Review of Gas Based Power

Technologies – Gas Turbines

Robin W. Ames
Project Manager, Advanced Energy Systems Division, SCC

U.S
U.S.DOS
DOSForeign
ForeignService
ServiceOfficer’s
Officer’sCoal
Coaland
andPower
PowerTraining
TrainingCourse,
Course,July
July17,
21,2013
2011
 Presentation Overview
• What is NG
• Natural Gas Based Electric Power
Generation
– Simple cycle & combined cycle
– Balance of plant
– Emissions
• Original Equipment Manufactures
– GE, Siemens, P&W
– Performance and cost
• NG Power Cycles Issues for Today’s World
– R&D topics
– Fuel supply and cost
– Marcellus Shale
– LNG
– CCS
• Summary

2
 What is Natural Gas

• Natural gas is a mixture of gases - 70 - 90 %

methane (CH4); 0 – 20 % ethane, propane
butane; ~ 8 % Carbon dioxide, 0 – 5 % H2S;
plus others (oxygen, nitrogen, rare gases).
• Nominal heating value ~ 24,000 Btu / lb (1000
Btu / ft^3)
– Gasoline -20,400 Btu/lb
– Wood – 6,500 Btu/ lb
• Natural Gas as a fuel provides ~ 20 % of the
U.S. electricity
– Home heating
– Transportation fuel

3
 World’s Reliance on Fossil Energy Will Continue
Energy Demand 2006 Energy Demand 2035
107 QBtu / Year
98 QBtu / Year
81% Fossil Energy
84% Fossil Energy

Coal Gas + 9% Coal Gas

21% 25% 20% 25%
Nuclear Nuclear
Oil 9% United States
Oil 9%
38% Renewables 35%
7% Renewables
11%
716 QBtu / Year
487 QBtu / Year 79% Fossil Energy
81% Fossil Energy
+ 47% Coal Gas
Coal Gas
29% 22%
27% 21% Nuclear Nuclear
World 8%
Oil 6%
Oil
33% Renewables 28% Renewables
13% 15%
4
U.S. data from EIA, Annual Energy Outlook 2012 ; world data from IEA, World Energy Outlook 2010
 U.S. Electrical Generation by Fuel Type
(2012 Data)

4,775 Billion kWh

3,879 Billion kWh
20% 10%

24%
23% Increase
45%

1%

Coal
2010 Petroleum
2035
Natural Gas
Nuclear Power Natural gas as a fuel provides
Renewable Sources ~ 25 % of the U.S. electricity

Source: EIA, Annual Energy Outlook 2012 Early Release, years 2010 and 2035
 Natural Gas Price Forecast ($2009)
DOE/EIA AEO 2011 Reference Forecast
$16.00

$14.00
Natural Gas Price ($/MMBtu)

$12.00
Residential

$10.00 Commercial

$8.00

Electric Power
$6.00 Industrial

$4.00
Average Wellhead Price

$2.00

$0.00
2005 2010 2015 2020 2025 2030 2035
Actual Henry Hub Spot
Price for 7/10/13 = $3.69 YEAR
MMBtu
6
 Overview of Natural Gas Simple Cycle
and Combined Cycle Power Systems

7
 Basic Gas Turbine Engine
Simple Cycle

Combustion
Chamber

(3) (5)
(2)

(1) (4) net work

Gas Generator

8
 Thermodynamic Diagrams for Basic GT Cycle

p
Τ
2 3
3

4 4

2 5
1
1
s υ

Temperature-entropy and pressure-specific volume

diagrams for an ideal air standard basic cycle.
9
 Basic Gas and Steam Turbine
Combined Cycle
Stack Gases

(6)
(d)
Fuel Pump

Recovery
Combustion Condenser
Boiler
Chamber

(2) (3)
(1) (4) (a) (b)
Turbine
(5)
ωnet (c)

Gas Turbine Steam Turbine

(a)

10
 Typical Balance Of Plant Equipment
In addition to the Basic Gas & Steam Turbine Power Island

• Heat Recovery Steam Generator (HRSG)

• Fuel system
• Exhaust stack
• Instrumentation & controls
• Equipment foundations
• Land
• Cooling tower
• Oil and lube system

11
 GE H-Class Gas Turbine

12
 Siemens SGT6-6000G (W501G)

13
 Gas Turbine Courtesy Siemens Power Generation
14
 Construction of Steam Turbines

15

From Michał Bieniek

 Steam Turbine Operation

• Impulse stage – whole

pressure drop in nozzle
(whole enthalpy drop is
changed into kinetic
energy in the nozzle)

• Reaction stage –
pressure drop both in
stationary blades and
in rotary blades
(enthalpy drop changed
into kinetic energy both
in stationary blades
and in the moving
blades in rotor)

16
 Gas Turbine Emissions
Major Species Typical Source
Concentration
(% Volume)
Nitrogen (N2) 66 – 72 Inlet Air

Oxygen (O2) 12 – 18 Inlet Air

Carbon Dioxide (CO2) 1–5 Oxidation of Fuel Carbon

Water Vapor (H2O 1–5 Oxidation of Fuel Hydrogen

Minor Species Typical Source
Pollutants Concentration
(PPMV)
Nitric Oxide (NO) 20 – 220 Oxidation of Atmosphere Nitrogen

Nitrogen Dioxide (NO2) 2 – 20 Oxidation of Fuel-Bound Organic Nitrogen

Carbon Monoxide (CO) 5 – 330 Incomplete Oxidation of Fuel Carbon

Sulfur Dioxide (SO2) Trace – 100 Oxidation of Fuel-Bound Organic Sulfur

Sulfur Trioxide (SO3) Trace - 4 Oxidation of Fuel-Bound Organic Sulfur

Unburned Hydrocarbons (UHC) 5 – 300 Incomplete Oxidation of Fuel or Intermediates

Particulate Matter Smoke Trace – 25 Inlet Ingestion, Fuel Ash, Hot-Gas-Path Attrition,
Incomplete Oxidation of Fuel or Intermediates
17

Reference: Gas Turbines Emissions Control, GE, GER 4211

 NOx Control Technologies

• SCR – Selective Catalytic Reduction

– Achieves 2 ppm NOx at 15 % O2
– Ammonia slip 2 ppm
– For simple and combined cycle
– Usually used in conjunction with dry low NOx
technology
– Installed in the HRSG
• Lean premix combustion
– In turbine / combustor control
– 9 > NOx < 25 ppm @ 15 % O2

18
 Siemens Combined Cycle Plant (60 Hz)
Payne Creek, Florida, USA

19
 Siemens Combined Cycle Plant (60 Hz)
Wansley, Georgia, USA

20
 GE 16 Simple-Cycle Gas Turbines
Duke Power - Charlotte, NC

21
 GE 4x2 Combined Cycle Configuration
Burrillville, RI

22
 TM
Pratt & Whitney FT8 TwinPac
CalPeak Border Site (Otay Mesa, CA)

FT8-2 (DLN)

23
 FT8 TWINPAC™

Exhaust
Fuel Fuel

Inlet Inlet
61.9
MW

Gas Power Electric Power Gas

Generator (GG8) Turbine Generator Turbine Generator (GG8)

FT8-3 FT8-3
Electricity

Installed Base Has Surpassed 400 Engines

24
 Pratt & Whitney FT8 MobilePac™

Eight to Twenty-Four Hour Installation

25
 Costs for Combined Cycle Power Plants
Model Power Efficiency Configuration Plant Price $/kW
Out (MW) (%) Brayton/Rankin ($K)

SCC6- 307 57 1xSGT6- 174,700 569

500F 5000F/1x101M
Siemens W,3P,R
107FA 319.6 57.7 1x7FA 181,400 568
GE .05/1x109.3MW,
3P,R
SCC6- 410 60 1xSGT6-8000H 231,800 565
8000H 1S /1x135MW,3P,R
Siemens
107H 400 60 1x7001H/1x137 220,600 552
GE MW,3P,R
207FA 559.7 57.9 2x7FA.04/1x199 279,200 499
GE MW,3P,R
Note: Cost includes a basic GT, ST, HRSG w/ R, generator and BOP system
Reference: 2012 Gas Turbine World Handbook, Vol. 29
26
 Number of Units by Prime Mover
Combined or Simple Cycle

Average
Prime Nameplate Average
Mover Capacity Heat Rate
(MW) (Btu/kWh)
Combined
Combined
Cycle, Cycle* 343 9,254
644 Simple
Cycle 52 15,270

* Combined cycle
units include the
Simple
entire generating
Cycle, 3003
package, e.g. two
GT’s and one ST
27

Data source: analysis and synthesis of Energy Velocity database, “Capacity by unit” and “generation by unit” queries filtered for
status and prime mover
 Manufacturer Distribution
Gas turbine number of units by manufacturer
32%
GE,1291
Not listed,969 GE
Siemens,338
11% Pratt & Whitney,216 dominates
Other,57
Solar,54 both GT and
Rolls Royce,48
ALSTOM,30
CC
7%
markets…
2%
Combined Cycle number of units by manufacturer
2% 19%
2%
1% GE,355
43% Siemens,120
14% Not listed,93
ALSTOM,27
Toshiba,15
…but there are many “not 55%
Other,23
4% Solar,11
listed” entries in the 4%
2%

2%
database
28
 Distribution of NOx Control Methods

NOx control method CC GT Grand Total

Low NOx Burners 336 537 873
Dry Low NOx Burners 296 531 827
Selective Catalytic Reduction 339 176 515
Ammonia Injection 15 8 23
Water injection 106 708 814
Steam Injection 66 9 75
Overfire Air 6 6
Combustion Modification or
Fuel Reburning 5 11 16

29
 Issues of The Day
Related to Gas Turbine Power Generation

30
 R&D Areas Advance Turbine Performance
Combustion Materials

Cost
Power
Efficiency
System Design Emissions Aerodynamics &
Heat Transfer

31
 Targeted Areas for H2 Turbine Improvement
Turbine
Improved aerodynamics, longer
airfoils for a larger annulus / higher
Combustor mass flow and improved internal
Combustion of hydrogen fuels cooling designs to minimize cooling
with single digit NOx, no flows while at higher temperatures
Compressor flashback and minimal
Improved compressor efficiency combustion instability
through three dimensional aero
dynamics for higher pressure
ratio

Exhaust Diffuser
Improved diffuser designs for higher
temperature exhaust, lower pressure
drop with increased mass flow

Rotor Leakage
Materials Reduced leakage at tip and wall
Increase rotor torque for higher
Improved TBC, bond coats and interface and reduced
power output and the potential
base alloys for higher heat flux, recirculation at nozzle/rotating
for lowering capital cost ($/kW)
thermal cycling and aggressive airfoil interface for higher turbine
conditions (erosion, corrosion efficiency and less purge
and deposition) in IGCC
applications
Photo courtesy of Siemens Energy
32
 Emerging Shale Plays in the US

5 plays are dominating

Barnett – North central Texas

Woodford – SW Oklahoma
Fayetteville – NE Oklahoma, NW
Arkansas
Haynesville – NE Texas, NW
Louisiana
Marcellus – Pennsylvania, Ohio,
West Virginia

33
 CC and SC Power Systems as Back Up for
Renewables
• Renewable systems tend to be diurnal
– Periods of no power
– Wind
– Solar
• Natural gas fueled simple and combined cycle power
system offer potential back
– Load balancing
– Quick startup
– low cost
– Clean
– Could integrate in well with H2 production from
renewable system
34
 U.S. CO2 Emissions by Fuel and Use
US Energy-Related Carbon Dioxide Emissions
(million metric tons)
6500

6000

5500
3000
Million Metric Tons

5000
Petroleum 2008 2035
2500
Natural Gas

2000 Coal
Electricity
1500

1000

500

0
2010 2035 2010 2035 2010 2035 2010 2035 2010 2035
Residential Commercial Industrial Transportation Electric Power

Delivered, Including Losses

35

Source: EIA, Annual Energy Outlook 2011

 Cost of Electricity for Fossil Fuel
Power Plants That Capture CO2
LCOE by Cost Component CO2 TS&M
Plant O&M
140 Plant Fuel Costs
118.6 Plant Capital Cost
114.7
120 106.3
97.4
100
LCOE, mills/kWh

77.9
80 63.9 63.2
68.4

60

40

20

0
Avg IGCC Avg IGCC sub-PC sub-PC super-PC super-PC NGCC NGCC
CCS CCS CCS CCS
January 2007 Dollars, Coal cost $1.80/106Btu, Gas cost $6.75/106Btu
CCS = Carbon capture and sequestration
TS&M = transport, storage, and monitoring
36
 Gas-Based Power Technologies
Summary
• Natural gas (NG) provides 25 % of the US
electricity
– Will continue as a power system of choice
• NG combined cycle (CC) power plants are
the cleanest and most efficient source of
fossil fuel based power generation
• NG CC power plants provide a
competitive cost of electricity only
slightly more expensive then PC coal
– Very dependent on NG cost

37