la flessibilità dei cicli combinati di tecnologia...

La flessibilità dei cicli combinati di tecnologia ALSTOM

D. Pezzella/A. Guizzetti

S.S. Giovanni 26 Giugno 2012

Convegno Animp (Sez. Energia) / ATI (Sez Lombardia)

© ALSTOM 2012. All rights reserved. Information contained in this document is indicative only. No representation or warranty is given or should be relied on that it is complete or correct or will apply to any particular project. This will depend on the technical and commercial circumstances. It is provided without liability and is subject to change without notice. Reproduction, use or disclosure to third parties, without express written authority, is strictly prohibited.

Agenda

Introduction Page 3

Flexible Combined Cycle Power Plant (KA26 example) Page 7

CO2 capture ready solutions 4

Fleet Experience Page 26

Summary Page 34


CCPP Operating Regime – Past & Present

Shift from base-load expectation to high cyclingOperational Flexibility today a key requirement for CCPP’s

24 hr

7000 – 8300 OH/y~25 starts/y

24 hr

3000 - 7000 OH/y~100-200+ starts/y

MSL or Shut-down during night/weekend

24 hr

3000 - 7000 OH/y~100-200+ starts/y

MSL or Shut-down during night/weekend

CCPP Load Profile Grid Load Profile (Typical)

In the past ..... Today .....


0

100

200

300

400

500

60020

09

2010

2011

2012

2013

2014

2015

2016

2017

2018

2019

2020

LAM50

Asia

Russia CIS

MEA

Oceania

India

China

Europe

The Winds of Change!

Source: Alstom 2011

GW

Forecast

By 2020 wind capacity is 11% of installed base in

Europe, and 20% in China

CCPP’s expected to called upon more and more to balance intermittent power sources in the future


Hourly Price Zones (IT) 2011 & 2012


Key Drivers of Product Development

• #1: Lower Cost of Electricity (CoE)– Initial CAPEX investment + O&M costs

– Net plant output, efficiency at full- and part-load

– Plant reliability & availability

• #2: Increased Operational Flexibility– Large turn-down capability

– Fast start-up & load changes

– Fuel flexibility (composition changes)

• #3: Lower Emissions– Under full- and part-load conditions


296 MW

193 MW

>200 MW

115 MW

Gas Turbine Product Portfolio

GT gross electrical output at the generator terminals, including gearbox (where applicable) and generator losses but excluding duct and auxiliary losses.Calculated with 100% methane at ISO conditions, GT cooling air cooler contribution included where applicable

GT26

GT24

GT13E2

GT11N2

Gas turbines with unique combustion technologies

>320 MW

>230 MW

50 Hz

60 Hz

60 & 50 Hz


KA26-1 SS “Reference Plant”• 1-on-1 Single-Shaft Power Train configuration on common foundation level• Alstom GT26 Gas Turbine with sequential combustion for high performance/flexibility• Alstom drum-Type HRSG as standard• Alstom hydrogen-cooled (TOPGAS) generator• Alstom Plant Control System (ALSPA )• Alstom Steam Turbine with both axial and lateral LP-exhaust• SSS-clutch between ST and GTG (no auxiliary boiler)• Alstom patented moveable generator foundation• Turbine Building dimensions: ca. 30m(w) x 60m(l) x 25m(h)• 3PRH water-steam cycle (conventional water-steam conditions )• 1 x GSU-Transformer

CL = Shaft Centre-LineSSS = Self-Shifting Synchronous3PRH = Triple Pressure ReheatGSU = Generator Step-Up


KA26-2 MS “Reference Plant”

• 2-on-1 Multi-Shaft Power Train configuration

• 2 x Alstom GT26 Gas Turbines, each with TOPAIR (air-cooled ) Generator

• 2 x Alstom drum-type HRSG as standard

• Alstom Steam Turbine with air-cooled (TOPAIR) or hydrogen-cooled (TOPGAS) Generator

• Alstom Plant Control System (ALSPA )

• 3PRH water-steam cycle (conventional water-steam conditions )

• 3 x GSU-Transformers

3PRH = Triple Pressure ReheatGSU = Generator Step-Up


Nominal Performance – KA26(2011)

Capable of more than 500 MW* (gross)Capable of more than 61% efficiency (gross)

<5688<5688Btu/kWh (LHV)Plant Net Heat Rate

<6000<6000kJ/kWh (LHV)

>60>60% (LHV)Plant Net Efficiency

947473MWPlant Net Output

KA26-2Multi Shaft

2-on-1

KA26-1Single Shaft

1-on-1

Plant performance data at ISO ambient conditions, methane fuel with Direct Cooling

57355739Btu/kWh (LHV)Plant Net Heat Rate

60506055kJ/kWh (LHV)

59.559.5% (LHV)Plant Net Efficiency

935467MWPlant Net Output

KA26-2Multi Shaft

2-on-1

KA26-1Single Shaft

1-on-1

Plant performance data at ISO ambient conditions, methane fuel with Indirect (WCT) Cooling

* With GT Power Augmentation


GT26/KA26 (2011) The Pioneer in Operational Flexibility

PE

RF

OR

MA

NC

E*

Standard EV-burner +LP-Turbine Upgrade

• Superior Part-Load Efficiency• Start up <60 min• High fuel flexibility

>10 x GT26 engines

Compressor Upgrade + Exhaust Housing

Upgrade

1999 features plus:• Increased mass flow• Improved all-round

performance (base-load and part-load)

>15 x GT26 engines

Compressor +Turbine + Combustor

Upgrade +Staged EV-combustion

2002 features plus: • Increased mass flow• Improved cooling and

leakage• Start-up optimization• Lower Emissions• Low Load Operation option• Fast Hot Start (< 30 min)

option

>50 X GT26 engines

Continuous evolutionary upgrade of a proven platform

PE

RF

OR

MA

NC

EF

LE

XIB

ILIT

Y

Compressor +SEV Burner +

LP-Turbine Upgrade

2006 features plus:• Increased mass flow• High all-round performance• Unprecedented

part-load efficiency (virtually constant from 100% to 80% load)

• Switchable Operation Modes (PO and MCO)

2002

2006

2012

1999


GT26/KA26 (2011) 2011 Engine Overview

GT26 (F-class) – same engine platform since mid 1990’s

4 rows VGV‘s

1-stage HP-turbine

4-stage LP-turbine

Solid Rotor

EV-combustor

SEV-combustor

22-stage compressor


Superior CCPP Part-Load Performance

Absolute η difference at 50% part-load possibly >2%-4%CCPP efficiency virtually constant from 100% to 80% load

100% 90% 80% 70% 60% 50% 40%

CCPP Load

Typical MSL Range

CC

PP

Rel

ativ

e E

ffici

ency

, ηη ηη r

el

single combustor engine

KA26

Single Combustor GT

2%-4% abs.

MSL = Minimum Stable Load


Performance Optimised(PO)

• Maximum Power and Efficiency• Normal Inspection Intervals• Normal Availability• Normal Maintenance Costs

On-line switchover

Maintenance Cost Optimised(MCO)

• Extended Inspection Intervalsof up to 30%

• ~3% lower Output• ~0.3% higher heat rate• Higher Availability• Lower Maintenance Costs

Flexible Operation Modes

One Common Hardware - Two Operation Modes

Perfect for volatile power markets


100% Load

Hot Start (max. ~8 hrs shutdown)

Warm Start(~60 hrs shutdown)

Cold Start(>120 hrs shutdown)

GT Ignition

Start-up times capabilities for KA26

No auxiliary boiler needed to assist start-up timesNo sparging steam needed to keep boiler warm in downtime

~30 min ~100 min ~150 min


LLO – 3 operational options instead of 2!

0%

10%

20%

30%

40%

50%

60%

70%

80%

90%

100%

110%

1 2 3 4 5 6 7 8 9 10 11Time

Com

bine

d C

ycle

Rel

ativ

e Lo

ad

Typical Minimum Stable Loadfor Single Combustor technology

Shut-down

KA26 Low Load Operation with entire CCPP online and emission compliant

ca. 40% less fuel consumedcompared with operating

at 50% CCPP load

1

2

3

Spinning / Minute Reserve from below 20% CC plant load350 MW available in 20 min per block


C2+ variation tolerance of more than 18% by volume.Wobbe index tolerance ±15%.

GT26’s Superior Fuel Gas FlexibilityC2+ flexibility

• High tolerance to gas variations withouthardware changes or gas preheating

• Fast-acting fuel composition measurement with on-line control

• Ready for changes in fuel gas supply (i.e. LNG)

C2+ varied by more than factor 10 in few hours!


• Evaporative Cooling- Cooling by water evaporation through cooling pads

• Fogging- Cooling by water injection with GT inlet humidity close to saturation

• High Fogging- Compressor inter-cooling by water injection with inlet humidity above saturation

compressor

filte

r

airin

combustor

turbine

Evaporative Cooler or Fogging Nozzles

High FoggingNozzles

Sile

ncer

Inlet Air CoolingFoggingHigh Fogging

Types of GT Inlet Cooling

Optimised power augmentation


EOH: Equivalent Operating Hours

GT Inlet Cooling Options

‘EOH-neutral’ on-line power augmentation

Air Inlet Cooling at 20% relative humidity

Indicative – Not Project Specific

Power Output off-set


NOx Emissions – Clean Power

Lowest NOx emissions over CCPP load range

10% 20% 30% 50% 60% 70% 80% 90% 100%

Relative CCPP Load

NO

xE

mis

sion

(m

g/N

m3 )

0

20

40

60

80

50

0%

Typical NOx Emission

40%

70

Average GT26 NOx Emission

Typical GT NOx Emission

10

LLOC30

Actual NOx emissions depending on fuel composition

EU Limit


CO Emissions – Clean Power

Very low CO emissions over wide load range

Relative CCPP Load

0

Typical CO Emission

20% 30% 40% 50% 60% 70% 80% 90% 100%10%0%

LLOC

CO

Em

issi

on (

mg/

Nm

3 )

40

60

100

80

20

Average GT26 CO Emission

Typical GT CO Emission

Actual CO emissions depending on fuel composition

EU Limit


KA26-1 ecoHEATTM

Power

Heat

Low LoadOperation

With bypass & duct firing

(Option)

Condensing Mode

Condensing-Heating Mode

Capable of> 300 MWth

Capable of > 500 MW

> 300 MW thermal for District Heating


GT26 Inspection ConceptEquivalent Operating Hours (EOH)

* For High Intermediate-Load Operation - actual intervals may vary depending on operation regime ** Actual inspection duration may vary depending on operating conditions,

outage scope, parts availability, and staff qualification** From generator breaker off to breaker on

VisualInspection

A(3-4 days **)

VisualInspection

B(incl. ControlSystem Insp.)(4-5 days**)

Hot Gas PathInspection

C(30 days**)

EOH*3500045000 4900063000

1400018000 4200054000

56000720002800036000

210002700070009000

Boroscopic GT Inspection(no burner/cans exchange foreseen, no combustor tuning)

GT Opening(no shipment of rotor forrefurbishment or maintenanceforeseen during service life of rotor)

• EOH-based Inspection Regime (Intermediate Dispatch)


KA26 Capture Ready Concept of KA26 with CCS

Future Flue Gas Recirculation (FGR)


Alstom activity on demonstrations 1st and 2nd Generation CCS

Tests complete

Vattenfall Schwarze-Pumpe Germany-

30 MWth Oxy - Lignite

Dow Chemical Co. US -2 MWth

Adv. Amines - coal

Datang- ChinaOxy 350 MWe lignite,

Post 350 MWe eq. coalAlstom BSF Windsor

US - 15 MWthOxy - coals

Getica - CET TurceniRoumania – >250MWenChilled ammonia - Lignite

PGE BelchatowPoland – 260 MWenAdv. Amines - Lignite

DOE/Alstom WindsorUS – 3 MWth

Chemical looping - coal

2nd Gen

NER300

NER300

Selected for receivingEEPR funding

NER300: Applied for EU ETS New Entrant Reserve funding

EoN KarlshamnSweden - 5 MWth

Chilled Ammonia–Fuel oil

WE – EnergieUS - 5 MWth

Chilled Ammonia, Coal

AEP MountaineerUS - 58 MWth

Chilled Ammonia, coal

Total LacqFrance - 30 MWth

Oxy - Gas

Operating

Alstom Labs VäxjöSweden – 0.25 MWthPost C. – multi purpose

Large-scale projects- under development

NER300

Under construction

TCM MongstadNorway - 40 MWth

Chilled Ammonia - Gas

EDF – Le HavreFrance – 5 MWth

Adv. Amines - Coal

RFCS EU -DarmstadtGermany –1 MWth

Chemical looping - coal

2 Gen


Gas Power Plants KA26 & KA24 References

red & italic = SCblue = CC single-shaft

blue underlined = CC multi-shaft

CYCOFOS 1xKA26-1FOS SUR MER 1xKA26-1

TERMOBAHIA 1x KA24-1*

TOCOPILLA 1x KA26-1

DOCK SUD 1x KA26-2

FLEVO 2xKA26-1CLAUS C 1xKA26-3**

RINGSEND 1xKA26-1AGHADA 1xKA26-1

SCANDALE 2x KA26-1(*)

GISSI 2x KA26-1MODUGNO 1x KA26-2

GHANNOUCH 1xKA26-1

ROCKSAVAGE 1xKA26-2ENFIELD 1xKA26-1SHOREHAM 1xKA26-1CORYTON 1xKA26-2LANGAGE 1xKA26-2GRAIN 3xKA26-1*STAYTHORPE 4xKA26-1PEMBROKE 5xKA26-1

RDK 1xKA26-1**KW EMSLAND 1xKA26-2

TPP26 1x KA26-1*

CHIBA 1x KA26-1

PORYONG 4x KA24-2

HAI FU 2x KA24-2

ALIVERI 1x KA26-1

GILBERT 1x GT24BURGIN 2x GT24AGAWAM 1x KA24-1MIDLOTHIAN 4x KA24-1ISLAND COGEN 1x KA24-1*LAKE ROAD 3x KA24-1MILFORD 2x KA24-1BLACKSTONE 2x KA24-1BAYSIDE 1x KA24-1**HAYS 4x KA24-1MIDLOTHIAN II 2x KA24-1BELLINGHAM 2x KA24-1LA PALOMA 4x KA24-1

BESOS 1x KA26-1BESOS 1x KA26-1SAN ROQUE 1x KA26-1SAN ROQUE 1x KA26-1CASTEJON 1x KA26-1CARTAGENA 3x KA26-1CASTEJON 2 1x KA26-1MALAGA 1x KA26-1SOTO DE RIBERA 2x KA26-1

TERGA 3x KA26-1

MONTERREY 2x KA24-1ROSARITO 2x KA24-1HERMOSILLO 1x KA24-1MONTERREY III 4x KA24-1EL SAUZ 1x KA24-1**

BOWIN 2x KA26-1BANG BO 1x KA26-1KHANG KHOI 2x KA26-2

SWANBANK 1x KA26-1TALLAWARRA 1x KA26-1

TARANAKI 1x KA26-1

SENOKO 1x KA26-1**SENOKO II 2x KA26-1**TUAS CCP5 1x KA26-1KEPPEL II 2x KA26-1Banyan 1x KA26-1

UTRAN 1x KA26-1JEGURUPADU III 2x KA26-1

FUJAIRAH 2xKA26-2; 1xKA26-1** CoGen Projects ** Repowering Projects(Status: Jan 2012)

80 GT26 and 50 GT24

Alstom Test Power Plant1x KA26-1

Tzafit 2x KA26-1


Fleet Leaders’ Operating Hours / Starts

KA26: F-class GTCC technology proven for all duties


Overall RAM status of KA24/KA26 Plants Last 5 Years average

ABOVE SLIDE REPRESENTING:38 KA24 Combined cycle power plants57 KA26-1 single shaft plants


Overall RAM status of KA26 Plants Capacity Factor progress - 12 monthly rolling average

Represents 56% of the KA26 Fleet


Overall RAM status of KA24/ KA26 Plants KA24/26 Fleet Operations regime in 2006-2010


KA24/KA26 RAM Fleet Status Report - 1st Quarter 2012 - - P 31

Overall RAM status of KA24/ KA26 Plants KA24/26 Fleet Operations regime 2011

Overall, reduced hours of operation observed in year 2011.


Overall RAM status of one specific KA26 Plant in EU Capacity Factor progress -12 monthly rolling average


Overall RAM status of one specific KA26 Plant in EU 12 monthly rolling average


Key KA26 Features / Customer Benefits

• Superior operational flexibility� High full-load performance (capable of >59% efficiency with ACC)� Superior part-load performance (virtually constant efficiency from 100% down to 80% load)� High reliability and availability� Turndown capability down to below 50% load� Fast starting options including <30 minutes hot start capability� Emission compliant parking of entire plant at ~20% CCPP load

offering spinning reserve of more than 350 MW per block in 15 minutes� Superior fuel gas composition flexibility (±15% WI tolerance)� Proven GT Inlet Cooling options for power augmentation� On-line choice between Performance Optimised (PO) and

Maintenance Cost Optimised (MCO) operation modes

• Reduced emissions� NOx emissions well below EU limits (50 mg/Nm3)� CO capability well below EU limits (100 mg/Nm3)� Low overall CO2 emissions due to high efficiency over full load-range� CO2 Capture Ready solutions already available

Clean – Efficient – Flexible – Reliable - Proven

www.alstom.com/power

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