Boosting Capacity of Electric Generation through the use...

Boosting Capacity of Electric Generation through the use of

Turbo-Expanders in Natural Gas Network

8 May 2014

September

2013

Main Objective

2

Investigation the possibility of increasing the generation capacity through the use of Turbo-Expanders in Natural Gas Networks.

13/05/2014 Boosting Capacity of Electric Generation through the use of Turbo-Expanders in NG Network

Basic Concept

3

Additional Electricity with No Fuel

High Pressure Level

Low Pressure Level

Throttling Valve

Gas Preheater

Turbo-Expander G

Extracting electric generation capacity from wasted energy in natural gas pressure reduction stations at electricity power plants.

Large amount of energy of high pressure gas is wasted during the pressure reduction process.


Natural Gas Network in Egypt

4 13/05/2014 Boosting Capacity of Electric Generation through the use of Turbo-Expanders in NG Network

National Gas Grid (NGG)

NGG length = 40 km

In 1975

NGG length = 18 thousand km

Capacity of 180 MMSCM/D

By June 2011

4.37 Mio clients in residential & commercial sectors 1800 clients in industrial sector 185 thousand vehicles

Today, NG is transmitted and distributed through the NGG, which extends from Matrouh in the northwest and the Western Desert to the Sinai in the east with high density in the Nile Delta and Suez areas.

5 13/05/2014 Boosting Capacity of Electric Generation through the use of Turbo-Expanders in NG Network

Pressure Levels in NG Network

6

70 barg

42 barg

7 barg

4 barg

20 mbarg

13 barg

Supply

Main Distribution

Gas Turbine Power Plant

Distribution Pressure for Industrial

and Residential Districts

Distribution Pressure

within Facilities

Working Pressure


The Recommended Pressure Reduction Levels for Turbo-Expander Installation

7

Supply

Main Distribution

Gas Turbine Power Plant

Distribution Pressure for Industrial

and Residential Districts

Distribution Pressure

within Facilities

Working Pressure

70 barg

42 barg

7 barg

4 barg

20 mbarg

13 barg


The Recommended Pressure Reduction Levels for Turbo-Expander Installation

8

Are the most attractive sites to install Turbo-expander units.

These stations enjoy steady, high pressure ratio as well as high flow rate.

Most of them are supplying large industrial companies as well as electric power plants.

They are close to the electricity grid.

70/42

42/13

42/7

Down Stream Reduction Stations

are not attractive sites.

They are highly dispersed and consequently supplying limited number of equipment.

They suffer from low diversity factor, which makes the gas flow less steady.

They have limited flow rates as well as low pressure ratios.

All these factors limit the potential of power per site as well as reduce the unit loading ratio.


Up Stream eduction Stations

Turbo-Expander Mechanism

9

A Turbo-Expander is basically a radial or axial gas turbine which produces power due to gas expansion from high pressure at its upstream to a low downstream pressure.

Expansion Process

produce Temperature Decrease

can cause

Cooling of the gas Condensation of the gas composition Erosion of expander blades

Therefore, gas preheating is used


Turbo-Expander Mechanism

Gas Preheating:

o boosts the power of the Turbo-expander due to the increase in the enthalpy of the upstream gas.

o prevents hydrate forming in natural gas stream.

10

When the Turbo-Expander is installed parallel to the throttling valve in a pressure reduction station, the pressure reduction is primary achieved by the Turbo-Expander while the throttling valve is only used during maintenance time of the expander.


Evaluating the Potential of Electricity Generation from NG Pressure Reduction

NG Flow (Standard

m3/hr)

Incoming Gas

Pressure (bar g)

Outlet Gas Pressure

(bar g)

Pressure

Reduction

Ratio

Power Generated

(kW)

10,000 60 2 30:1 700

45,000 37 15 2.45:1 1500

6,500 55 9 6.1:1 750

9,000 40 7 5.6:1 470

16,000 18 6 3:1 850

5,500 50 3 16.7:1 570


11

Additional Power Generation of Cairo Electricity Production Company

12

1,260 350

1,360 700 450

165

1,500

100

450

4.21

0.72

4.87 2.68 1.96

0.79

5.3

0.15 0.47

0

1

10

100

1,000

10,000

Installed Capacity (MW) Additional Power Generation (MW)


Additional Energy Generation of Cairo Electricity Production Company

13

5,168.4

625

6,803.7 4,010.05 2,630.83

709.21

10,207.18

126.2

625.34

36.84

6.31

42.65 23.47 17.13

6.94

46.41

1.36 4.1

1.0

10.0

100.0

1,000.0

10,000.0

Annual Energy Generated (GWh)

Additional Annual Energy Generated (GWh)


Additional Power Generation of East Delta Electricity Production Company

14

900 600

100 73 66

640 1,200 500 1,000

3.44 3.02

0.12 0.07 0.3

3.51 4.59 2.42 5.23

0.01

0.1

1

10

100

1000

10000



Additional Energy Generation of East Delta Electricity Production Company

15

3,974.77 3,399.47

104.82 61.6

338.7

5,012.7 7,352.8 2,963 5,978.02

30.14 26.43

1.08 0.64 2.6

30.78 40.21 21.2 45.8

0.10

1.00

10.00

100.00

1,000.00

10,000.00




Additional Estimated Power Generation of Middle Delta Electricity Production Company

16

290 420

750

2,250

316

750

1.27 1.69 1.82

5.78

1.53 2.87

1

10

100

1000

10000

Talkha (CC) Talkha steam 210

(St)

Talkha 750 (CC)

Nubaria 1,2,3 (CC)

Mahmoudia (CC)

El-Atf (CC)



Additional Energy Generation of Middle Delta Electricity Production Company

17

1,670.4 2,039.72 3,393.93

10,994.82

2,031.78 5,549.4

11.13 14.81 15.91

50.68

13.37 25.16

1.0

10.0

100.0

1,000.0

10,000.0

100,000.0

Talkha (CC) Talkha steam 210

(St)

Talkha 750 (CC)

Nubaria 1,2,3 (CC)

Mahmoudia (CC)

El-Atf (CC)




Additional Power Generation of West Delta Electricity Production Company

18

440 300 195 156.5

911 200

640 750

60

1.85

0.43 0.97 0.71

4.04

0.26

2.68 2.74

0.33

0.1

1

10

100

1000



Additional Energy Generation of West Delta Electricity Production Company

19

1,957.7

522.53 982.67 1,035.26

4,871.3

209.141

3,848.41 5,315.94

339.909

16.19

3.76 8.52 6.25

35.4

2.3

23.47 24.02

2.93

1.0

10.0

100.0

1,000.0

10,000.0




Additional Power Generation of Upper Egypt Electricity Production Company & BOOT

20

1,254 750 750

2,754 2,754 2,754

5.13

2.5 2.44 2.89 2.68 2.79

1

10

100

1,000

10,000

Kuriemat (St)

Kuriemat 1 (CC)

Kuriemat 2 (CC)

Sidi Krir 3,4 (St)

Suez Gulf North (St)

Port Said East (St)



Additional Energy Generation of Upper Egypt Electricity Production Company & BOOT

21

7,397.7 4,986.38 4,348.29 4,614 3,994 4,247

44.97 21.89 21.34 25.32 23.44 24.44

1.0

10.0

100.0

1,000.0

10,000.0

Kuriemat (St)

Kuriemat 1 (CC)

Kuriemat 2 (CC)

Sidi Krir 3,4 (St)

Suez Gulf North (St)

Port Said East (St)




The turbo-expander additional electricity is generated without affecting the natural gas consumption by power plant. Hence, a certain amount of natural gas is avoided.

This amount will result in carbon dioxide release avoidance .


22

Annual NG Avoided

Annual Co2 Avoided

Annual NG Avoided Cost ($)

ktoe Ton CO2 Subsidized NG Unsubsidized NG

Total 129.85 44,753 8,656,038 55,348,802

Final Results


23

Total additional

power generation = 91.25 (MW)

Total additional

annual electricity

generated = 799.39 (GWh)

Annual NG Avoided

= 129.85

(ktoe)

Impact of Inlet Temperature Variation on Power Generation

Total Power =88.67 MW

Total Power = 91.26 MW

Total Power = 93.84 MW

24

Tin=70C

Tin=80C

Tin=90C


If the inlet temperature changes by 10 degrees Celsius

reduction, then the capacity will fall by 2.8% and vice versa.

Potential Profit Margin

Owner Capital Cost (Mio EGP)

Profit (Thousand EGP)

Payback Period (year)

(Subsidized)

1,450

60,652 27

(Unsubsidized)

228,382 6


25

Ownership and Operational Responsibility


26

Meter

High Pressure Gas

Pressure Reduction Station

Throttling Valve

Meter

Boiler Turbine Generator



27

Meter

High Pressure Gas


Throttling Valve Turbo-Expander

Meter Meter


Generator

Meter



28

Meter

High Pressure Gas



Meter Meter


Generator

Meter

Sync



29

Meter

High Pressure Gas



Meter Meter


Generator

Meter

Sync

Regulatory framework for the Electricity Market

Transmission and

distribution networks

Electricit

y users

Generation

Co.

Bilateral agreement

Payment through

escrow account

IPP expansion

13/05/2014 30 Boosting Capacity of Electric Generation through the use of Turbo-Expanders in NG Network

Exports

& Imports

MV & LV

Customers

Gov. PP

BOOT(s)

Generation

Co.(s)

Target Market

Phase one

HV

Customers

MV

Customers UHV

Customers

Dis

Co(s)

Private

Distributor

LV customers

ISP

ISP MOEE/EEHC

IPP expansion

Trans Co(s)


Exports

& Imports

MV & LV

Customers

Gov. PP

BOOT(s)

Generation

Co.(s)

IPP expansion

Trans Co(s)

HV

Customers

MV

Customers UHV

Customers

Dis

Co(s)

Private

Distributor

ISP

LV customers

ISP

Target Market

Proposed phase two

MOEE/EEHC


MOEE/EEHC

Exports

& Imports

Dis

Co(s) MV & LV

Customers RE: Gov PP

& IPP

..

BOOT(s)

Generation

Co.(s)

IPP expansion

Trans. co.

Target market

proposed

phase

three

HV

Customers MV

Customers UHV

Customers

EEUCPRA

Ministry of Electricity and Energy

Independent Merchant Transmission & Distribution

ISP(s)

TSO


Possible demo implementations

At plants with large/steady flow rate of NG, and with high pressure reduction

In power plants

At current power plants in the industrial sector

At large scale industrial sector


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