Hochflexible GUD-Kraftwerke für die Anforderungen der Energiewende

Transcription

1 Hochflexible GUD-Kraftwerke für die Anforderungen der Energiewende TÜV Nord - Kraftwerkssymposium Klaus Eurich Sales Director CCPP Central Europe Duisburg, 7. November 2012 Siemens AG All rights reserved.

2 Agenda Herausforderung Energiewende Einflüsse auf Netz- und Lastsituation Nachhaltige technische Lösungen Die Antwort auf den Einfluss der Erneuerbaren Siemens GUD Lösungen mit Kraft-Wärme-Kopplung (KWK) Back up Page 2 Nov 2012 Klaus Eurich

3 Shut down of 7+1 oldest power plants means a deficit of 8,5GW installed secured capacity Power Plants Σ MW Biblis A 1167 Biblis B Isar 1 Brunsbüttel Neckarwestheim 1 Philippsburg 1 Unterweser Phase out NPPs: 8457 MW (41% of the net output) Krümmel Grafenrheinfeld Gundremmingen 2 Philippsburg 2 Gundremmingen Grohnde 1360 Brokdorf Isar Emsland 1329 Neckarwestheim Source: BMWI Page 3 Nov 2012 Klaus Eurich

4 8,5 GW Nuclear Power shut down until end of 2011 with an impact on electricity price and climate targets Merit order of the German power plant portfolio Marginal costs [ /MWh] Promoted production of renewables increased over the last year Capacity of nuclear power plants was reduced from 20,5 to 12GW by the phase out Low gas prices and new built CCPP lead to a flattening of the merit order and to decreasing electricity prices Max. Demand Hydro Renewables Nuclear Lignite Hard Coal Gas-CCPP Gas Source: A.T. Kearney: Paradigmenwechsel Erzeugung Juni 2011 Oil Page 4 Nov 2012 Klaus Eurich

5 Existing overcapacity GW Installed capacity Max. demand 50 of electricity power output 0 Secured capacity 25% reserve margin 98,6 0,2 6,4 20,0 70, ,0 ~10% reserve margin 86,5 10,4 0,5 6,3 66, Increasing numbers of renewables in the energy mix leads to an decrease in secured capacity caused by low availability 3,3 Source others renewable** solar wind nuclear fossil Factor* 0,8 0,01 0,08 0,9 0,9 * Calculation factor for secured capacity based on availability and reliability ** Other renewables are: Biomass, geothermal, hydro Source: BMWI Page 5 Nov 2012 Klaus Eurich

6 Potential of additional demand in Germany until GW Nuclear phase out Retirement Fossil 1 Total demand Source: 1) VGB/SRU (Sachverständigenrat für Umweltfragen) Secured capacity renew. & savings Already under construction or awarded GW additional flexible CCPPs required to provide an environmental friendly back-up solution for renewables Demand fossil Potential for BHPP & SPP Demand for CCPP Page 6 Nov 2012 Klaus Eurich

8 Renewable as well as decentralized generation leads to new challenges in power supply Large-scale renewable Unpredictable generation Wind power plants Solar power plants Challenge: Grid Stability Power Unpredictable Overload Power production due to renewables Underload Load Decentralized generation Consumers turn to producers numerous small renewable Mixture between self-supply and feed-in Solutions Time Flexible generation technology Installed overcapacity Grid extension Intelligent grids and devices Energy storage Page 8 Nov 2012 Klaus Eurich

9 Combined Cycle Power Plants can comply with all major market drivers Lowest Investment Highest Efficiency Highest Flexibility FlexPlant SCC5-8000H 1S Hybrid Power Plants FACY Starting Reliability Market requirements Gas meets all major market drivers and demands Availability Adequate gas reserves for hundreds of years Kyoto, Cancún & fuel price development Regenerative resources Page 9 Nov 2012 Klaus Eurich

10 We need flexible plants in the future: Power Generation Scenario 2020 (Germany) Typical Summer Week (June 2020) High wind day Peaks 6h 8h 9h 10h 11h residual load [MW] Load ramps: Average: 52 MW/min Max.: 181 MW/min Min.: 0,467 MW/min Overload time [h] Peak 4 11h 2 6h 2 8h GW 1 2 9h 6 10h 100% daily start-stop Germany 2020: Up to 100% of the non-renewable fleet requires daily start-stop operation, load ramps of about 200 MW/min to be covered Page 10 Nov 2012 Klaus Eurich

11 Long term electricity storage in Germany not realizable! I. Enormous fluctuation, in future temporary electricity excess Total installed wind capacity: MW ( ) II: Extreme output gradients III: Long dead calms to bridge Actual available pump storage capacity in Germany 2009 Data Source: ISET Page 11 Nov 2012 Klaus Eurich

13 Siemens gas turbine product portfolio from 5 to 375MW to satisfy the customer demands Gas turbine output in MW at ISO conditions SGT5-8000H SGT5-4000F SGT6-8000H SGT6-5000F SGT6-4000F SGT5-2000E SGT6-2000E SGT-800 SGT-700 SGT-600 SGT-500 SGT-400 SGT-300 SGT-200 SGT New gas turbines Large-scale gas turbines Industrial gas turbines Page 13 Nov 2012 Klaus Eurich

14 Energy Solutions Business Unit Innovation highlight: FACY Siemens has introduced FACY to enhance a plant s fast-cycling and fast start-up capability Features BENSON HRSG High-capacity attemperator ST stress controller Stack damper BENSON technology High-capacity attemperator ST/HRSG stress controller Process Optimized GT load ramp Maintain warm-start conditions during plant standstill Automation concept with enhanced stress control Start-on-the-fly: improved start-up sequence Customer benefits HRSG stand-by heating Condensate polishing plant Continuous max. GT load ramp to base load No negative impacts on lifetime Highest start-up reliability Page 14 Nov 2012 Klaus Eurich

15 FACY improves the start up efficiency by 14%-points during a hot start Start up times hot start Improvements No hold phase for Steam Turbine, simultaneous Gas- and Steam Turbine startup Avoid dumping energy to the condenser during start-up Allows optimized Fleet Management Efficiency advantage* Conventional hot start Hot start with FACY Fuel consumption (start up only) Average efficiency (time frame for conventional start) ~514 MWh ~326 MWh ~36 % ~50 % FACY technology enables optimized start-up operation, saves fuel consumption and increases profit * Reference SCC5-8000H 1S Page 15 Nov 2012 Klaus Eurich

16 Customer benefits CO 2 - and fuel cost reduction Fuel consumption and CO 2 emission reduction (per night) 8h part load vs. one shutdown & one startup Fuel consumption (in t) CO 2 emissions (in t) Savings (per year)** Part load operation / shutdown and start up (in Mio. ) t t Mio Part load* Nightly shutdown Part load Nightly shutdown Part load Nightly shutdown SCC5-8000H 1S arrangement w/ cooling tower at ISO ambient conditions (570MW, 60% efficiency) Fuel cost: 20.2 /MWh Electricity price, night: 29.4 /MWh CO 2 costs: 2.88 /MWh Nightly shutdowns save 430 t CO2 per night and appr. 5,4 Mio per year. * Part load operation at 25%-base load and 40%-effiency ** Comparison based on 200 hot-starts per year instead of overnight part load operation Page 16 Nov 2012 Klaus Eurich

17 Improvement of Starting Reliability of SGT5-4000F as reaction on fluctuating renewables Program of Improvement of Starting Reliability started in 2008 and shows benefit Page 17 Nov 2012 Klaus Eurich

18 Dynamic load tests Plant fast hot start up Plant start-up time < 30 min. CC full load 60 Plant load ramps of up to > 55 MW/min at of > 25 MW/min during start-up Plant Output GT speed ST speed Plant output 40 Turbine Speed GT load GT load ramps of up to 35 MW/min 10 0 GT ignition Time Time [min] More than half a GW in less than half an hour base load 0 Page 18 Nov 2012 Klaus Eurich

19 Load tests: Plant fast shutdown 600 Plant fast shut down Plant shut down time < 30 min. 760 Minimum stable load GT speed ST speed 50 Plant Output Plant output GT load 560 ST speed GT speed Turbine Speed GT load ~ 60 MW Plant min. load ~100 MW base load Time Geno. breaker open Plant ramp down to minimum load at 100 MW (~ 20%) or shutdown in less than 30 minutes Time Page 19 Nov 2012 Klaus Eurich

20 Dynamic load tests Plant load changes 600 HP Steam Temp. 600 C 27 MW/min 22 MW/min ± 35 MW/min 600 Plant base load 500 Plant Output MW/min 16 MW/min Plant Output GT Load 500 Steam Temperature Time Time Plant cycling operation with over 200 MW load change in less than 7 minutes 0 Page 20 Nov 2012 Klaus Eurich

21 Typical operation profile of Ulrich Hartmann (Irsching 4) CCPP in 2012 GT speed Plant output Mon Tue Wed Thu Fri Sat Sun Daily start / stop cycle and load following Page 21 Nov 2012 Klaus Eurich

22 Combination of frequency response, start up times and emissions Secondary frequency response Primary frequency response Hot Start up Time 150 min 180%/min 180%/min 120 min 10%/min 60%/min Nuclear Power Plant 6%/min >60%/min Coal fired Power Plant 8%/min CCPP F-class (Siemens) 30 min 35 min 9%/min CCPP H-class (Siemens) are showing that most modern CCPPs are the best choice as back up power Page 22 Nov 2012 Klaus Eurich

23 Innovative design features and proven technologies enable SCC5-8000H 1S to reach η > 60% HRSG: Benson TM 3Pr/RH 600 C/170 bar Gas Turbine: SGT5-8000H Steam Turb.:SST Combined HP/IP Dual flow LP HP: 170 bar / 600 C IP: 35 bar / 600 C LP: 5 bar / 300 C Generator: SGen5-3000W Water cooled stator winding Hydrogen cooled rotor winding MICALASTIC Stator insulation World class efficiency Two main levers to reach highest efficiency Gas Turbine Increased pressure ratio Increased turbine inlet temperature combined with cooling air optimization Improved component efficiencies Water Steam Cycle Fuel preheating of 215 C Advanced water/steam cycle (up to 600 C) with Benson TM HRSG Page 23 Nov 2012 Klaus Eurich

25 Combined heat and power in Germany and Europe CHP share of district heating and process steam production in Europe CHP share of electricity production in Europe Germany has a very high share of 84% of CHP in its DH production. However the CHP share compared to electricity production is fairly low upside potential for new plants Source: AGFW, EuroHeat & Power Page 25 Nov 2012 Klaus Eurich

26 Combined Heat and Power with CC power plants in Single-Shaft configuration by Siemens the combination of standardization and customizing for the full benefit of the owner and operator Page 26 Nov 2012 Klaus Eurich

27 Possible heat extraction per GT-Type in large CHP CCPP, Examples Possible heat extraction [MWth] and electr. Output CC [MWth] per GT-type SGT5-8000H ~585 MWe SGT5-4000F ~440 MWe SGT5-3000E ~300 MW SGT5-2000E ~220 MWe SGT5-800 ~60 MWe Possible heat extraction [MWth] SGT5-800 SGT5-2000E GT5-3000E / 4000F SGT5-8000H Page 27 Nov 2012 Klaus Eurich

28 References KWK - GUD Plants with district heating or process steam extraction > 250MWel in Europe Cond-Operation Heating operation Process Steam Köln-Niehl ~ 410 MW el. ~ 265 MJ/s th. Mainz-Wiesbaden ~ 415 MW el. ~ 160 MJ/s th. Timelkam ~ 410 MW el. ~ 100 MJ/s th. Mellach ~ 420 MW el. ~ 200 MJ/s th. Simmering ~ 825 MW el. ~ 470 MJ/s th. Donaustadt ~ 380 MW el. ~ 265 MJ/s th. Ryavaerket ~ 260 MW el. ~ 300 MJ/s th. D dorf Lausward ~ 595 MW el. ~ 300 MJ/s th. Dormagen ~ 570 MW el. 490t/h (at 31, 16, 6 bar) BASF Ludwigshafen ~ 450 MW el. 560t/h (at 50, 21, 6 bar) Antwerpen ~ 400 MW el. 300t/h (at 19bar, 240 C) 45 power plants with steam extraction between 4,5 und 135MWel for processor district heating purposes since 1990 Page 28 Nov 2012 Klaus Eurich

29 Economics: Highest fuel efficiency in CHP Plant by Siemens Lausward / Düsseldorf SCC5-8000H 1S Customer Stadtwerke Düsseldorf Total el. Power Output 596 MW Plant efficiency >61 % ST Type Generator Type SST SGen5-3000W Date of contract 05 / st comm. operation end 2015 Special features District heating 300 MWth 85 % fuel efficiency Page 29 Nov 2012 Klaus Eurich

30 The latest generation of CCPP are a key element for environmental friendly security of energy supply New market challenges: Uncontrolled feed-in and oversupply of renewable power Decreasing operating hours on fossil plants High flexible of fossil units have to stabilize the grid! Our answer: Highest efficiency CCPPs to reduce fuel costs and CO 2 CoGen/ CHP design with max. utilization of heat and power Design to daily start-stop operation with shortest startup times Full grid code compliance for todays and tomorrows requirements Page 30 Nov 2012 Klaus Eurich

32 Disclaimer This document contains forward-looking statements and information that is, statements related to future, not past, events. These statements may be identified either orally or in writing by words as expects, anticipates, intends, plans, believes, seeks, estimates, will or words of similar meaning. Such statements are based on our current expectations and certain assumptions, and are, therefore, subject to certain risks and uncertainties. A variety of factors, many of which are beyond Siemens control, affect its operations, performance, business strategy and results and could cause the actual results, performance or achievements of Siemens worldwide to be materially different from any future results, performance or achievements that may be expressed or implied by such forward-looking statements. For us, particular uncertainties arise, among others, from changes in general economic and business conditions, changes in currency exchange rates and interest rates, introduction of competing products or technologies by other companies, lack of acceptance of new products or services by customers targeted by Siemens worldwide, changes in business strategy and various other factors. More detailed information about certain of these factors is contained in Siemens filings with the SEC, which are available on the Siemens website, and on the SEC s website, Should one or more of these risks or uncertainties materialize, or should underlying assumptions prove incorrect, actual results may vary materially from those described in the relevant forward-looking statement as anticipated, believed, estimated, expected, intended, planned or projected. Siemens does not intend or assume any obligation to update or revise these forward-looking statements in light of developments which differ from those anticipated. Trademarks mentioned in this document are the property of Siemens AG, it's affiliates or their respective owners. Page 32 Nov 2012 Klaus Eurich

34 n (Alle) Alter in Jahren (Alle) Age distribution of the German generation system demands several replacements e von MWLocal e) Alter in Intervallen (Alle) Alter in Jahren (Alle) Commercial operation date [year] Summe von MWLocal hme Fuel COAL GAS NUKLEAR Total installed: 152GW Differences to operating are: - Projects under construction - PP < 70MW local - Not available capacity - Renewables Total operating fossil: 77GW <10 years operating: 7,8 GW >10 years operating: 9,9 GW >20 years operating: 27,1 GW >30 years operating: 26,1 GW >40 years operating: 6,1 GW Fuel COAL GAS NUKLEAR More than 75% are older than 20 years More than 40% are older than 30 years Installed capacity [MW] Source: Siemens BUD Page 34 Nov 2012 Klaus Eurich

35 These new CCPPs reach full load in ~30 minutes after hot start due to FACY in Europe Pont sur Sambre, France 1S configuration ~27 min Sloe Centrale, Netherland 2 units 1S configuration ~30 min Irsching 5, Germany 2x1 configuration ~30 min Reduced start-up times, proven in several Siemens Combined Cycle plants in Europe Page 35 Nov 2012 Klaus Eurich

36 Dynamic capability: Frequency response Irsching 4 test results Achieved results: Plant load increase by 12% within 10 s No load reduction followed Achieved results: De-loading by 45% followed within 6 s Stable behavior of plant and components CC load Load decrease 250 MW (45%) in 6 s Frequency simulation 500mHz Frequency response target overachieved Potential for more stringent future demand Page 36 Nov 2012 Klaus Eurich

37 The evolution of Siemens Combined Cycle Technology ~2015 SGT5-2000E SGT5-4000F (Introduction) SGT5-4000F (actual upgrade) SGT5-8000H (introduction) SGT5-8000H (future developm.) CCPP Killingholme (2x1) 2 x 470 MW CCPP Didcot B (2x1) 2x 705 MW CCPP Mainz (1x1) 405 MW CCPP Irsching 4 (1S) 557 MW CCPP SCC5-8000H 1S > 600 MW 525 C / 80 bar 2pressure w/o RH 540 C / 110 bar 3pressure w RH 565 C / 125 bar 3pressure w RH 600 C / 170 bar 3pr RH, Benson t.b.d 3pr RH, Benson Advanced GT technology allows for significant improvement of competitiveness and serves as basis for CO2-reduction of gas fired generation Page 37 Nov 2012 Klaus Eurich

38 SGT5-4000F Performance development and operation hours SGT5-4000F Experience The SGT5-4000F is a proven product with more than 14 years of a successful track record in the market. 309 units under contract > EOH whole fleet > EOH fleet leader Reliability is at a level of 99,4%. The current Availability is 94,8%. High customer benefit while keeping proven design features Page 38 Nov 2012 Klaus Eurich

39 Gas Turbine SGT5-4000F Engine Evolution Performance Cooling Air Reduction 1st Compressor Upgrade Market Introduction (1) 1. Upgrade (2) M W / % (CC: 367 MW / 57.0%) Adjusted Pressure Ratio 2. Upgrade (4) M W / % (CC: 407 MW / 57.7%) 3 rd Compressor Upgrade (CMF++) 3. Upgrade (6) M W / % (CC: 416 MW / 58.2%) 4. Upgrade (7) M W / % (CC: 423 MW / 58.4%) 5. Upgrade (8) >300 MW / 40.0% (CC: >440 MW / 58.6%) M W / % (CC: 432 MW / 58.6%) 2 nd Compressor Upgrade (CMF+) Combustor Cooling Air Saving Hydraulic Clearance Optimization Fuel Gas Preheating All ISO ambient conditions. GT-gross; CC-net Page 39 Nov 2012 Klaus Eurich

40 SGT-8000H Efficient & Flexible Evolutionary 3D blading 4 stages of fast acting variablepitch guide vanes (VGV) allowing for improved part load efficiency and high load transients Advanced Can Annular combustion system > 60% combined cycle efficiency Proven rotor design (Hirth serration, central tie rod, internal cooling air passages) for world class fast (cold) start and hot restart capability 3D Four stage turbine with advanced materials and thermal barrier coating High cycling capability due to fully internally air cooled turbine section HCO for reduced clearance losses Transient protection of clearances for reduced degradation with hydraulic clearance optimization (HCO) active clearance control Designed for >60% efficiency in combined cycle and best in class operational flexibility Performance features Flexibility features Page 40 Nov 2012 Klaus Eurich

41 Hydraulic Clearance Optimization (HCO) Increased performance and power output HCO on ~5 MW HCO off The Siemens HCO system: Simple. Fail-safe. Proven for >10 years. Page 41 Nov 2012 Klaus Eurich

42 SGT-8000H engine concept based on harmonization and new technology Siemens V Design Siemens W Design Single tie bolt Compr. stat. design Turbine cylinder Turbine vane carrier Exit housing Front hollow shaft Bearings Compressor cylinder Turbine features Turbine diffuser Harmonized Compressor ULN can-annular combustion system Secondary Air System The SGT-8000H concept uses proven features from Siemens and (former) Westinghouse engines and introduces new technology Page 42 Nov 2012 Klaus Eurich

43 SCC5-8000H 1S Highest base and part load Eff. = ~1.5%-Points CC Gross Efficiency F class SCC5-8000H 1S or same efficiency also at ~75% CC Re. Power (%) Highest performance in base and part load promised & delivered Page 43 Nov 2012 Klaus Eurich

44 Efficiency improvement enables reductions in fuel consumption and CO 2 emissions 1.5%-point efficiency improvement Savings in fuel gas consumption Reduction in CO 2 emissions 14,700 t/year 41,000 t/year Based on 570 MW plant electrical output, 8000 base load hours/year Increase your profitability and save the environment Page 44 Nov 2012 Klaus Eurich

45 Energy Solutions Business Unit Reference: Irsching 4 - SCC5-8000H 1S - Turnkey Customer: E.ON Location: Irsching, Germany Date: 2011 Customer requirements Innovation leadership High power output High efficiency High availability High flexibility Products Gas turbine: SGT5-8000H Steam turbine: SST Generator: SGen5-3000W Boiler: BENSON HRSG with 600 C steam temperature Customer benefits Performance: >550 MW, >60.4% Highest reliability and availability Reduced lifecycle costs CO 2 emission reduction World-class flexibility: From zero to 500 MW in only 30 minutes Page 45 Nov 2012 Klaus Eurich

46 Ulrich Hartmann CCPP EOH - Combustor Inspection (May 2012) Turbine Vane 1 Turbine Blade 1 Compressor outlet Combustor Basket Turbine Hot Gas Path in excellent condition after EOH / 1 Year Commercial Operation Page 46 Nov 2012 Klaus Eurich

47 Energy Solution Business: ~ 40 Projects in Execution Americas Brigadier Lopez 280 MW El Segundo 560 MW Ensenada 560 MW Lake Side II 600 MW Lodi Energy Center 300 MW La Caridad I 250 MW La Caridad II 250 MW Malacas 200 MW Marsh Landing 800 MW Santo Domingo 200 MW Termocentro 1200 MW Termozulia III 600 MW Europe / Russia / Africa Geregu II 430 MW Knapsack II 420 MW Lünen STPP 750 MW Mellach 830 MW Diemen 420 MW Hemweg 430 MW Toul 410 MW Middle East / South Asia Barka III 900 MW Dgen 1250 MW Raz Az Zwar 2400 MW Shuweihat S MW Sohar II 840 MW Tabouk Ext IV 310 MW Unosugen 380 MW Asia Pacific Bugok III 400 MW Chana II 800 MW GMR Energy 800 MW Mortlake 560 MW Wang Noi 800 MW Tuas II 400 MW Ansan 800 MW Andong 400 MW NN1 Korea 1200 MW NN2 Korea 400 MW Status April 2012 Page 47 Nov 2012 Klaus Eurich