Antworten auf neue Brennstoffanforderungen in der … · 2016-07-04 · (e.g. Siemens Gas Turbine SGT-400: ≈ 15 ... Improve economics of Crude Oil application in E-Class Gas Turbine

Confidential © Siemens AG 2016 siemens.com

Antworten auf neue Brennstoffanforderungen in

der Kraftwerkswelt

– auch Brennstoffe wollen gut behandelt werden - Mai 2016

Ralph Joh; Markus Kinzl; Ansgar Kursawe; Rüdiger Schneider

Mai 2016 Seite 2

Confidential © Siemens AG 2016

All rights reserved.

Fuel Classification Overview

0

5

10

15

20

25

30

0 10 20 30 40 50 60

LNG

LPG Ethane

Sour Gas

Natural Gas

Naphtha Methanol

Pe

rce

nt H

yd

rog

en

(w

t%)

Heating Value [MJ/kg]

Gas condensate

SynGas

Weak

Natural Gas

Blast Furnace Gas

Bio-

diesels

Propane Butane

Kerosene Fuel Oil

Ethanol

Landfill gas

Crude Oil

Bio-Pyrolysis Oil

Hydrogen(H2): Hu ~ 120 MJ/kg

Methane (CH4): Hu ~ 50 MJ/kg

Carbon monoxide (CO): Hu ~ 10 MJ/kg Methane

Coal

Residual Fuel

Biogas

Liquid Fuels

Shale Gas

Mai 2016 Seite 3



Sour Gas Pre-Treatment

Mai 2016 Seite 4



Power Generation with Natural Gas

Sour Gas Estimated at >40% of Gas Reserves

Foster

Wheeler,

2004

Inter-

national

Energy

Agency,

2008

Proven sour gas

reserves, 2006

• Sour gas

sweetening is

mandatory to

secure long term

energy supply

• Cost effective

solutions are

required at a

variety of markets,

at different scales,

and in many

locations

Mai 2016 Seite 5



• Utilization of a challenging but huge energy resource.

• Saving of maintenance costs, prolongation of turbine live time.

• Pre-treatment much less expensive compared to a flue gas desulfurization.

Limits of Sour Gas Usage

for Turbine Applications

H2S concentration in sour gas 10 ppmv

Suitable for all

types of turbine

1 %vol

• Suitable with

modifications

• Increased

maintenance

• Shorter life time

4 %vol

• Harm of legal SOx

emission (400 ppm SOx)

• Further increased

maintenance costs

• Even shorter life time

• Sour Gas with more than

4 %vol H2S is currently not

applicable for turbine

usage

H2S Separation with pre-treatment

from 30% H2S down to 10 ppmv

Current Limitations:

Siemens Solution:

Benefits:


All rights reserved. Mai 2016 Page 6

Siemens Low Cost Sour Gas Treatment

Technology…

Basic Comparison with Conventional Treatment

Air

Tail Gas Treatment

Waste

Off Gas

Amine Wash

… enables utilization of sour gas in Gas Turbines

with reduced capex and footprint



Development Path and Scale Up

for Siemens Sour Gas Treatment

Lab-Scale Sour Gas: 1 Nm3/h

Mobile Pilot Plant Sour Gas: 100 Nm3/h (max H2S: 30%)

Demo Plant Sour Gas: 5000 Nm3/h (e.g. Siemens Gas Turbine SGT-400: ≈ 15 MW el)

Validation

Agreement

Demo Plant

Agreement

Site

Selection

Start

Operation

Proof of Concept

Full Scale

Power Plant 1 GW 300000 Nm3/h

Risk mitigation via reasonable scale up strategy

For comparison: Gas consumption of a single-family

home: about 1600 Nm3 per year



Current Status of Development

Lab Results:

Continuous lab operation of absorbtion/oxidation (>1000h; ambient pressure)

H2S purity (lower smell threshold <0.1 ppm) H2S in Sour Gas up to 30 vol% CO2 in Sour Gas up to 10 vol% Solvent Concentration optimized Filtration in Lab Scale Solvent Stability Tests

Proof of Concept in Lab Scale!



Pilot Plant:

Mobile Research Prototype

Integration of all process steps

Pressures: Field/Turbine Conditions

Long term demonstration of reliability

and performance

Draft!

Mai 2016 Seite 10



Fuel Oil Pre-Treatment

Mai 2016 Seite 11



Application of Crude Oils and Heavy Fuel Oils (HFO)

in Gas Turbines

Mai 2016 Seite 12



Challenge: Without special mitigation measures, oil impurities, especially alkaline metals (Na, K)

and Vanadium (V), cause corrosion in the hot-gas-path of gas turbines

Conventional Mitigation Methods: • Alkaline salts are removed by fuel water-washing ( centrifuge)

• Vanadium effects are mitigated by means of Mg-additive dosing

Formation of high-melting water soluble mixed oxides

Periodic removal of mixed oxides by means of turbine blade water-washing

Disadvantages of the Conventional Strategy • Cost intensive due to the continuous consumption of additives and large amounts of demineralized water

• High effort for maintenance ( fuel factor 3-4) and the increased numbers of shutdowns for washing

• Lower efficiency due to ash layers on GT blades

Source: Alstom

Na corrosion effect

on blades

Source: Siemens

Mg salt on blades

(before washing)

Application of Crude Oils and Heavy Fuel Oils

(HFO) in Gas Turbines

Vanadium Removal in front of the Gas Turbine (Pre-Treatment) is desirable

Mai 2016 Seite 13



New Siemens GT Fuel Oil Treatment Process

enables and improves Power Plant Applications

Vanadium Concentration [ppm]

Case 2:

Improve economics of Crude Oil

application in E-Class Gas Turbine

Case 3:

Enabling of

HFO

application

in E-Class

Gas Turbine

Case 1:

Enabling of ASL, AXL application as

F,H-Class Gas Turbine backup fuels

0

100

200

300

400

500

600

700

800

900

0,1 1 10 100

Blue curve: Vanadium-related O&M costs

Target: Reduce V to decrease

operation and service costs Target: Reduce

Vanadium to < 0.5 ppm

F, H-Class

Limit: 0.5 ppm

E-Class Limit:

100 ppm

Target: enable E-Class

application

Van

ad

ium

-rela

ted

O&

M c

osts

Mai 2016 Seite 14



Technology and Potential in Large Scale

New SIEMENS Process

Asphaltenes + Vanadium

Feasibility in commercial scale e.g. 1 GW)

Life Cycle Cost reduction

Less inhibitor consumption

Additionally: - commercialization of asphaltene product ( road asphalt)

- increased GT efficiency

- reduced heavy metal and sulfur emissions

Expected Payback Time: < 3 years

Mai 2016 Seite 15



Development Path and Scale Up

Liquid Non-Spec Fuel Treatment

Lab-Scale 1kg/h of oil

Mobile

Pilot Plant 100 kg/h of oil

Demo Plant

10.000 kg/h of oil

Validation

Agreement

Demo Plant

Agreement

Site

Selection

Operation

Finalized

Process

Verification

Full-Scale

Plant 100.000 kg/h of oil

For comparison: Oil consumption of a single-family home:

around 2000 kg of oil per year

Mai 2016 Seite 16



Project Status

Experimental Results in Lab Scale

Selection of pre-treatment method Construction and operation of a continuous lab plant Confrimation of vanadium removal rate Moderate conti-process parameters

Risk Mitigation as a Basis for Pilot Plant Operation

Test of operation units Optimization operation units tbd

In Parallel: Pilot Plant Assembling

Purchasing of pilot plant equipment started

Mai 2016 Seite 17



Pilot Plant Concept

Crude Oil Tank for GT

Pre-Treatment Pilot Plant

Storage Tank

Modular Pilot Plant: 3 Containers plus Utilities

Location: - IP Höchst, B695 for 2016

- Customer for 2017

Capacity: 𝑉 𝑂𝑖𝑙 = 100 kg/h

Test Targets: - Integration and testing of

all equipment types which will be used in large scale

- Process validation in pilot scale

- Long-term demonstration of process performance and reliability

Integration into Power Plant Environment:

Mai 2016 Seite 18



Danke für die Aufmerksamkeit

Documents

Antworten auf neue Brennstoffanforderungen in der … · 2016-07-04 · (e.g. Siemens Gas Turbine SGT-400: ≈ 15 ... Improve economics of Crude Oil application in E-Class Gas Turbine