Modular Power Plant Concepts from Siemens

Report
Modern Combined Cycle Power Plants –
Improvement of a high efficient and clean
technology
O. Kreyenberg, H. Schütz, H. Friede
Oct. 21, 2004
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
1
Authors: Schütz, 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
Oct. 21, 2004
Modern Combined Cycle Power Plants –
Improvement of a high efficient and clean technology
Power Generation
2
Authors: Schütz, Kreyenberg, Friede SPG
Market Conditions
The Market Conditions Have Changed
Dramatically in the Power Industry
Over the Last 10 Years
Efficiency
Risk Guarantee*
Overall
Construction Time
Price
Years
* technical warranties (NOx, et. al.), delivery time
Oct. 21, 2004
Modern Combined Cycle Power Plants –
Improvement of a high efficient and clean technology
Power Generation
3
Authors: Schütz, Kreyenberg, Friede SPG
Life Cycle Cost (LCC) Analysis
Parameters
Parameters influenced
by the supplier
Costs
Investment costs
Financing costs
Service life
Capital
costs
Demolition costs
Fuel contract
conditions
Efficiency
Fuel
Costs
Personnel costs
Consumables/waste
Spare parts
Maintenance
Oct. 21, 2004
Reduction of specific
investment costs
Operating
costs
Global sourcing
Live
Cycle
Costs
Modular design
Short delivery times
High process and
component efficiencies
Optimized level of
automation
High availability
Ease of maintenance
Modern Combined Cycle Power Plants –
Improvement of a high efficient and clean technology
Power Generation
4
Authors: Schütz, Kreyenberg, Friede SPG
Reference Power Plant
Product Overview
Oct. 21, 2004
Modern Combined Cycle Power Plants –
Improvement of a high efficient and clean technology
Power Generation
5
Authors: Schütz, Kreyenberg, Friede SPG
Our Reference Power Plants are Focused on
International Main Market Demand for IPP’s
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
100, 290, 400 MW
100, 270, 365 MW
Gas/Oil
Multi-Shaft 50 Hz
Modern Combined Cycle Power Plants –
Improvement of a high efficient and clean technology
60 Hz
200, 580, 800 MW
200, 540, 730 MW
Power Generation
6
Authors: Schütz, Kreyenberg, Friede SPG
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
Modern Combined Cycle Power Plants –
Improvement of a high efficient and clean technology
Power Generation
7
Authors: Schütz, Kreyenberg, Friede SPG
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
Modern Combined Cycle Power Plants –
Improvement of a high efficient and clean technology
Power Generation
8
Authors: Schütz, Kreyenberg, Friede SPG
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
Modern Combined Cycle Power Plants –
Improvement of a high efficient and clean technology
Power Generation
9
Authors: Schütz, Kreyenberg, Friede SPG
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
Modern Combined Cycle Power Plants –
Improvement of a high efficient and clean technology
Power Generation
10
Authors: Schütz, Kreyenberg, Friede SPG
Reference Power Plant
Design Philosophy
Oct. 21, 2004
Modern Combined Cycle Power Plants –
Improvement of a high efficient and clean technology
Power Generation
11
Authors: Schütz, Kreyenberg, Friede SPG
Evolution of Combined Cycle Power Plant
Efficiency
Steam cycle
Single pressure
60
Dual pressure
Net efficiency
(%)
58
56
54
52
50
48
46
Tripple pressure with reheat
960°C
—
50 bar
460°C
1983/84
1000°C
—
60 bar
485°C
1987/88
1050°C
—
75 bar
510°C
1120°C
—
80 bar
520°C
1160°C
—
100 bar
520°C
1190°C
200°C
110 bar
540°C
1230°C
130°C
110 bar
550°C
1250°C
1230°C 200°C
130°C
160 bar
125 bar 580°C
565°C
Turbine inlet
temp. (ISO)
Fuel preheating
Life steam
pressure
Life steam
temperature
Fuel gas firing
ISO ambient conditions
(15°C, 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
Source: Siemens Gas Turbines
Oct. 21, 2004
Modern Combined Cycle Power Plants –
Improvement of a high efficient and clean technology
Power Generation
12
Authors: Schütz, Kreyenberg, Friede SPG
Economical Evaluation Factors
Evaluation Factors (price related)
(at 12% targeted Internal Rate of Return for additional investment)
0.55
0‘6 mill
mill€€/ /MW
MW
Power Output
0
0.2
0.4
0.6
0.8
0
4
6
8
10
1.0
7.1
9‘8millmill
€ /€%-point
/ %-point
Efficiency
12
2.5
0‘9millmill
€ /€month
/ month
Lead Time
0
0.5
1
1,5
0
1
2
3
2
2.7
2‘6millmill
€ /€%-point
/ %-point
Availability
4
Boundary Conditions
Power Output
397 MW
Lead Time
Efficiency
57.00 %
Overall Project Costs
Load Regime
Electricity Price
Fuel Price
Oct. 21, 2004
Base Load (7000hr/a)
Debt/ equity ratio
37 € / MWh (escalation 1%/a)
Income Tax
(escalation 1%/a)
Operating Period
3.9 € / GJ
24  22 months
185 mill €
70 / 30
35 %
20 years
Modern Combined Cycle Power Plants –
Improvement of a high efficient and clean technology
Power Generation
13
Authors: Schütz, Kreyenberg, Friede SPG
Power Output, Efficiency, NOx-Emission and
Cooling Air Demand versus Combustion
Temperature
Gas turbine
Tcomb.
Fuel
2%
Combustion
air 80%
Air intake
Exhaust
gas
102%
Boundary conditions:
The same technology for
blade cooling, combustion
chamber cooling and
burner.
NOX
Heat recovery
steam generator
Combustion
chamber
NOX
100%
Electricity
Cooling air 20%
Generator
TCool.-air
hGUD
Steam turbine
Circulating
water
Electricity
Condenser
TIT
Generator
1570°C
Oct. 21, 2004
.
mKL
Modern Combined Cycle Power Plants –
Improvement of a high efficient and clean technology
1700°C TCombustion
Power Generation
14
Authors: Schütz, Kreyenberg, Friede SPG
Efficiency Improvements due to Increasing the
Number of Pressure Stages
Temperature curves in a
heat recovery steam generator
Temperature [°C]
1-pressure process
2-pressure process
600
3-pressure process
Efficiency increase
D h net
[%-points]
125 bar/565 °C
28 bar/565 °C
4 bar/235 °C
3
125 bar/565 °C
29 bar/320 °C
5 bar/200 °C
500
Exhaust gas
400
2
80 bar/540 °C
5 bar/210 °C
300
2.8
2.1
1
200
1.6
100
65 bar/540 °C
0
Oct. 21, 2004
Transfered heat
0
54.1%
1-pressure
2-pressure
Modern Combined Cycle Power Plants –
Improvement of a high efficient and clean technology
3-pressure
without
reheat
3-pressure
with
reheat
Power Generation
15
Authors: Schütz, Kreyenberg, Friede SPG
Quick Start up Increases Plant Utilisation
Factor...
GT at full load/
Bypass System closed
Start-up after 8h Shut-down
400
Plant Load [MW]
350
Plant start-up with
improved equipment
Typical plant start-up
300
250
200
150
100
50
0
≈ 40 min
Oct. 21, 2004
≈ 90 min
Modern Combined Cycle Power Plants –
Improvement of a high efficient and clean technology
Time
Power Generation
16
Authors: Schütz, Kreyenberg, Friede SPG
Limiting Values for Flue Gas Emissions
Oct. 21, 2004
Modern Combined Cycle Power Plants –
Improvement of a high efficient and clean technology
Power Generation
17
Authors: Schütz, Kreyenberg, Friede SPG
Relationship between turbine inlet temperature
and NOx emissions
2,5
2,0
NOx
*
1,5
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 !
Oct. 21, 2004
Modern Combined Cycle Power Plants –
Improvement of a high efficient and clean technology
Power Generation
18
Authors: Schütz, Kreyenberg, Friede SPG
Design Targets
Oct. 21, 2004
Modern Combined Cycle Power Plants –
Improvement of a high efficient and clean technology
Power Generation
19
Authors: Schütz, Kreyenberg, Friede SPG
One the way to the Technical leadership
now
tomorrow
Efficiency
58%*
> 59%
TIT**
1230°C
1290°C
NOx
25 ppm
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
Modern Combined Cycle Power Plants –
Improvement of a high efficient and clean technology
Power Generation
20
Authors: Schütz, Kreyenberg, Friede SPG
References
Oct. 21, 2004
Modern Combined Cycle Power Plants –
Improvement of a high efficient and clean technology
Power Generation
21
Authors: Schütz, Kreyenberg, Friede SPG
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
Modern Combined Cycle Power Plants –
Improvement of a high efficient and clean technology
Power Generation
22
Authors: Schütz, Kreyenberg, Friede SPG
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
Modern Combined Cycle Power Plants –
Improvement of a high efficient and clean technology
Power Generation
23
Authors: Schütz, Kreyenberg, Friede SPG

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