Environmental. Compressed Air Energy Storage Solutions. dresser-rand.com

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1 Environmental SMARTCAES Compressed Air Energy Storage Solutions dresser-rand.com

2 Compressed air energy storage Dresser-Rand SMARTCAES Compressed Air Energy Storage (CAES) Solutions With the rapid increase of renewable energy deployment, SMARTCAES technology is fast becoming the solution of choice for bulk, flexible, fast response, and long duration energy storage. SMARTCAES technology provides a solution capable of rapid start-up, high turn-down ratio and ramp rate, simultaneously operating in compression and generation mode and starting completely isolated from the grid. Turbo-expander train A typical SMARTCAES system consists of independent compressor and turboexpander equipment trains. The SMARTCAES packaged equipment trains are modular and comprise turboexpanders, generators, compressors, a motor with variable frequency drive, gearbox, turning gears, and couplings. The SMARTCAES system offering also incorporates all auxiliary subsystems including an inlet air filter system, fastacting compressor and expander control valves, air and water heat exchangers, fuel conditioning skid, integrated recuperator and selective catalytic reduction system with exhaust stack, transformers, switch gear, black start back-up generation, a plant-wide control system, and grid dispatch interconnection software. Compressor train Confidence comes from Dresser-Rand s extensive experience in rotating machinery, and helps to ensure plant uptime and operational robustness. Each SMARTCAES system comes with system performance and emission guarantees, equipment warranties and operating diagnostics. Dresser-Rand custom engineers each SMARTCAES train to provide a system designed specifically to meet site conditions and operating requirements. We optimize the offering with flexibility on the compression sizing, turbine generation output and reservoir storage pressure. SMARTCAES systems can be configured for various air storage mediums including salt (both domal and bedded), hard-rock caverns, aquifers, or depleted natural gas fields. 2

3 Turnkey solutions DATUM compressor Independent compressor train One DATUM Unit Back-to-back DATUM compressor Speed Increasing Gear Gear DATUM compressor Axial From Inlet Air Filter Motor Independent turbo-expander train Generator LP Expander LP Combustors Natural Gas 135 MW Option HP Expander 160 MW Option VHP Expander Aftercooler Intercooler Intercooler Intercooler SCR HP Combustors Natural Gas Bypass Control Valve Recuperator Trip Motive Air Valve Control Valve Cavern To stack Schematic of conventional CAES process showing air flow into and out of the storage cavern. McIntosh CAES Plant Success In 1991, Dresser-Rand was asked to supply a CAES train for the first CAES facility ever commissioned in North America the Power South Plant in McIntosh, Alabama. Only the second of its type in the world, Power South s McIntosh, Alabama, U.S.A. facility has built an impressive record of starting and operating reliably. Dresser-Rand supplied the entire 140-foot (43 meter) machinery train (shown at right), including compressors, expanders, motor/generator, and other associated equipment. We drew from our experience with Power South in Alabama and combined it with an unrivaled degree of expertise in the field of rotating equipment applications to further enhance our product offering. The result: our SMARTCAES solution a one-stop power island that includes all rotating equipment and auxiliary equipment required to meet highly specific grid-scale requirements. Turnkey power plant solutions Siemens, of which Dresser-Rand is now a part, has 130 years of experience constructing turnkey power plants. With more than 1,500 Siemens power plants currently in commercial operation worldwide, each power plant is tailored to the specific needs of each client. As part of Siemens, the Dresser-Rand business can now provide turnkey power plant solutions from a single source for a wide range of different requirements, from simple-cycle gasfired power plants for peak load generation and combined-cycle power plants with heat extraction, to power plants with integrated fuel gasification. Well Heads CAES Building Support Plant Stacks Process & Security Building GIS Building Solution Mining Photo provided by Gaelectric 3

4 Operational flexibility Ancillary services electrical products complement renewables. SMARTCAES equipment can serve as effective tools for a smart grid by having excellent load following capability, allowing base load assets to be used more efficiently and providing ancillary services. The impact of renewables on our electricity grids cause: Curtailment of renewables to satisfy reserve requirements using conventional resources. This causes conventional resources to operate at low load and energy inefficient conditions; therefore, from a system-wide standpoint, the value of renewables is lost. Lower energy prices at all times, reducing profitability of conventional generating resources and causing a lower incentive for conventional generators to enter market. This leads to scarcity and extreme prices in peak hours with system operators unable to satisfy reserve targets, thus causing grid reliability risk. Increased non-synchronous (inverterbased) generation leading to less inertia and lower grid stability. Our SMARTCAES system provides up / down regulation, responsive and nonspinning reserves, frequency and voltage regulation, rapid start-up in generation and compression modes, low load operation, inertial response, and black start capability. Regulate Grid Load Both the generation and compression trains in a SMARTCAES system can serve as regulating tools. The generation train can efficiently operate from 100 percent to approximately 10 percent of rated output. This feature, coupled with a 20 percent ramp rate, allows it to follow large load swings in real time. Similarly, the compression train can load follow, operating between 65 percent to110 percent of the compression train rated output. Both compression and generation trains are interruptible, whereby either train can be quickly isolated from the grid. Minimize Grid Events The SMARTCAES system provides a positive contribution to system inertia, frequency and voltage control. If the frequency of the grid deviates outside specified grid frequency limits, the generation train will respond by adjusting its output power proportionately to stabilize the grid frequency. Because both trains consist of heavy rotating equipment, their large inertia enables the trains to act as system absorbers when grid disruptions occur. Quick Response SMARTCAES generation trains can be brought to full load in less than 10 minutes. This eliminates the need for intermediate-load generation assets and provides a cost-effective way to meet reserve requirements. Compression trains can be engaged quickly and come up to full load in five minutes. Speed - RPM Speed - RPM 4,000 3,500 3,000 2,500 2,000 Black Start Capability SMARTCAES plants can also be designed to incorporate black start capability. With the help of a back-up generator (typically less than a onemegawatt (MW) unit) a SMARTCAES train can be brought online completely isolated from the grid. This is critical in times of blackouts when the grid has no power for plant start-up. Once the SMARTCAES plant is synchronized, it can provide the power necessary to bring other generating assets online, thus restoring power to the grid. Compression Mode Normal Start-up Sequence Start to full load in less than four minutes Accelerate To Speed w/vfd Synchronize 1,500 Prep 40 Close Blow-off Valve 1,000 Open Throttle Valve Time - Minutes 4,000 3,600 3,200 2,800 2,400 2,000 1,600 1, Prep Power Generation Mode Normal Start-up Sequence Start to full generation in less than 10 minutes SPEED 30 RPM/sec. Ramp Rate Reach Synchronous Speed Time - Minutes 160-MW 32 MW/min. Ramp Rate POWER 26 MW/min. Ramp Rate Reach Full Rated Load Inital Loading and LP Combustor Light-up 135-MW Compression Mode - MW Power - MW 4

5 SMARTCAES technology differentiators Through technological advancements in Dresser-Rand rotating equipment applications, SMARTCAES technology has become one of the most versatile, single-source CAES solutions on the market today. Expander Train The Dresser-Rand business offers two configurations of the SMARTCAES turbine expander train, each of which can be designed for 50 hertz (Hz) or 60 Hz applications. The 135-MW variant uses two gas-fired expanders and the 160-MW version adds an additional unfired expander. Each train is offered in modular form, so they can easily be duplicated to achieve the overall desired (MW) output. The train is capable of ramping at 20 percent of the rated output per minute. The expander train is capable of going from offline to full generation in less than 10 minutes. Additionally, Dresser-Rand SMARTCAES expander turbines maintain a relatively flat heat rate from 10 percent to 100 percent, allowing the operators to keep the expanders online even when operating at very low loads. This characteristic results from the ability of CAES technology to maintain separate control of air and gas enabled by the motive air control valve. Located upstream of the expander train, this fast-acting precision valve accurately regulates the air coming into the expanders and ensures predictable, precise power output. The fired expanders use one-third the amount of fuel compared to a conventional gas turbine and operate at relatively low firing temperatures. This provides lower cost and longer life for critical flow path components. The system is optimized to maximize the amount of energy that can be delivered per unit energy consumed. With more than 1,000 installations worldwide, the DATUM product line represents the most advanced turbo compressor technology available for use in process industries today. D-R s axial compressors are very reliable and require only simple maintenance. The horizontally-split design provides easy accessibility and variable stator adjustment via external drive rings. Compressor Train A variable frequency drive (VFD) system allows for start-up times of less than five minutes in compression mode. Once air is flowing to storage, the compressors may be turned down using variable inlet guide vanes to any load between 65 percent to 110 percent of rated power. Also, the compressor train is capable of ramping at a rate of 30 percent per minute. Dresser-Rand s DATUM centrifugal compressor technology, coupled with advanced axial compressor flow path aerodynamics and careful design of the intercooled compression cycle, allow for extremely high efficiencies. Our axial compressor is a robust 13-stage compressor equipped with movable inlet guide vanes that enable the airflow volume to be optimized depending on the load profile required by the grid. We also use heat exchangers to cool the air through the compression cycle which can be optimized to meet specific client demands. Enhanced Recuperator Design The SMARTCAES exhaust recuperator has a 90 percent heat transfer effectiveness. The recuperator preheats the air coming out of the storage reservoir prior to the air going into the generation expanders. Strategically placed rows of stainless steel tubes help prevent corrosion and exfoliation problems, and the entire recuperator is designed to operate at maximum air storage pressure, thus eliminating the cost and maintenance of pressure-reducing valves. 5

6 Enabling renewable integration with CAES Our SMARTCAES solutions include: Development planning and permitting Plant front end engineering design execution Program management Supply and warranty of the complete power island Engineering, procurement and construction (EPC) Performance, emissions and operational guarantees Installation, commissioning and start-up Operation and maintenance (O&M) and service contract agreements Enabling Renewables Our SMARTCAES solution provides a cost-effective solution for balancing grids, thus enabling renewable technologies to be effectively integrated into the electrical grid. When used with renewables, SMARTCAES technology yields the lowest carbon footprint for each incremental firm kilowatt-hour. With off-peak generation becoming increasingly dominated by carbon-free sources, SMARTCAES solutions deliver a lower on-peak carbon footprint than a combined cycle gas turbine (CCGT), simple cycle gas turbine (SCGT) or any liquid-fueled peaker. When compared to CCGT, SCGTs and peakers, the SMARTCAES system offers a superior heat-rate across the entire operating range and unmatched flexibility. A conventional gas turbine turndown and, furthermore, its heat rate rapidly deteriorates as the load decreases. This is because the gas turbine is always dragging the compressor along and incurring the associated power losses. With SMARTCAES equipment, the heat rate remains relatively flat from 10 percent to 100 percent generation. This is because we optimize the air-fuel ratio, thus providing a lean mixture at the specific operating point. Dynamics of the Worldwide Energy Market Have Changed Renewable energy sources can benefit from the bulk energy storage capabilities that SMARTCAES equipment offers. SMARTCAES equipment is also complementary to energy conservation and development efforts associated with the smart grid, giving grid operators the means to run their systems more efficiently. Today s operators have to cycle coal and gas-fired generating assets which were designed for base load operation. Thus, under these constraints, renewable generators are indirectly causing additional pollution as these base load generators cycle to balance renewable intermittency. SMARTCAES technology can improve overall grid asset management, dispatch and reliability, and it enables the development of renewable projects by mitigating the risk associated with the unpredictability of these variable energy sources. SMARTCAES technology drastically reduces curtailment of renewable energy resources, lowers overall energy costs, offers greater electrical grid security, and reduces our reliance on fossil fuels. The dynamics of the worldwide energy market are changing, and SMARTCAES solutions are one example of how the Dresser-Rand business is repositioning its offerings to address global needs. SMARTCAES technology compensates for renewable energy s biggest shortcomings: intermittency; curtailment; and constrained dispatchability. Dresser-Rand s SMARTCAES technology offers the only proven solution with the flexibility to provide energy and ancillary services. 15,000 Heat Rate Comparison Dresser-Rand CAES solution versus simple-cycle gas turbine The compressed air is withdrawn from storage when power is needed. Heat Rate (Btu/KW-Hr) 13,000 11,000 9,000 7,000 5,000 3, % Rated Load Typical simple-cycle gas turbine Dresser-Rand CAES expanders Heat rate comparison D-R SMARTCAES solution versus simple-cycle gas turbine 6

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8 For a complete list of products and services, visit or contact the following: Corporate Headquarters Regional Headquarters Dresser-Rand West8 Tower Suite Westheimer Rd Houston, TX USA Tel: (Int l +1) Fax: (Int l +1) The Americas West8 Tower, Suite Westheimer Road Houston, Texas Tel: (Int l +1) Fax: (Int l +1) EMEA (Europe, Middle East & Africa) Dresser-Rand S.A. 31 Boulevard Winston Churchill Cedex 7013 Le Havre 76080, France Tel: (Int l +33) Fax: (Int l +33) /5367 Asia-Pacific Dresser-Rand Asia Pacific Sdn Bhd Unit 9-4, 9th Floor Bangunan Malaysian Re 17 Lorong Dungun Damansara Heights Kuala Lumpur, Malaysia Tel: (Int l +60) Fax: (Int l +60) DRESSER-RAND is a registered trademark of Dresser-Rand Company. Printed in U.S.A Dresser-Rand. Form This brochure comprises a general overview of the Dresser-Rand products described herein. It is solely for informational purposes, does not represent a warranty or guarantee of the information contained herein, and is not to be construed as an offer to sell or solicitation to buy. Contact Dresser-Rand for detailed design and engineering information suitable to your specific applications. Dresser-Rand reserves the right to modify its products and related product information at any time without prior notice.