Modern Combined Cycle Power Plants - Improvement of A High Efficient and Clean Technology

Modern Combined Cycle Power Plants Improvement of a high efficient and clean technology
O. Kreyenberg, H. Schtz, H. Friede Siemens PG "Energy Efficiency in IPPC-installations" 21 and 22 October 2004 Vienna Modern Combined Cycle Power Plants Power Generation
Improvement of a high efficient and clean technology
Oct. 21, 2004
Authors: Schtz, Kreyenberg, Friede SPG
Agenda
Market Drivers Reference Power Plant Product Overview - Steam Power Plant - Combined Cycle Power Plant Reference Power Plant Design Philosophy Design Targets References
Power Generation 2
Oct. 21, 2004
The Market Conditions Have Changed Dramatically in the Power Industry Over the Last 10 Years
Market Conditions
Efficiency
Risk Guarantee*
Overall Construction Time Price
Years
* technical warranties (NOx, et. al.), delivery time
Oct. 21, 2004
Power Generation
Life Cycle Cost (LCC) Analysis
Parameters
Investment costs
Financing costs Service life Demolition costs Fuel contract conditions
Costs
Parameters influenced by the supplier

Reduction of specific investment costs
Global sourcing
Capital costs
Efficiency
Personnel costs Consumables/waste Spare parts
Fuel Costs
Live Cycle Costs
Modular design Short delivery times High process and component efficiencies Optimized level of automation High availability
Operating costs
Maintenance
Ease of maintenance
Oct. 21, 2004
Power Generation
Reference Power Plant Product Overview

Oct. 21, 2004
Power Generation
Our Reference Power Plants are Focused on International Main Market Demand for IPPs Varioplant 300 300- 450 MW 700 500- 750 MW 900 800- 1000 MW Coal/Oil
Customized...
of the shelf...
Components, Islands and Turnkey Gas/Oil

Single-Shaft 50 Hz 60 Hz
Oct. 21, 2004
Gas/Oil
Multi-Shaft 50 Hz 60 Hz
100, 290, 400 MW 100, 270, 365 MW
200, 580, 800 MW 200, 540, 730 MW

6
Power Generation
Multi-Shaft Combined Cycle Power Plant Econopac Arrangement
ECONOPAC
Gas turbine Gas turbine generator Air intake Exhaust gas system Fuel system Electrical package (SFC/SEE) GT - Auxiliaries Fire protection Options
Oct. 21, 2004
Power Generation
Multi-Shaft Combined Cycle Power Plant Power Island Arrangement
POWER ISLAND
Econopac Steam turbine Steam turbine generator incl. SEE Heat recovery steam generator Major pumps Condenser Critical valves ST - Auxiliaries
Cycle optimization
Fuel gas pre-heater Options
Oct. 21, 2004
Power Generation
Multi-Shaft Combined Cycle Power Plant Turnkey (Cooling Tower)
TURNKEY
Power Island Fuel supply systems Cooling systems Water treatment Raw water system Waste water system Tanks Cranes/ hoists Buildings/ structures Fire protection Plant piping/ valves Plant electrical Further options
Oct. 21, 2004
Power Generation
Multi-Shaft Combined Cycle Power Plant Turnkey with House (Cooling Tower)
TURNKEY
Power Island Fuel supply systems Cooling systems Water treatment Raw water system Waste water system Tanks Cranes/ hoists Buildings/ structures Fire protection Plant piping/ valves Plant electrical Further options
Oct. 21, 2004
Power Generation
10
Reference Power Plant Design Philosophy

Oct. 21, 2004
Power Generation
11
Evolution of Combined Cycle Power Plant Efficiency
Steam cycle Single pressure

60 58 56 Net efficiency (%) 1160C 100 bar 520C 1230C 130C 110 bar 550C 1250C 1230C 200C 130C 160 bar 125 bar 580C 565C
Dual pressure
Tripple pressure with reheat

Turbine inlet temp. (ISO)
54
52 50 960C 50 bar 460C 1983/84 1000C 60 bar 485C
1050C 75 bar 510C
1120C 80 bar 520C
Fuel preheating
Life steam pressure Life steam temperature
1190C 200C 110 bar 540C
48
46
Fuel gas firing ISO ambient conditions (15C, 1013 mbar, 60% rel. humidity) Condenser back pressure 0.04 bar 1990/91 1992/93 1994/95 1996/97 1998/99 2001 2005/06 Year of commissioning
1987/88
Source: Siemens Gas Turbines
Oct. 21, 2004
Power Generation
12
Economical Evaluation Factors

Evaluation Factors (price related)
(at 12% targeted Internal Rate of Return for additional investment)
Power Output
0 0.2 0.4 0.6 0.8 1.0
0.55 mill / MW 06 mill / MW 7.1 mill / / %-point 98 mill %-point

0 4 6 8 10 12
Efficiency Lead Time

0 0.5 1 1,5 2
2.5 mill / / month 09 mill month 2.7 mill / / %-point 26 mill %-point
0 1 2 3 4
Availability
Boundary Conditions
Power Output Efficiency Load Regime Electricity Price Fuel Price
Oct. 21, 2004
397 MW 57.00 % Base Load (7000hr/a) 37 / MWh (escalation 1%/a) 3.9 / GJ (escalation 1%/a)
Lead Time Overall Project Costs Debt/ equity ratio Income Tax Operating Period
24 22 months 185 mill 70 / 30 35 % 20 years

Power Generation 13
Power Output, Efficiency, NOx-Emission and Cooling Air Demand versus Combustion Temperature
Boundary conditions: The same technology for blade cooling, combustion chamber cooling and burner.
Gas turbine
Tcomb. Fuel 2% Combustion air 80% Air intake 100% Cooling air 20%
Exhaust gas 102%
. mKL
NOX
Combustion chamber
Heat recovery steam generator
NOX
Electricity Generator TCool.-air
Steam turbine
hGUD
Electricity
Circulating water Condenser Generator
TIT
1570C 1700C TCombustion
Oct. 21, 2004
Power Generation
14
Efficiency Improvements due to Increasing the Number of Pressure Stages
Temperature curves in a heat recovery steam generator

D h net [%-points] 3
Efficiency increase
Temperature [C] 600 500
1-pressure process 2-pressure process 3-pressure process
125 bar/565 C 28 bar/565 C 4 bar/235 C 125 bar/565 C 29 bar/320 C 5 bar/200 C
Exhaust gas 400 300 200 100

65 bar/540 C
80 bar/540 C 5 bar/210 C
2.8 1 1.6 54.1% 1-pressure 2-pressure 3-pressure without reheat 3-pressure with reheat 2.1
Transfered heat
Oct. 21, 2004
Power Generation
15
Quick Start up Increases Plant Utilisation Factor...

GT at full load/ Bypass System closed
Start-up after 8h Shut-down

400 350
Plant start-up with improved equipment
Typical plant start-up
Plant Load [MW]
300 250 200 150 100 50 0
40 min
Oct. 21, 2004
90 min
Time
Power Generation 16
Limiting Values for Flue Gas Emissions
Oct. 21, 2004
Power Generation
17
Relationship between turbine inlet temperature and NOx emissions
2,5
2,0
1,5
NOx
1,0 0,5 0,0 1220 1230 1240 1250 1260 1270 1280 1290 1300 1310 Temperatur in C
A temperature increase by 70K doubles the NOx- emissions !

Power Generation 18
Oct. 21, 2004
Design Targets
Oct. 21, 2004
Power Generation
19
One the way to the Technical leadership
now Efficiency TIT** NOx 58%* 1230C 25 ppm
tomorrow > 59% 1290C 9 15 ppm
* depending on cooling conditions ** turbine inlet temperature Details on additional measures will be presented at a VDI Symposium in Leverkusen 23./24. November 2004
Oct. 21, 2004
Power Generation
20
References
Oct. 21, 2004
Power Generation
21
Mainz-Wiesbaden, Germany Combined Cycle Power Plant V94.3A with Steam Extraction
Mainz - Wiesbaden (Germany) Concept: Multi Shaft 1+1 V94.3A Output (nat. gas, site) : 1 x 400 MW Efficiency (nat. gas, site): >58,4 %* COD: July 2001 Fuels: Natural Gas (Fuel oil Back up) Contract: EPC TK plus 10 y. S&M
Oct. 21, 2004
Power Generation
22
Pulau Seraya, Singapore: 2 CC 1S.V94.3A The Most Efficient Plant in SEA
Pulau Seraya (Singapore) Concept: Single Shaft 1S.V94.3A Output (nat. gas, site) : 2x 367 MW Efficiency (nat. gas, site): >57.2 % COD: November 2002 Fuels: Natural Gas (Fuel oil Back up) Contract: EPC TK plus 10 y. S&M
Oct. 21, 2004
Power Generation
23

Modern Combined Cycle Power Plants - Improvement of A High Efficient and Clean Technology

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Modern Combined Cycle Power Plants - Improvement of A High Efficient and Clean Technology

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Modern Combined Cycle Power Plants Improvement of a high efficient and clean technology

Oct. 21, 2004

Authors: Schtz, Kreyenberg, Friede SPG

Oct. 21, 2004

Authors: Schtz, Kreyenberg, Friede SPG

Overall Construction Time Price

Oct. 21, 2004

Authors: Schtz, Kreyenberg, Friede SPG

Life Cycle Cost (LCC) Analysis

Parameters influenced by the supplier

Live Cycle Costs

Oct. 21, 2004

Authors: Schtz, Kreyenberg, Friede SPG

Reference Power Plant Product Overview

Authors: Schtz, Kreyenberg, Friede SPG

Components, Islands and Turnkey Gas/Oil

100, 290, 400 MW 100, 270, 365 MW

200, 580, 800 MW 200, 540, 730 MW

Authors: Schtz, Kreyenberg, Friede SPG

Multi-Shaft Combined Cycle Power Plant Econopac Arrangement

Authors: Schtz, Kreyenberg, Friede SPG

Multi-Shaft Combined Cycle Power Plant Power Island Arrangement

Authors: Schtz, Kreyenberg, Friede SPG

Multi-Shaft Combined Cycle Power Plant Turnkey (Cooling Tower)

Authors: Schtz, Kreyenberg, Friede SPG

Authors: Schtz, Kreyenberg, Friede SPG

Reference Power Plant Design Philosophy

Authors: Schtz, Kreyenberg, Friede SPG

Evolution of Combined Cycle Power Plant Efficiency

Steam cycle Single pressure

Tripple pressure with reheat

1050C 75 bar 510C

1120C 80 bar 520C

1190C 200C 110 bar 540C

Source: Siemens Gas Turbines

Oct. 21, 2004

Authors: Schtz, Kreyenberg, Friede SPG

Economical Evaluation Factors

(at 12% targeted Internal Rate of Return for additional investment)

0.55 mill / MW 06 mill / MW 7.1 mill / / %-point 98 mill %-point

Efficiency Lead Time

24 22 months 185 mill 70 / 30 35 % 20 years

Authors: Schtz, Kreyenberg, Friede SPG

Exhaust gas 102%

Heat recovery steam generator

Circulating water Condenser Generator

Oct. 21, 2004

Authors: Schtz, Kreyenberg, Friede SPG

Efficiency Improvements due to Increasing the Number of Pressure Stages

Temperature curves in a heat recovery steam generator

Temperature [C] 600 500

1-pressure process 2-pressure process 3-pressure process

125 bar/565 C 28 bar/565 C 4 bar/235 C 125 bar/565 C 29 bar/320 C 5 bar/200 C

Exhaust gas 400 300 200 100

Oct. 21, 2004

Authors: Schtz, Kreyenberg, Friede SPG

Quick Start up Increases Plant Utilisation Factor...

Start-up after 8h Shut-down

Plant start-up with improved equipment

Typical plant start-up

Plant Load [MW]

300 250 200 150 100 50 0