Meeting the demand for high fuel flexibility: the Ansaldo Energia experience

Transcription

1 Meeting the demand for high fuel flexibility: the Ansaldo Energia experience Federico Bonzani Ansaldo Energia Product Development NTPC's O&M Indian Power Station February 2012 New Delhi, India

2 Content 1. Introduction 2. AE94.2K: a proven design 3. AE94.2K2: a step beyond 4. Conclusions

3 Ansaldo Energia Gas Turbine Fleet AEN site AEN Headquarters and Workshop

4 Introduction Market Demands Use of lower quality / lower cost fuels Flexibility in fuel supply and operation Low environmental impact Proven design / Operating experience

5 Introduction Market Demands Use of lower quality / lower cost fuels Flexibility in fuel supply Low environmental impact Proven design / Operating experience Ansaldo Energia response Design flexibility to meet customer demands Proven Technology EOH on AE94.2K fuelled by low BTU Fuel Due to this successful experience Ansaldo Energia act as leader in the field of alternative fuel operation

6 Content 1.Introduction 2. AE94.2K: a proven design 3. V94.2K2: a step beyond 4. Conclusions

7 AE94.2K: a proven design E class Dual fuel 167 MWe ISO 16+1 compressor stage 4 turbine stage Two silo type combustor 16 syngas burner

8 AE94.2K: a proven design AE94.2K Power Plant ISAB Energy Priolo Elettra GLT Servola EniPower Ferrera E. Net Power (GT/CC) 2x162 MW / 516 MW 1x110 MW / 170 MW 1x 166 MW / 255 MW First Firing (Sec. Fuel/Syngas) November, 1998 August, 1999 August, 2000 November, 2000 March, 2004 March, 2006 Equivalent Operating Hours (EOH) Unit 1: Unit 2: Fuel Loading 0-100% BL % BL 0 100% BL NOx, CO emissions [ppm] GT/CC efficiency [%] 75/10 ppm 30/10 ppm 25/10 ppm 34.5/ / /50.1

9 AE94.2K: a proven design ISAB Energy (I) Elettra GLT Servola (I) EniPower Ferrera E. (I) Feedstock Asphalt Steel mill process gas Asphalt Gasification Texaco - Shell Natural Gas Integration (as thermal Input to Gas Turbine) 0% 45-49% 0-35% Fuel Gas Temperature 195 C 260 C 190 C Fuel Gas Pressure 22 barg 20 barg 22 barg H2/CO ratio Fuel Gas Comp. [% vol.] A B C H2- H2+ H CO H2O N CO CH C LHV [MJ/Nm3]

10 AE94.2K syngas burner: flexibility is a must 1) Pressure drop 2 Outlet section lenght 2) Flame Stability 4 Nozzle angle adjustment 3 1 3) NOx emissions Syngas - air mixing Nozzle design on DoE 4) Operational and fuel flexibility Single or dual passage

11 AE94.2K: compressor optimisation 1.8 Natural Gas Flow split AE IGV fully open Syngas AE94.2K 90 IGV control at BL 100 Pressure ratio increase due to higher fuel flow and IGV control Additional final stage to the compressor delivery side (identical to the previous one)

12 AE94.2K2: combustion system optimisation Fuel Supply & Control System: Syngas Fuel and NG system Purging and Inertisation system Steam Dilution system Steam for NOx abatement Syngas - highly reactive (H2) -toxic (CO) Additional Natural gas Flare Nitrogen for inertisation and purging Back up Natural gas

13 NOx, CO ppm Meeting the demand on high fuel flexibility: Ansaldo Energia experience AE94.2K: typical operating conditions CO 50 NOx NOx control by steam dilution Power [%] Closed IGV IGV Control Open

14 AE94.2K: Ferrera Erbognone unit 3 records

15 Content 1.Introduction 2. V94.2K: a proven design 3. AE94.2K2: a step beyond 4. Conclusions

16 AE94.2K2: a step beyond Steel mill process gas: a resource for power generation and a technology challenge Fuel Properties CH 4 BFG COG OxG LHV [MJ/kg] LHV [MJ/Nm 3 ] Flame speed in air [cm/s] Stoich. Comb. Temp. [K] Density [kg/nm3] Specific heat [kj/kg K] Lower caloric value leads to higher flow rate Higher fuel flexibility due to industrial process

17 AE94.2K2: compressor optimisation Natural Gas Flow split AE94.2 IGV fully open Additional stage 25 Syngas Steel mill gas AE94.2K Base Load with closed IGV shows reduced 100 margin against surge The compressor efficiency is negatively affected with closed IGV Max air mass flow must be reduced to fit the design point (IGV 100%) AE94.2K2

18 AE94.2K2: compressor optimisation Strut IGV Distribuzione di pressione di parete Densità

19 AE94.2K2: combustion system optimisation ) Steel mill gas blend line 2) Natural Gas Steel mill gas blend line 3) Natural Gas Pilot Line

20 Content 1.Introduction 2. V94.2K: a proven design 3. V94.2K2: one step beyond 4. Conclusions

21 Ansaldo Energia AE94.2 family: engines for wide fuel flexibility Engine Model AE94.2 AE94.2K AE94.2K2 LHV MJ/ kg 7 30 MJ/ kg MJ/ kg Compressor Standard K model K2 model Combustor Standard Standard Standard Burner Standard K model K model, enhanced Turbine Standard Standard Standard Fuel System Standard K model K model, enhanced Control System Standard K model K model, enhanced Lay out Standard Standard Standard Power 166 MW 170 MW 147 MW

22 Conclusions Successful operating experience: EOH+ cumulated on 4 units Flexible and proven design Capacity to tailor power plant to the customer needs: AE94.2K2 released on market R&D effort to meet future demands for higher efficiency on F class

23 Meeting the demand on high fuel flexibility: Ansaldo Energia experience MANY THANKS FOR YOUR ATTENTION NTPC's O&M Indian Power Station February 2012 New Delhi, India