Work Package 5 CHP Component Integration

Ulf Linder, Head of Future Technology Geraldine Roy, Lead Market Analyst Siemens Industial Turbomachinery Ltd

Work Package 5 CHP Component Integration

Overview of WP5 Objectives Conclusions
Overview, SIEMENS Industrial Turbomachinery Ltd Activities within Component Integration for Industrial Gas Turbines

What are the benefits of the CHAPNET Network?

A focus for the industry to improve its R&D A knowledge centre for who is doing what, where and with whom A place to develop new ideas for projects for
6th or 7th Framework Programme Energy Intelligent Europe Programme

A strategic platform for identifying needs and pulling together actors to address these needs A place to inform the Commission, Member State Governments on the requirements of the industry

WorkPackage 5 -Component Integration

RTD Cluster on CHP Component Integration Objective / Purpose To share information on RTD activities on Component Integration and Systems Integration for CHP. EU programmes, and Accession countries National programmes Industrial activities Universities

To Address the European competency in RTD with regard to whole CHP systems not individual components Evaluate long term possibilities and technologies

WorkPackage 5 -Component Integration

Workshops Two per year Report Activities, Results and Plans Discuss and Recommend new activities, areas of interest, and potential
1st Workshop held 28 August 2002 in Lincoln 2nd Workshop held 21 February 2003 in Brussels 3rd Workshop held 8 May 2003 in Dsseldorf 4th Workshop held 17 December 2003 in Brussels 5th Workshop held 28 & 29 January 2004, Vsters, Sweden 6th Workshop held 26 & 27 May 2004, Barcelona, Spain Often combined with WP7 Cooling & Trigeneration

WorkPackage 5 -Component Integration

Workshops 1-6:
CAME GT Clean And more Efficient Gas Turbines BIOCOGEN -Biomass Cogeneration Thematic Network CHP Sewage Gasification - Sewage sludge gasification for CHP applications BAGIT - Biomass and gas integrated CHP technology Nedalo - Packaged CHP Systems, Linnhoff March - CHP Process and Utility Integration and Optimisation Promocell - Fuel Cell Cogeneration Hybrid CHP - Hybrid Solar collector CHP system OSCOGEN - Optimisation of Cogeneration Systems CHP Club - CHP Information, Advice and Networking ALSTOM - Using Fuels derived from Biomass and MSW in Industrial Gas Turbine SimTech - Thermodynamic simulations software CE-IGT - Increase awareness of industrial gas turbines

WorkPackage 5 -Component Integration

Workshops 1-6:
ICEHT - Natural gas fuelled SOFCs for cogeneration of elect. & chemicals Baxter Eng. Ltd - LG Cable Absorption Chillers KKK Ltd - New high speed turbo-generator with electronic gear Aircogen - Aircogen Activities ALSTOM - Current & Potential Gas Turbine Technologies Wartsila - Current & Potential Gas Reciprocating Engine Technologies ALSTOM - Steam Turbine Technologies Dalkia - CHP: A CEM contractors perspective TBE - Phosphoric Acid Fuel cells & Digester Gas operation ALSTOM - Carbo-V gasification system Innogy - Iso-engine Farmatic - Cogeneration using Anaerobic Digestion Southeast Research Inst. - Gas Engine Research

WorkPackage 5 -Component Integration

Workshops 1-6:
Gasification of Biomass and Power Generation, TPS Gasification and Gas Engine, Wartsila Gas turbines Technology Development trends, DDIT The Evaporative Gas Turbine demonstration Project, Lund University Connecting to the grid, Powerformer Technology, ABB Research and Development at Mlardalens University Absorption chillers in Cooling and Tri-generation applications, WEIR Entropie Gas Turbines and Chillers Integration, DDIT Fogging and High Fogging : ALSTOMs Experience and Customer Benefits, ALSTOM Power SOFC - Future CHP, Siemens Gas engines Maintenance philosophies, Wrtsil CHP Systems Integration, Tecnicas Reunidas Biofuel based CHP production in Sweden and CHP R&D at CEDER (Soria/Spain), CIEMAT

Current Technologies, Topics

Gas Turbines Improvements made to increase both electrical and overall fuel efficiencies and future potential Fuel Flexibility Steam Turbines Improvements to increase efficiencies and future potential Novel features like High speed alternators Gas Engines Recent developments and future areas for research Improved availability Fuel flexibility

Current Technologies, Topics

Absorption Chillers GT Air Inlet Chilling Heat recovery Use of non-fossil fuels Increasing awareness of local, low cost wastes and use of biomass resources Biomass Gasifiers Sewage sludge gasification Cogeneration using anaerobic digestion Plant Modelling and Optimisation Engineering solution Economics

The Customers Perspective Topics High Reliability

Of supreme importance in Liberalised Energy Markets Unwilling / unable to take technical and commercial risks associated with new technologies

Reduced Operating costs

Lower fuel consumption Fuel flexibility Reduced maintenance

Low Capital costs

Future and Emerging Technologies, Topics

Fuel Cells PEM Phosphoric Acid using digester gas SOFC Complex Cycle Gas Turbines Improved Efficiency Integration with SOFC Isopower Engine High efficiency

INNOGY Isoengine Cycle Diagram

Turbocharger Exhaust

Recuperator

Engine HX
Water Injection

Separator Aux. Cooler

Turbo HX

Air Cooler

Fuel

Spray Water LP Air Cooler HP Air Water Air-Water (Two-Phase) Fuel Combustion gas

Isothermal Compressor (2 cylinders)

Isobaric Combustors (6 cylinders) Engine

~
Generator

A biogas plant

The simplest biogas plant is a cow...

Functional scheme of a biopower station

Cleaned waste air

Deliv. solid residues

Crushing

Pulper Pump

Waste gas to biofilter

Heat exchanger

Deliv. liquid residues

Homogenization Hygienization

Digestion

Flare Heat
CHP unit

Storage tank

Heat storage

Electricity

Gas storage

Drying

Desulphurisation

Transport digested substrate

Key figures, Sweden*

A total energy supply of 615,8 TWh 16 % (98,2 TWh) of the energy supply was based on biofuels. Fuel supply for district heating amounted to 55 TWh of which 33 TWh was based on biofuels Biofuel based electricity production amounted to 6,2 TWh (CHP in district heating systems 2,5 TWh and industrial back pressure 3,7 TWh) * Facts and figures 2003, ET21:2003, The Swedish Energy Agency

Activities within Component Integration, Industrial Gas Turbines, Integration of Chillers

GT-Inlet Chillers,
Future potentials The use of absorption chillers + Integration with CHP + Improved heat rate - Higher investment
Net Output
60.0

50.0

Net Output MW

40.0

30.0

Net Output MW Net Output MW, Chiller in operation

20.0

10.0

0.0 -40.0 -30.0 -20.0 -10.0 0.0 10.0 20.0 30.0 40.0 50.0

Ambient Temperature

WorkPackage 5 -Component Integration

After Six WorkShops: Presentations from; Several EU projects (RTD and Thematic Networks) Several CHP players -equipment, plant optimisation, concepts 3 Main themes & conclusions: Most efficient design not necessarily most economic solution !
Economics is the key !

Deregulated market raises issues

Difficulty launching new technologies with associated technical and commercial risks

Fuel flexibility to maximise economic benefits

Non-standard fuels, i.e. gasification of biomass and wastes Avoid disposal costs, Benefit from green energy financial incentives

Outputs
Suggested RTD areas! Further research in both conventional & emerging technologies, required to improve: Reliability Fuel flexibility Efficiencies First costs Need for Government to help underwrite Commercial Risks associated with new technologies International competitors receive company and technology specific funding from concept to commercial demonstration

Work Package 5 CHP Component Integration

Overview of WP5 Objectives Conclusions

Overview, SIEMENS Industrial Gas Turbines Activities within Component Integration for Industrial Gas Turbines

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Integration is a major challenge

Industrie Turbinen Power Generation KWU AG AEG Westinghouse Mannesmann Demag DemagDelaval Delaval I-Segment KWU Industrial Applications

ASEA BBC Ruston Alsthom 1960 1970 1980 GEC ABB ABB Alstom Power Alstom Alstom

GEC Alsthom 1990

2000

2003

Siemens Gas Turbine product range

PGF Gas Turbine range
W501G W501F W501D5A V64.3A V94.3A V94.2A V94.2 V64.3A GTX100
43 MW 30 MW 25 MW 17 MW 13 MW 8 MW 7 MW 5 MW Cyclone V94.3A 67 MW 182 MW 159 MW 67 MW 121 MW 190 MW 253 MW

60HZ
266 MW

50HZ

PGI Gas Turbine range

GT10C GT10B GT35C Cyclone Tempest Tornado Typhoon

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Activities within Component Integration, Industrial Gas Turbines, Gasification

Power from Biomass & Wastes

Not new technologies Many years experience in chemical industry Little experience of Biomass Integrated Gasification Combined Cycle (BIGCC) Growing experience using these technologies BIGCC concept has been proven at Vrnamo, Sweden

Activities within Component Integration, Industrial Gas Turbines, Gasification

Gasifier Fuel Input Flare

BIGCC Scheme

Gas Cooler Booster Compressor

Hot Gas Filter

Gas Turbine

Start-up fuel store

Steam Turbine Stack Air HRSG

Heat Load

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Activities within Component Integration, Industrial Gas Turbines, Gasification

Power from Biomass & Wastes

Net efficiency comparison for sub-40MW plant
Air blown or oxygen-blown Atmospheric or pressurised Circulating, bubbling or fixed beds
Bio Oil CCGT Pressurised BIGCC

Atmospheric BIGCC Atmospheric Gasifier + Gas Engine CFB

All systems produce different fuel gas compositions and calorific values !
3.5 to 30MJ/Nm, 5 to 50% hydrogen Combustion issues
0 5 10 15 20 25 30 35 40 45

Direct Combustion

Activities within Component Integration, Industrial Gas Turbines, Gasification Potential Future Applications
Integrated Agriculture & Biomass-IGCC Plants of 5 - 20MW output Use waste from main crop to provide fuel for CHP scheme to heat greenhouses etc. Atmospheric or pressurised gasifiers Potentially >35% net efficiency Large scale Biomass-IGCC Plants of 20 - 40MW output optimised for power generation Atmospheric or pressurised gasifiers Potentially > 40% net efficiency

Conclusions
Use of Gas Turbine-based schemes could: Assist in the development of advanced thermal conversion technologies and ecofriendly CHP Offer high efficiency, low emission, carbon neutral power generation from biomass and wastederived fuels

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Activities within Component Integration, Industrial Gas Turbines, Integration of Chillers

GTX100 Nominal Generator Output vs Inlet Temp A Typical Gas Turbine Characteristic

Activities within Component Integration, Industrial Gas Turbines, Integration of Chillers

General description of the system
The system consists of 2 parallel chillers and 1 common water loop to the air inlet coil. The air inlet coil is a part of the air inlet system

Evaporators Compressors. Condensers

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