GE Perspectives – Advanced IGCC/Hydrogen Gas Turbine ... · PDF fileGE Perspectives...

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Copyright 2010 General Electric CompanyOctober 2010, UTSR

GE Perspectives – Advanced IGCC/Hydrogen Gas Turbine Development

Reed AndersonSenior Program ManagerTechnology External Programs

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.

2


0 500 1000 1500 2000 2500

GTSC (FA)

New CoalIGCC or PC

Existing CoalU.S. Average

CO2 Emission Rate (lbs/MW-hr)

Coal

Natural Gas

Thermal EfficiencyIndicated (xx%)CC = Carbon Capture %

eff = 40%

eff =45%

IGCC with CCSCC% 90%

GTCC (FA)

65% 50%

References: DOE NETL; EIA; IEA and GE Energy Internal Data

eff = 33%

IGCC with CCS – Part of the Solution for the Carbon Constrained World

So What’s the Hold Up?

Impact on Emissions Technology Available

2 GE 7F Syngas Units Shipped in 2010 toDuke Edwardsport for Operation in 2012

3


500

550

600

650

0% 20% 40% 60% 80% 100%

CO2 Capture %

Out

put,

MW

GEEPRI

Current Barriers – Cost & Policy• With existing technology, adding

CCS to an IGCC plant increases COE beyond what most markets are currently willing to pay.

• Uncertainty with respect to indemnity, etc. on CO2 storage

• Technology Improvements and Legislative Action on CO2 Needed

– Carbon Pricing– Storage Clarity– More efficiency & output to lower

$/kW

29%

31%

33%

35%

37%

39%

0% 20% 40% 60% 80% 100%

CO2 Capture %

HH

V Ef

ficie

ncy,

%

GEEPRI

Sources: GE Internal Study, 2007 and EPRI IGCC Design Considerations for CO2 Capture: Engineering and Economic Assessment of IGCC Coal Power Plants for near-term Deployment, 2008

Impact of CCS on Output

Impact of CCS on Efficiency

As Engineers & Scientists We Can Be A Key Part of the Solution

4


Gas Turbine Technology Advancements – High Leverage, High Impact on IGCC Plant

• More efficient GT’s use less fuel, require smaller, less costly gasification systems

• Advanced GT’s could enable improved ST operation

• Advanced combustion systems requiring less diluent for NOx control enables increased efficiency levels and improved plant integration flexibility

Technology advancements in the gas turbine propagate

through the rest of the plant:

5


DOE Advanced H2/IGCC GT ProgramDOE goalsPerformance:

• +2 to 3 % pts efficiency by 2010• +3 to 5 % pts efficiency (total) by 2015

Emissions:• 2 ppm NOx by 2015• Fuel flexibility – Syngas & H2

Cost:• Contribute to IGCC capital cost reduction

‘06 ‘07 ‘08 ‘09 ‘10 ‘11 ‘12 2013 - TBD‘05

Phase IConceptual

Phase IIComponent Validation & Development

Phase III(Not currently awarded)

Final Design & Field Validation

Program timeline

Key Technologies

• Combustion

• Turbine • Materials • Systems

emiss

ions

effic

ienc

you

tput

cost

6


Systems Analysis and Performance Validation

• Translate Goals in to Key Plant Level, CC Level, and GT Level Parameters• Create Baseline Performance Models & Understand Gaps/Sensitivities• Quantify Benefits of Turbine Technology Improvements• Recommend Turbine Technology Design Path• Re-evaluate and Adjust Plan If Needed As Results of R&D Are Obtained

Requirements Flow-Down

IGCC Plant Level

Combined Cycle Level

Gas/Steam Turbine Level

Capability Flow-Up

GA

SIFIERG

ASIFIER

RG

CR

GC

CG

CC

GC

SCR

UB

BER

SCR

UB

BER

CO

2 SHIFT

CO

2 SHIFT

SYNG

AS H

T

FW H

EATER

SYNG

AS H

T

FW H

EATER

AC

ID G

AS

Absorber

AC

ID G

AS

Absorber

AC

ID G

AS

Rem

ovalA

CID

GA

SR

emoval

CO2Sulfur

Air SeparationUnit

Gas Turbine Generator


Steam Turbine Generator

HRSG

HRSG

BALANCE OF PLANT AUXILIARIES (COAL PREP, COOLING SYSTEM, UTILITIES)

Air Extraction

COAL

COAL

O2

O2

Water

Water

Air

RawSyngas

RawSyngas

Clean

Syngas

SLAG

SLAG

EXH

EXH

STEAM

STEAM

PROCESS

STEAM

N2

Syngas Fuel

O2

GA

SIFIERG

ASIFIER

RG

CR

GC

CG

CC

GC

SCR

UB

BER

SCR

UB

BER

CO

2 SHIFT

CO

2 SHIFT

SYNG

AS H

T

FW H

EATER

SYNG

AS H

T

FW H

EATER

AC

ID G

AS

Absorber

AC

ID G

AS

Absorber

AC

ID G

AS

Rem

ovalA

CID

GA

SR

emoval

CO2Sulfur

Air SeparationUnit



Steam Turbine Generator

HRSG

HRSG

BALANCE OF PLANT AUXILIARIES (COAL PREP, COOLING SYSTEM, UTILITIES)

Air Extraction

COAL

COAL

O2

O2

Water

Water

Air

RawSyngas

RawSyngas

Clean

Syngas

SLAG

SLAG

EXH

EXH

STEAM

STEAM

PROCESS

STEAM

N2

Syngas Fuel

O2

7


Estimated Project Benefits: Current Status

• Line of Sight to Program Efficiency Goal (+ 3 to 5 pts)

• NOx emissions of 2ppm

• CO2 emissions reductionconsistent with 90%Carbon Capture and Storage (CCS) Level

• CCS Cost Penalty Neutralized ($/kW basis)

NOTES: Values assume use of Advanced Combustion System and SCR GT Technology

% C

hang

e in

Pla

nt C

ost

No CCS CCS

CCS Penalty

Program TechnologyImprovements

Base

2010

2015

Base CCS

2010 CCS

2015 CCS

GT Technology

% C

hang

e in

Pla

nt C

ost

No CCS CCS

CCS Penalty


Base

2010

2015

Base CCS

2010 CCS

2015 CCS

Efficiency

Cost

GT Technology

Plan

t Effi

cien

cy H

HV

No CCS CCS

CCS Penalty


base

2010

2015

Base CCS

2010 CCS

2015 CCS

GT Technology

Plan

t Effi

cien

cy H

HV

No CCS CCS

CCS Penalty


base

2010

2015

Base CCS

2010 CCS

2015 CCS

8


NG H2

BaselineNozzle

ImprovedNozzle

NG H2

BaselineNozzle

ImprovedNozzle

Combustion Challenges

NOx

Flashback

Dynamics

Fuel Flexibility

Entitlement (perfectly premixed) NOx Data

0.75

2.75

4.75

6.75

Tflame (°F)

NO

x @

15%

O2 (

ppm

vd)

~~

2ppm

target range

NaturalGas 100%

H2

Syngas

C-Free SG+ N2

NaturalGas 100%

H2

Syngas

C-Free SG+ N2

9


Combustion Development

• Simple & Combined Cycle

• Part load to Full Load

Gas TurbineFull Can Scale Nozzle Scale

• NG / Syngas / High H2

• Combustor Performance

• NG / Syngas / High H2

• Emissions, Dynamics, Lean Blow Out

• Modeling & Design

• Entitlement Data

• Concept Characteristics

• Fundamental Research

Technology Basics 2010 Focus

10


TEXIT [°F]

NO

x @

15%

O2 [

ppm

vd]

Entitlement - High N2 in Fuel

Single Nozzle - High N2 in Fuel

Full Can - Low N2 in Fuel

Full Can - High N2 in Fuel Target R

ange

• Extensive Modeling & Testing at Component Scale

• Best Concepts Carried Forward for Full Can Multi Nozzle Testing

• Single digit NOx emissions at F-Class + temperatures and pressures

• Promising operability and dynamics on hydrogen, natural gas, and syngas

• 60+ hours operation, multiple 6-hour blocks at full load

• Next Steps• Further optimize, scale up, and address

manufacturability, reliability, durability, etc.

Combustion Development Status

Full Can Testing

NOx Emissions vs. Temperature

11


Turbine System Goals

Increasing firing temp and output– Enable advanced materials &

coating in IGCC/H2 environment– Increased mass flow

Advanced turbine technology– Reduced cooling flows– Reduced leakage/purge flows– Advanced aerodynamics for improved

turbine efficiency

Aero

MechHT

12


Turbine Aero & Heat Transfer Development

Cooling Flow Reduction:• Develop & validate advanced cooling schemes

Leakage & Purge Flow Reduction:• Develop & validate improved seal designs

• Optimize flow geometries to minimize hot gas ingestion

Aerodynamics:

• Improve CFD accuracy & validate turbine aero efficiency improvements provided by new technology

Aero Rig Test Parts

Advanced Film Cooling Hole Shapes

AdvancedDiffuser Shaped

12

Baseline Improved

Hybrid RotatingCascade Rig & CFD

13


Location on Component

Film

Eff

ecti

vene

ss

New Design

Existing (Baseline) Design

Heat Transfer Development Status

Achieved target flow reductions for Round 1 Technologies• Airfoil film cooling• Transition Piece to Stage 1 Nozzle• High Pressure Packing• Angel Wing

Jugular experiments completed for Round 2 Cooling Technologies• Entitlement supports targeted improvement levels

Advanced Film Cooling

TP/S1N Seal

Effe

ctiv

e A

rea

OriginalImproved

Effe

ctiv

e A

rea

Original Improved

TP/S1N Seal

TP/S1N Seal Parts

14


Aerodynamic Development Status

Turbine Aero Validation RigTest Setup & Results

Turb

ine

Effic

ienc

y

Turbine Exit Mach Number

IGCC

Prediction

Data

Natural Gas

Turb

ine

Effic

ienc

y

Turbine Exit Mach Number

IGCC

Prediction

Data

Natural Gas

• First round rig testing completed

• Turbine aerodynamics

• Diffuser aerodynamics

• Stable, repeatable performance, consistent with engine experience

• Results to date support projected performance improvement –preparing for next round of testing

15


Advanced Materials (Coatings)Goals

• Enable higher temperature operation for increased efficiency and output

• Address unique conditions associated with IGCC environment, validate durability

Overall Approach• Characterize the environment and devise

representative laboratory tests• Benchmark degradation of baseline TBC’s

and Bond Coats• Develop new coatings • Downselect to best performers• Evaluate best performing TBC’s and BC’s

Challenges & Risks• Target conditions beyond current experience

Thermal Shock Test

Field Hardware Inspection

Optimized Coating

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• Reproduced damage modes seen on IGCC field hardware

• Many architectures evaluated over 2+ rounds of optimization

• Performance improvement demonstrated at targeted operating temperatures

• Down selections made to final TBCsand bond coats

Microstructural Evolution of TBCAfter Accelerated Isothermal Exposure

Baseline 8YSZ New TBC

Advanced Materials (Coatings) Status

50 μm

Cr-Ni-Co rich scale

Alumina particles

Ti rich needles

Cr-Ti rich particles

Chromium sulfides

Cr-Ti rich scale

50 μm50 μm50 μm

Cr-Ni-Co rich scale

Alumina particles

Ti rich needles


Chromium sulfides

Cr-Ti rich scale

50 μm

Cr-Ni-Co rich scale

Alumina particles

Ti rich needles


Chromium sulfides

Cr-Ti rich scale

50 μm50 μm50 μm

Cr-Ni-Co rich scale

Alumina particles

Ti rich needles


Chromium sulfides

Cr-Ti rich scale

Field Hardware Inspection Results

Resistance to Sulfidation

0

1

2

3

4

5

6

(baseline) A B C D E(Prime)

Modified CoNiCrAlY + X

Resi

stan

ce to

Sul

fidat

ion

Atta

ck

Sulfidation Resistance Test Results

17


• Evaluate integrated system rig test data for down selected TBCs/BCs

• Generate design quality data

• Process optimization

Prelinimary Design Curves

Cycles for a given hot time

FCT Design Curves

Rig Test Setup

Spray DiagnosticsFor Improved

Coating Quality

Advanced Materials (Coatings) Next Steps

18


Summary

• GE building on successful field operational experience for gas turbines in IGCC and high Hydrogen fuel applications

• GE offering IGCC product today, including carbon capture technologies

• GE working with DOE on gas turbine technology advances for future IGCC products with CCS.

•Higher efficiency, lower cost, lower emissions

• Technical Challenges Remain for Future Designs Universities play a critical role in the gas turbine technology R&D process

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AcknowledgementsGE would like to extend a special thanks to the US Department of Energy National Energy Technology Laboratory and the following individuals for their past and continued support on the DOE/GE High Hydrogen Program:

Rich Dennis

Turbine Technology ManagerOffice of Fossil EnergyUS DOENational Energy Technology Laboratory

Robin Ames

Project ManagerPower Systems DivisionU.S. Department of EnergyNational Energy Technology Laboratory

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