19 th SYMPOSIUM ON INDUSTRIAL APPLICATIONS OF GAS TURBINES

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1 19 th SYMPOSIUM ON INDUSTRIAL APPLICATIONS OF GAS TURBINES Combined cycle opportunities for small gas turbines by Michael Lucente - Found Energy, An Aecon Company Kristen Cofrancesco - Pratt & Whitney Power Systems Riccardo Vescovo - Turboden Presented at the 19th Symposium on Industrial Application of Gas Turbines (IAGT) Banff, Alberta, Canada - October 17-19, 2011 The IAGT Committee shall not be responsible for statements or opinions advanced in technical papers or in symposium or meeting discussions.

2 Agenda Introduction Project Participants Plant Description Plant Construction Opportunities Beyond the Case Study Conclusions

3 Introduction Many small gas turbines are run simple cycle An opportunity for improved system efficiency However, at existing sites there is rarely a local use for the heat Until recently, the emphasis has been on recovering heat from large gas turbines Waste heat to power plants have been developed at natural gas compressor stations using the heat from gas turbines with a capacity 11 MW (15,000 HP)

4 TransGas Rosetown Project Natural gas compressor station in southwestern Saskatchewan Compressor driven by Solar Centaur Gas Turbine (4500 HP) Found Energy supplying an EPC turnkey 1MW power plant utilizing waste heat from the Solar Centaur GT

5 Major Project Participants TransGas Ltd Owners of waste heat source Found Energy Responsible for turn-key project Turboden Suppliers of core ORC technology Canonbie Contracting Ltd Responsible for plant construction

6 Project Participants: TransGas Ltd Natural gas transmission company in Saskatchewan Wholly owned subsidiary of SaskEnergy, a Saskatchewan Crown corporation Corporate goal to be net zero in electricity consumption

7 Project Participants: Found Energy Industrial EPC Equity & Project Financing Essential Components O&M Agreement ORC Unit 3rd Party or IST

8 Project Participants: Turboden European leader in ORC technology for the generation and cogeneration of heat and power More than 200 ORC plants operating in 23 countries worldwide

9 Project Participants: Canonbie Multi-discipline construction, fabrication, and maintenance services contractor Headquartered in Alberta Projects throughout Western Canada

10 Plant Systems The waste heat to power plant is composed of the following four systems: 1. The gas turbine exhaust system 2. The thermal oil circuit 3. The Organic Rankine Cycle (ORC) 4. The water cooling circuit

11 Process Flow Diagram

12 Turbine Exhaust

13 Thermal Oil System

14 Organic Rankine Cycle Process Description: 1. Liquid working fluid is pumped to higher pressure and sent through the regenerator to the evaporator 2. Hot thermal oil preheats and evaporates the pressurized working fluid 3. High-temperature, higher-pressure vapor expands through a turbine which spins an electrical generator 4. Lower-temperature, lower-pressure vapor exiting the turbine preheats the liquid working fluid in a regenerator 5. Vapor is condensed to a low-pressure liquid by transferring heat to the water cooling loop Step 3 Step 2 Step 4 Step 1 Step 5

15 Advantages of ORC Lower boiling point Fully automated plants Operate at lower system pressures than comparable steam systems. Higher molecular weights. Low speed turbines that increase the system reliability and efficiency. Dry fluids : Vapour always leaves the turbine in a supersaturated condition. Recover heat from vapour exiting turbine No risk of damaging turbine with liquid.

16 ORC Plant Layout

17 Water Cooling Circuit

18 Plant Performance Nominal 1 MW plant Cold Moderate Hot Ambient Ambient Ambient Ambient Temperature C Exhaust Gas Temperature C Exhaust Gas Flow kg/h Thermal Power Recovered kw ORC Gross Electrical Power kw

19 Construction Modular prefabricated design for all major components Reduced site costs Typical construction time of 6-8 months

20 Plant Site Layout

21 ORC Power vs Gas Turbine Power Notes: 1. Smallest PWPS/Turboden HR ORC Turbogenerator produces 600 kwe 2. Largest PWPS/Turboden HR ORC Turbogenerator produces 11,500 kwe RB211 RR FT8 PWPS SGT-700 Siemens UGT Zoyra LM2500 GE SGT-500 Siemens Titan 130 Solar SGT-200 Siemens Mars 100 Solar Centaur 40 Solar

22 ORC Power vs Recip Engine Power 12xMWMTCG2032V1616V32 4xWartsila 18V46 3xWartsila 18V46 2xWartsila 18V46 3xWartsila 18V32 1xWartsila 18V46 4xMAN 9L32/40 1xCAT CM43 1xMAN 18V48/60 1xWartsila 20V32 3xMWMTCG2032V1616V32 1xWartsila 16V32 1xMAN 18V32/40

23 Conclusion ORC plants are a viable means to use waste heat Even small gas turbines are potential candidates for a waste heat to power plant In North America, the natural gas industry is actively developing waste heat to power plants