Gmrc Conf

GMRC conferenceGMRC conferenceEmissions Reduction from Emissions Reduction from Legacy Gas Turbines in Legacy Gas Turbines in Compression ServiceCompression Service

Zero Stage, Inc. – Dennis J. Cousino, P.E.Zero Stage, Inc. – Dennis J. Cousino, P.E.

Gas Turbines in CompressionGas Turbines in Compression

According to Industry Info Resources, According to Industry Info Resources, Inc., there are over 2,200 gas turbine Inc., there are over 2,200 gas turbine powered compressor stations in the powered compressor stations in the US, averaging 7,200 HP per station, US, averaging 7,200 HP per station, for over 16,000,000 installed HP.for over 16,000,000 installed HP.

Most of this capacity was installed over Most of this capacity was installed over 25 years ago, some as much as 50 25 years ago, some as much as 50 years ago, still functional, and in active years ago, still functional, and in active service.service.

Demand for Pipeline CapacityDemand for Pipeline Capacity

The use of natural gas as a fuel for The use of natural gas as a fuel for electric power is growing exponentially, electric power is growing exponentially, and Green House Gas legislation will and Green House Gas legislation will drive additional pipeline demand.drive additional pipeline demand.

Natural gas as a vehicle fuel is expected Natural gas as a vehicle fuel is expected to grow at double digit rates in the US, to grow at double digit rates in the US, from 0.4% currently, to over 22% by from 0.4% currently, to over 22% by 2030, adding further to the current 2030, adding further to the current pipeline capacity shortagepipeline capacity shortage

Compressor Station EmissionsCompressor Station Emissions

All pipeline companies are experiencing All pipeline companies are experiencing a need to meet demand and increase a need to meet demand and increase compression horsepower, which compression horsepower, which triggers changes in Operating Permits.triggers changes in Operating Permits.

In order to increase their capacity In order to increase their capacity pipelines have been faced with pulling pipelines have been faced with pulling out old, dirty gas turbine compressors, out old, dirty gas turbine compressors, and replacing them with either;and replacing them with either;– Larger, low emission, gas turbines, or,Larger, low emission, gas turbines, or,– Electric motor driven compressorsElectric motor driven compressors

A Brief History of Emissions A Brief History of Emissions Reduction StrategiesReduction Strategies

In the mid 1980’s, when emissions from vehicles In the mid 1980’s, when emissions from vehicles were first legislated, car companies turned to a were first legislated, car companies turned to a technology that could be added-on to their old technology that could be added-on to their old design, dirty engines, and used to improve design, dirty engines, and used to improve emissions. This technology was emissions. This technology was turbochargingturbocharging..

By adding a turbo, the amount of air flow thru By adding a turbo, the amount of air flow thru the engine was increased, this caused;the engine was increased, this caused;– Increased power capability of the engine, allowing Increased power capability of the engine, allowing

it to meet the demand at a lower throttle setting, it to meet the demand at a lower throttle setting, – Improved fuel efficiency, and, Improved fuel efficiency, and, – Lower peak combustion temperatures. Lower peak combustion temperatures.

All of which lowered NOx & CO emissionsAll of which lowered NOx & CO emissions

Everything Old is New Again!Everything Old is New Again!

Turbocharging works on reciprocating Turbocharging works on reciprocating engines and gas turbines alike, with engines and gas turbines alike, with similar emission and performance resultssimilar emission and performance results

Compressor set manufacturers, like car Compressor set manufacturers, like car companies, are not in the business of companies, are not in the business of encouraging customers to keep old units encouraging customers to keep old units in place, it hurts their sales!in place, it hurts their sales!

Government legislation is focused on Government legislation is focused on getting polluters to make as large a getting polluters to make as large a reduction as possible, no mater the cost.reduction as possible, no mater the cost.

But, there’s another, better way!But, there’s another, better way!

Combustion 101Combustion 101 The basic principals of all combustion The basic principals of all combustion

processes are; processes are; –TimeTime (combustion gas residence time) (combustion gas residence time)–TemperatureTemperature (even flame temperatures) (even flame temperatures) –TurbulenceTurbulence (good air/fuel mixing) (good air/fuel mixing)

Every combustion chamber is designed Every combustion chamber is designed by the manufacturer to optimize these by the manufacturer to optimize these three components, three components, at a specific at a specific design pointdesign point, for the best efficiency , for the best efficiency and lowest emissions.and lowest emissions.

New, auto tuning, Wobbe Index, fuel New, auto tuning, Wobbe Index, fuel control systems work this way.control systems work this way.

Combustion 101Combustion 101 Since gas turbine OEM’s rate their engines Since gas turbine OEM’s rate their engines

at sea level, 59 F, 60% RH and no inlet or at sea level, 59 F, 60% RH and no inlet or exhaust restrictions, this becomes the exhaust restrictions, this becomes the design point for the combustion system.design point for the combustion system.

Unfortunately, Unfortunately, –packaging the units builds in duct losses,packaging the units builds in duct losses,–most sites are not at sea level, most sites are not at sea level, –ambient temperatures change,ambient temperatures change,– relative humidity fluctuates, relative humidity fluctuates,

so, the engine is operating off its so, the engine is operating off its optimum combustion point optimum combustion point

all the time.all the time.

Combustion 101Combustion 101 Off-design combustion conditions Off-design combustion conditions

result in higher emissions related to;result in higher emissions related to;– poor air/fuel mixing & mis-matched A/F poor air/fuel mixing & mis-matched A/F

ratio = high CO emissionsratio = high CO emissions– high flame temperatures = high NOx high flame temperatures = high NOx

emissions & combustion system damageemissions & combustion system damage

External, controlled pressurization of External, controlled pressurization of the inlet, the inlet, the ZSI Solutionthe ZSI Solution, allows , allows the engine to operate at its optimum the engine to operate at its optimum point point all the timeall the time..

Zero Stage TechnologyZero Stage Technology The Company name says it all, The Company name says it all,

““Zero Stage”Zero Stage”

We add an external compression stage We add an external compression stage in front of the gas turbine compressor, in front of the gas turbine compressor, a “0” row in front of the 1a “0” row in front of the 1stst row. row.

This compression stage forces more air This compression stage forces more air into the engine & optimizes combustion into the engine & optimizes combustion by operating at the best point, all the by operating at the best point, all the time, resulting in lower emissions, time, resulting in lower emissions, better efficiency and more power.better efficiency and more power.

Zero Stage TechnologyZero Stage Technology Mechanical power used to drive this external Mechanical power used to drive this external

compression stage translates directly into gas compression stage translates directly into gas horsepower, in the pipeline, horsepower, in the pipeline, increasing increasing station capacity.station capacity.

Power for the system can be electricity or Power for the system can be electricity or energy recovered from the exhaust, either of energy recovered from the exhaust, either of which comes which comes without any additional without any additional station emissions.station emissions.

Net emissions reductions of over 50%, in Net emissions reductions of over 50%, in tons/yr are possible tons/yr are possible in legacy enginesin legacy engines, with , with a +20% efficiency improvement.a +20% efficiency improvement.

New, low emissions engines are able to New, low emissions engines are able to operate without costly, seasonal emissions operate without costly, seasonal emissions “tuning”, at full, MCR power, all the time.“tuning”, at full, MCR power, all the time.

Boost HP to IGHP ConversionBoost HP to IGHP Conversion Actual Test - 1,100 HP (ISO) – 1980 Solar SaturnActual Test - 1,100 HP (ISO) – 1980 Solar Saturn

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Gas Generator Inlet Pressure (Inches H20)

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Zero Stage TechnologyZero Stage Technology The external stage has a separate, variable speed The external stage has a separate, variable speed

control system, which allows for adjustments to meet control system, which allows for adjustments to meet site specific conditions of altitude, temperature, site specific conditions of altitude, temperature, barometric pressure and humidity, and keeps barometric pressure and humidity, and keeps emissions levels consistently at the lowest point.emissions levels consistently at the lowest point.

The existing gas turbine control system is un-The existing gas turbine control system is un-affected by the addition of this compression stage, affected by the addition of this compression stage, since it is still controlling gas generator speed and since it is still controlling gas generator speed and limiting firing temperature, by adjusting fuel flow.limiting firing temperature, by adjusting fuel flow.

The inlet air density, at the first stage of the gas The inlet air density, at the first stage of the gas turbine compressor is set by regulating the speed of turbine compressor is set by regulating the speed of the ZSI compressor to match sea level, cold ambient the ZSI compressor to match sea level, cold ambient conditions, keeping the engine controls within spec., conditions, keeping the engine controls within spec., by using an absolute pressure transmitter, just like by using an absolute pressure transmitter, just like your car does!your car does!

Fuel Valve Response to BoostFuel Valve Response to Boost Actual Test - 1,100 HP (ISO) – 1980 Solar SaturnActual Test - 1,100 HP (ISO) – 1980 Solar Saturn

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Zero Stage TechnologyZero Stage Technology Most gas turbine driven compressor stations are not Most gas turbine driven compressor stations are not

able to use all the mechanical capability of the able to use all the mechanical capability of the compressor, except on very cold days. The ZSI compressor, except on very cold days. The ZSI system unlocks this un-used capacity every day, all system unlocks this un-used capacity every day, all day, at every site, under any ambient condition.day, at every site, under any ambient condition.

The added pressure ratio, improved cycle efficiency, The added pressure ratio, improved cycle efficiency, improved combustion system mixing & increased air improved combustion system mixing & increased air mass flow result in lower combustion temperatures. mass flow result in lower combustion temperatures. Along with reduced emissions of CO & NOx, these Along with reduced emissions of CO & NOx, these lower temperatures extend the time-between-lower temperatures extend the time-between-overhaul interval for the engine.overhaul interval for the engine.

The variable compression stage can be used to The variable compression stage can be used to compensate for internal air seal leakage within the compensate for internal air seal leakage within the gas turbine, resulting in improved flexibility in gas turbine, resulting in improved flexibility in planning maintenance outages.planning maintenance outages.

Comb. Efficiency Improvement & Load ControlComb. Efficiency Improvement & Load ControlActual Test - 1,100 HP (ISO) – 1980 Solar SaturnActual Test - 1,100 HP (ISO) – 1980 Solar Saturn

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Gas Generator Inlet Pressure (Inches H2O)

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Electric Powered ZSI Boost Unit Energy BalanceElectric Powered ZSI Boost Unit Energy Balance 26,000 HP (ISO) – 1972 GE Frame 5 @ 100 F, 2,600’ ASL26,000 HP (ISO) – 1972 GE Frame 5 @ 100 F, 2,600’ ASL

Typical Electric Powered ZSI Boost UnitTypical Electric Powered ZSI Boost Unit Application; 26,000 HP – 1972 GE Frame 5Application; 26,000 HP – 1972 GE Frame 5

Typical Electric Powered ZSI Boost UnitTypical Electric Powered ZSI Boost Unit 4,000 HP Boost Fan – Application; GE Frame 54,000 HP Boost Fan – Application; GE Frame 5

Zero Stage Technology CostsZero Stage Technology CostsReplacing a 10,000 hp Existing Turbine CompressorReplacing a 10,000 hp Existing Turbine Compressor

New mid-range (ISO rating), gas turbine compressor New mid-range (ISO rating), gas turbine compressor set costs are about $350/hp, not counting project set costs are about $350/hp, not counting project support, engineering & installation costs. support, engineering & installation costs.

New turbines are still susceptible to significant New turbines are still susceptible to significant altitude, temperature, barometric pressure & humidity altitude, temperature, barometric pressure & humidity de-rates, as high as 40% on hot days, for stations at de-rates, as high as 40% on hot days, for stations at elevations of 3,000’ ASL and higher.elevations of 3,000’ ASL and higher.

To assure flow capacity during peak demand season, To assure flow capacity during peak demand season, the proper selection is a new 16,700 hp set, with an the proper selection is a new 16,700 hp set, with an un-installed, equipment only, cost of approximately un-installed, equipment only, cost of approximately $5,800,000, and more than $10,000,000 all costs in.$5,800,000, and more than $10,000,000 all costs in.

The ZSI boost technology can “flat-line” the existing The ZSI boost technology can “flat-line” the existing engine @ 10,000 hp for $1,000,000, installed, with a engine @ 10,000 hp for $1,000,000, installed, with a 480 V utility interconnection sized at 1,000 kVa.480 V utility interconnection sized at 1,000 kVa.

ZSI is 10% of the cost

Zero Stage Technology CostsZero Stage Technology CostsReplacing a 10,000 hp Existing Turbine CompressorReplacing a 10,000 hp Existing Turbine Compressor

With a 10,000 hp Electric Drive CompressorWith a 10,000 hp Electric Drive Compressor

New mid-range electric drive compressor set costs are New mid-range electric drive compressor set costs are about $600/hp, or $6,000,000, not counting project about $600/hp, or $6,000,000, not counting project support, engineering & installation costs, which can support, engineering & installation costs, which can easily double the project cost to over $12,000,000. easily double the project cost to over $12,000,000.

Utility build-in & the required 7,500 kVa, medium Utility build-in & the required 7,500 kVa, medium voltage substation costs are substantial, and added voltage substation costs are substantial, and added into the rates, electric pricing tariffs are into the rates, electric pricing tariffs are uncontrollable, and not always in sync with the market uncontrollable, and not always in sync with the market price of natural gas, adding substantially to the cost of price of natural gas, adding substantially to the cost of transportation thru the pipeline, especially during high transportation thru the pipeline, especially during high flow demand seasons, driving customers to other more flow demand seasons, driving customers to other more stable PL’s.stable PL’s.

ZSI boost technology can deliver 10,000 hp for ZSI boost technology can deliver 10,000 hp for $1,000,000, installed, and keep the transportation $1,000,000, installed, and keep the transportation costs directly tied to gas market prices.costs directly tied to gas market prices.

Heat Recovery from Heat Recovery from Compressor StationsCompressor Stations

Energy recovery potential from pipeline compressor Energy recovery potential from pipeline compressor stations has been documented in numerous papers stations has been documented in numerous papers and reports, by various industry groups since 1979.and reports, by various industry groups since 1979.

The President of the United States has highlighted The President of the United States has highlighted compressor station heat recovery, as an energy compressor station heat recovery, as an energy efficiency and GHG reduction opportunity, three efficiency and GHG reduction opportunity, three times in speeches, since September 2009, and has times in speeches, since September 2009, and has implemented tax credits for these specific projects.implemented tax credits for these specific projects.

Yet, penetration of this technology into the US Yet, penetration of this technology into the US pipeline industry has been anemic at best, with pipeline industry has been anemic at best, with seven documented applications, in a population of seven documented applications, in a population of over 2,200 compressor stations, over 2,200 compressor stations, 0.3%!0.3%!

Why?Why?

Heat Recovery Powered ZSI Boost UnitHeat Recovery Powered ZSI Boost Unit

26,000 HP (ISO) – 1972 GE Frame 5 & HRSG26,000 HP (ISO) – 1972 GE Frame 5 & HRSG

Heat Recovery from Heat Recovery from Compressor Stations w/ZSICompressor Stations w/ZSI

Previous methods of recovering the capital and Previous methods of recovering the capital and operating expense of these projects required the operating expense of these projects required the pipeline to get into the electricity generation and pipeline to get into the electricity generation and sale business, outside of their historical area of sale business, outside of their historical area of expertise.expertise.

Employing ZSI technology, powered by recovered Employing ZSI technology, powered by recovered heat, the energy obtained from the gas turbine heat, the energy obtained from the gas turbine exhaust is delivered directly back to the pipeline, exhaust is delivered directly back to the pipeline, reducing fuel otherwise burned in the turbine, or at reducing fuel otherwise burned in the turbine, or at the electrical power station, reducing emissions of the electrical power station, reducing emissions of NOx, CO, SO2 & GHG at both locations.NOx, CO, SO2 & GHG at both locations.

ZSI allows the mid-stream company to do ZSI allows the mid-stream company to do what mid-stream companies do best, what mid-stream companies do best,

move gas, as cheap as possible!move gas, as cheap as possible!

The following Companies are licensed The following Companies are licensed

““Technology Implementation Partners”,Technology Implementation Partners”, Offering Engineering, Construction, Project Offering Engineering, Construction, Project Management & EPC services for Zero Stage, Management & EPC services for Zero Stage, patent pending, Emission Reduction Systems patent pending, Emission Reduction Systems

Ambitech EngineeringAmbitech EngineeringPogany ConstructionPogany Construction

Twin City/ClarageTwin City/ClarageWorley ParsonsWorley Parsons

Call one of our Partners today to hear how Call one of our Partners today to hear how ZSI technology can help meet your needs!ZSI technology can help meet your needs!