Operational experience of the OP16 gas turbine in small scale CHP installations in Europe Lars-Uno Axelsson, Ruud van Groenewoud and Mark Stulp, OPRA Turbines Dr. L. Axelsson, Chief Engineer, Development
Outline of today s presentation 1. Introduction to OPRA Turbines 2. The OP16 gas turbine 3. Example of CHP applications in Europe 4. Operational experience 5. Summary and conclusions Page 2
OPRA Turbines is a leading provider of on-site gas turbine driven energy solutions in the 1.5 10.0 MW OPRA was established in the Netherlands in 1991 The OP16 combines robustness and simplicity with high performance OPRA has demonstrated market success for oil & gas as well as industrial and commercial CHP applications OPRA has sold more than 90 gas turbines since 2006 The OP16 gas turbine fleet has accumulated 2 million operating hours OPRA is ISO 9001, DNV according to API standards and GHOST certified Page 3
Growing demand for small-scale CHP applications The power generated by CHP has steadily increased in Europe from the 90 s Today 20% of the capacity of the conventional power plants are based on CHP Increased interest for small-scale CHP applications Independency from the grid Stricter emission regulations Utilization of the fuel locally available Many possibilities for utilizing the exhaust heat Direct drying in industrial applications Steam generation for industrial applications District heating and cooling Electrical energy using (organic) Rankine cycles Page 4
The 1.85 MWe OP16 gas turbine Reduction gear 6.7:1 ratio compressor Dual-fuel & low emissions combustors (4) Bearings in cold part of engine High-efficiency radial turbine ELECTRIC EFFICIENCY 25% EXHAUST FLOW 8.7 kg/s EXHAUST GAS TEMP. 570ºC ROTOR SPEED 26,000 rpm Page 5
The OP16 product line OP16-3A OP16-3B OP16-3C Conventional diffusion type combustor Gaseous and liquid fuels between 20-70 MJ/kg Dual fuel operation Dry low emission combustor Gaseous fuels between 30-51 MJ/kg Diesel as back-up fuel Advanced diffusion type combustor Gaseous and liquid fuels between 5-25 MJ/kg High calorific fuel as back-up Page 6
The OP16 product line covers a wide range of fuels OP16-3A (2006) OP16-3B (2007) OP16-3C (2014) Lower heating value [MJ/kg] 0 10 20 30 40 50 60 70 Waste gases Biogases Syngases Flare gas Natural gas Hydrogen rich fuels Pyrolysis oil Ethanol Diesel Kerosene Page 7
The OP16-3B (DLE) OPRA Turbines introduced the OP16-3B gas turbine in 2007 The OP16-3B has four dry low emission tubular combustors Lean pre-mixed operation with swirl stabilized flame The OP16-3B gas turbine Impingement cooled liner to prevent cooling air from entering the combustion zone Optimized to provide low emissions on gaseous fuels between 30-50 MJ/kg Diesel can be used as a back-up fuel (diffusion mode) The OP16-3B DLE combustor Page 8
The OP16 containerized solution for CHP applications Performance: 1.85 MW electric output 4 5 MW thermal output ~90% fuel utilization Compact: 2x20 ft ISO container Low weight: ~20 tons Clean: Ultra low NOx Quiet: 70-85 db at 1 meter Reliable: TBO* 40,000 hours *TBO=Time between overhauls Page 9
Starch manufacturing plant 1 OP16-3B unit was installed in 2012 The gas turbine operates at 24/7 at full load The exhaust heat of about 4.5 MW is used for direct drying of the wheat starch The electricity is fed to the grid The process requires clean exhaust gas The OP16 gas turbine has no bearings on the hot side and the exhaust gases contains no oil residues Page 10
Tobacco manufacturer 1 OP16-3B unit installed in 2013 OP16-3B Gen-set Connected to 1 parallel-fired WHRSB Cyclic operation depending on steam demand The GT produces 6.5 tons of steam (10 bar) per hour With the WHRSB the total amount is 14.5 tons Strict safety requirements - The installation is approved by TÜV WHRSB Page 11
Tobacco manufacturer in Germany- Primary Energy Savings Germany has implemented subsidy schemes to promote the use of CHP By qualifying as a high-efficiency CHP installation the end-user gets economic benefits Primary Energy Savings (PES) is used to quantify the efficiency PES = 1 CHP Hη Ref Hη 1 + CHP Eη Ref Eη x 100 % The PES shall be higher than 10% The installation at the tobacco manufacturing plant has a PES>16% as measured by TÜV Page 12
Operational experience Emissions (1/2) NOx is created due to four mechanisms Thermal nitric oxide Nitrous oxide mechanism Prompt nitric oxide Fuel nitric oxide CO represents incomplete combustion of the fuel Basic approaches to minimize the NOx are: Lower the flame temperature Eliminate hot spots Decrease the combustion residence time Page 13
NOx @ 15% O2 [ppm] CO @ 15% O2 [ppm] Operational experience Emissions (2/2) TA Luft requires compliance between 70-100% The OP16-3B meet this with ample margin Combustor module is the same independent on the natural gas type Effect of the higher flame temperature results in slight higher NOx 100 90 80 70 60 50 40 30 20 10 0 LHV=31.6 MJ/Nm3 LHV=36.1 MJ/Nm3 TA Luft req. 65 70 75 80 85 90 95 100 Load [%] 100 90 80 70 60 50 40 30 20 10 0 LHV=31.6 MJ/Nm3 LHV=36.1 MJ/Nm3 TA Luft req. 65 70 75 80 85 90 95 100 Load [%] Page 14
Operational experience Combustor module The combustors have been inspected after 8,000 and 16,000 hours The combustor are in good condition No cracks in the liner can be seen The TBC is in good condition Combustor interior after 8,000 hours Combustor interior after 16,000 hours Page 15
Operational experience Rotor module Both the turbine impeller and compressor impeller are in good condition after 16,000 hours of operation The turbine impeller shows no sign of overheating or rubbing Compressor impeller is clean and no material loss found Turbine impeller leading edge after 16,000 hours Compressor impeller leading edge after 16,000 hours Page 16
Summary and conclusions Increasing demand for small-scale gas turbines for CHP applications The OP16 has a high exhaust temperature making it well-suited for CHP applications The OP16-3B is designed to meet the strictest emission regulations The OP16-3B gen-set has been enhanced further to meet the customers demand The OP16-3B provides a high overall efficiency The OP16-3B has been operated successfully in CHP installations across Europe Page 17
Thank you for your attention!