DOE Advanced IGCC/H2 Gas Turbine · GE Energy’s DOE Advanced IGCC/Hydrogen Gas Turbine Program...

GE Energy

October 2011, UTSR © 2011, General Electric Company. Proprietary. All Rights Reserved.

GE Energy’s DOE Advanced IGCC/Hydrogen Gas Turbine Program

Roger Schonewald – Manager, Technology External Programs

2


DOE Advanced H2/IGCC Gas Turbine

Program

DOE goals

Performance:

Emissions:

Cost:

Program timeline

IGCC /CCS – H2 GT

(7F class)

IGCC/CCS for smaller Industrial Apps

(6FA class)

+3 to 5 % pts efficiency

2 ppm NOx by 2015

Fuel flexibility – Syngas & H2

Contribute to IGCC capital cost

reduction

3


IGCC-CCUS Power

NG Combined Cycle

Technology Advancement

Update

Innovation & Development,

Test & Learn

IGCC-CCUS Industrial

4


Pre-Mix H2 Combustion . . . 6+ yr Journey (many said it could not be done)

Challenge

NOx

Flashback

Dynamics

Fuel Flexibility

H2 Fundamentals

Innovation Sub-component

(rapid prototyping)

Subscale Test (test, analyze, learn)

Full Size Test (test, analyze, learn)

Engine Test (validation, learn)

NOx:

Entitlement Data

Modeling & Design Concept Characteristics

Optimized Modeling &

Preliminary Design

Optimized Modeling & Detailed Design

technology

innovation – ph 2

5


Combustion - Full Can Testing

T39=2700oF, 75/17/8% H2/N2/CH4T39=2700oF, 75/17/8% H2/N2/CH4

1.E+03

1.E+04

1.E+05

1.E+06

0 10 20 30 40 50 60

Wobbe Index (Btu/scf)

1/B

OT

(s

-1 )

100% NG

100% H2

O 2 - Blown Syngas (H2/CO/N2)

C - Free SG +N2

NG diluted w/N2

H2 - doped NG + N2

(short duration)

“ R

ela

tiv

e R

ea

ctiv

ity

”

• Fuel 60-100% H2, balance N2 and/or

Natural Gas (NG)

• Exceeded F-class temp and pressure

• Operability with NG and syngas

• 24 Rig Tests in 2009-2011

• 90+ hours operation on high-H2 fuels

• Single digit NOx emissions at target

conditions with H2-N2 fuels.

Successful operation

@ DoE “ 2012 ” conditions

6


Combustion – Technology Development

•Robustness

Gain operating margin

Design for durability

•Scale-Up

• Trade-offs (e.g. performance, durability, and cost)

Frequency

Am

pli

tud

e Sample Response

H2 Fuel Nozzle

Frequency response testing to guide design.

0 0.05 0.1 0.15 0.2

Additional N2 / Inlet Air (by mass)

(NO

x) E

mis

sio

ns N2 in fuel and air impacts NOx,

Operability, Efficiency

Single Nozzle

Mfg #1

Full Can

Mfg #1

Full Can

Mfg #2

Target

Entitlement

(NO

x) E

mis

sio

ns

Exit Temperature

7


Turbine System Goals

• Increasing firing temp and output • Advanced materials & coatings

• Increased mass flow

• Advanced turbine technology • Reduced cooling flows

• Reduced leakage/purge flows

• Advanced aerodynamics

Advanced

Diffuser Shaped

Advanced

Diffuser Shaped

8


Location on Component

Fil

m E

ffe

cti

ve

ne

ss New Design

Existing (Baseline) Design

Heat Transfer Development

Achieved target flow reductions for Round 1

Jugular experiments completed for Round 2

Advanced Film Cooling

TP/S1N Seal

Eff

ecti

ve A

rea

Original

Improved

Eff

ec

tiv

e A

rea

Original Improved

TP/S1N Seal

9


Aerodynamic Development – Round 1

Test Setup & Results

Turbine Aero Validation Rig

10


Advanced Materials (Coatings)

Goals • Enable higher temperature operation for

increased efficiency and output

• Address unique conditions

Overall Approach • Characterize the environment

• Devise representative laboratory tests

• Benchmark degradation

• Develop new coatings

• Downselect to best performers

• Evaluate best performing TBC’s and BC’s

Thermal Shock Test

Field Hardware Inspection

Optimized Coating

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• Reproduced damage modes

• Many architectures evaluated

• Performance improvement demonstrated

• Down selections made to final TBCs and bond coats

Microstructural Evolution of TBC

After Accelerated Isothermal Exposure

Dimensional Stability of TBC

Baseline 8YSZ New TBC

Larsen Miller Parameter

ph

ase c

on

ten

t %

% s

hri

nkag

e

monoclinic

t + m

cubic

t' tetragonal

Coating 1

Coating 2


ph

ase c

on

ten

t %

% s

hri

nkag

e

monoclinic

t + m

cubic

t' tetragonal

Coating 1

Coating 2


ph

ase c

on

ten

t %

% s

hri

nkag

e

monoclinic

t + m

cubic

t' tetragonal

Coating 1

Coating 2


ph

ase c

on

ten

t %

% s

hri

nkag

e

monoclinic

t + m

cubic

t' tetragonal

Coating 1

Coating 2

Aging Parameter, T[27+ln(t)]

Dim

en

sio

na

l C

ha

ng

e [

%]

AG1 WAN2007-2-2

SG1190

Baseline

Improved

Aging Parameter, T[27+ln(t)]

Dim

en

sio

na

l C

ha

ng

e [

%]

AG1 WAN2007-2-2

SG1190

Baseline

Improved

Advanced Materials (Coatings)

50 m

Cr-Ni-Co rich scale

Alumina particles

Ti rich needles

Cr-Ti rich particles

Chromium

sulfides

Cr-Ti rich scale

50 m50 m50 m

Cr-Ni-Co rich scale

Alumina particles

Ti rich needles


Chromium

sulfides

Cr-Ti rich scale

50 m

Cr-Ni-Co rich scale

Alumina particles

Ti rich needles


Chromium

sulfides

Cr-Ti rich scale

50 m50 m50 m

Cr-Ni-Co rich scale

Alumina particles

Ti rich needles


Chromium

sulfides

Cr-Ti rich scale

7FA S1B 1 Gas Turbine- 24,000 Hours of Service

Field Hardware

Inspection Results

Resistance to Sulfidation

0

1

2

3

4

5

6

(baseline) A B C D E(Prime)

Modified CoNiCrAlY + X

Resis

tance to S

ulfid

ation

Att

ack

Sulfidation Resistance Test Results

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• Continue thermal gradient rig testing of down selected TBC/BC systems

• Generate design quality data

• Process optimization

Prelinimary Design Curves

Cycles for a given hot time

FCT Design Curves

Rig Test Setup

Spray Diagnostics

For Improved

Coating Quality

Adv Materials (Coatings) Next Steps

13


Technology Advancement: . . . Fundamentals & Innovation Today . . . Tomorrow's Advanced Turbines

Efficiency

Tf

Adv Materials

Adv Controls Adv Combustion

Adv Compressor Aero

Adv Cooling & Sealing

Adv Coatings

~

~

IGCC NGCC

Adv Manufacturing

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Acknowledgements Special thanks to the US Department of Energy National Energy Technology Laboratory and their support on the DOE/GE “Advanced Hydrogen Gas Turbine Development Program”

Rich Dennis Turbine Technology Manager Office of Fossil Energy U.S. Department of Energy

National Energy Technology Laboratory

Robin Ames Project Manager Power Systems Division U.S. Department of Energy National Energy Technology Laboratory

1. This material is based upon work supported by the Department of Energy under Award Number DE-FC26-05NT42643

2. This report was prepared as an account of work sponsored by an agency of the United States Government. Neither the United States

Government nor any agency thereof, nor any of their employees, makes any warranty, express or implied, or assumes any legal liability or

responsibility for the accuracy, completeness, or usefulness of any information, apparatus, product, or process disclosed, or represents that its

use would not infringe privately owned rights. Reference herein to any specific commercial product, process, or service by trade name,

trademark, manufacturer, or otherwise does not necessarily constitute or imply its endorsement, recommendation, or favoring by the United

States Government or any agency thereof. The views and opinions of authors expressed herein do not necessarily state or reflect those of the

United States Government or any agency thereof.

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Thank you!

DOE Advanced IGCC/H2 Gas Turbine · GE Energy’s DOE Advanced IGCC/Hydrogen Gas Turbine Program...

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