Externally-Fired Combined Cycle Repowering of Existing Steam Plants

1993 ◽  
Author(s):  
Christian L. Vandervort ◽  
Mohammed R. Bary ◽  
Larry E. Stoddard ◽  
Steven T. Higgins
Keyword(s):  
Heat Exchanger ◽  
Steam Turbine ◽  
Gas Turbine ◽  
High Efficiency ◽  
Low Cost ◽  
Operating Experience ◽  
Capital Cost ◽  
Combined Cycle ◽  
Plant Design ◽  
Generating Capacity

The Externally-Fired Combined Cycle (EFCC) is an attractive emerging technology for powering high efficiency combined gas and steam turbine cycles with coal or other ash bearing fuels. The key near-term market for the EFCC is likely to be repowering of existing coal fueled power generation units. Repowering with an EFCC system offers utilities the ability to improve efficiency of existing plants by 25 to 60 percent, while doubling generating capacity. Repowering can be accomplished at a capital cost half that of a new facility of similar capacity. Furthermore, the EFCC concept does not require complex chemical processes, and is therefore very compatible with existing utility operating experience. In the EFCC, the heat input to the gas turbine is supplied indirectly through a ceramic heat exchanger. The heat exchanger, coupled with an atmospheric coal combustor and auxiliary components, replaces the conventional gas turbine combustor. Addition of a steam bottoming plant and exhaust cleanup system completes the combined cycle. A conceptual design has been developed for EFCC repowering of an existing reference plant which operates with a 48 MW steam turbine at a net plant efficiency of 25 percent. The repowered plant design uses a General Electric LM6000 gas turbine package in the EFCC power island. Topping the existing steam plant with the coal fueled EFCC improves efficiency to nearly 40 percent. The capital cost of this upgrade is 1,090/kW. When combined with the high efficiency, the low cost of coal, and low operation and maintenance costs, the resulting cost of electricity is competitive for base load generation.

2nd Generation PFB Plant With W501G Gas Turbine

2005 ◽  
Author(s):  
A. Robertson ◽  
Zhen Fan ◽  
H. Goldstein ◽  
D. Horazak ◽  
R. Newby ◽  
...  
Keyword(s):  
Steam Turbine ◽  
Gas Turbine ◽  
Fluidized Bed ◽  
Conceptual Design ◽  
Combined Cycle ◽  
Department Of Energy ◽  
United States Department ◽  
Plant Design ◽  
2Nd Generation ◽  
New Type

Research has been conducted under United States Department of Energy (USDOE) Contract DE-AC21-86MC21023 to develop a new type of coal-fired, combined cycle, gas turbine-steam turbine plant for electric power generation. This new type of plant — called a 2nd Generation or Advanced Pressurized Fluidized Bed Combustion (APFB) plant — offers the promise of efficiencies greater than 48 percent (HHV) with both emissions and a cost of electricity that are significantly lower than those of conventional pulverized-coal-fired plants with scrubbers. In the 2nd Generation PFB plant coal is partially gasified in a pressurized fluidized bed reactor to produce a coal derived syngas and a char residue. The syngas fuels the gas turbine and the char fuels a pressurized circulating fluidized bed (PCFB) boiler that powers the steam turbine and supplies hot vitiated air for the combustion of the syngas. A conceptual design and an economic analysis was previously prepared for this plant, all based on the use of a Siemens Westinghouse W501F gas turbine with projected gasifier, PCFB boiler, and gas turbine topping combustor performance data. Having tested these components at a pilot plant scale and observed better than expected performance, the referenced conceptual design has been updated to reflect that test experience and to incorporate more advanced turbines e.g. a Siemens Westinghouse W501G gas turbine and a 2400 psig/1050°F/1050°F/2-1/2 in. Hg steam turbine. This paper presents the performance and economics of the updated plant design along with data on some alternative plant arrangements.

scholarly journals The Coal-Fired PFBC Machine: Operating Experience and Further Development

1996 ◽  
Author(s):  
Sven A. Jansson ◽  
Dirk Veenhuizen ◽  
Krishna K. Pillai ◽  
Jan Björklund
Keyword(s):  
Steam Turbine ◽  
Gas Turbine ◽  
Fluidized Bed ◽  
Future Development ◽  
Operating Experience ◽  
Combined Cycle ◽  
Inlet Temperature ◽  
Turbine Inlet Temperature ◽  
Under Construction ◽  
Further Development

The key components of Pressurized Fluidized Bed Combined Cycle (PFBC) plants are the specially designed gas turbine, which we refer to as the PFBC machine, and the pressurized fluidized bed boiler used to generate and superheat steam for expansion in a steam turbine, in ABB’s P200 and P800 modules, ABB Stal’s 17 MWe GT35P and 70 MWe GT140P machines, respectively, are used. Particulate cleanup before expansion in the turbine sections is with cyclones. So far, over 70,000 hours of operation has been accumulated on P200 modules in the world’s first PFBC plants, demonstrating that PFBC meets the expectations. The GT35P machines have been found to perform as expected, although some teething problems have also been experienced. The next P200 plant will be built in Germany for operation on brown coal. The first GT140P machine has been manufactured. After shop testing in Finspong, it will be shipped to Japan for installation in the first P800 plant, which is under construction. Future development of the PFBC machines are foreseen to include raising the turbine inlet temperature through combustion of a topping fuel in order to reach thermal efficiencies which ultimately may be in the range of 50 to 53% (LHV).

The Operating Experience of the Next Generation M501G/M701G Gas Turbine

2001 ◽  
Author(s):  
Y. Tsukuda ◽  
E. Akita ◽  
H. Arimura ◽  
Y. Tomita ◽  
M. Kuwabara ◽  
...  
Keyword(s):  
Power Plant ◽  
Gas Turbine ◽  
High Efficiency ◽  
Thermal Power ◽  
Operating Experience ◽  
Combined Cycle ◽  
Cycle Performance ◽  
Next Generation ◽  
Gas Temperature ◽  
Combined Cycle Power Plant

The combined cycle power plant is recognized as one of the best thermal power plant for its high efficiency and cleanliness. As the main component of the combined cycle power plant, the gas turbine is the key for improvement of the combined cycle power plant. The next generation G class gas turbine, with turbine inlet gas temperature in 1,500°C range has been developed by Mitsubishi Heavy Industries, Ltd. (MHI). Many advanced technologies; a high efficiency compressor, a steam cooled low NOx combustor, a high temperature and high efficiency turbine, etc., are employed to achieve high combined cycle performance. Actually, MHI has been accumulating the operating experiences of M501G (60Hz machine) a combined cycle verification plant in MHI Takasago, Japan, and achieving the high performance and reliability. Also, M701G (50Hz machine) has been accumulating the operating experience in Higashi Niigata Thermal Power Station of Tohoku Electric Power Co., Inc. in Japan. This paper describes the technical features of M501G/M701G, and up-to-date operating status of the combined cycle power plant in MHI Takasago, Japan.

Degradation Effects on Combined Cycle Power Plant Performance—Part II: Steam Turbine Cycle Component Degradation Effects

2003 ◽  
Vol 125 (3) ◽  
pp. 658-663 ◽  
Author(s):  
A. Zwebek ◽  
P. Pilidis
Keyword(s):  
Power Plant ◽  
Steam Turbine ◽  
Gas Turbine ◽  
Heat Recovery ◽  
Combined Cycle ◽  
Plant Performance ◽  
Graphical Form ◽  
Plant Design ◽  
Heat Recovery Steam Generator ◽  
Fortran Code

This is the second paper exploring the effects of the degradation of different components on combined cycle gas turbine (CCGT) plant performance. This paper investigates the effects of degraded steam path components of steam turbine (bottoming) cycle have on CCGT power plant performance. Areas looked at were, steam turbine fouling, steam turbine erosion, heat recovery steam generator degradation (scaling and/or ashes deposition), and condenser degradation. The effect of gas turbine back-pressure on plant performance due to HRSG degradation is also discussed. A general simulation FORTRAN code was developed for the purpose of this study. This program can calculate the CCGT plant design point performance, off-design plant performance, and plant deterioration performance. The results obtained are presented in a graphical form and discussed.

Degradation Effects on Combined Cycle Power Plant Performance: Part 2 — Steam Turbine Cycle Component Degradation Effects

2001 ◽  
Author(s):  
A. Zwebek ◽  
P. Pilidis
Keyword(s):  
Power Plant ◽  
Steam Turbine ◽  
Gas Turbine ◽  
Heat Recovery ◽  
Combined Cycle ◽  
Plant Performance ◽  
Graphical Form ◽  
Plant Design ◽  
Heat Recovery Steam Generator ◽  
Fortran Code

This is the second paper exploring the effects of the degradation of different components on Combined Cycle Gas Turbine (CCGT) plant performance. This paper investigates the effects of degraded steam path components of steam turbine (bottoming) cycle have on CCGT power plant performance. Areas looked at were, steam turbine fouling, steam turbine erosion, heat recovery steam generator degradation (scaling and/or ashes deposition), and condenser degradation. The effect of gas turbine back-pressure on plant performance due to HRSG degradation is also discussed. A general simulation Fortran code was developed for the purpose of this study. This program can calculate the CCGT plant design point performance, off-design plant performance, and plant deterioration performance. The results obtained are presented in a graphical form and discussed.

Commercialization and Fleet Experience of the 7/9HA Gas Turbine Combined Cycle

2019 ◽  
Author(s):  
Christian Vandervort ◽  
David Leach ◽  
David Walker ◽  
Jerry Sasser
Keyword(s):  
Gas Turbine ◽  
Gas Turbines ◽  
Power Plants ◽  
High Efficiency ◽  
Operating Experience ◽  
Combined Cycle ◽  
Lessons Learned ◽  
Operational Flexibility ◽  
Industrial Gas Turbine ◽  
Cycle Efficiency

Abstract The power generation industry is facing unprecedented challenges. High fuel costs and increased penetration of renewable power have resulted in greater demand for high efficiency and operational flexibility. Imperatives to reduce carbon footprint place an even higher premium on efficiency. Power producers are seeking highly efficient, reliable, and operationally flexible solutions that provide long-term profitability in a volatile environment. New generation must also be cost-effective to ensure affordability for both domestic and industrial consumers. Gas turbine combined cycle power plants meet these requirements by providing reliable, dispatchable generation with a low cost of electricity, reduced environmental impact, and broad operational flexibility. Start times for large, industrial gas turbine combined cycles are less than 30 minutes from turning gear to full load, with ramp rates from 60 to 88 MW/minute. GE introduced the 7/9HA industrial gas turbine product portfolio in 2014 in response to these demands. These air-cooled, H-class gas turbines (7/9HA) are engineered to achieve greater than 63% net combined cycle efficiency while delivering operational flexibility through deep, emission-compliant turndown and high ramp rates. The largest of these gas turbines, the 9HA.02, is designed to exceed 64% combined cycle efficiency (net, ISO) in a 1×1, single-shaft (SS) configuration. As of December 2018, a total of 32 7/9HA power plants have achieved COD (Commercial Operation Date) while accumulating over 220,000 hours of operation. These plants operate across a variety of demand profiles including base load and load following (intermediate) service. Fleet leaders for both the 7HA and 9HA have exceeded 12,000 hours of operation, with multiple units over 8,000 hours. This paper will address four topics relating to the HA platform: 1) gas turbine product technology, 2) gas turbine validation, 3) integrated power plant commissioning and operating experience, and 4) lessons learned and fleet reliability.

Combined Cycles for High Performance, Low Cost, Low Environmental Impact Waste-to-Energy Systems

2000 ◽  
Author(s):  
Stefano Consonni
Keyword(s):  
Environmental Impact ◽  
Steam Turbine ◽  
Gas Turbine ◽  
High Performance ◽  
Low Cost ◽  
Combined Cycle ◽  
Waste To Energy ◽  
Saturated Steam ◽  
Medium Size ◽  
Combined Cycles

This paper assesses the integration between natural gas-fired combined cycles and grate combustors for municipal solid waste (MSW). Saturated steam generated in the grate combustor is exported to the heat recovery steam generator (HRSG) of the combined cycle, where it is superheated and then fed to a steam turbine serving both the combined cycle and the Waste-to-Energy (WTE) plant. Using a single steam turbine reduces costs and increases efficiency; in addition, superheating steam with the clean combustion products discharged by the gas turbine avoids all penalties (and extra-costs) caused by the corrosive gases generated in the grate combustor, which follow a path and are discharged from a stack completely separated from those of the CC. The optimal CC/WTE plant match is achieved when evaporation is carried out almost exclusively in the grate combustor, with the HRSG bearing the load for superheat (and reheat) and part of feedwater heating. Performance estimates for a combined cycle centered around a medium-size, heavy-duty gas turbine show that WTE/CC integration increases the efficiency of energy recovery from waste by 50% and more, with MSW disposal costs lower by 30–40%. Higher energy conversion efficiencies imply lower environmental impact, notably greater reductions of greenhouse gas emissions.

The Chronological Development of the Cheng Cycle Steam Injected Gas Turbine During the Past 25 Years

2002 ◽  
Author(s):  
Dah Yu Cheng ◽  
Albert L. C. Nelson
Keyword(s):  
Gas Turbine ◽  
High Efficiency ◽  
Low Cost ◽  
The United States ◽  
Combined Cycle ◽  
Peak Efficiency ◽  
25Th Anniversary ◽  
Load Following ◽  
Future Performance ◽  
Cogeneration System

The Cheng Cycle gas turbine has enjoyed its 25th anniversary since its conception. More than 100 sites around the world including the United States, Japan, Australia, Italy, Germany, and the Netherlands have used the Cheng Cycle. A chronology will be presented in this paper which will highlight the steps taken to develop the fully automated, load following power and cogeneration system. The Cheng cycle operates with a steam to air ratio trajectory that has its highest “peak efficiency” at the onset of a turbine’s operation. The peak efficiency point was coined as the Cheng point by Dr. Urbach [ref.1] of the US Navy’s David Taylor Research Center. Many thermodynamic and professional textbooks refer to the original Dual Fluid Cycle as the Cheng Cycle. Besides the high efficiency feature, the Cheng Cycle is mechanically simple and flexible in operation. It can put power on line faster than a combined cycle, and it has extremely clean emissions at low cost. The future performance of the Advanced Cheng Cycle will also be projected.

scholarly journals Design Characteristics and Operating Experience of Nuovo Pignone PGT 16 Gas Turbine

1994 ◽  
Author(s):  
D. Sabella ◽  
S. Sferruzza
Keyword(s):  
Gas Turbine ◽  
High Efficiency ◽  
Operating Experience ◽  
Paper Mill ◽  
Combined Cycle ◽  
Heavy Duty ◽  
Gas Generator ◽  
Package Design ◽  
Power Turbine ◽  
Design Characteristics

The paper outlines the main features of the PGT 16 gas turbine with its auxiliaries and summarizes the experiences made in the field with the first seven units put in service starting in the first quarter of 1992. The PGT 16 gas turbine utilizes an aero-derivative gas generator, the LM 1600 manufactured by General Electric, coupled with a heavy-duty power turbine designed and manufactured by Nuovo Pignone. This power turbine is the same utilized for the 14000 HP heavy-duty gas turbine Nuovo Pignone PGT 10. The nominal shaft power is 18600 HP, with 36.4% efficiency. The design shaft speed of 7900 rpm makes this unit particularly suitable for mechanical drive applications, matching the typical speed range of centrifugal compressors in its power range. At the same time the high efficiency makes this unit attractive for both simple cycle and combined cycle power generation plants. The package design privileges maintenance requirements to minimize the downtime and to provide the highest possible degree of availability. The first 5 units in service have been installed along the Transcanada Pipeline and drive pipeline booster ‘compressors, PCL and BCL type: the other two units are in operation in a cogeneration facility in a paper-mill. At October ’93 the seven units have totalled 60,000 fired hours and the fleet leader 13,000 fired hours approximately.

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