integrated gasification combined cycle system ......2 pg6581 (b) 42.10 2682 32.1 145.6 544 3 pg6591...

BRIGHTENING LIVES…..POWERING PROGRESS………BRIGHTENING LIVES…..POWERING PROGRESS………

ENHANCING CAPACITY ENHANCING CAPACITY –– EMPOWERING NATION EMPOWERING NATION 1111THTH DECEMBER 2007DECEMBER 2007

INTEGRATED GASIFICATION COMBINED

CYCLE SYSTEM (IGCC) AND

COMBINED CYCLE TECHNOLOGY

G.S. BINDRA

GENERAL MANAGER – ENGG

BHEL-PEM, NOIDA



HISTORICAL DEVELOPMENT OF POWER PLANTS



SOURCE: INDIAN POWER DAYS – 2004 - SIEMENS



COMBINED CYCLE TECHNOLOGY



Gas Turbine



ENTROPY

• EFFICIENCY INCREASES BY 1 POINT FOR EVERY 600 C OF T3

• COMBINED CYCLE COMBINES BEST OF :– BRAYTON CYCLE VIZ: HIGH TEMP HEAT ADDITION (~14000 C)– RANKINE CYCLE VIZ: LOW TEMP HEAT REJECTION (~45 0C)

• EXPECTED COMBINED CYCLE EFFICIENCY = 50% TO 60%

1400 0 C

16000 C

TEMPERATURE

Steam Cycle

Gas Cycle

Q in

A

BC

D

E1

2

3

4

00 C

450 C

3000 C

6000C

13000 C

Q out



ADVANTAGES OF COMBINED CYCLE PLANTS

• HIGH EFFICIENCY

• LOW COOLING WATER REQUIREMENT

• FAST START

• LOW ENVIRONMENT POLLUTION

• LOW INSTALLATION COSTS



CONTEMPORARY CLASS GAS TURBINES

536.7530.734.72476168.00SGT5-2000ESIEMENS3

542.8418.233.82545126.10PG9171 (E)GE/ BHEL2

M701

GT 13 E2

V94.2

510562.936.92330179.90ALSTOM4

542.2

540.0

EXHAUST TEMP.

(C)

440.934.82472144.09MHI5

513.534.42500157.00BHEL1

EXHAUST FLOW

(KG/SEC)

EFFICIENCY%

HEAT RATE(KCAL/KWHR)

ISO RATING

(MW)

MODELS. NO.

SOURCE: GTW – 2007 PERFORMANCE SPECS



ADVANCE CLASS GAS TURBINES

M701G

M701F

GT 26

PG9371 (FB)

PG9351 (FA)

SGT5-4000F

--37.92272279.2GE/ BHEL3

600.6649.538.22220278.3MHI5

587.2

615.0

602.2

577.2

EXHAUST TEMP.

(C)

737.139.52175334.0MHI6

639.639.12196289.139ALSTOM4

640.936.92331255.6GE/ BHEL2

689.439.52177286.6SIEMENS1

EXHAUST FLOW

(KG/SEC)

EFFICIENCY%


ISO RATING

(MW)

MODELS. NO.




CONTEMPORARY CCPP (350 - 450 MW RANGE)

MPCP2 (M701)

KA13E2-2

SCC5-2000E 2X1

CC 2.94.2

S209E

CC 209EA

51.71663467.5BHEL3

53.01621.6507.4ALSTOM5

51.6

52.5

52.7

51.7

NET PLANTEFFICIENCY

%

1666426.6MHI6

1637505.0SIEMENS4

1633391.4GE2

1663384.0BHEL1


NET PLANT OUTPUT

(MW)

MODELS.NO.




ADVANCE CLASS CCPP (350 - 450 MW RANGE)

58.01482412.9S109FBGE3

MPCP1 (M701G)

MPCP1 (M701F)

KA26-1Single Shaft

SCC5-4000F Single Shaft

S109FA

CC 109FA

58.21476416.0SIEMENS4

59.01458416.4MHI6

59.3

58.3

56.7

55.4

NET PLANTEFFICIENCY

%

1450498.0MHI7

1474424.0ALSTOM5

1517390.8GE3

1553383.6BHEL1


NET PLANT OUTPUT

(MW)

MODELS.NO.




ADVANCE CLASS CCPP (700 MW RANGE)

59.51445999.4MPCP2 (M701G)MHI7

MPCP2 (M701F)

2.KA26-1

S209FB

S209FA

CC209FA

SCC5-4000F 2X1

57.11507786.9GE3

59.01458857.7ALSTOM5

59.2

58.0

55.7

58.2

NET PLANT EFFICIENCY

%

1453835.6MHI6

1483825.4GE4

1543772.0BHEL2

1477832.0SIEMENS1


NET PLANT OUTPUT

(MW)

MODELS.NO.




GLOBAL TRENDS• HIGHER GT RATINGS

INCREASE IN TURBINE INLET TEMPERATURES

STEAM COOLED GAS TURBINE COMPONENTS

HIGH TEMP. TOLERANT COATINGS

DIRECTIONALY SOLIDIFIED CAST BLADES

• CLEAN LOW NOx (CLN) TECHNOLOGY

• ONCE THROUGH HRSGs

• STEAM TURBINES

ADVANCE STEAM PARAMETERS

DEAERATING CONDENSER



PLANT DESIGN TRENDS

• LARGE HIGH EFFICIENCY CCPPs

• SINGLE SHAFT MACHINES

• NO BYPASS STACK

• LOW MOUNTING ARRANGEMENTS

• FAST START-UP

• 3-D ENGINEERING



TRENDS IN CCPP EFFICIENCY



DETAILS OF 9H COMBINED CYCLE PLANT IN JAPAN

JULY 2008:COMMISSIONING DATE

YET TO START:OPERATION

3 X (1+1+1):ONFIGURATION

:

:

:

:

60%CCPP EFFICIENCY

TOSHIBASTEAM TURBINE

TWO FROM TOSHIBA/ IHI

ONE FROM HITACHI

HRSG

3 NOS. MS9001H (GE POWER SYSTEMS)

GAS TURBINE

SOURCE: DIESEL & GAS TURBINE WORLD MAY-2007



SIEMENS H CLASS CCPP

• JOINTLY DEVELOPED BY SIEMENS & E.On ENERGIE AG

• SITE - IRCHING, BAVARIA

• GT MODULE – SGT5-8000H

• HRSG – VERTICAL TUBE BENSON HRSG

• CCPP OUTPUT – 530 MW

• THERMAL EFFICIENCY – 60%

• PROTOTYPE – 2007

• FIRST COMMERCIAL OPERATION - 2011

SOURCE: MPS, NOV 2005



FUTURE TRENDS

• COMBUSTION TEMPERATURE = 17000C

• CC THERMAL EFFICIENCY (LHV) = 62-65%

APPROACH:

NEW MATERIALS

INNOVATIVE COOLING TECHNOLOGIES

AERODYNAMIC TECHNOLOGIES

LOW NOx COMBUSTION TECHNOLOGIES



FUTURE TRENDS (CONTD.)



INDIAN PERSPECTIVE



CCPP DEVELOPMENTS IN INDIA

• SIXTIES & SEVENTIES

OPEN CYCLE GAS TURBINE PLANTS PLANNED IN SIXTIES &

SEVENTIES

PLANTS PREDOMINANTLY LOCATED IN NORTH-EASTERN

REGION DUE TO CHEAP NATURAL GAS AVAILABILITY IN

ABUNDANCE

FIRST OPEN CYCLE PLANT INSTALLED BY ASSAM STATE

ELECTRICITY BOARD IN NAMRUP IN MID SIXTIES AS A BASE

LOAD STATION

MORE GAS TURBINE PLANTS INSTALLED AS PEAKING

STATIONS TO TAKE CARE OF ACUTE POWER SHORTAGE



CCPP DEVELOPMENTS IN INDIA (CONTD.)

• NINETIES

COLLABORATIONS AGREEMENT OF BHEL FOR MANUFACTURE OF

LARGE SIZE GAS TURBINES WITH M/S. SIEMENS, GERMANY 1990

MAJOR NTPC PROJECTS COMMISSIONED IN NINETIES

KAWAS

DADRI

GANDHAR

KAYAMKULAM

FARIDABAD



BHEL RANGE OF GAS TURBINES

487.2122.528.5302126.30PG5371 (PA)1

544145.632.1268242.10PG6581 (B)2

574117.036.3237942.30PG6591 (C)3

605210.035.0246175.90PG6111 (FA)4

MODEL EXHAUST TEMP.

(C)

EXHAUST FLOW

(KG/SEC)

EFFICIENCY%


ISO RATING

(MW)

S. NO.



BHEL RANGE OF GAS TURBINES

542.8418.233.82545126.10PG9171 (E)5

540.0513.534.42500157.00V94.26

602.2640.936.92331255.6PG9351 (FA)7

627636.837.92272279.2PG9371 (FB)8

MODEL EXHAUST TEMP.

(C)

EXHAUST FLOW

(KG/SEC)

EFFICIENCY%


ISO RATING

(MW)

S. NO.



54.1159162.70CC106C6

49.81726130.70CC206B5

41.7206138.50CC 105P1

CC106B

CC305P

CC205P

MODEL

42.32034117.203

49.0

42.1

NET PLANTEFFICIENCY

%

175464.304

204477.802


NET PLANT OUTPUT

(MW)

S.NO.

BHEL RANGE OF CCPP



52.01653577.00CC309E12

51.71663384.00CC209E11

54.41581126.20CC206C7

CC109E

CC206FA

CC106FA

MODEL

54.41583234.809

51.4

54.2

NET PLANTEFFICIENCY

%

1673109.7010

1588117.008


NET PLANT OUTPUT

(MW)

S.NO.

BHEL RANGE OF CCPP



55.71543772.00CC209FA17

51.51671232.50CC1.94213

CC109FA

CC3.942

CC2.942

MODEL

51.71663701.0015

55.4

51.7

NET PLANTEFFICIENCY

%

1553383.6016

1663467.5014


NET PLANT OUTPUT

(MW)

S.NO.

BHEL RANGE OF CCPP



PERFORMANCE OF 3x109FX

SR. NO.

PARAMETER UNIT VALUE

1 GT OUTPUT* MW 3x252.7

2 ST OUTPUT* MW 3x139.3

3 CCPP OUTPUT (3x109FX) MW 1176.0

4 CCPP HEAT RATE KCAL/KWH 1498

5 CCPP EFFICIENCY % 57.4

*AMB. TEMP. 32 DEG C, RH 60%, SEA LEVEL & CW TEMP. 33 DEG C



BHEL’s PREPOSITION OF 309FX CONFIGURATION

• CCPP WITH MULTIPLE GAS TURBINES AND SINGLESTEAM TURBINE HAS BETTER PERFORMANCE THANMULTIPLE CCPP MODULES

• SPACE REQUIREMENTS OF SINGLE MODULE CCPPARE MUCH LOWER THAN MULTI-MODULE CCPP

• 1x309FX CONFIGURATION FOR COMBINED CYCLE ISTECHNO-ECONOMICALLY BETTER OPTION COMPAREDTO 3x109FX CONFIGURATION



COMPARATIVE PERFORMANCE1x309FX vs 3x109FX

97.5

98

98.5

99

99.5

100

100.5

101

101.5

102

102.5

GT Output ST Output CCPPOutput

Heat Rate Efficiency

Series1Series23x109FX

1x309FX



ENERGY SECURITY : A CRITICAL ISSUE



Variation in fuel prices over the years

SOURCE: WORLD ENERGY COUNCIL 2007



ENERGY SECURITY OBJECTIVES

- AVAILABILITY OF PRIMARY ENERGY AT AFFORDABLE

PRICE

- REDUCING ENERGY REQUIREMENT

- INCREASE IN ENERGY USE EFFICIENCY



WORLD ENERGY SCENARIO



GAS RESERVES: WORLD & INDIA

0.00

10.00

20.00

30.00

40.00

50.00

60.00

70.00

80.00

TotalNorth

America

Total S.& Cent.America

TotalEurope &Eurasia

TotalMiddleEast

TotalAfrica

TotalAsia

Pacific

India

RES

ERV

E(T

RIL

ION

CU

BIC

ME

TER

S)



COAL RESERVES : WORLD & INDIA

0

50000

100000

150000

200000

250000

300000

350000

TotalNorth

America

Total S.& Cent.America


TotalAfrica &MiddleEast

TotalAsia

Pacific

India

RESE

RVE

(MIL

LIO

N TO

E)



COAL RESERVES : WORLD & INDIA

0

50

100

150

200

250

300

Total NorthAmerica

Total S. &Cent.

America


TotalAfrica &MiddleEast

Total AsiaPacific

India

R/P

RATI

O



KEY FUEL



KEY INFERENCES

• COAL IS THERE TO STAY

• ISSUES RELATED TO COAL FOR EFFICIENT ELECTRICITY GENERATION NEEDS TO BE ADDRESSED

•ISSUES RELATED TO COAL FOR POLLUTION FREE ELECTRICITY GENERATION NEEDS TO BE ADDRESSED

• EMPHASIS ON CLEAN COAL TECHNOLOGIES



IGCC : FUTURE OF POWER THROUGH COAL

• POWER GENERATION THROUGH INTEGRATED GASIFICATION COMBINED CYCLE

1. EFFICEINT

2. POLLUTION FREE

3. COST EFFECTIVE



INTEGRATED GASIFICATION COMBINED CYCLE

• IGCC COMPRISES TWO MAIN BLOCKS

1. GASIFICATION ISLAND

- GASIFICATION SYSTEM

- SYNGAS CLEAN UP SYSTEM

2. POWER ISLAND

- GAS TURBINE

- HRSG

- STEAM TURBINE



SCHEMATIC OF IGCC



CONTEMPORARY IGCC PLANTS

260

320

350

260

253

OUTPUT (MW)

1996GE7FATAMPA ELECTRIC, USA

1998SIEMENSV94.3AELCOGAS, SPAIN

1996GE9ESUV-VERSOVA, CZECH

1995GE7FAPSI WABASH, USA

1994SIEMENSV94.2NUON (DEMKOLEC), NETHERLANDS

YEARMAKEGT MODELPROJECT



CONTEMPORARY IGCC PLANTS

220

350

510

240

OUTPUT (MW)

2007*MHIM701DANAKOSO, JAPAN

2004GEM701FNIPPON PETROLIUM, JAPAN

1999SIEMENSV94.2KISAB ENERGY, ITALY

2000GE6FAVALERO, USA

YEARMAKEGT MODELPROJECT

* SCHEDULED



ELCOGAS 300 MW COAL BASED IGCC



NAKOSO 250 MW DEMO PLANT



SOURCE: NETL PRESENTATION



FUTURE IGCC

2011800UKProgressive Energy

Post-2012900UKPowerfuel

Post-2012450UKE.ON

2009250ChinaGreenGen

201050AustraliaZeroGen

EXPECTED YEAR OF START-UP

CAPACITYLOCATIONPROJECT

SOURCE: WORLD ENERGY COUNCIL



FUTURE IGCC

2011500USACarson Project

2012275USAFutureGen

2014400-450GermanyRWE

EXPECTED YEAR OF START-UP

CAPACITYLOCATIONPROJECT

SOURCE: WORLD ENERGY COUNCIL



FUTUREGEN PLANT

FutureGen is an initiative to build the world's first integrated sequestration and hydrogen production research power plant.

Project is intended to create the world's first zero-emissions fossil fuel plant. When operational, the prototype will be the cleanest fossil fuel fired power plant in the world.

The project will require 10 years to complete and will be led by the FutureGen Industrial Alliance, Inc., a non-profit industrial consortium representing the coal and power industries



FUTUREGEN PLANT – THE ALLIANCE

•American Electric Power

•Southern Company

•CONSOL Energy, Inc.

•Rio Tinto Energy America (RTEA)

•Peabody Energy

•E.ON U.S.

•PPL Corporation

•BHP Billiton

•Foundation Coal Corp.

•China Huaneng Group

•Anglo American

•Xstrata Coal

PROPOSED SITES :

• Mattoon, Illinois

• Tuscola, Illinois

• Heart of Brazos near Jewett, Texas

• Odessa, Texas.



A LOOK OF FUTURE IGCC



IGCC IN BHEL



• 6.2 MW IGCC PILOT PLANT AT ITS TRICHY COMPLEX.

• TECHNICAL FEASIBILITY OF UPGRADING THE 6.2 MW COMBINED CYCLE DEMONSTRATION PROJECT OF BHEL TO ~100 MW HAD BEEN ESTABLISHED

• PRELIMINARY ASSESSMENT MADE FOR 400 MW IGCC PLANT

• PLAN TO SET UP 125 MW IGCC DEMONSTRATION PLANT

IGCC POWER GENERATION -DEVELOPMENT IN BHEL



PFBG SCALE - UP



Clean

ACID FEED & MAKEUP

TO ETP

Gasifier

To HRSG

Gas

Gas Turbine

GT

LP HP From HRBBottom ash

Extract Air

To DA LP HP

Gland System Condenser

TO ASM

makeup blowdown

Air SB : Startup Burnar Comp : CompressorABC : Air Booster Compressor HRSG : Heat Recovery steam GeneratorSuC : Supplementary Compressor GSC : Gas Booster CompressorAPH : Air Pre Heater CC : Combustion ChamberFWH : Feed Water Heater HRB : Heat Recovery BolierASM : Air steam Mixture LPH : Low Pressure (steam) heaterFT : Flash Tank LP,HP : Low,High pressure respectively

cooling tower

C C

Clean

HeaterTO ETP

GSC

FROM ETP MAKEUP

ASM To LPH

FT

Gasifier

Purging

From LP

DA

APH

SuC

Ash disposal

Ash disposal

LDO

From ST

FWH

LPH

To stack H R S G

Cooling Tower

Fly Ash Removal and ash cooling system

SB

Turbine

Steam Turbine

Comp~

~

ABC SuC

GasAirSteamWaterAsh

PPP

P

Scrubbing system

CyclonesSyngas coolers

Coal125 MW IGCC SCHEME



To HRSG

HRSG

Fr-9Fa

261.5 MW

214.1 MW

CW inCW out

GHP IP LP

PIGCC = 475.6

QIN = 1071.7MW

EFFY = 44.39%

RHStack

SH

HRB2 WGCS2 GT GG2 C Y2

Ash Disposal System

Coa

l Sto

rage

& C

oal H

andl

ing

Plan

t

400 MW IGCC SCHEME



THANK YOUTHANK YOU

http://www.bhel.com

integrated gasification combined cycle system ......2 pg6581 (b) 42.10 2682 32.1 145.6 544 3 pg6591...

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