hydrogen and syngas combustion: pre-condition for igcc …˜fuel flexibility and igcc experience of...

Power GenerationW8IN, G233, CTET

Hydrogen and Syngas Combustion: Pre-Condition for IGCC and ZEIGCC

F. Hannemann, B. Koestlin, G. Zimmermann, G. Haupt, Siemens AG Power Generation

17 Jun 2005 Power GenerationW8IN , G233, CTET 2

Content

Ø Introduction

Ø Fuel flexibility and IGCC experience of Siemens gas turbine technology

Ø Syngas combustion development under the EC Program HEGSA – Status and recent activities

Ø EC Program ENCAP / Low-NOx hydrogen combustion / challenges, targets and recent activities

Ø Outlook


Fuel Flexibility and Integrational Features of Siemens Gas Turbine Applications

DOW Plaquemine (USA)

Nuon Power Buggenum (NL)

Elcogas Puertollano (E)

ISAB Energy Priolo Gargallo (I)

Elettra GLT Servola (I)

Feedstock Coal Coal/biomass Coal/petroleum coke

Asphalt Blast furnace gas Coke oven gas

Natural gas

Gasification DOW Shell Prenflo Texaco

Fuel gas temperature 149 °C/300 °F 300 °C/ 572 °F 302 °C/ 576 °F 195 °C/ 383 °F Fuel gas compositions % vol % vol % vol % vol % vol H2 41.4 12.3 10.7 31.3 9.0 CO 38.5 24.8 29.2 28.5 16.3 CO2 18.5 0.8 1.9 3.2 13.6 N2 1.5 42.0 53.1 - 41.0 (incl. Ar, O 2) CH4 0.1 - 0.01 - 14.6 Ar - 0.6 0.6 - - H2O - 19.1 4.2 36.9 5.5 O2 - 0.4 0.3 - - H2/CO ratio (vol) 1.07 0.50 0.36 1.10 0.55

Lower heating value 239 BTU/SCF 10.4 MJ/kg

113 BTU/SCF 4.3 MJ/kg




Secondary fuel Natural gas Natural gas Natural gas Fuel oil Natural gas Gas turbine 2 x W501D5 1 x V94.2 1 x V94.3 2 x V94.2K V94.2K

Air extraction form GT related to ASU 0 % 100 % 100 % 0 % related to compressor 0 % 16 % 18 % 0 % Nitrogen integration 0 % 100 % 100 % 0 %

Net power output 208 MW 253 MW 300 MW 521 MW 180 MW

Net efficiency (LHV) Not available 43.2 % 45.0 % *) < 40.0 %

*) ISO conditons and use of high quality coal


Advanced Syngas Combustion -Project Outline

EC project NNE5/644/2001 (HEGSA)

High Efficient Gas Turbine with Syngas ApplicationTargetsØ Increasing theoretical and technological knowledge of syngas combustionØ Improving the flexibility of current gas turbine syngas combustion systems Ø Developing an advanced combustion system for annular burner

technology operating at higher pressure and temperature using low-BTU syngasesScopeSpecification of requirements - adjusted CFD simulations including generic burner experiments - thermo-acoustic investigations - design studies -prototype design - atmospheric and pressure combustion testsPartners Duration• Siemens AG PG (Coordinator, D) 01/2003 – 12/2005• ANSALDO ENERGIA Spa (I)• Universiteit Twente (NL)• Deutsches Zentrum für Luft- und Raumfahrt e.V. (D)• Enel Produzione SpA (I)• NV NUON Energy Trade & Wholesale (NL)


HEGSA /Improvements to 50 Hz Commercial Systems

Ø Use of 2 passages for syngas enhances flame stabilityØ Optimal adaptation of nozzle design to specific application

Improved Syngas Burner for Silo-type Vx4.2, Vx4.2K

Lean atmospheric blow-off limit tests ðEnhanced flame stability ðSyngas start-up capability

AirAir

Syngas 1

Syngas 2/Natural Gas

Fuel Oil


HEGSA / Low-NOx Syngas Combustion Concept for SGT5-4000F Application

Advanced Syngas Burner for SGT5-4000F

Ø Derived from well proven Hybrid Burner technologyØ Adaptation to annular combustion chamberØ Use of 2 passages for syngasØ Premix low-NOx combustion at elevated firing

temperature

• Manufacturing of new burner design finished• Atmospheric combustion test campaign in June at Ansaldo Caldaie/Gioia del Colle• Pressurised combustion tests in September at DLR/Cologne

Manufacturing phase: Advanced low–NOxsyngas burner

Development phase: burner design optimisation by CFD calculation


Improvements to 60 Hz Commercial SystemsSGT6-5000F Syngas Combustion Tests

ØIn 2002 3 syngas combustion test campaigns were completed. Results from observations indicate that:ØCombustor is extremely stable during syngas

operation over a wide range of loads and gas compositionsØNOx target of 25 ppm was achieved with dilution by

steamØCO emissions were low

SGT6-5000F SyngasCombustor Basket

SGT6-5000F Test RigØAdditional tests to be completed at full pressure in 2005

ØTarget W501F emissions: 15 ppm NOx on syngas @ 15% O2


Pre-Combustion Carbon Capture –Project Outline

6th EU Framework Programme Integrated Project ENCAP

Enhanced CO2 CaptureTarget: Concepts/technology for CO2 capture from natural gas and coal fired

power plants at 50% capture cost reduction & at least 90% capture ratePartners: Vattenfall AB (leader) and 32 partners

(energy and technology providers, RTD institutes) Schedule: 4.5 years (18+36 months), started March 2004

Process & PowerSP1

Oxyfuel Boiler TechnolgySP3

Chemical Looping CombustionSP4

High-Temperature O2Generation for Power Cycles

SP5

Novel Pre-CombustionCapture Concepts

SP6

Siemens main focus

Development of Low-NOx Hydrogen Burner for SGT5-4000F Technology

Basic Design of ZEIGCC / ZEIRCC


Criteria / Challenges for H2 Combustion in Gas Turbines

Ø Clearly higher stoichiometriccombustion temperature

Ø Smaller volumetric calorific values

Ø High flame speed

12.5 - 744 - 755 - 15Flammability limits [vol %]

1.0514.242.18Specific heat [kJ/kg K]

1.250.090.72Density [kg/m3STP]

237423702227Stoich. comb. temp. [K]

2035043Flame speed in air [cm/s]

12.610.233.9[MJ/m3]

10.1119.950.3LHV [MJ/kg]

COH2CH4Fuel Properties

Ø Large increase in volumetric fuel flow rates

Ø Prevent pre-ignitionØ Care for avoiding flashback

Ø Near-homogeneous mixing of fuel and air within shortest possible timeØ Elimination of any flow separation, stagnation or vortex breakdownØ High gas flow velocity to compensate increased flame speed to keep

the flame lifted offØ Avoidance of high NOx emission due to high flame temperature

NOxemissions

Risk of flashback


Hydrogen-rich Fuel Gas / Experience and Limits of Existing Syngas Diffusion Burner

0%

50%

100%

150%

200%

250%

300%

0% 10% 20% 30% 40% 50% 60%

hydrogen content [vol%]

lam

inar

flam

e sp

eed

Risk ofOverheating

Risk of Lean Blow-off

max. H2 for Steam Dilution

max. H2 for N2 Dilution

Standard SyngasCombustion SystemEngine References

Buggenum

ISAB

Puertollano

Servola


Combustion of H2 rich fuels with N2 dilution / Diffusion or DLN Combustion

Diffusion mode: slH2/slCH4=10

DLN mode: slH2/slCH4=3

• H2 shifts the maximum oflaminar flame speed to rich regions

• Maximum laminar flame speed represents fuel gas reactivity

High flashback risk

Ø Diffusion mode:Need of much higher dilution

Ø DLN challenge:Avoidance of rich zones

Ø Risk mitigation for DLN:Increase dilution and gas velocity

0

100

200

300

400

500

600

0.6 0.8 1.0 1.2 1.4 1.6 1.8 2.0air fuel ratio [/]

lam

inar

flam

e sp

ped

[cm

/s]

H2=100% N2=0%

H2=80% N2=20%

H2=60% N2=40%

H2=40% N2=60%

Refrence 100% CH4

Tair=400°CTfuel=15°Cp=17barGRI 3.0

100%H2

80%H2

60%H2

40%H2 CH4

Diffusion mode

DLNmode


Roadmap for Low-NOx H2 Burner Development under ENCAP

1. H2/N2 combustion tests to verify stability limits of Standard Siemens Hybrid Burner

2. Development of reduced reaction mechanism for H2-rich combustion (SINTEF/DLR)

3. Evolutionary development of low-NOx H2 burners for SGT5-4000F

CFDDesign Atm. tests pres. tests

Development Status:• First atmospheric test campaign performed and design modification underway• High pressure combustion tests with modified burner planned for June/July 2005

Atmospheric test rig at Siemens/MülheimH2/N2 flame


Outlook –SGT5-4000F Roadmap for Hydrogen-rich Combustion

Phase 1 (ENCAP):

• Development of H2-Burner • Review of Cooling air and hot gas path requirements

Phase 2 (BMWA Program COORIVA):

• Analysis of operational experience (e.g. operational obstacles, effects of corrosion and plugging, degree of GT and overall plant integration )

Phase 3 (project specific)• Adaptation of GT for air extraction • Design of I&C and GT fuel gas system

(e.g. piping, valves, saturation and flushing procedure)

AirAir

Air

Hydrogen(+ Inert)

Hydrogen(+ Inert)

hydrogen and syngas combustion: pre-condition for igcc …˜fuel flexibility and igcc experience of...

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