas Turbines Electrical Output 42.5 MW Efficiency 40.5 % Flue Gas Temperature 460 degrees C NOx-emissions 13-15 ppm HRSG’s Boilers HT-steam @ 55 bar / 450 C / 11.2 kg/s LT- steam @ 4.5 bar / 235 oC / 4.2 kg/s Flue Gas Temp. after HRSG’s Boiler 68 °C Steam Turbine Electrical Production, net 19.2 MW Yearly Production: Electrical Production 450 GWh District Heating Production 1375 TJ Gas Consumption 80 mill m3

District Heating Silkeborg Kraftvarmevæ rk A/S, Denmark

Commercial Ops in Dec 1995 Upgraded in 2008 LM6000-PB to –PD & Bypass stack

Increase output by ~4% Reduced Thermal Output by~4MWth Overall cogen efficiency +1.7% points


Belgorod TEC and Looch Power* – Belgorod, Russia

Situation

• City of Belgorod had very old, non-efficient and high NOx/CO emission district heating system with gas fired boilers and ST. Lack of extra gas fuel, high emissions and limitations for power inside the city grid limited further development of Belgorod.

Solution

• Two identical power stations inside the city for 60 MW power + 60 Gcal/hr hot water for DH each

• 2xLM2500+ HSPT DLE units @ 29 MW on each station • City closed 2 old stations and built many new apartment buildings and

business/industrial centers based on heat and power they got Environmental Benefits • Emissions are less now vs old boiler houses, even though power was increased

from 24 to 120 MW


Trigeneration

• Simultaneous and/or seasonal provision heating and cooling together with power generation

• Typically based on steam generation with heat exchangers for heating and steam driven absorption chillers for cooling to allow flexible load shifting between heating/cooling

27


Texas Medical Center in Houston

6,500 hospital beds

900 bassinets

$1B of medical research

5.5 million patient visits

8 hospitals

8 colleges/universities

TECO’s total plant capacity

122,000 tons chilled water

850,000 PPH steam

61MW power generation

82% energy efficiency

Substantial environmental benefits

New LM6000-PC … for additional CHP

LM6000 providing CHP to critical infrastructure


MG&E, U of Wisconsin, 150 MW

2 x LM6000PC Sprint, 60 MW STG, CC

Steam & chilled water to campus physical

plant (500 kph & 20,000 RT)

Electricity for municipal utility


Aero Combined Cycle

GE Aero Combined Cycle Highlights

• Class-leading efficiency, nominal up to ~54 % ISO available

• Flexible operation

• High availability

• Efficient inlet chilling solutions for peaking performance

• LM6000 SPRINT option for high efficiency output increase

• Inlet heating for part load efficiency improvement

31


HP IP

IP Process Steam

LP Process Steam

to HRSG

HRSG

2 x GTG

STG

Typical Cogen Combined Cycle


In Santa Clara California GE’s LM6000

technology is providing 1/3 of all the

power used by industrial, residential, and

high-technology customers. Producing

power where its needed reduces

transmission congestions and lower costs.

Powering Silicon Valley and the Web


Two GE Aero LM6000s are producing 74

MW in combined cycle, sending 7,000

tons of chilled water to keep 9 million

passengers per year cool while powering

the infrastructure that gets 31,000

flights on their way each year.

Keeping the lights on at JFK Airport


Faster starts for full CC power

Constructed in 2005 to provide electrical power for the town of Gorizia. The LM6000-PD 56 MW power plant is optimized to achieve low cost operation, reliable power delivery and sufficient steam production for the town.

Daily dispatching:

0

5

10

15

20

25

30

35

40

45

50

1 3 5 7 9 11 13 15 17 19 21 23 25 27 29 31

80% load in 10 min … Full Power in <60 minutes

No maintenance impact to plant maintenance schedule due to cycling


Right-sizing the combined cycle plant

Selecting the right product size is key … to meet demands for flexibility at highest possible efficiency

Flexibility advantages of smaller block sizes

• Faster grid response … increase

revenue (price spikes, ancillary)

• Smaller incremental steps more

closely track demand growth …

higher capacity factors

• More time at higher % loads

with higher efficiency

• Lower reliability risk


LM6000-PF Sprint + Chilling provide great value!

Ambient Temperature (ºF)

Ou

tpu

t a

t te

rmin

als

(kW

e)

28000

32000

36000

40000

44000

48000

52000

-5 5 15 25 35 45 55 65 75 85 95 105

Sea level, Nat Gas Fuel: 19000Btu/lb LHV

RH => 60% below 90oF; RH => Wet bulb temp = 77.1oF above 90oF 4” H2O Inlet loss + 1” H2O Chiller loss 12” H2O Exhaust loss

Chilled cases include chiller plant auxiliary losses

LM6000-PF @ 90ºF inlet

+7MW with Sprint

… and 11MW more if Sprint + chilling

46 to 50 MW GT output over a wide range of ambient temperatures


Flat LM6000 CC Efficiency through

SPRINT control and inlet /chilling heating

6,000

6,200

6,400

6,600

6,800

7,000

7,200

7,400

7,600

7,800

8,000

60,000 70,000 80,000 90,000 100,000 110,000 120,000 130,000

Net Plant KW

BT

U/K

WH

, N

et

Pla

nt

Control Limit Turndown

With Inlet Heating

Sprint Off

Reduce Chilling

2 GTs Operating


Concept for inlet heating

1. Compressor Inlet Temp Correction Factor < Direct Part Load Correction Factor

2. Increasing of CIT Reduces Output With Lesser Drop in C/C Efficiency

3. Higher CIT Increases GT Exhaust Temp Resulting in Higher Bottoming Cycle Efficiency

4. SprintTM On/Off Capability Increases More Flexibility in Operation


HP IP

HP Steam

IP Steam

to HRSG

HRSG

2 x GTG

STG

Heat Exchanger

Inlet Coil

IP Steam Condensate

Hot water

Inlet heating water circulation


CC Performance curve across designed load range

2 x PD

2 x Industrial HD GT

2 x PH

32C, 78%RH, Cooling Tower, Full Condensing

45.0%

46.0%

47.0%

48.0%

49.0%

50.0%

51.0%

52.0%

53.0%

60 65 70 75 80 85 90 95 100 105 110 115 120 125 130 135 140

Net CC Output , MW

Ne

t C

C E

ffic

ien

cy


Other applications / opportunities

Steam cogen plant repowering/replacement

Technology BP steam *) Extr Cond steam *)

LM6000 PF SPT, HRSG + DF

Fuel Coal Coal Nat Gas

Net el output 9.0 42 42

Fuel input, GJ/h HHV 250 630 445

Add output, BP vs gas, MW Base N.A. 33

Additional fuel BP vs gas, GJ/h Base N.A 195

Marginal etael BP vs gas Base N.A. 67-68 %

Fuel input red EC vs gas. GJ/h N.A. Base -185 (-30%)

43

Example: 75 tph process steam at 10 bar abs / dry saturated steam, 100 % return condensate @ 80 °C. Site conditions: 25 °C, 60 % RH

*) 100 bar/ 500 °C, 180 °C FW temp, coal HHV/LHV: 1.035

Concept viability is dependent on value of additional electricity relative fuel prices; coal/ash handling costs; emissions tax/emissions limitations and maintenance + staff costs


LM GT for peaking in utility steam plant

Exhaust gas heat recovery for D/A or LP feed heater use:

• LM6000 PF SPT @ 25 °C ambient can produce ~65 tph of 10 bar d/s

steam, and 42 MW net el output, or 45 -50 MJ/s hot water at 120 °C

• Depending on arrangement, using this heat in a ~400 MW reheat steam

plant can increase SPP plant output by 10 MW or possibly better

without changing fuel input.

• This arrangement can increase the peaking aero-type GT efficiency

from ~ 40 % open cycle to towards 50 % LHV.

• Comparatively small incremental investment cost for the additional

overall efficiency

• Fast response

44


ge adgt application chp-cogen-cc

Technology

capable of load

peak load wind generation

load multiple

wind net system load

addition of wind generation

steep wind generation

hours continuous base

ge lm6000 gas turbines