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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 4
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All rights reserved.
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
Confidential © Siemens AG 2016
All rights reserved.
• 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:
Confidential © Siemens AG 2016
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
Confidential © Siemens AG 2016
All rights reserved. Mai 2016 Page 7
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
Confidential © Siemens AG 2016
All rights reserved. Mai 2016 Page 8
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!
Confidential © Siemens AG 2016
All rights reserved. Mai 2016 Page 9
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 11
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Application of Crude Oils and Heavy Fuel Oils (HFO)
in Gas Turbines
Mai 2016 Seite 12
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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
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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
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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
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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
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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
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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: