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1GE Title or job number
6/27/2012
GE
Solutions for Steel
Metals Solutions
2GE Title or job number
6/27/2012
Global Challenges
What if …you could reduce operational energy costs?
20-40% of the cost of steel comes from energy costs
3GE Title or job number
6/27/2012
Global Challenges
What if …you could considerably increase your power output & efficiency utilizing the same amount of process gas?
30-40Typical power increase seen when shifting from BSTG to HDGT configuration
4GE Title or job number
6/27/2012
Global Challenges
What if …you could utilize by-pass gases as a means to reduce or eliminate your plants oxygen load?
10/700Pressure and temperature of compressor off-gassing in low-BTU applications
5GE Title or job number
6/27/2012
Global Challenges
What if …you could rapidly shift from one fuel source to the next without worrying about the calorific value?
1050+Currently advertised lowest heating value of a GE 9E low-BTU HDGT
6GE Title or job number
6/27/2012
You can… Technology & constant Innovation are the keys to answering these challenges
6
GE Low BTU fuel experience:• 4.7 GW installed (21 plants)• 47 gas turbines with LBTU/syngas• Over 2,000,000 operating hours• Plants in USA, Germany, Italy, Canada, Netherlands, Singapore, Czech Rep., China, Middle East
China170 MW Fuel: COREXSteel mill gases
Singapore173 MW Fuel: Refinery ResidueGE Gasification
Czech Republic350 MW Fuel: Brown CoalLurgi Gasification
7GE Title or job number
6/27/2012
38,000The number of homes’ equivalent of energy saved by installing one of GE’s 9E Gas Turbines
Power: From Process Gases
Combined Cycle Power: China175 MW Power houseBFG/COG fueledSaves $32 MM/yearReduces CO2 by 2 MM tons/year
8GE Title or job number
6/27/2012
IGCC Demo (1984)120 MW, 107E
GE Gasifier on Coal
IGCC (1996)350 MW, 209E
ZVU Gasifier on Coal
Clean Coal Proj. IGCC (1996)250 MW, 107FA
E-gas Gasifier on Coal/Coke
IGCC (1996)70 MW, 6B
GSP Gasifier on Coal
Refinery (1996)40 MW, 6B Cogen
GE Gasifier on Coke
Refinery (1997)120 MW, 206B Cogen/H2
Shell Gasifier on Coke
Refinery (2001)550 MW, 3x109E Cogen
GE Gasifier on TarRefinery (2000)180 MW, 2x6FA Cogen
GE Gasifier on Coke
Refinery (2000)173 MW, 2x6FA Cogen
GE Gasifier on Oil
Refinery (2008)160 MW, 2x7EA Cogen
Shell Gasifier on Asphaltene
Refinery (2009)253 MW, 2x9E CogenShell Gasifier on Oil
Steel Mill (1996)520MW, 3x109E Cogen
BFG/COG/LDG
Steel Mill (2001)180MW, 1x109E Cogen
BFG/COG/LDG
Steel Mill (2003)50MW, 6B Cogen
BFG/COG
Steel Mill (2008)450MW, 9x106B Cogen
BFG/COG
Steel Mill (2010)348MW, 2x109E Cogen
COREX
More than 4.7 GW of installed base operating on low BTU fuels, with over 2,000,000 operating hours
Clean Coal Proj. IGCC (1996)250 MW, 107FA
GE Gasifier on Coal/Coke
Heavy Duty Gas Turbine Syngas Experience
Steel Mill (2010)328MW, 2x109E Cogen
BFG/COG
GTL Project (2011)209 MW, 6x6B CogenShell Process Off-gas
Refinery (2003)105 MW, 3x6B Cogen
Lean Methane
9GE Title or job number
6/27/20129
9E Medium Btu fuel blend – Steelworks, Italy (BFG-COG-LDG-NG fuel blend solution)
• Syngas operation since 1996
• 520 MW 3x9E combined cycle w/cogeneration steam
• Blast furnace/coke oven/LDG fuel gas blend w/NG … 1810 kcal/Nm3 (~193 Btu/scf)
• Integrated single-shaft gas turbine/fuel gas compressor
• Availability >94% since ‘97
10GE Title or job number
6/27/2012
9E steel mill - Corex gas, China• 1x9E combined cycle in operation since 2008; 1x109E operation 1Q2011• COREX gas (~20%H2, 45%CO, 30%CO2) … 1950 kcal/Nm3 (~208 Btu/scf)• Integrated single-shaft gas turbine/fuel gas compressor designs• Multi-shaft combined cycle power generation• 1st plant achieved over 24,000 hrs. of operation with COREX gas in June ‘11
Alternative steel process- export gas 1x9E in operation since 2008
1x109E
11GE Title or job number
6/27/2012
9E, Steel Mill – BFG/COG Gas, China
12GE Title or job number
6/27/2012
9E Low Heating Value ModificationsIncreased S1N Throat Area
Tfire OptimizationSyngas Combustor
Air Extraction
Minimal changes….maintain 9E Robust Reliability
13GE Title or job number
6/27/2012
Syngas turbine controls & accessoriesVentilation mods
Inlet filter house
Inlet duct & plenum
Gas fuel module
Water injection skidExhaust system
Controls hardware and software
Accessory module
Liquid fuel and atomizing air
Static starter
Inlet bleed heat system
IGCC Controls with added I/O
N2/Steam injection skid
Syngas fuel skid with N2 purge
Optional air extraction skid
Enclosure modifications:• Piping for syngas, diluent, etc.• Explosion proofing• Hazardous gas detection• Fire protection
14GE Title or job number
6/27/2012
Packaging modifications for ultra LHV blended fuelgas PipingEnclosure
Air Extraction Fuel Skid
15GE Title or job number
6/27/2012
Summary• GE has considerable operational experience using low
calorific fuel gas for both steel mill and IGCC applications
• Blending of available mill fuel gas must be considered to meet minimum fuel heating value constraints
• Mill fuel gas must be extensively cleaned…removing particulate and tars to comply with turbine fuel specification requirements
• GT fuel control systems with load turndown, co-firing, and automation response capability provide flexibility with variable mill operations
• GE Gas turbine/combined cycle plants can be successfully utilized with ultra low heating value steel mill fuels
16GE Title or job number
6/27/2012
GE
Solutions for Steel
Metals Solutions
Questions?