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Nov 09, 2015
2012, General Electric Company. Proprietary Information. All Rights Reserved.
GE Energy
2013, General Electric Company. Proprietary Information. All Rights Reserved.
Fuel Flexible Gas Turbines for Sustainable
Power Generation
Indian Power Stations O & M Conference February 13-14, 2013 NTPC, India
Dr Suresh M V J J Regional Lead Application Engineer, GE India (Bengaluru) Ranjith Malapaty Engineering Technical Leader, GE Power & Water (Hyderabad)
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2013, General Electric Company. Proprietary Information. All Rights Reserved.
General Electric Company, 2013.
GE Proprietary Information - The information contained in this document is General Electric Company (GE) proprietary information. It is the property of GE and shall not be used, disclosed to others or reproduced without the express written consent of GE, including, but without limitation, it is not to be used in the creation. manufacture. development, or derivation of any repairs, modifications, spare parts, or configuration changes or to obtain government or regulatory approval to do so, if consent is given for reproduction in whole or in part, this notice and the notice set forth on each page of this document shall appear in any such reproduction in whole or in part. The information contained in this document may also be controlled by the US export control laws. Unauthorized export or re-export is prohibited.
GE Power & Water
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2013, General Electric Company. Proprietary Information. All Rights Reserved.
Outline
Introduction
Fuel Flexibility Options Liquefied Natural Gas (LNG) Syngas Oils
OpFlexTM Model Based Controls
Summary
4
Introduction
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Hydrocarbon consumption 2011 ~85% of primary energy
Hydrocarbon consumption, 2011 Million Tonnes Oil Equivalent
10,522 Total
41.2% 31.5% 27.3%
Million Tonnes Oil Equivalent, 2011
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Fuels experience broad range
Industry drivers for fuel flexible solutions: Diversified power generation mix (in terms of both fuel sources & suppliers)
Greater energy independence/autonomy
Efficient use of energy/emissions
LNG & Natural gas variation
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2013, General Electric Company. Proprietary Information. All Rights Reserved.
LNG & Natural gas variation
Gas composition variation will increase as more LNG is injected into pipelines
Variation poses gas turbine operability challenges
Auto-ignition
Flashback
Combustion dynamics
Combustor lean-blowout
Emissions compliance (NOx, CO)
Addressed by OpFlex* offerings
Constituent Min Max
Nitrogen (N2) [%] 0 0.4
Carbon-Dioxide (CO2) [%] 0 0.7
Methane (C1) [%] 85 96
Ethane (C2) [%] 3 13
Propane (C3) [%] 0 4
Iso-Butane (IC4) [%] 0 0.9
n-Butane (NC4) [%] 0 0.9
Iso-Pentane (IC5) [%] 0 0.1
n-Pentane (NC5) [%] 0 0
LHV [BTU/scf] 1045 1170
Potential NG/LNG compositional range (volume %)
Source: Tuning on the Fly, Turbomachinery International, Sept/Oct 2007
1200
1250
1300
1350
1400
1450
1500
1550
Florida
California
NGC+
Mexico
EU HarmonizationSpain
France
UK
Wo
bb
e N
um
be
r
*Trademark of General Electric Company.
Syngas
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Syngas production in an IGCC plant
42
Gasification Gas Turbine
H2 & CO
(syngas)
Partial oxidation
Solid feedstock is gasfied
MNQC Combustor
Diluent (N2, Steam)
Gas clean-up
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Syngas to hydrogen (CO2 separation)
Gasification Shift Process CO2 Capture + Compression
Gas Turbine
CO + H2O => CO2 + H2
(H2 rich syngas)
H2 & CO
(syngas)
H2
CO2 EOR or Storage
Partial oxidation
AGR & CO2 Compression Steam/Syngas Reactor
Solid feedstock is gasfied
Catalyst based Water-Gas converts CO to CO2
Acid Gas Reactor system removes CO2, which is compressed and
piped off-site
MNQC Combustor
Diluent (N2, Steam)
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Ventilation modifications
Inlet filter house
Inlet duct & plenum
Gas fuel module
Water injection skid
Exhaust system
Controls hardware and software
Accessory module
Liquid fuel and atomizing air
Static starter
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
IGCC Controls with added I/O
*Fuel and diluent skids/modules may need to be customized for specific fuel/plant configurations
Syngas turbine controls and accessories
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MNQC for E/F Syngas Turbines
MNQC (Multi Nozzle Quiet Combustor) Diffusion (Not DLN)
Same combustor architecture for 6FA, 7EA, 9E, 7F Syngas, and 9F Syngas turbines
End cover/fuel nozzle assembly nearly identical, except for minor scaling
Combustor liner and cap designs similar, scaled to different operating conditions
Diluent N2 or Steam or a blend
Air extraction available for integration with process
N2/Steam
Natural gas/ syngas
Syngas
Air extraction
Air from compressor
Liner
Flow sleeve Transition piece
Fuel nozzle
Typical modifications on 9E gas turbine for low calorific value gases
Oils
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2013, General Electric Company. Proprietary Information. All Rights Reserved.
Biofuels field tests ready when opportunity is right Biodiesel Fuel used met ASTM D-6751 & GE liquid fuel specification
Operated from start-up to full power on a range of fuel mixtures
Confirmed that NOx emissions were comparable to turbine running on distillate fuel
Ethanol Successful test performed on a 6B Gas Turbine in 2008
Commonalities with naphtha: high volatility, poor lubricity, miscible
6B Gas Turbinestandard combustor Fuel: B20 B100 Fuel: Ethanol
7EA Gas TurbineDLN1 combustor Fuel: B20 B100
LM6000* SAC Fuel: B100
* LM6000 is a trademark of General Electric Company.
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Crudes decreasing OpEx; increasing availability Shift to heavier oils and sour gas Field reserves and refinery ends Leads to corrosion, ash deposition and
emissions concerns
Impacts CapEx (Capital Expenditure) and OpEx (Operational Expenditure)
Technical solutions Heavy fuel oil (HFO) availability package 4 key attributes
Smart cool down Automated water wash Model based control Open S1 nozzle
Decreases offline time to perform water wash (from 48 to
OpFlexTM Model Based Controls
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OpFlexTM Model Based Controls Overview
Direct Boundary Protection (In The Boundaries Physical Space)
Accommodation Of Machine Deterioration (Adaptive Model Ensures Accurate Surrogates)
Implicitly De-Coupled Effectors (Automatic Performance Optimization)
Robust / Flexible / Expandable (Additional Boundaries / Loops)
Proven GT Control Technology
Approximate Boundary Protection (Calculated Off-line to Accommodate Worst-Case Condition)
No Explicit Accommodation Of Machine Deterioration (New & Clean / Mean Machine Assumption)
Coupled Effectors Prohibit Optimization (Part-Load Exhaust Temperature & Fuel Splits)
W_fuel
/ IGV
Fuel
Splits
+ _
+ _
+ _
+ _
+ _
+ _
+ _
+ _
+ _
Loop-In-
Control
Loop-In-
Control
Loop-In-
Control
IBH
ARES - Parameter
Estimation
Engine Model
16.0
27025.1
3
*394.6
95.3
3
*
*
T
SH
eP
eW
Physics-Based
Boundary Models
Lim
it S
ch
ed
uli
ng
Surrogates
Today: Indirect (Tx Space) Boundary Control
Model Based Controls : Direct (Boundary Space) Boundary Control
Iso-Therm
M
INIM
UM
Tx_req
Tx
P+I +
-
W_fuel
/ IGV
TTRF ~ Tx
Sp
lits
TTRF
Fuel
Splits
CPR
TCD
Tx Control
Curve
IBH
IGV
IBH
IGV
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Model-Reference Adaptive Control
Boundary
Transfer
Functions
Boundary
Scheduling
Logic + _
TF Tuning
Model-Based
Control Structure
(Loop Selection Logic)
Boundary Targets
Estimated Boundary
Levels Surrogates
Effectors
Errors
Commands
ARES - Parameter Estimation
Engine Model
Gas Turbine
Combustion Dynamics Measurement
Boundary Transfer Functions
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Fuel Flexibility with OpFlexTM MBC
Model-Based Control
1st : Fuel Splits 2nd : Fuel Temperature 3rd : Load Reduction
W_fuel
/ IGV
Fuel
Splits
+_+_
+_+_
+_+_
+_+_
+_+_
+_+_
+_+_
+_+_
+_+_
Loop-In-
Control
Loop-In-
Control
Loop-In-
Control
IBH
ARES - Parameter
Estimation
Engine Model
16.0
27025.1
3
*394.6
95.3
3
*
*
T
SH
eP
eW
Physics-Based
Boundary Models
Qe
eNOxNOx
ref
ref
SHSH
TflTfl
refO
**
*)(5.9
)*(006.
%15@ 2
Lim
it S
ch
ed
uli
ng
Surrogates
Combustor Capability Unleashed
30 35 40 45 50 55 60 65
Wide-Wobbe Capability
GEI-41040
Modified Wobbe Index (MWI) (22%) (-44%)
5%
20%
7FA
9FA
Prioritized Dynamics Control
6
7
8
9
10
-20 0 20 40 60 80 100
Time [sec]
NO
x [p
pm
@15
%O
2]
80
90
100
110
120
Gas
Turb
ine
Outp
ut [%
]NOx
Load
(Simulated +/- 10% WI over 30sec)
Wide Wobbe
Fuel Flexibility
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2013, General Electric Company. Proprietary Information. All Rights Reserved.
0
10
20
30
40
50
60
70
80
90
100
11:24 AM 11:38 AM 11:52 AM 12:07 PM 12:21 PM
Time
Co
mb
ust
ion
Dy
na
mic
s
Am
pli
tud
e (
% T
arg
et)
42
42
43
43
44
44
45
45
46
46
47
MW
I
Frequency 1
Frequency 2
MWI
41.5
42.0
42.5
43.0
43.5
44.0
44.5
45.0
45.5
46.0
46.5
11:24 AM 11:38 AM 11:52 AM 12:07 PM 12:21 PM
Time
MW
I
7.0
7.2
7.4
7.6
7.8
8.0
8.2
8.4
8.6
8.8
9.0
NO
x (
pp
m @
15
% O
2)
MWI
NOx LNG terminal less than 200 km from 207FA combined-cycle power plant
LNG storage tank originally purged with CO2 not all CO2 removed before LNG was introduced to tank
CO2 / LNG entered pipeline and reached site at 11:24 am
Initial Modified Wobbe Index (MWI) value decreased 5.6% due to presence of CO2 in fuel
MWI increased 8.7% due to LNG
Maximum rate of change in MWI reached 9.5%/minute
Modular control maintained acceptable emissions and dynamics levels throughout event
Automated DLN Tuning with OpFlexTM MBC
22
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Summary
Regional trends, design/operational constraints and fuel availability will continue to drive the power generation industry towards non-traditional fuels
Gas turbines have demonstrated capability to operate on a wide variety gaseous and liquid fuels
GE has successfully tested/operated many of these fuels and decreased OpEx and CapEx impacts to the heavy duty gas turbine goal is for performance like it is operating on natural gas
Powering the World Responsibly
Thank You. Questions?