World Energy Congress, Istanbul, Turkey, October 09-13, 2016

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1 World Energy Congress, Istanbul, Turkey, October 09-13, 2016 Off to new frontiers: Latest Gas Turbine Power Plant technology drives most environmental friendly, resource saving, affordable and reliable power generation Lothar Balling, Siemens AG, Power & Gas, Germany Gero Meinecke, Siemens AG, Power & Gas, Germany Zafer Gürsoy, Siemens AG, Power & Gas, Turkey Copyright Siemens AG, All rights reserved.

2 Abstract This paper shows that combined-cycle power plants driven by advanced H-class GT technology have proven to explore new terrain and to open frontiers in terms of wide-ranged and diverse market and customer requirements. Highest power output, power density and efficiency, enhanced operational flexibility and grid support abilities, and advanced heat extraction solutions, as well as overall improved plant profitability and return on invest make them the power plant solution of choice for different power generation markets worldwide. The recent projects in Germany and Egypt have shown that the improved plant performance and abilities combined with comprehensive plant solution optimization and executional excellence will enable customers to successfully implement such different power plant configurations as highly flexible combined heat and power plants with world record efficiency and fuel utilization factors or, for example, large-scale base-load configurations with highest power density and optimized cost of electricity. In any case, customers can expect to achieve a real, quantifiable added value through optimized generation costs and at the same time set new standards in terms of environmental friendliness and resource conservation. This makes advanced H-class gas turbine combined cycle power plants the ideal solutions to support further growth of renewable power generation worldwide. Keywords: combined-cycle power plants, gas turbine, H-class, advanced technology, operational flexibility, profitability, sustainability, affordability, reliability, renewables Copyright Siemens AG All rights reserved. 2

3 1. LATEST TECHNOLOGY COMBINED-CYCLE POWER PLANTS: A GLOBAL SUCCESS STORY Power generation markets around the world are facing constant change and the speed of change and market diversification has also been rapidly increasing in recent years. In some regional markets, e.g. in Europe, fossil fired and especially gas fired power generation is under pressure from the massive growth of subsidized renewable power generation and declining electricity feed-in prices. At the same time, regulators, grid operators and utilities are scrambling for generation solutions to cover residual load and provide backup for fluctuating renewable infeed and to increase fuel utilization rates to reduce fuel consumption and CO 2 emissions. In other regions, e.g. in Asia, Middle East and Northern & Central Africa, national economies and along with it local power generation industries are still growing. Here market players face the challenge to quickly build up a sustainable power generation landscape, often within limited national investment budgets and to satisfy an ever growing electricity demand triggered by population and economic growth, industrialization and urbanization. In this dynamic and diverse market environment, combined-cycle power plants (CCPP) driven by advanced H-class gas turbine technology have gained significant market share over the last years and have firmly established themselves globally as advanced technology carriers and enable successful power plant projects in a wide range of applications and plant configurations. The gas turbine of the Ulrich Hartmann power plant unit in Irsching, Germany was the first of its kind to be installed anywhere in the world by Siemens, establishing a new advanced gas turbine technology and performance class with world records for efficiency and power density in It had already undergone extensive testing as a prototype prior to entering commercial operation, producing excellent results. Siemens has since sold about 80 H-Class turbines, of which more than 20 are in commercial operation since Other OEMs are now following this advanced technology path. The characteristics and value drivers of these advanced combined-cycle power plants are: Higher power output Significantly improved fuel efficiency Reduced fuel consumption Reduced CO 2 and other emissions Overall improved conservation of natural resources Enhanced operational flexibility Improved integration of district heating and steam extraction applications Advanced grid support abilities Better economy of scale and increased power density Copyright Siemens AG All rights reserved. 3

4 In the following chapters we would like to discuss two fundamentally different power generation markets as examples: Germany and Egypt. We will show how advanced combined-cycle power plants can be adapted to support demands and customer needs in these very diverse market environments and to drive successful power plant projects, which provide maximized customer value to their owners and operators. 2. FOCUS MARKET GERMANY Looking at Germany, we do see a power generation market, which reached saturation many years ago and where electricity demand is expected to decline in mid- and long-term due to increasing efficiency on the consumption side in industrial, commercial and residential sectors. At the same time renewable share in power generation is continuously growing, achieving already > 25% in 2015, and is expected to contribute more than 55% of total power production in Hard coal Gas Oil Others Wind Biomass Nuclear Renewables Solar Water Waste Lignite preliminary renewable part Fig. 1 Power generation in Germany 2014, 625 TWh in total Source: German Federal Ministry for Economic Affairs and Energy (BMWi) This development was triggered by the energy change policy of the German Federal Government. Renewables are not only expected to fill the production gap of nuclear power plants, which will be shut down step by step by 2022, but are today already displacing fossil fired power generation via low electricity production cost. Copyright Siemens AG All rights reserved. 4

5 Fig. 2 Power plant structure in the Reference Forecast and Trend Scenario by energy source, in GW. Source: German Federal Ministry for Economic Affairs and Energy (BMWi) According to the reference forecast and most likely scenario, installed generation capacity of German power plants is expected to rise at a low although steady rate due to further expansion of solar and wind power. At the same time, generation from coal-fired plants is going to be reduced continuously by phasing out old, inefficient generation. The speed of decrease mainly depends on further political decision and on the value of CO 2. This will most probably influence the growth of gas fired power generation in large, medium or small scale beyond 2020 with the goal to cover residual load and to provide back-up capacity for the fluctuating and not fully predictable renewable power generation. High ramps High power output Fig. 3 Challenging energy market in Germany: February 2016 Source: Fraunhofer ISE, last update: :14 Copyright Siemens AG All rights reserved. 5

6 The figure above shows the volatile and in part unpredictable nature of renewable power infeed. In the selected time period in February 2016 everything was possible between 0 and 40 GW productive capacity, about 50% of the installed renewable capacity. This means that fossil fired power plants need to cover the resulting residual load between demand and renewable infeed and also need to function as backup for unforeseen events like clouds or calms and renewable generation prediction errors. These situations call for fast starting, highly flexible power plants, which are able to load follow the changing residual load curve rapidly and which are large enough to provide the necessary generation capacities with high efficiency, highest power density and lowest CO 2 footprint. Advanced gas turbine technology CCPPs are the ideal partners for renewables to do this job H-class technology is the key to successful cogeneration projects A major application for gas turbine based power plants in Germany is combined heat and power (CHP) projects also termed cogeneration. The importance of CHP plants for the German power generation market is highlighted by the current market forecast that 2 out of 3 new built large combined-cycle power plants are expected to be combined heat and power configurations in the next years. In a CHP plant a part of the steam is extracted at suitable steam conditions and used as process steam, e.g. for industrial or chemical processes or for district heating. Although electricity production is going down a little bit in a CHP plant, because steam flow through the steam turbine is reduced, the overall fuel utilization rate of a CHP plant considering electricity and heat production is considerably higher compared to conventional power plants in condensing mode. With electrical efficiency higher than 61% and an overall fuel utilization efficiency in cogeneration of up to 85%, the carbon footprint of a modern H- class combined-heat and power plant with an output of 600MW will always have a markedly lower footprint, higher electrical efficiency and lower emissions compared to a highly distributed generation setup. Initial power infeed to compensate for grid fluctuations is also available within five minutes after startup command when the gas turbine synchronizes with the grid. The rotating mass of the large scale unit alone is an essential factor to grid stability. The inertia of the rotor of a 400-ton gas turbine combined with that of a coupled steam turbine and generator at 3,000 revolutions per minute dampens frequency fluctuations in the system. Combined heat and power generation provides further leverage for optimizing fossil fuel utilization and thereby reducing emissions. Many independent organizations such as the International Energy Agency (IEA) advocate cogeneration, and Germany's Federal Government would also like to see about one quarter of net controllable power generation in Germany coupled with heat production by Germany's amended Combined Heat and Power Act of 2016 now supports cogeneration plants with outputs exceeding 2MW. This applies up to a plant's 30,000th hour of full-load operation. The change from a maximum time period for subsidization to the number of operating hours takes into Copyright Siemens AG All rights reserved. 6

7 account the reduced operating times of combined-cycle power plants in their new role, thereby providing additional incentives for investment Showcase CHP: the Fortuna combined-cycle unit at Düsseldorf s Lausward Power Station The new combined heat and power plant Fortuna developed by Stadtwerke Düsseldorf and executed in cooperation with Siemens at Lausward Power Station in Düsseldorf's inland harbor is a cutting edge combined-cycle power plant with performances far exceeding those customarily achieved by power generating units of this type. By using innovative technologies, state-of-the-art engineering and the pooled expertise for optimum power plant solutions, the project partners have ensured that environmentally friendly electric power and district heat can be generated most economically for a low-carbon future under the new CHP scheme and in doing so have set three new world records. Highest electrical power generating density The centerpiece of the power plant is a single Siemens model SGT5-8000H gas turbine. Together with the downstream steam turbine of Siemens SST series, these combined cycles deliver 603.8MW of net electrical generating capacity out of the single generator in between a level unmatched by any other single unit combined-cycle plant in the world. Highest efficiency Fortuna's 61.5% proven electrical net efficiency exceeds even the previous world record of 60.75% set by the Ulrich Hartmann combined-cycle unit at Irsching Power Station in southern Germany. A triple-pressure Benson steam generator that produces steam to temperatures of up to 600 C at 170 bar and further innovations in the cycle makes this high electric efficiency rating possible. Best use of waste heat To supply the city of Düsseldorf with district heat, steam is extracted from three different steam turbine sections in volumes of up to 300MW of thermal energy in combinedcycle operation the most thermal energy extracted from a single power plant unit anywhere in the world. The plant's high electrical efficiency combined with its efficient use of heat generated in the power production process increases fuel efficiency of the natural gas in this case to around 85%. The implementation of the new high-efficiency combined-cycle power plant in Düsseldorf presents the solution to the task of substantially expanding the city's network for environmentally friendly and convenient district heating. Copyright Siemens AG All rights reserved. 7

8 Fortuna Düsseldorf SCC5-8000H 1S Multi Purpose Building incl. District Heating Steam Turbine: SST Generator: SGen5-3000W Electrical generating capacity MW el net Heating Condensers Steam Extraction Efficiency Gas turbine Generator District heat extraction Overall fuel efficiency 61.5% net SGT5-8000H SST Steam turbine SGen5-3000W 300 MW th approx. 85% District Heating Pipelines Transformers Fig. 4 Key facts: Fortuna Düsseldorf CHP power plant Gas Turbine: SGT5-8000H Architectual Highlight (City Window to Center of Duesseldorf) HRSG: Benson TM 3Pr/RH 600 C/170 bar The project for "Expanding the district heating grid on the west bank of the Rhine River at Düsseldorf" kicked off already in October 2011 by installing the piping network in the city's districts of Heerdt and Lörick where one of the most modern office building complexes in Germany has been built, in terms of efficiency and environmental compatibility and further expansions are to follow. Infrastructure and spatial conditions at the power plant site also enable the economical erection of a large heat storage facility that will significantly increase the use of thermal energy produced by the combinedcycle plant for cogeneration purposes. Stored cogeneration heat can then be fed to the grid when the combined-cycle unit is not in operation. Integrating this large industrial facility into the center of a major city also succeeded because importance was placed on harmonic architecture and minimal emission of noise and other pollutants. A design competition was held to ensure the facility's architecture was optimally integrated into the surrounding environs, which produced the winning design created by the architectural firm kadawittfeldarchitektur. The building complex not only enhances the cityscape, but also embraces and communicates the pioneering nature of the facility. One particular highlight is the large "City Window" that faces the center of the city and encloses portions of the facility in glass. Special design features ensure a high level of protection for birds. Visitors take an elevator to reach a 45-meter-high viewing platform. Compared to the average plant emissions of all coal-fired power plants within the European Union, a natural gas-fueled combined-cycle power plant operating at 61.5 percent efficiency for 3,800 operating hours cuts carbon dioxide emissions by some 1.6 million tons. This is equivalent to the emissions of 800,000 new automobiles, each clocking 15,000 kilometers a year. A forest covering some 160,000 hectares - corresponding to the area of London - would be needed to compensate for this quantity of Copyright Siemens AG All rights reserved. 8

9 CO 2. Even compared to the most modern combined-cycle power plants fitted with Siemens F-Class gas turbines, that 61.5% figure represents savings of 6,700 tons of natural gas fuel and 18,500 tons of CO 2 emissions, every year. Fig. 5 Architectural highlight: the Fortuna combined-cycle unit at Düsseldorf s Lausward Power Station. Source: kadawittfeldarchitektur In district heating operation emissions sink even further, to 230 grams per kilowatt-hour (g/kwh) equivalent. The design is thus sustainable and ecological, and contributes significantly towards the city of Düsseldorf's ambitious climate protection goals of achieving climate and thus carbon neutrality by the year 2050, which for Düsseldorf means reducing carbon dioxide emissions to two tons per capita Operational flexibility enables power plant dispatchability and profitability Fossil fuel power plants will continue to play an important role in the energy mix of the future. Our highly efficient combined-cycle power plants and cogeneration plants demonstrate that climate protection and fossil fuel power generation can go hand in hand. These plants are used when available wind and solar power is inadequate. Ultimately, all of us, and especially our industries, rely on continuous, uninterrupted supply of electric power and need power plants that unite a number of fundamental characteristics: They must be highly efficient, environmentally compatible, economical and - in particular - flexible. In the Fortuna power plant unit at Lausward Power Station a broad range of Siemens technologies were introduced to enable the project to meet this requirement for the greatest possible flexibility and thereby offer the customer true added value over conventional solutions. Below are presented the various technologies and solutions implemented in Lausward's Fortuna unit that enable this flexibility. All noted results and performance values have been tested and validated in operation. Fast Starting (hot and warm Co-Start) Our Co-Start technology enables plant operators to start their units quickly and efficiently under hot-start conditions, i.e. to re-start units after a period of shutdown typically lasting eight hours or Copyright Siemens AG All rights reserved. 9

10 less. We consequentially reduce fuel costs during the startup phase and increase plant responsiveness to rapidly changing market conditions, enabling plant operators to start units rapidly and precisely at that point in time when favorable market conditions are effective. We succeed in shortening startup times under hot-start conditions by starting the gas and steam turbines simultaneously, contrary to conventional startup procedures for combined-cycle units. The gas turbine starts and runs up, increasing its output at the steepest possible gradient right up to full load without waiting for staggered startup of the steam turbine, as customarily practiced. The new hot-start procedure with this Co-Start solution is governed by optimized instrumentation and controls in the DCS system. Warm starts, meaning unit re-start after a weekend shutdown lasting typically up to 48 hours, have also been accelerated by using our Co-Start technology. The improved startup procedure is basically achieved by implementing the same technical measures and modifications of the startup process as for hot starts, the only difference being the different temperature and pressure conditions in the heat recovery steam generator considered by the instrumentation and control system after the longer period of shutdown. Despite extensive acceleration of these startup processes, component service life is not adversely impacted. Co-Start hot Plant Load < 25 min Plant Load Co-Start warm 45 min. 50 min Conventional start 90 min. Conventional Start Start-up Time Start-up Time Fig. 6 Hot Co-Start Warm Co-Start The verification and validation of the performance improvements enabled by Co-Start technology at the Fortuna unit of Lausward Power Station showed that run-up time for hot starts was drastically shortened from the customary 50 minutes to under 25 minutes. Significant fuel savings were achieved by raising efficiency during startup, which resulted in reduced CO 2 emissions and improved unit cost-effectiveness and thus profitability thanks to lower fuel costs. Material stress test results showed reduced fatigue stressing of the steam turbine. The overall lower plant startup costs lead to more operating hours due to increased plant demand and capacity utilization by the load distributor. Copyright Siemens AG All rights reserved. 10

11 Increasing load change gradients (Flex-Ramp) Enhanced power plant flexibility involves not just fast startup procedures: load change gradients during load operation (meaning the speed at which unit output can be changed) should also be as high as possible in a flexible, rapidly responsive power plant. We achieve this by using our Flex- Ramp technology. The load-change gradient of a combined-cycle power plant is determined by the combined ramping speeds of the gas turbine and steam turbine. In order to achieve the highest possible overall gradient, the gas turbine load is changed at the highest possible and technically allowable gradient. And when a rapid drop in power output is desired, ramping down the steam turbine load is extensively accelerated with the aid of Flex-Ramp. This technology increases the load change gradient of a combined-cycle power plant unit by 20MW per minute over and above the gradient of the gas turbine. As a result of these measures, the Fortuna unit at Lausward Power Station is able to run upward and downward load ramping at 55MW per minute. Baseline CC MW/min Plant Load 3 min 5 min Flex-Ramp +20 MW/min 3 min ~ 40%. 5 min 11 min 11 min Fig. 7 Flex-Ramp Operating Time These improvements enable power plant operators to enhance their participation in the secondary reserve market and increase the cost-effectiveness and thus profitability of their units thanks to increased revenue. Operators can also increase the capacity utilization and operating hours of their units, as the load distributor will more frequently turn to flexible, rapidly responding power plants with high load change gradients. Impacts of increased operating flexibility All of the solutions described above contribute to improving profitability, lowering the variable generating costs and emissions of power plants. As in liberalized electricity markets like Germany's those power plants with the lowest variable power production costs are granted first access to the grid in accordance with the merit order, all in all these new technologies will gain a power plant more advantageous positioning in the merit order curve against high emission coal plants. The preferential grid access and more frequent demand from the grid operator result in more operating hours, better capacity utilization and optimized power production, and ultimately improves total emission situation. Copyright Siemens AG All rights reserved. 11

12 3. FOCUS MARKET EGYPT The power generation market in the Middle East and North Africa is currently one of the largest and most active in the world. Providing energy to fuel domestic economic and population growth remains a key priority for the region particularly in Saudi Arabia, Kuwait, the UAE and Egypt. The power generation in this region is not only supplying electricity, but is also powering water desalination (reverse osmosis and thermal desalination) and thus directly influencing the availability of potable water in the region. More generation, including more gas fired generation is needed to achieve these goals. Energy demand in this region is continuously increasing and the expectation of continued growth at the current pace is leading some countries to re-think their basic energy mix policies. Power plant projects with up to 3-4 GW per project are common in this region. These projects are significantly larger than in any other region worldwide and the successful execution of these mega projects become both technically and logistically an increasingly important factor for the Middle East and North African power generation market. Any delay in project execution implies an immediate threat on the security of supply. The future power generation market development in Egypt is characterized by the constant growth of power generation as well as installed capacity driven by population and economic growth, in line with the overall market development trends in the region as discussed above. In the next decade an annual electricity production growth rate of around 4.5% and the more than doubling of current installed capacity are expected. 80% of power generated is currently produced from natural gas. This share is expected to remain stable in the future, making gas fired power plants the key elements of the energy landscape in Egypt now and tomorrow. Power Generation Installed Capacity [TWh/a] % Renewables Wind Nuclear Gas Oil Coal [GW] Ret Cap. Add Engines Wind Solar Hydro Nuclear SPP SCPP CCPP (incl. IGCC) Fig. 9 Egypt Power generation market , Source: Siemens Egypt s energy policy is characterized by a liberalized but government driven energy sector with longterm successful international collaboration. In the power sector current mega projects for power plants and grid extension are needed to stabilize power supply and to enable economic growth. Available power generation capacity is currently directly absorbed by demand. Recent gas discoveries in the Mediterranean may allow Egypt to return to a net energy export country soon and a limited LNG im- Copyright Siemens AG All rights reserved. 12

13 port infrastructure is being build-up. Limited national budgets or financing constraints in developing countries are calling for cost effective power generation solutions, which means that not only the low specific investment of large plants due to their economy of scale is in focus, but also highest possible power density. High environmental standards are also an important aspect when it comes to ensuring and unlocking necessary international funding and financial aid for such large international power plant projects. And finally, project execution speed is of the essence as every MW power generation capacity going online will immediately help to further develop the country and its economy. Reviewing the above mentioned market requirements it becomes clear that H-class advanced GT technology combined-cycle power plants are the ideal solution to meet these requirements Showcase: Egypt Mega Projects Together with Egypt s people, Siemens is building a foundation for progress to unlock Egypt's vast potential with the three mega combined cycle projects Burullus, New Capital and Beni Suef and further power generation and distribution infrastructure. Siemens has signed contracts worth 8 billion for high-efficiency natural gas-fired power plants and wind power installations that will boost Egypt's power generation capacity by more than 50 percent compared to the currently installed base. Fig. 10 Egypt Mega projects, Source: Siemens The projects will add an additional 16.4 gigawatts (GW) to Egypt's national grid to support the country's rapid economic development and meet its growing population's demand for power. Together with local Egyptian partners Elsewedy Electric and Orascom Construction, Siemens will supply on a turnkey basis three highly efficient and environmental friendly natural gas-fired combined cycle power plants, each with a capacity of 4.8GW, for a total combined capacity of 14.4GW. Copyright Siemens AG All rights reserved. 13

14 Each of the three power plants - Beni Suef, Burullus and New Capital will be powered by eight advanced Siemens H-Class gas turbines, selected for their highest power density, record-breaking efficiency and subsequently low emissions. In addition, Siemens is also supplying about 600 wind turbines for 12 wind farms with another 2 GW clean power generation spread over the country and adds value and education to the people by creating more jobs in the generation facilities and also in blade factories. Siemens has been doing business in Egypt since 1859 and has maintained a continuous presence in the country since opening its first office in Cairo in The company's technology has been implemented in the Attaka, Nubaria, Talkha, Damietta, Sidi Krir, Cairo West, Ayoun Mousa, Midelec and El Kureimat power plants. The three mega fossil plants will add power to the grid in stages. Once completed, the three power plants will be the largest H-class plants in the world providing efficient and clean power generation into the region. Copyright Siemens AG All rights reserved. 14

15 4. CONCLUSION Combined-cycle power plants using most advanced H-class GT technology provide highest power output, power density and efficiency, enhanced operational flexibility and grid support abilities. The possibility to power advanced heat extraction solutions, as well as overall improved plant profitability and return on invest make them the preferred power plant solution for a wide range of customer and market requirements in different power generation markets worldwide. Improved plant performance and abilities combined with comprehensive plant solution optimization and executional excellence will enable customers to successfully implement such different power plant configurations as highly flexible combined heat and power plants with world record efficiency and fuel utilization factors or, for example, large-scale base-load configurations with highest power density and optimized cost of electricity. Best examples for this wide and flexible application and solution range are the recent combined-cycle power plant projects in Korea,Germany and Egypt. Customers will achieve a real, quantifiable added value through optimized generation costs and at the same time set new standards in terms of environmental friendliness and resource conservation. Advanced H-class gas turbine combined cycle power plants are the ideal solutions to satisfy an increasing power generation demand in a sustainable, resource-saving and affordable way and to support further growth of renewable power generation worldwide. Copyright Siemens AG All rights reserved. 15

16 5. REFERENCES [1] Schlesinger, M., Lindenberger, D., Lutz, C Development of Energy Markets Energy Reference Forecast. Project No. 57/12, Study commissioned by the German Federal Ministry of Economics and Technology, Berlin [2] Fraunhofer Institue for Solar Energy Systems ISE German Renewable Energy Production, update :14, Copyright Siemens AG All rights reserved. 16

17 PERMISSION FOR USE The content of this paper is copyrighted by Siemens and is licensed to WEC for publication and distribution only. Any inquiries regarding permission to use the content of this paper, in whole or in part, for any purpose must be addressed to Siemens directly. DISCLAIMER This document contains statements related to our future business and financial performance and future events or developments involving Siemens that may constitute forward-looking statements. These statements may be identified by words such as expect, look forward to, anticipate intend, plan, believe, seek, estimate, will, project or words of similar meaning. We may also make forward-looking statements in other reports, in presentations, in material delivered to shareholders and in press releases. In addition, our representatives may from time to time make oral forwardlooking statements. Such statements are based on the current expectations and certain assumptions of Siemens management, of which many are beyond Siemens control. These are subject to a number of risks, uncertainties and factors, including, but not limited to those described in disclosures, in particular in the chapter Risks in the Annual Report. Should one or more of these risks or uncertainties materialize, or should underlying expectations not occur or assumptions prove incorrect, actual results, performance or achievements of Siemens may (negatively or positively) vary materially from those described explicitly or implicitly in the relevant forward-looking statement. Siemens neither intends, nor assumes any obligation, to update or revise these forward-looking statements in light of developments which differ from those anticipated. Trademarks mentioned in these documents are the property of Siemens AG, its affiliates or their respective owners. Copyright Siemens AG All rights reserved. 17