Meeting the demand for high fuel flexibility: the Ansaldo Energia experience Federico Bonzani Ansaldo Energia Product Development NTPC's O&M Indian Power Station 2012 13-14 February 2012 New Delhi, India
Content 1. Introduction 2. AE94.2K: a proven design 3. AE94.2K2: a step beyond 4. Conclusions
Ansaldo Energia Gas Turbine Fleet AEN site AEN Headquarters and Workshop
Introduction Market Demands Use of lower quality / lower cost fuels Flexibility in fuel supply and operation Low environmental impact Proven design / Operating experience
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 300.000+ 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
Content 1.Introduction 2. AE94.2K: a proven design 3. V94.2K2: a step beyond 4. Conclusions
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
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: 137188 Unit 2: 109975 94157 61649 Fuel Loading 0-100% BL 40 100% BL 0 100% BL NOx, CO emissions [ppm] GT/CC efficiency [%] 75/10 ppm 30/10 ppm 25/10 ppm 34.5/48.9 32.3/47.2 36.0/50.1
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 0.95-1.05 0.09-0.99 0.55-0.92 Fuel Gas Comp. [% vol.] A B C H2- H2+ H2 31.25 9.03 9.56 1.52 15.71 24.45 CO 29.78 16.25 9.61 7.02 28.68 26.67 H2O 34.59 5.46 29.55 5.55 48.76 45.78 N2 0.98 40.36 22.42 41.60 0.92 1.21 CO2 3.27 13.61 7.48 13.92 1.59 1.57 CH4 0.13 14.60 20.73 20.08 4.15 0.32 C2+ 0.00 0.53 0.54 0.21 0.19 0.00 LHV [MJ/Nm3] 7.2 8.67 10.21 9.71 7.15 6.31
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
AE94.2K: compressor optimisation 1.8 Natural Gas Flow split AE94.2 98.2 IGV fully open 10 100 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)
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
NOx, CO ppm Meeting the demand on high fuel flexibility: Ansaldo Energia experience AE94.2K: typical operating conditions 100 75 CO 50 NOx NOx control by steam dilution 25 0 0 10 20 30 40 50 60 70 80 90 100 Power [%] Closed IGV IGV Control Open
AE94.2K: Ferrera Erbognone unit 3 records
Content 1.Introduction 2. V94.2K: a proven design 3. AE94.2K2: a step beyond 4. Conclusions
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] 50.3 2.5 39.0 5.5 LHV [MJ/Nm 3 ] 33.9 3.4 18.3 7.4 Flame speed in air [cm/s] 43 19 148 30 Stoich. Comb. Temp. [K] 2227 1425 2106 1945 Density [kg/nm3] 0.72 1.35 0.47 1.34 Specific heat [kj/kg K] 2.18 1.03 3.04 1.02 Lower caloric value leads to higher flow rate Higher fuel flexibility due to industrial process
AE94.2K2: compressor optimisation 98.2 1.8 Natural Gas Flow split AE94.2 IGV fully open 10 100 90 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%) 75 100 AE94.2K2
AE94.2K2: compressor optimisation Strut IGV Distribuzione di pressione di parete Densità
AE94.2K2: combustion system optimisation 3 1 2 1) Steel mill gas blend line 2) Natural Gas Steel mill gas blend line 3) Natural Gas Pilot Line
Content 1.Introduction 2. V94.2K: a proven design 3. V94.2K2: one step beyond 4. Conclusions
Ansaldo Energia AE94.2 family: engines for wide fuel flexibility Engine Model AE94.2 AE94.2K AE94.2K2 LHV 30 50 MJ/ kg 7 30 MJ/ kg 3.5 7 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
Conclusions Successful operating experience: 300.000 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
Meeting the demand on high fuel flexibility: Ansaldo Energia experience MANY THANKS FOR YOUR ATTENTION E-mail: federico.bonzani@aen.ansaldo.it NTPC's O&M Indian Power Station 2012 13-14 February 2012 New Delhi, India