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Advanced Hydrogen Turbine Development
Joseph Fadok
Siemens Energy, Inc
UTSR WorkshopState College PA, October 19, 2010
The content of this presentation is copyrighted by Siemens Energy, Inc. and is licensed to NETL for publication and distributiononly. Any inquiries regarding permission to use the content of this paper, in whole or in part, for any purpose must be addressed to Siemens Energy, Inc. directly.
Page 2 UTSR Workshop, October 2010 Copyright Siemens
Contents
• Recent IGCC and Gasification Highlights
• Advanced Hydrogen Turbine Program
• Technologies
• University Collaboration
Page 3 UTSR Workshop, October 2010 Copyright Siemens
Recent Siemens IGCC and Gasification Highlights
9 SFG-500 Gasifiers Shipped
7 SFG-500 gasifiers delivered to projects in China
2 SFG-500 gasifiers for Secure Energy at site
Shenhua Ningxia Coal Group, NCPP Project
5 x SFG-500 Gasifiers
New IGCC / Gasification Contracts:- Mississippi Power, Kemper County
(2 IGCC GT-G Packages)
- Capital Power Corp., Genesee IGCC Facility (Power Block + Gasifier (2008))
- Tenaska, Taylorville Energy Center(2 Gasifiers, Gasification Island FEED)
- Summit Power, Texas Clean Energy Center(Air Permit Support)(FEED + Gasifiers + Power Block + O&M)
- 9 FEEDs and 20 feasibility studies completed since 2006
New Siemens gasifiers introduced in Oct. 2009 & May 2010
Page 4 UTSR Workshop, October 2010 Copyright Siemens
IGCC Market Challenges
IGCC plant capital and O&M costs… “Duke Energy Indiana told regulators the
cost of its 618 MW Edwardsport coal gasification plant under construction in
southwest Indiana will rise from $2.35 billion (or $3,800/kW) to $2.88 billion (or
$4,660/kW)”… Power Gen Worldwide April 2010
Waxman-Markley Kerry-Liberman
Legislative and regulatory uncertainty related to CO2
Improved IGCC plant performance and availability
Minimizing the impact of CO2 capture
Demonstrating that IGCC technology is a viable coal based power generation option
Page 5 UTSR Workshop, October 2010 Copyright Siemens
SFG-500Gasifier
SFG-1200Gasifier
Optimizing Gasifiers and gas turbines to improve IGCCeconomics
60 Hz Gas Turbines
F ClassAdvancedH2 Turbine
50 Hz Gas Turbines
E Class F Class
Objective is to Improve Plant Economics
Page 6 UTSR Workshop, October 2010 Copyright Siemens
Over 50% of the CCS penalty could be recoveredwith advanced turbine technology
With the improvements of power block efficiency pursued under the DOE hydrogen turbine development, over 50% of the penalty for CCS could be recovered.
Gas shiftCO2 compressionGasification
Page 7 UTSR Workshop, October 2010 Copyright Siemens
DOE Advanced Turbine Program Goals
2010 2012 2015
•2-3% pt. improvement in CC efficiency over baseline
•20-30% reduction of CC capital cost compared to baseline
•2 ppm NOx on Syngas
•IGCC-based power systems that capture carbon
•3-5% pt. improvement in CC efficiency over baseline
•H2 Turbine with 2 ppmNOx
Page 8 UTSR Workshop, October 2010 Copyright Siemens
Turbine Program Development and Major Activities
IGCC Plant
CO2Sequestration
Ready
Low Emissions
Improved Efficiency
Fuel Flexibility
NG,Syngas,H2
Reduction in Plant Cost $/KW
Program Development and Major Activitiesare Driven by Plant Level Goals
Targeted Areas of Improvement
Page 9 UTSR Workshop, October 2010 Copyright Siemens
1956 1966 1976 1986 1996 2006 2016
800
1200
D
F
G
Commercial Operation
Tur
bine
Inle
t Tem
pera
ture
o C
1800
1000
1400
1600
A Steep Growth In IGCC Turbine InletTemperature is the Target
Natural Gas Engines
IGCC Engines
Page 12 UTSR Workshop, October 2010 Copyright Siemens
Combustion System Options for IGCC applications
Premix Combustion System
- Demonstrated rig testing at high temperature without N2dilution.
- Susceptible to flashback and dynamics.
- Proven single digit NOxemissions with natural gas.
Diffusion Flame Combustion
- <15 ppm NOx achievable at high firing temperature
- Requires dilution for NOx
- 25 ppm NOx emissions with dilution on natural gas
Current Offering Development Target12
Page 13 UTSR Workshop, October 2010 Copyright Siemens
Combustion Systems Development ChallengesHigh Hydrogen Content Fuels
There are significant benefits to Premix combustion, higher firing temperature, and lower dilution.
Challenges:• Flame Speed
• Flashback
• Combustion Dynamics / Acoustics
• Fuel Flexibility (Always need back-up fuel)
• Low Emissions at Increased Temperature
• Potential for Large variation in fuel properties depending on feedstock.
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Page 14 UTSR Workshop, October 2010 Copyright Siemens
Impact of Dilution On EmissionsCase for Premixed Systems
Premixed design has potential to lower emissions without dilution.Diffusion flame requires steam and/or nitrogen to get sub 20 ppm NOx
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Page 15 UTSR Workshop, October 2010 Copyright Siemens
University Programs
Goals -• Improve modeling tools for hydrogen / syngas• Obtain basic kinetics data and improve models• Validation of CFD models• Develop and utilize advanced diagnostic techniques (flame
visualization and characterization)
Turbulent Flame Speed
Nozzle testing - air/fuel mixtures
Single Nozzle Test Rig
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Page 17 UTSR Workshop, October 2010 Copyright Siemens
Turbine component development process
Heat Transfer Development
Novel Component Construction
Core / Casting Development
Aerodynamic Development
Materials & Coatings
Advanced Turbine Component Design
Large Rear Stage BladesAdvanced Airfoil Cores
Flow Path Optimization
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Page 18 UTSR Workshop, October 2010 Copyright Siemens
Turbine Development Challenges & Features
Challenges:
• Reduced cooling at elevated temperature
• High moisture content with H2 fuel
• Manufacturing of novel component concepts
Improved Sealing and Prevention of Hot Gas Ingestion
Advanced Cooling Technologies
High Temperature Materials and
Coatings
Novel Manufacturing Technologies
Improved Aerodynamic and
Thermal Performance
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Page 19 UTSR Workshop, October 2010 Copyright Siemens
Fundamental Research and Development Areas
Improved Aerodynamic and Heat Transfer Predictions
Advanced 3D CFD Modeling
Rapid Design Iterations. Rapid Prototyping
Sealing technology and validation
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Page 21 UTSR Workshop, October 2010 Copyright Siemens
Materials & Coatings Development Process
Leveraging IGCC and NGCC Experience
• Target Demonstration• Design data generated• Design tools updated• Environmental Testing
Advanced or novel materials and coatings are critical to the successful advanced engine components and systems development
Challenges:
• High Temperature Low Conductivity TBC
• Environmental Issues with Syngas & High Hydrogen Fuels
• Corrosion & Oxidation Capability
Baseline• Literature Search• Initial Hypotheses• Design of Experiments• Target Setting
Experiments Validation
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Page 22 UTSR Workshop, October 2010 Copyright Siemens
Environmental Validation
Quantification of and ranking of current alloys and coatings in relevant environments
Alloy 1 Degradation
Alloy 2 Corrosion Species
Alloy 3 Mechanisms
Syngas High H2 Natural Gas
Coating and alloy development
Environmental validation of new material and coating systems
Quantification of and ranking of new alloys and coatings
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Page 23 UTSR Workshop, October 2010 Copyright Siemens
Leveraging relationships
Government
U.S. DOE
Industrial
Partners (OEM, AE’s, etc.)
Customers
(Utilities, IPP, etc.)
Market Trends
• Efficiency
• Emissions
• Life Cycle Costs
Energy Policy
• Global Warming
• Create New Jobs
• Energy Independence
Basic Research
University, Small Business
Key Success Factor will be our ability to leverage our relationships in order to be “pulling” synergistically in the same direction
UTSR, SBIR
Collaborative agreements
Industrial Review Board
CURC
GTA
Needs Assessments
Incentives, Tax Credits
Regulations (EPA, etc.)
Commercial Projects
R&D
Page 24 UTSR Workshop, October 2010 Copyright Siemens
Technology Risk Mitigation
• Full scale engine testing
• Calibrated high pressure combustion test rigs
• Early adaptation to near term IGCC and NGCC projects
• Field testing in existing fleet
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Page 25 UTSR Workshop, October 2010 Copyright Siemens
Ensuring Commercial Viability
Advanced Gas Turbine Technology which….
Siemens SGT6-5000F
Through advanced technology we will be able to offer a more attractive, state of the art turbine, that is aligned with future industry drivers.
• Is carbon capture and sequestration ready
• Improves gas turbine and combined cycle efficiency
• Supports clean coal technology initiative
• Must Be Reliable
• Significantly reduces CO2 and NOx emissions
• Lowers $/kw cost with increased output and efficiency
• Provides near term technology infusion into current engines
Page 26 UTSR Workshop, October 2010 Copyright Siemens
Acknowledgements
This material is based upon work supported by the US Department of Energy, under Award Number DE-FC26-ONT42644.
The Siemens team wishes to thank Mr. Robin Ames, NETL Project Manager and Mr. Rich Dennis, NETL Turbine Technology Manager forthe opportunity to collaborate on the development of these noveltechnologies for the Advanced Hydrogen Turbine.
Page 27 UTSR Workshop, October 2010 Copyright Siemens
Thank You
The content of this presentation is copyrighted by Siemens Energy, Inc. and is licensed to NETL for publication and distributiononly. Any inquiries regarding permission to use the content of this paper, in whole or in part, for any purpose must be addressed to Siemens Energy, Inc. directly.