ge adgt fuel flexibility

GE Power & Water

July 09, 2014 | Pangyo, South Korea

© 2013 General Electric Company. All rights reserved.

This material may not be copied or distributed in whole or in part, without prior permission of the copyright owner.

LM1600® , LM2500® , LM6000® , LMS100® , and LM5000® are registered trademarks of General Electric Company (USA).

Alternative Fuels/Fuel Quality

Jim DiCampli

© 2013, General Electric Company. All rights reserved. Subject to restrictions on cover page.

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© 2013, General Electric Company. 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, 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


3


Introduction


4

Welcome

1. Introduction

a) Presenters

2. Standard fuels

3. Non-standard fuels

a) Gas fuels

b) Liquid fuels

4. Fuel quality


5


Standard Fuels


6

Basic fuel requirements for LMs

Can burn Gas Fuels

• Ample heating value

• Kept as gas

• Clean

Can burn Liquid Fuels

• Ample heating value

• Atomized

• Clean

− Can’t burn Solid Fuels

Unless gases or liquids synthesized from solids like coal


7

Fuels for GE’s LM Aero Derivative gas turbines

Well defined fuel specifications for both fuel gases and liquid fuels are already established:

• MID-TD-0000-1, rev.2009 for gas fuels

• MID-TD-0000-2, rev.2010 for liquid fuels

Non-standard Fuels can be used in your LM Gas Turbine

GE can support your efforts to start using a Non-

standard Fuel


8


Non-standard Fuels


GE Aero non-standard fuel capabilities

†Contact GE for specific engine options and package configurations

P Design or experience DLE and SAC

Would quote for DLE, may require

requisition custom fuel system

LM2500

LM6000

LMS100

P P

P

P

P

P

P

P

P

P

P P

P

P

P Design or experience SAC

Would quote for SAC, may require

requisition custom fuel system P


10


Non-standard Gas Fuel


11

Fuels characterized by the following LHV and constituents:

• Modified Wobbe Index < 40 or > 60

• Low to med BTU fuels, LHV < ~800 BTU/SCF

• High BTU fuels, LHV > ~1200 BTU/SCF

What are non-standard gas fuels? • High H2 fuels > 5% by volume

• High CO, CO2, N2, C2+

Mo

dif

ied

Wo

bb

e In

de

x P

ara

me

ter

0 10,000 20,000 30,000 40,000 50,000 0

10

20

30

40

50

60

70

80

90

100

NG

N 2 , CO,

CO

Mo

dif

ied

Wo

bb

e In

de

x P

ara

me

ter

Heating value – Btu/lb – Btu/lb 0

0

10

20

30

40

50

60

70

80

90

100

H2

2

Refinery, process off gases • High H2, CO2, CO

LNG, associated flare gas • High C2+

LNG • High N2, CO2

COG, low BTU Syngas • High H2, CO2, CO

C2+

Increased C2+ LM6000

30 %

24 %

LM2500+G4

Latest fuel spec Sept ‘09

15 %

15 %

LM2500+G4 G

Increased inerts LM6000

MWI 40

MWI 40 35.8

See spec MID-TD-0000-1 for final determination on acceptable fuel usage

http://www.europavalve.com/images/oil-refinery-crop2.jpg


12


Applications of non-standard fuels

Low BTU syngas (landfill, biogas)


13

Low energy content gas solution

• Plant is designed to convert waste to obtain syngas

• One ton of the combustible waste derived syngas equals:

• 19,700 ft3 of methane

• 1100 lb of fuel oil

• 1650 lb of coal

• How to utilize this low energy (~4880 BTU/lb, MWI ~13), high H2 syngas for power generation?

• LM2500+G4 gas turbine selected

• Design modifications include

• Fuel system

• Increased nozzle capacity

• High fuel flow rate

• N2 purge system (high H2 syngas)

• Associated control system changes

The Challenge The Solution


14

Biogas case example

Gas Mixer

MWI <20

Bio Gas

From Digester

Mix Gas

MWI <40

Gas Analyzer

Gas Analyzer

Gas Analyzer

Pipeline Gas

MWI 40-60

Fuel Treatment

/ Drier

Gas Comp

Increased fuel pressure

requirements for DLEs

10000

20000

30000

40000

50000

60000

70000

0

200

400

600

800

1000

1200

20 30 40 50 60

Fue

l Flo

w (

pp

h)

Fue

l Su

pp

ly P

ress

ure

(p

sig)

Modified Wobbe Index

Pressure, psig

Fuel Flow, pph


15

Aero related high-H2 experience

Experience:

• Aero has experience in burning high-H2 fuels

• Gas composition and site specific needs may induce engine and package changes

Applications:

• Synthetic gases

• ‘Steel’ gases

• Refinery/process off gases

• Blends

LM2500, USA, 20% H2

LM2500, Brazil, 14% H2

LM5000, Germany, 50% H2

LM6000, Japan, 10% H2

LM2500, China, 65% H2

LM6000, USA, 33% H2

http://www.europavalve.com/images/oil-refinery-crop2.jpg


16


Applications of non-standard fuels Coke oven gas


17

Coke oven gas Medium BTU - Coking

• Coking temp: 1650-2000°F

• Material: Bituminous coal

• Main product: coke

• Application: steel production, power generation

COG composition (vol%):

H2 (55-65)

CH4 (24-28)

CO (6-8)

N2 (4-7)

CO2 (2-4)

C2+ (2-4) 1 ton coke ~220 m3 surplus COG

> 1 MT/ yr to power LM2500+

LHV ~420-500

BTU/SCF

MWI 31-34 Henan LiYuan Coal and Coking

Group Co., Ltd


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Potential contaminants (Tar, H2S, NH3,

Benzene and Naphthalene) affect the

engine, engine performance, emission,

and lowers maintenance intervals

Gas purification system, removes

contaminants from COG; allows for

power generation w/ performance and

maintenance intervals

Risk Concern

Constant flow and large volume of

fuel required

COG often has high levels (>50% vol)

of hydrogen; risk of ignition in a

confined volume

Solution

Fuel delivery sized to handle added gas

flow requirement

Inert purge system, which removes

possibility of a premature ignition

Class III certified electrical equipment

Heavy industrial environment with

particulates and other air

contaminants; alkalis in water

Proper design for air filtration and

water sampling regimen and cleaning

Fuel LHV

%Vol H2

Contaminants

Water and air

Coke oven gas – concerns and solutions


19

COG Compressor

ESP

GTCC output: 32.7 MW, Efficiency 47%gross, 43% net

COG power generation LM2500+/+G4 Combined Cycle

Water

HRSG

GEN 24.5 MW

Exhaust Gas

Coke oven gas

Coke Oven

15800 m3/h

Coke Oven Gas

De-Water/Tar

Steam

3 MW

Electric Motor

Steam Turbine and Generator

8.2 MW

LM2500

Gas turbine

Liquid

Fuel treatment system: Cleans contaminants and

brings fuel within spec

Specialized delivery: Updated fuel pumps, motors, valves and other hardware

Secondary fuel source: Alternate fuel for starting purposes

Inert purge system: Purge piping and manifold; mitigate risk of self-ignition (high H2)

Specialized gas turbine: LM2500+

and +G4 capable of burning COG, Med BTU gas fuel w/ high H2

NOx abatement: Water injection should be available when required to meet reduced emissions (39ppm)


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Flare gases


21

140-150 bcm flared gas annually

Source: World Bank - GGFR, NOAA (2006 - 2010), GE Energy Flare Gas Reduction white paper (2011)

Annual gas use of France and Germany combined

150 bcm equivalent to:

$9-20 billion per year in lost value

Annual emission from 77 million cars (1/3 of US fleet)

5% of global gas production

Flare gas - a global concern


22

Flare gas properties survey

• ~60 flare gas samples analyzed, 90% within Aero fuel specification

• Most outside of spec could be approved after engineering review

• Standard Modified Wobbe Index (MWI) range is 40-60 (avg LHV value 950 BTU/scf)

• Additional consideration for DLE: high hydrocarbon (C2+) limits

• 95% flare gas samples meet DLE configuration limit for higher hydrocarbons,

others could be approved pending specific C2+ components and volumes

Aero turbines can burn majority of flare

gases without engine modifications


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Aero applications for flare gas today Experience growing … • LM2500 power plant in S. America

• 16M ft3/day flare generates >40MW

• Operates with low BTU fuel

• >50K Hours reliable operations

• PGT16 in Nigeria • Associated gas gathering (AGG) system

• FG converted to LNG

• TM2500 in Nigeria • Compression station and

power generation

• FG converted to LNG via

distributed power

• Installed end 2009

GE Aero is ready to help put out flares


24



LNG


25

LNG fuel gases

• LNG production facilities required to

maintain tight control of LNG composition

– Separate Natural Gas liquids (primarily C2+, N2, CO2) from liquefaction stream

• LNG plants need gas turbines to be able

to handle high C2+, N2, CO2

• Aeroderivatives with SAC combustors can

burn NGL blends maximizing investment

recovery from the feed gas

NGL Composition


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For offshore facilities, topside equipment and construction costs are extremely sensitive to weight and space. GE's compact marine configuration provides the lowest weight and

smallest footprint of any standard gas turbine package in the 20 to 34 MW power segment.

Challenge: • LNG and offshore facility gas may

contain high inert (un-processed gas)

• Design a new fuel system capable of running medium BTU fuel with constraints on max supply pressure

Solution: • LM2500+G4 538 dual fuel

package

• New nozzles, fuel delivery systems and control modifications to meet modified Wobbe index 37 – 45

• Diesel as back up fuel

LM2500+G4 SAC FPSO Med BTU GT + 538 Package


27


Expanding Fuel Flex


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Why fuel flex? • Lower cost fuel alternatives = Customer

OPEX savings

• Step changes in capabilities enabled

through:

Technical innovations

Extensive testing

• Result - in the last three years our

customers have ordered 35 gas turbines

with some form of fuel flexibility features

• Expanding capabilities for:

Medium BTU fuels

High BTU fuels

Gas variability


29

Fuel flex testing to date High propane testing completed

LM2500+G4 DLE Q4’10

High N2 testing completed

LM2500+ DLE Q4’09

LM6000PD/PF Q3’10

LM6000PH Q1’11

LM6000PD Q4’12

High CO2 testing completed

LM2500+G4 SAC Q4’11

Test objectives

• Establish DLE capability limits – Combustion mode window sizes

– Emissions

– Acoustics

– Starting

• Demonstrate SAC reliable start and operation on low-BTU fuel


30

Features of mixing system

• LM2500+G4 Test 4Q 2014

Out with the old in with the new …

Schedule for 2013 Fuel-flex engine tests

• Permanent infrastructure for dynamic blending

NG and inert vol. fraction of max. 57.3% (MWI 20)

• Sized for LM2500 Base through LM6000PH fuel

flow rates and pressures

• WIM and GC integrated for fast fuel properties

measurement

• Performance entitlement tests for low-BTU

fuels :

− Low MWI limits down to 28

− True High MWI rate of change limits with

new solution, up to 48MWI units/min.

change

− Low MWI starts, load transients, drops

and accepts

2012 fuel-flex engine tests

2013 Fuel flex engine tests


31

Test setup schematic N2 system

• Mixing system PLC maintains set natural

gas : nitrogen mix ratio or rate of change

• Turbine fuel flow demand signal input to

mix system PLC; mix ratio maintained from

start up to base load

• Flare provides continuous flow when

engine not operating to maintain mix ratio

• Wobbe index meter for LHV and SG near

real time response; gas chromatograph

provides accurate gas composition analysis

Exhaust continuous monitor


32


Non-standard Liquid Fuels


33

What are the liquid fuel capabilities?

See spec MID-TD-0000-2 for final determination on acceptable fuel usage

BTU/lb

11,500 18,500 15,000 13,000 8,500 19,000 20,000 17,000

BTU/gal 56,000 76,000 96,000 106,000 116,000 126,000 136,000

Lower heating value (per density)

Lower heating value (per volume)

MJ/kg 25 43 35 30 20 45 50 40

MJ/L 16 21 27 30 32 35 38

Demonstrated


34

Biodiesel Ethanol Is it really a GT fuel?

Biodiesel blends up to 100% allowed per ASTM D6751 and EN14214 specs

ASTM D4806 for gasoline blends

Biodiesel Ethanol

LHV Lower (10% higher flow) Lower (60% higher flow)

Flash point Higher (start/ignition) Lower (start fuel req’d)

Lubricity Higher Lower (pump)

Solvent Higher (material compatibility) Little change

Stability Lower (logistics) No change

Contaminants Phosphorous, particulates Sodium

Fuel characteristics vs. #2 diesel …

Yes

Biodiesel and ethanol are GE Aero approved fuels

LM Biofuel applications


35

30%

32%

34%

36%

38%

40%

42%

23 32 41 50 59 68 77 86 95

24000

30000

36000

42000

48000

54000

60000

-5 0 5 10 15 20 25 30 35

Power, efficiency and emissions

Efficiency

Power (kW) oF

oC

LM6000-PC-NLW Water Injection for NOx control to 42ppm 4”/10”; 101.6/254mmH2O inlet/exhaust losses 328ft/100m above sea level; 60%RH LHV (Btu/lb): Diesel=18400; Biodiesel=16800; Bioethanol=11531

Diesel Biodiesel Ethanol

Biofuel Nox emission control


Petrobras ethanol demonstration

• LM6000PC conversion from gas only to dual fuel

• 1,000 hour demo, Q1 2010

• May operate on hydrous or anhydrous (hydrous for demo)

• Less water to control NOx than NG (~25% less) or distillate (~50% less)

• Liquid fuel valve design accommodates higher flow

• Alternate fuel recommended for starting and low power ops

• Estimate operation life equivalent to diesel

Ethanol storage tanks

Ethanol unloading

Turbine adapted for using ethanol

UTE-JUIZ DE FORA AFTER THE CONVERSION


37

• +12 x LM2500+ on cruise ships have ran on biodiesel

• 2 x LM6000 have run on biodiesel at a New York site

• 2 x LM1600 successfully tested on biodiesel

• 2 x LM6000 are now ethanol capable at Brazilian plant

Results – cleaner engine and lower emissions

37



38


Fuel Quality


39

Fuel Quality is important for all fuels

Gas fuels

Proper analysis

Basic conditioning

Dew point

Particulates

Siloxanes

Other

Liquid fuels

Proper analysis

Basic treatment

Particulates, asphaltenes

Trace metals

Bubble point

Other

Fuel quality monitoring is a continuous process

See spec MID-TD-0000-1 and MID-TD-0000-2 for detailed guidelines and requirements


40

Aero commercial marine product Incat Wave-Piercing, All-Aluminum, High-Speed, Ro-Pax, 99m Fast Ferry

The concept:

Replace FOUR 20-cylinder (48-ton) 9MW Liquid-Fuel reciprocating marine propulsion trains with

TWO (50-ton) Dual Fuel LM2500 SAC Turbine propulsion trains

Liquid fuel start/port maneuvering

LNG primary fuel high-speed transits

Capacity of 150 cars and 1000 passengers

Customer benefit:

• Tier-III level emissions where required

• Fuel savings using LNG vs HFOs

• 18-point gain in operational availability vs. recips

Project status:

• “Francisco” sea trials completed successfully

• First transfer to LNG from liquid May 27, ‘13

• First operation on LNG May 30, ‘13

• 58.1 knots reached using LNG fuel June 18, ‘13

• Left Tasmania July 15 arrived Buenos Aires Aug 2, ‘13

Offshore oil platform service ships opportunities

© 2013 General Electric Company


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HD5 Propane • “Consumer Grade" propane

• Most widely sold and distributed grade in the U.S. market

• Highest grade available and ordinarily sold to consumers in the U.S.

• Specified as suitable and recommended for engine fuel use

• was the original purpose of the HD5 grade propane specification

• HD5 spec propane consists of:

• Based on "allowable" contents

• Minimum of 90% propane

• Maximum of 5% propylene - propylene is used in the manufacture of plastics

• Other gases constitute the remainder (iso-butane, butane, methane, etc.)

• Can be -

• 99% propane and 1% propylene

• 95% propane and 5% propylene

• 90% propane, 5% propylene and 5% other gases


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HD5 Gas Properties Compound

Chemical

Formula

Methane CH4 0.000000 2.5 0.918935 1 0.364808

Propane C3H8 99 99.045280 90 90.930967 95 95.260382

i-Butane C4H10 0.000000 1.5 1.997594 1 1.321707

n-Butane C4H10 0.000000 1 1.331729 0.5 0.660854

Propylene C3H6 1 0.954720 5 4.820775 2.5 2.392249

100.000000 100.000000 100.000000 100.000000 100.000000 100.000000

250 degF 250 degF 250 degF

300 degF 300 degF 300 degF

Dew Point DP 194 degF 191 degF 194 degF

550 psia 550 psia 550 psia

Molecular Weight [g/mol] 44.0758 g/mol 43.6445 g/mol 43.9754 g/mol

0.0972 lb/mol 0.0962 lb/mol 0.0969 lb/mol

Lower Heating Value 19920 BTU/lb 19915 BTU/lb 19916 BTU/lb

Modified Wobbe Index at Tmin 72.1 BTU/SCF/R^0.5 71.7 BTU/SCF/R^0.5 72.0 BTU/SCF/R^0.5

Modified Wobbe Index at Tmax 69.7 BTU/SCF/R^0.5 69.3 BTU/SCF/R^0.5 69.6 BTU/SCF/R^0.5

1.5217 - 1.5068 - 1.5182 -

0.118905525 lb/SCF 0.117680878 lb/SCF 0.118616995 lb/SCF

4.711612226 lb/CF 4.584518824 lb/CF 4.676260322 lb/CF

3.919856483 lb/CF 3.842167614 lb/CF 3.899134530 lb/CF

1.0996675 - 1.1009024 - 1.0999498 -

1.0940923 - 1.0952875 - 1.0943706 -

1.0967968 - 1.0980116 - 1.0970771 -

0.04505606 BTU/lb/degF 0.04550131 BTU/lb/degF 0.04515890 BTU/lb/degF

HD5 Max Propane HD5 Max Propylene HD5 Ave Propylene

Composition

Mol %

Composition

Mass %

Composition

Mol %

Composition

Mass %

Composition

Mol %

Composition

Mass %

HD5 Max Propane HD5 Max Propylene HD5 Ave PropyleneFuel Gas Name

CompoundChemical

Formula

Heat Capacity Ratio K=Cp/Cv at Tmin

Heat Capacity Ratio K=Cp/Cv at Tmax

Heat Capacity Ratio K=Cp/Cv within (Tmin Tmax)

Fuel Gas Constant

Min. Fuel Gas Temperature Tmin

Max. Fuel Gas Temperature Tmax

Fuel Gas Pressure P

Molecular Weight

Specific Gravity

Density at Normal Conditions

Density at P and Tmin

Density at P and Tmax

PROPERTY

TOTAL


43

LPG as a back-up fuel for GE LM2500 site

• Wichita Falls Electric Co., a 3x1 LM2500 (75 MW) plant installed in Ely, TX in the late ‘80s.

• Primary fuel is natural gas blended with steam for NOx emissions control.

• Vaporized LPG, blended with compressed air to reduce MWI toward the NG value, was used as a back-up in a SAC (diffusion flame) LM2500.

• Four 30,000 gallon LPG tanks used to store Propane/Butane blend as a liquid, 72 hour back-up supply at load.

LPG/Air/Steam vaporizer/blender

30k gallon LPG storage tanks


44

Design considerations Fuel

• Heat to meet superheat requirements 20°F (11°C) at manifold inlet

• Butane or higher hydrocarbons drive dew point temperature higher

• Nozzle pressure ratio (PMan / PS3)

• Start on standard fuel, transfer to propane

• Start-run on propane-air mix with MWI 40 – 60

Technical scope

• Boost propane to pressure as a liquid, vaporize and superheat

• Fuel transfer design as required

• Review water injection for pressure and flow changes to meet NOx

• Review components (meters, valves etc.) check / replacement for handling

temperature of gas fuel

• Heat tracing and purge mechanism to deal with condensate

• CFD analysis, enclosure ventilation system to handle heavy fuel

• Gas detection / fire protection system for detecting leakage


45


Questions?


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Thanks!

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ge adgt fuel flexibility

Technology

cover page

gas fuels b liquid fuels

high h2 fuels

solid fuels

nonstandard gas fuel

btuscf high btu fuels

med btu fuels

gas fuels ample heating