GE Metals Solutions. Solutions for Steel

Transcription

1 GE Metals Solutions Solutions for Steel 1

2 Global Challenges What if you could reduce operational energy costs? 20-40% of the cost of steel comes from energy costs 2

3 Global Challenges What if you could considerably increase your power output & efficiency utilizing the same amount of process gas? Typical power increase seen when shifting from BSTG to HDGT configuration 3

4 Global Challenges What if you could utilize by-pass gases as a means to reduce or eliminate your plants oxygen load? 10/700 Pressure and temperature of compressor off-gassing in low-btu applications 4

5 Global Challenges What if you could rapidly shift from one fuel source to the next without worrying about the calorific value? Currently advertised lowest heating value of a GE 9E low-btu HDGT 5

6 You can Technology & constant Innovation are the keys to answering these challenges China 170 MW Fuel: COREX Steel mill gases Singapore 173 MW Fuel: Refinery Residue GE Gasification GE Low BTU fuel experience: 4.7 GW installed (21 plants) 47 gas turbines with LBTU/syngas Over 2,000,000 operating hours Plants in USA, Germany, Italy, Canada, Netherlands, Singapore, Czech Rep., China, Middle East Czech Republic 350 MW Fuel: Brown Coal Lurgi Gasification 6

7 Power: From Process Gases 38,000 The number of homes equivalent of energy saved by installing one of GE s 9E Gas Turbines Combined Cycle Power: China 175 MW Power house BFG/COG fueled Saves $32 MM/year Reduces CO 2 by 2 MM tons/year 7

8 Heavy Duty Gas Turbine Syngas Experience Refinery (2008) 160 MW, 2x7EA Cogen Shell Gasifier on Asphaltene Refinery (1996) 40 MW, 6B Cogen GE Gasifier on Coke IGCC Demo (1984) 120 MW, 107E GE Gasifier on Coal Refinery (2000) 180 MW, 2x6FA Cogen GE Gasifier on Coke Refinery (2003) 105 MW, 3x6B Cogen Lean Methane Clean Coal Proj. IGCC (1996) 250 MW, 107FA GE Gasifier on Coal/Coke Clean Coal Proj. IGCC (1996) 250 MW, 107FA E-gas Gasifier on Coal/Coke Steel Mill (1996) 520MW, 3x109E Cogen BFG/COG/LDG Refinery (1997) 120 MW, 206B Cogen/H2 Shell Gasifier on Coke Refinery (2001) 550 MW, 3x109E Cogen GE Gasifier on Tar IGCC (1996) 70 MW, 6B GSP Gasifier on Coal IGCC (1996) 350 MW, 209E ZVU Gasifier on Coal GTL Project (2011) 209 MW, 6x6B Cogen Shell Process Off-gas Steel Mill (2001) 180MW, 1x109E Cogen BFG/COG/LDG Steel Mill (2010) 328MW, 2x109E Cogen BFG/COG Steel Mill (2003) 50MW, 6B Cogen BFG/COG Steel Mill (2008) 450MW, 9x106B Cogen BFG/COG Refinery (2009) 253 MW, 2x9E Cogen Shell Gasifier on Oil Steel Mill (2010) 348MW, 2x109E Cogen COREX Refinery (2000) 173 MW, 2x6FA Cogen GE Gasifier on Oil More than 4.7 GW of installed base operating on low BTU fuels, with over 2,000,000 operating hours 8

9 9E Medium Btu fuel blend Steelworks, Italy (BFG-COG-LDG-NG fuel blend solution) Syngas operation since MW 3x9E combined cycle w/cogeneration steam Blast furnace/coke oven/ldg fuel gas blend w/ng 1810 kcal/nm3 (~193 Btu/scf) Integrated single-shaft gas turbine/fuel gas compressor Availability >94% since 97 9

10 9E steel mill - Corex gas, China 1x9E combined cycle in operation since 2008; 1x109E operation 1Q2011 COREX gas (~20%H2, 45%CO, 30%CO2) 1950 kcal/nm3 (~208 Btu/scf) Integrated single-shaft gas turbine/fuel gas compressor designs Multi-shaft combined cycle power generation 1st plant achieved over 24,000 hrs. of operation with COREX gas in June 11 Alternative steel process- export gas 1x9E in operation since x109E 10

11 9E, Steel Mill BFG/COG Gas, China 11

12 9E Low Heating Value Modifications Air Extraction Increased S1N Throat Area Syngas Combustor Tfire Optimization Minimal changes.maintain 9E Robust Reliability 12

13 Syngas turbine controls & accessories Inlet bleed heat system Inlet filter house Inlet duct & plenum Ventilation mods Syngas fuel skid with N2 purge Static starter Gas fuel module Optional air extraction skid IGCC Controls with added I/O Controls hardware and software Accessory module Liquid fuel and atomizing air Water injection skid Exhaust system Enclosure modifications: Piping for syngas, diluent, etc. Explosion proofing Hazardous gas detection Fire protection N2/Steam injection skid 13

14 Packaging modifications for ultra LHV blended fuelgas Enclosure Piping Air Extraction Fuel Skid 14

15 Summary GE has considerable operational experience using low calorific fuel gas for both steel mill and IGCC applications Blending of available mill fuel gas must be considered to meet minimum fuel heating value constraints Mill fuel gas must be extensively cleaned removing particulate and tars to comply with turbine fuel specification requirements GT fuel control systems with load turndown, co-firing, and automation response capability provide flexibility with variable mill operations GE Gas turbine/combined cycle plants can be successfully utilized with ultra low heating value steel mill fuels 15

16 GE Metals Solutions Questions? Solutions for Steel 16