Siemens Technology Improvements Enhance IGCC Plant Economics

Transcription

1 . Siemens Power Generation All Rights Reserved Siemens Technology Improvements Enhance IGCC Plant Economics Harry Morehead, Frank Hannemann, Siemens Power Generation Gasification Technologies 2005 San Francisco, CA

2 Agenda Experience Update Product Enhancements Technologies in the Pipeline Integrated Approach to Improving Economics Power Generation 2

3 Siemens Power Generation Product and Service Businesses Group Executive Management Power Generation Gas turbines and combinedcycle power plants Steam turbines and power plants Electrical generators Plant Diagnostics Operating Plant Service Klaus Voges, Ralf Guntermann, Norbert König, Randy Zwirn Industrial Applications Industrial size turbines and power plants Turbo compressors Oil and Gas Sector Service Wind Energy On shore and off shore renewable wind energy solutions Instrumentation & Controls Instrumentation and control systems IT solutions for power plant management Joint Venture Framatome Advanced Nuclear Power (Siemens stake 34%) Stationary Fuel Cells Voith Siemens Hydro (Siemens stake 35%) Regional Offices Worldwide Integrated global network for power generation Power Generation 3

4 Siemens Worldwide Global Experience and Capabilities Comprehensive Power Plant Design, Operating Experience Single-Point Responsibility for Complete Plant Long-Term Partnership with Constructors and Vendors World (GW) 535 USA, Canada, Mexico Central & South America 25 Western Europe 174 Steam Turbine Gas Turbine Africa & Middle East 55 Eastern Europe 8 China 15 Asia Pacific (w/o China) 72 Partnership Concept with Owner/Operator FY00 FY03 represent ~33% of U.S. fleet and ~20% of world s installed base Advanced Project Implementation Tools Plant Design with O&M In In Mind Over 110 Successful EPC Projects (~30 GW) // O&M Contracts (~17 GW) Power Generation 4

5 Experience on Syngas from Modern IGCC Plants Customer/Plant (Location) Hörde Steelworks (Dortmund, Germany) Electrical Output (net) Gas Turbine Main Features Start-up Blast-furnace-gas-fired, gas turbine as 1960/ 8 MW VM5 Handan Iron & Steel compressor drive 2000 (Handan, P.R. China) U. S. Steel Corp. (Chicago, USA) 20 MW CW201 Blast-furnace-gas-fired gas turbine 1960 STEAG/Kellermann First CC plant in the world with integrated 163 MW V93 (Lünen,Germany) LURGI coal gasification (hard coal) 1972 DOW Chemicals 208 MW 1) CC plant with integrated DOW coal 2 x W501D5 (Plaquemine, USA) gasification 1987 Nuon Power Buggenum CC plant with integrated SHELL coal ) 253 MW V94.2 (Buggenum, Netherlands) gasification (hard coal and biomass blend) 1994/95 HRL CC plant with integrated drying gasification 10 MW Typhoon (Morwell, Australia) process (lignite) 1996 Sydkraft First CC plant in the world with integrated 6MW Typhoon (Värnamo, Sweden) biomass gasification 1996 ELCOGAS CC plant with integrated PRENFLO coal ) 300 MW V94.3 (Puertollano, Spain) gasification (coal and petroleum coke blend) 1997/98 ISAB Energy CC plant with integrated TEXACO heavy-oil ) 521 MW 2 x V94.2K (Priolo Gargallo, Italy) gasification (asphalt) 1999 ELETTRA GLT (Servola, Italy) 180 MW V94.2K CC plant with steel-making recovery gas 2000 ARBRE (Eggborough, UK) 8 MW Typhoon CC plant with integrated biomass gasification 2002 EniPower CC plant with integrated SHELL heavy-oil 250 MW V94.2K (Sannazzaro, Italy) gasification ) 160 MW from syngas and 48 MW from natural gas; 2) Natural gas firing; 3) Oil firing 300,000+ Operating Hours Power Generation 5

6 Compressors, Instrumentation & Control Systems for IGCC Applications Customer/Plant (Location) DOW Chemicals (Plaquemine, USA) Nuon Power Buggenum (Buggenum, Netherlands) Global Energy/Wabash River (West Terre Haute, USA) Tampa Electric/Polk County (Mulberry, USA) ELCOGAS (Puertollano, Spain) NPRC/Negishi (Negishi/Japan) Siemens Scope Start-up ASU main air compressor 1987 ASU air compressor (for start-up) N 2 compressors, O 2 compressor ASU main air compressor O 2 compressor ASU main air compressor N 2 compressors, O 2 compressor IGCC plant Instrumentation & control system Claus gas compressor IGCC plant optimization and integration study ASU main air compressor N 2 /air compressors, O 2 compressor ) 1994/ ) 1997/ Air / N 2 / O 2 / Syngas Compressor Trains IGCC Plant Instrumentation and Control Systems Power Generation 6

7 Agenda Experience Update Product Enhancements Technologies in the Pipeline Integrated Approach to Improving Economics Power Generation 7

8 60 Hz Gas Turbines Available for IGCC Applications SGT6-3000E SGT6-5000F SGT6-6000G Gas Turbine IGCC Performance Estimates [ISO Conditions] (Preliminary Study) Gross GT Output, MW SGT6-5000F Natural Gas Syngas SGT6-6000G Natural Gas Syngas NOx, 15% O2 (w/o SCR) Diluents: Natural Gas Steam, Syngas Nitrogen Estimates based on SGT6-5000F with Syngas Combustion System, SGT6-5000F Emissions Verified in Higher Output From Proven Gas Turbine Technology Power Generation 8

9 Today s Fuel Flexible SGT6-5000F SGT6-5000F for IGCC Applications Based on proven standard product and fleet experience Siemens IGCC Experience Base Full Scale Test Facilities Lessons learned from prior and current IGCC Plants are the foundation for adaptations for IGCC Full scale testing forms the basis for new technology improvements 95% Fleet Availability Power Generation 9

10 SGT6-5000F Modifications for IGCC Applications Syngas Combustion System Syngas Fuel Supply / Purge Skid & Manifolds Diluent (N 2 or Steam) Injection Skid & Manifolds Extraction Air Skid & Manifolds Control System Modifications Enclosure Modifications Protection System Modifications Syngas manifold Power Generation 10

11 SGCC6-5000F 2X1 IGCC Power Block Reference Plant for 60 Hz Applications IGCC Power Block Design Based on: Syngas primary fuel with natural gas as backup fuel 2 x 1 turbine configuration 0-50 % air-side integration capable Integrated steam cycle Based on the SGT6-5000F and SCC6-5000F 2X1 Reference Plant Design Power Generation 11

12 Agenda Experience Update Product Enhancements Technologies in the Pipeline Integrated Approach to Improving Economics Power Generation 12

13 Burner Development for Syngases and Hydrogen-enriched Gases Operational Experience Fuel Oil (diffusion) Natural Gas (diffusion) Syngas Buggenum, Puertollano and ISAB Advanced syngas/hydrogen burner to be used in F-class Challenges: syngas/hydrogen highly reactive (flame speed, combustion temperature) risk of flash-back high volume flux Air Air Concept: DLN combustion for syngas / hydrogen rich fuels European R&D projects HEGSA High Efficient Gas Turbine Enhanced CO 2 Capture First design phase completed and high pressure combustion tests successfully performed Power Generation 13

14 Low Emission Combustion Ultra Low-NO x IGCC Combustion Technology DOE // Siemens Ultra Low NOx Combustion System for Fuel Flexible Gas Turbines Program Objectives < 2-3 ppm NOx w/o SCR Cost Effective and Retrofitable Fuel Flexible Schedule Syngas, Natural Gas, H 2 Currently in Phase 2 Program Complete in 2007 Goals for Phase 2 Select Final Basket Design for Syngas/Natural Gas Select Final Coating for Syngas/Natural Gas Perform Verification Testing at Module and Subscale Level Subscale Verification for Hydrogen Fuel Final Design for Fuel Flexible STG6-5000F Basket NO x Emissions Catalytic Elements Diffusion RQL Lean Premix Combustor Technologies Syngas NG Only Fuel Flexible Catalytic Catalytic Module Catalytic Basket Power Generation 14

15 Enabling Turbine Technologies for High-Hydrogen Fuels DOE // Siemens Advanced Hydrogen Turbine for FutureGen Program Objectives (2015) Advanced GT with H2 and Syngas Operating Capability 3-5% Points Plant Efficiency Improvement from Gas Turbine Plant Capital Cost < 1000 $/kw Schedule Program Start: Oct 1, 2005 Phase 1: Two years Phase 2: Four years Phase 3: TBD Goals for Phase 1 Conceptual Design R&D Implementation Plan Power Generation 15

16 Agenda Experience Update Product Enhancements Technologies in the Pipeline Integrated Approach to Improving Economics Power Generation 16

17 Accelerating Market Acceptance of IGCC Reducing IGCC Capital Cost Standardized IGCC Reference Plant Maximize use of gasifier and gas turbine output Improved interfaces Optimized plant integration between gasifier island and combined cycle Reduction of contingencies Cost Reduction Target $ /kW Technology Advancements Technologies that lowers O&M and eliminates need for spare gasifier Technologies that have the potential for 50% cost reduction of gas clean up system Technologies that improve efficiency and lower capital cost Competitive Level with Other Coal Options Power Generation 17

18 Accelerating Market Acceptance of IGCC Technology is not Enough Strong Partnership Provides Single Source for IGCC Plants Proposed for Southern IL Clean Energy Center Technology Steelhead Energy Project EPC Consortium Turnkey EPC Product Joint & Several Guarantees Siemens Technology Helps Improve IGCC Performance and Economics but It is the Business Structure of the Project that Makes it Happen! Power Generation 18

19 Questions? IGCC Power Block for 60 Hz Applications 50 and 60 Hz Gas Turbine Generators with Syngas / Natural Gas (or Oil) Capability Steam Turbine Generators IGCC Plant Instrumentation and Controls IGCC Compression Solutions IGCC Power Block O&M Services Puertollano at Night Power Generation 19