Methanol As Low Cost Alternative Fuel For Emission Reduction In Gas Turbines and Utilities Boilers

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1 Methanol As Low Cost Alternative Fuel For Emission Reduction In Gas Turbines and Utilities Boilers IEC and Dor Chemicals Jan 13 th, 2013 Weizman Institute of Science, Rehovot, Israel 1

2 Organization Chart C E O Senior Vice President Generation & Transmission Senior Vice President Engineering Projects Senior Vice President Strategic Resources Senior Vice President Marketing & Customer Rel Senior Vice President Organization & Logistics Senior Vice President Finance & Economics Generation Division Transmission & Distribution Division Engineering Division Construction Division Business Development Human Resources Division Planning, Development & Technology Division Information Systems/Comm. Division Marketing Division Districts Southern Dan Jerusalem Haifa Northern Logistics & Real Estate Division Quality & Systems Eng. Division Accounting & Economics Division Financing Division Supply & storage Division 2

IEC s Engineering Project Group Organization Engineering Pr0jects Group Engineering Division Legal Advisor Cost Engineering Construction

Electrical & Controls Engineering Civil Engineering Sub-Station Engineering Computerized Sys.

3 IEC s Engineering Project Group Organization Engineering Pr0jects Group Engineering Division Legal Advisor Cost Engineering Construction Division Business Development Legal Advisor Administration Public Relation Legal Advisor Projects Management Mechanical Engineering Electrical & Controls Engineering Civil Engineering Sub-Station Engineering Computerized Sys. Technical Services Budget Control Administration Projects Tenders and Contracts Mechanical Construction Electrical Construction Civil Construction Administration Budget Control Human Resources 3

Power Plants Rutenberg 2X575 2X550 2X630* Orot Rabin Reading 2X575 Eshkol 2X214214 4X360 4X228 + 1X370 Haifa 2X370 2X141 Alon Tavor 1X370 Hagit 1X370+2X350 The Israel Electrc

4 Power Plants Rutenberg 2X575 2X550 2X630* Orot Rabin Reading 2X575 Eshkol 2X X360 4X X370 Haifa 2X370 2X141 Alon Tavor 1X370 Hagit 1X370+2X350 The Israel Electrc Corp. 4 * Projects under execution Ramat Hovav 1X340 Gezer 2X370 Tzafit 1X370 Total Installed power: ~13000 Mw Coal Fired Oil/Gas Fired Oil Fired Combined Cycles Gas Turbine 2,540 Mw

5 Fuel Burned Bituminous coal very wide range of properties Sub-bituminous bituminous coal Low Sulfur Heavy Fuel Oil#6 Light fuel Oil#2 Natural Gas Methanol Preparation for Biomass (Biocoal( Biocoal) ) and Coal co-firing Preparation for Coal and Sewage co-firing Oil Shale 5

6 Emission Reduction activity Low NOx Firing System Implementation Post Combustion Treatment: SCR installation for NOx Reduction FGD installation for SO 2 Reduction ESP for ash reduction 6

7 Outline Engineering Division Methanol Fuel properties Chemical Formula CH3OH Molecular weight Flash point 12 C (to 41 C) Auto ignition temperature 464 C Combustion (Adiabatic) temperature 2045 C Low heating value 4777 kcal/kg Density 793 kg/ M 3 at 30 C 7

8 Overview Methanol is an attractive future fuel for utility boilers and gas turbine engines. Methanol can achieve: 1. Lower NOx emissions due to the lower flame temperature and no FBN. 2. Since methanol has no sulfur there are no SO2 emissions. 3. The clean burning characteristics of methanol are expected to lead to clean heat surfaces and lower maintenance than with HFO or even with LFO. 4. Relative to NG and FO, methanol can achieve higher power output due to higher mass flow in GT engines. 8

9 Mechanism of NOx Emission Formation There are three known mechanism of NOx formation - Thermal NO x - Fuel NO x - Prompt NO x 9

10 10 NOx formation mechanism

11 Combustion temperature of blend of methanol and HFO Combustion temperature of blend of methanol and HFO vs metanol heat fraction 2240 Blend combustion temperature,c Methanol heat fraction, % 11

12 12 Methanol and HFO Co-Firing At Large Utility Boiler of 140 Mw Unit

13 13 Haifa Power Plant Site Engineering Division Engineering Division

14 14 Steam Generator of Haifa C General view 140 Mw unit Engineering Division

15 15 Primary measures implementation Furnace crossection Engineering Division

16 16 Primary measures implementation Burner General view Engineering Division

17 17 Primary measures implementation Burner Design Engineering Division

18 18 Primary measures implementation HFO Atomizer General view Engineering Division

19 19 Primary measures implementation HFO Atomizer General view Engineering Division

20 20 Upgrading for Methanol Firing Methanol Atomizer General view Engineering Division

21 21 Upgrading for Methanol Firing Key Diagram Engineering Division

22 22 Methanol Storage Tank

23 23 Methanol supply display

24 24 NOx reduction tests results Unit#3 Haifa PS Boiler

25 NOx reduction tests results DOR Chemicals boiler (Capacity 10 t/h) 25

26 Particulates reduction tests results Unit#3 Haifa PS Boiler 26

27 27 SO2 reduction tests results Unit#3 Haifa PS Boiler

28 Other emission reduction tests results Unit#3 Haifa PS Boiler CO emission - 0 Formaldehyde

29 Comparison of furnace heat absorption for HFO and HFO-metanol co-firing 29

30 30 Secondary Superheater metal temperature (90MW)

31 31 Reheater metal temperature (90MW)

32 32 Primary superheater metal temperature (90MW)

33 HFO-Methanol Co-Firing Test Results NOx, mg/dnm CO, mg/dnm Particulates mg/dnm SO 2, mg/dnm Unit Load, Mw HFO HFO-Met Co-Firing HFO HFO-Met Co-Firing HFO HFO-Met Co-Firing HFO HFO-Met Co-Firing Negligible Negligible Negligible Negligible Negligible Negligible

34 34 Methanol Firing at FT4C TWIN PAC 50 MWe GT Unit

35 Engineering Division Caesarea Power Plant Site Tested unit 35

36 36 TP -1 1 Base Plate Assembly

37 37 FT4 Engine & Power Turbine Engineering Division

38 38 Liner General view Engineering Division

39 39 Liner General view Engineering Division

40 40 Liner General view Engineering Division

41 41 Nozzle General view Engineering Division

42 42 FO Atomizer Assembly General view Engineering Division

43 43 FO Atomizer General view Engineering Division

44 44 FO Supply Scheme Engineering Division

45 Calculated Flame Temperature Distribution 100% Load Flame temperture distribution through liner length Temperature, C Calculation zone number Fuel oil#2 Methanol 45

46 Calculated Liner Wall Temperature Distribution 100% Load Relative liner wall metal temperature reduction during methanol burning Metanol to FO#2 wall metal temperature ratio Calculation zone number 46

47 Comparison of NOx Formation Through Liner Length for FO#2 and Methanol Firing 100% Load NOx emission formation through liner length O2, Calculation zone number Fuel oil#2, calculated Methanol, calculated Fuel oil#2, measured Log. (Fuel oil#2, calculated) Log. (Methanol, calculated) 47

48 48 Upgrading for Methanol Firing Key Diagram Engineering Division

49 49 Methanol Test Methanol Test Methanol tank Methanol tank

50 50 Methanol Test piping connection

51 51 Methanol Test Methanol Test Control Room Display Control Room Display

52 Methanol Test Emission measurements instruments general view 52

53 Methanol Test Results Average TT7 as function of GT load Tamb=22-24C TT7, F GT load, Mw Oil#2 Methanol Power (Oil#2) Linear (Methanol) 53

54 54 Methanol Test Results

55 55 Methanol Test Results

56 56 Methanol Test Results

57 57 Methanol Test Results

58 58 Methanol Test Results

59 59 Methanol Test Results

60 60 Methanol Test Results

61 Methanol Test Results Formaldehyde as function of GT load Formaldehyde Limit GT load, Mw Methanol Formaldehyde, mg/dnm3@15%o2

62 Methanol Test Results GT Load, Mw NOx, mg/dnm LFO#2 Met CO, mg/dnm LFO#2 Met Particulates mg/dnm LFO#2 Met SO 2, mg/dnm LFO#2 Met

63 NEXT PHASE RESTORE CAPACITY We need to double the fuel flow We need to open the bottle necks: High Pressure Pumps (replaced by external pumps) Modulating valve (replaced by VSD) Pressure & Dump valves (internal strainer replaced) Spraying nozzles (replaced from Excello nozzles to Delevan) Two phase Test (In Eilat) Run a short term test to check feasibility of such a system and validate perfomance & low emissions (2-3 weeks) Run a long term test to gain operational experience and confidence in the system (2-3 years, hrs each year) 63

64 PEPCO Fuel Control Proposal for dual Methanol system (one skid) Control Air psi Restoring Capcity fuel control & external pumps Engine Fuel SOVs (shut-off valves) Mixing Block Inlet piping both fuels 3 Fuel oil Methanol 40 gpm pump 80 gpm pump gpm gpm ps i ps i 1.25 SS pipe 1.5 SS pipe Filters By others 400V 50Hz ~75KVA Motor power wire from VSD 75 HP VSD 30 HP VSD Control wires: 2 digital outputs 2 analog inputs 2 analog outputs Control wires: 2 digital outputs 6 digital inputs 5 analog inputs 64 Control House PEPCO Fuel Control

65 Eilat test restoring capicity Replacing nozzles to Delevan high flow 65

66 Adding external high perssure pumps 66

67 Adapting fuel unloading and storage sytem New unloading piping Tank adaptation floating roof 67

68 68 Adapting fire fighting system

69 69 Fuel unlouding platform

70 70 Danger zone analysis

71 71 Time Schedule

72 Engineering Division Long Term Methanol Firing Modification in Eilat The IEC in cooperation with Dor Chemicals are in advanced stage of the project converting FT4C TWIN PAC 50 MWe GT Unit in Eilat to mehanol firing. The target is to collect long term data of operating the GT on methanol, which is scheduled to start later this year. 72

73 Summary The results presented here clearly show that with minor low cost fuel system retrofit methanol firing leads to significant NOx, SO2 and particulates emission reduction while similar facilities performance characteristics are preserved. We believe that the conclusions of the present work are general and can be applied to other boilers and gas turbines as well. 73 July 2008

74 74

Kapaia Power Station (KPS) Feasibility Study of Simple-Cycle GE LM2500-PH GT Conversion to Methanol Firing

Kapaia Power Station (KPS) Feasibility Study of Simple-Cycle GE LM2500-PH GT Conversion to Methanol Firing November, 2013 Table of contents 1. Executive Summary 2. Simple-Cycle LM2500-PH GT operation mode