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Work Package 5 CHP Component Integration

Ulf Linder, Head of Future TechnologyGeraldine Roy, Lead Market Analyst

Siemens Industial Turbomachinery Ltd


Overview of WP5ObjectivesConclusions

Overview, SIEMENS Industrial Turbomachinery LtdActivities within Component Integration for Industrial Gas Turbines

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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

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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 Düsseldorf• 4th Workshop held 17 December 2003 in Brussels• 5th Workshop held 28 & 29 January 2004, Västerås, Sweden• 6th Workshop held 26 & 27 May 2004, Barcelona, Spain

• Often combined with WP7 – Cooling & Trigeneration


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


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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


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 Mãlardalens University• Absorption chillers in Cooling and Tri-generation applications, WEIR Entropie• Gas Turbines and Chillers Integration, DDIT• Fogging and High Fogging : ALSTOM´s Experience and Customer Benefits,

ALSTOM Power • SOFC - Future CHP, Siemens• Gas engines – Maintenance philosophies, Wärtsilä• CHP Systems Integration, Tecnicas Reunidas • Biofuel based CHP production in Sweden and CHP R&D at CEDER (Soria/Spain),

CIEMAT


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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

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The Customer’s PerspectiveTopics

• 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

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INNOGY Isoengine Cycle Diagram

Recuperator

Turbo HX

Engine Generator

Isot

herm

alC

ompr

esso

r(2

cyl

inde

rs)

~

Engine HX

HP AirWater

FuelCombustion gas

LP Air

Air-Water (Two-Phase)Isobaric

Combustors(6 cylinders)

Water Injection

Turbocharger Exhaust

Separator

Spray WaterCooler

Air CoolerAux.Cooler Fuel

A biogas plant

The simplest biogas plant is a cow...

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Functional scheme of abiopower station

Deliv. solid residues Crushing Pulper

Deliv. liquid residues

Waste gas to biofilterPump

Homogenization Hygienization

Cleaned waste air

Heat exchanger

Digestion

Heat storage

CHP unit

Flare

Gas storageDesulphu-

risationDrying

Storagetank

Transport digested substrateElectricity

Heat

• 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

Key figures, Sweden*

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GT-Inlet Chillers, Future potentials

• The use of absorption chillers

+ Integration with CHP

+ Improved heat rate

- Higher investmentNet Output

0.0

10.0

20.0

30.0

40.0

50.0

60.0

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

Ambient Temperature

Net

Out

put M

W

Net Output MW

Net Output MW, Chiller in operation

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

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


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OutputsSuggested 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


Overview of WP5ObjectivesConclusions

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

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Power Generation

AEGKWU AG

20001990198019701960

KWU

IndustrieTurbinen

2003

Industrial Applications

Westinghouse

Mannesmann Demag

DelavalDemagDelaval

Alstom

ABB

GEC AlsthomAlsthom

GEC

BBC

ASEAABB

AlstomPower

I-Segment

AlstomRuston

Integration is a major challenge

Siemens Gas Turbine product range

W501G

W501F

W501D5A

V64.3A

V94.3A

V94.2A

V94.2

V64.3A

GTX100

GT10C

GT10B

GT35C

Cyclone

Tempest

Tornado

TyphoonPGI G

as T

urbi

ne ra

nge

PGF

Gas

Tur

bine

rang

e

Cyclone

50HZ

60HZ

V94.3A

5 MW

7 MW

8 MW

13 MW

17 MW

25 MW

30 MW

43 MW

67 MW

159 MW

182 MW

266 MW

67 MW

121 MW

190 MW

253 MW

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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 Värnamo, Sweden

Activities within Component Integration, Industrial Gas Turbines, Gasification

BIGCC Scheme

Start-up fuel store

Gasifier Flare

Heat Load

Steam Turbine

Gas Turbine

AirStack

Hot Gas FilterGas Cooler

BoosterCompressor

Fuel Input

HRSG


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Power from Biomass & WastesNet efficiency comparison for sub-40MW plant

0 5 10 15 20 25 30 35 40 45

Direct Combustion

CFB

Atmospheric Gasifier +Gas Engine

Atmospheric BIGCC

Pressurised BIGCC

Bio Oil CCGT


–Air blown or oxygen-blown–Atmospheric or pressurised

–Circulating, bubbling or fixed beds

All systems produce different fuel gas compositions and calorific values !

–3.5 to 30MJ/Nm³, 5 to 50% hydrogen

•Combustion issues

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

Potential Future Applications

Use of Gas Turbine-based schemes could:

• Assist in the development of advanced thermal conversion technologies and eco-friendly CHP

• Offer high efficiency, low emission, carbon neutral power generation from biomass and waste-derived fuels

Conclusions


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GTX100 Nominal Generator Output vs Inlet Temp

A Typical Gas Turbine Characteristic


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


Compressors.

Evaporators

Condensers

Education

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