Effective NOx reduction for IED compliance of existing older gas turbines

Transcription

1 Effective NOx reduction for IED compliance of existing older gas turbines

2 Power-Gen Europe 2013 conference track & session information Conference: Power-Gen Europe, June , Messe Wien, Vienna, Austria Track 6 : Operation, Maintenance, Refurbishment & Optimization Session 1A : Retrofits & Upgrades 1 Tuesday June 4, 14:00 15:30 hrs. Room Stoltz 2, Messe Wien, Vienna Presentation: Effective NOx Reduction for IED Compliance of Existing Older Gas Turbines Speaker : Sjirk van der Goot Marketing & Communications Director VBR Turbine Partners Expo booth : VBR Turbine Partners, B3349 (Holland Pavilion), Hall B, Messe Wien

3 Questions? Questions?

4 Summary For owners and operators of an older gas turbine in Europe there are at least three NOx emission reduction technologies available to achieve compliance with the IED: DLE / DLN (Dry Low NOx) SCR (Selective Catalytic Reduction) ASI (Advanced Steam Injection) For owners and operators of an older gas turbine in Europe that is already fitted with a properly dimensioned steam injection system an ASI NOx reduction retrofit will most likely be: the most effective, the most cost effective, the most reliable and the most sustainable solution to comply with the IED as of January 1, 2016 (or 2020)

5 Effective NOx reduction for IED compliance of existing older gas turbines Content 1. Power-Gen Europe 2013 conference track & session information 2. Questions? 3. Summary 4. Content 5. Introduction to VBR Turbine Partners 6. The European Industrial Emissions Directive (IED) for gas turbines 7. Five options for existing older gas turbines to deal with the IED 8. Benefits, concerns & bottom line of each option to deal with the IED 9. A closer look at Advanced Steam Injection (ASI) emission reduction 10. ASI NOx emission reduction a LM2500 case study 11. Examples of specially designed and patented ASI hardware 12. ASI emission reduction retrofits available for Europe 13. Considerations for decision making about IED compliance of existing older gas turbines 14. Summary 15. Questions?

6 Introduction to VBR Turbine Partners - 1 VBR Turbine Partners are independent ISO 9001 / 2008 certified maintenance experts for GE LM gas turbines and their auxiliaries, control systems & packages. We support the owners and operators of GE LM gas turbines to reduce their operating costs, maintenance costs & exhaust emissions and to increase their levels of availability, reliability, performance & maintainability. VBR Turbine Partners were founded in 2000 by three former Thomassen & GE engineers. We have maintenance service locations in Dubai / UAE, the Netherlands & the United Kingdom and qualified maintenance service agents in Spain, Russia, Nigeria and Australia. VBR provides GE LM maintenance solutions and maintenance services to customers in Europe, Russia, the Middle East & North Africa and provides GE LM spare parts to customers all over the world (excluding USA). Our certifications: ISO 9001 / 2008 SCC Petrochemical Achilles & FPAL

7 Introduction to VBR Turbine Partners - 2 Our core expertise: Cost effective inspection, maintenance, repair, overhaul, emission reduction, lifetime extension and power plant relocation of GE LM1600, LM2500, LM5000 & LM6000 aero-derivative gas turbines and their auxiliaries, control systems & packages. Our maintenance solutions: * 24/7 Maintenance agreements * Maintenance management support * Trip reduction / performance upgrade * CLN NOx emission reduction retrofits * Inspection, repair and replacement * Engine overhaul & hot section exchange * DLE mapping * Control system upgrades & retrofits * Strategic spare parts planning * Power plant relocation

8 Introduction to VBR Turbine Partners - 3 Our maintenance services: * I&C services * Mechanical field service * Meggitt OEM valve overhaul * Condition monitoring * Consultancy * Education & training * Spare parts European distribution: * Meggitt / Whittaker Controls * CLN NOx reduction retrofits by CPS * MetalSCAN by GasTOPS * Esterline / Weston Aerospace * JADwash green performance cleaner

9 Introduction to VBR Turbine Partners - 4 The VBR systematic maintenance improvement philosophy for GE LM gas turbines: From re-active corrective maintenance to pro-active preventive maintenance. 1. Investigate and determine current maintenance situation: a. Investigate current maintenance situation engine, auxiliaries, control system, package b. Determine existing maintenance issues and maintenance gaps 2. Develop corrective maintenance plan(s) and deploy corrective actions: a. Develop corrective maintenance plan(s) project approach b. Deploy corrective actions during scheduled engine stop(s) 3. Shift to pro-active preventive maintenance management: a. Install diagnostic tools and data logging applications to improve maintainability b. 24/7 remote monitoring & maintenance support for pro-active preventive maintenance The essential element in the VBR systematic maintenance improvement philosophy: Educate & train the engine operators and maintenance engineers at the customer site.

10 Introduction to VBR Turbine Partners - 5 A selection of our customers: AGSM Verona S.p.A ACTV - Verchelli Air Liquide Air Products AKZO-Nobel Ansaldo Energia SpA Bairnsdale Power Station Bornholms Trafikken BP-Exploration BP Europe SE Cofely Italia S.p.A Cofely France ConocoPhillips Corus Dalkia Dong - Energy Dong - Horsens Dong - Lyngby Dresser-Rand DSM Dupont Ecocarburantes EDF Edison S.p.A Electrabel Elettrogorizia E.ON - Benelux E.ON - Ruhrgas E.ON UK Essent Energie Productie EVH GmbH Fenice SpA Iride KVV-Silkeborg KVV-Sønderborg Maersk Oil & Gas MTU Marathon Oil NAM National Grid NUON Power Nexen Petroleum UK Open Grid Europe Shell SoGiCo SPE Stadtwerke Brandenburg Stadtwerke Schwerin StatoilHydro Tortosa Energia Trans Alta Venture Production (CH4) Volvo Aero Corporation... and more...

11 The European Industrial Emissions Directive (IED) for gas turbines The new emission limit values as defined in the European Industrial Emissions Directive (IED): From January 1, 2016 (or 2020 when you qualify for an exception): Existing gas turbines > 50 MWth : 50 mg NOx / Nm3 (approx. 24 ppm) Existing gas turbines > 50 MWth in CHP operation : 75 mg NOx / Nm3 (approx. 36 ppm) Consequences of the IED for existing older gas turbines: Existing older gas turbines need to apply some form of effective NOx emission reduction technology before January 1, 2016 (or 2020) to remain in operation.

12 Five options for existing older gas turbines to deal with the IED Owners & operators of older gas turbines have at least five options to deal with the IED: 1. Stop your gas turbine operation before January 1, 2016 (or 2020) 3. Keep operating after January 1, 2016 (or 2020) without investing in emission reduction 4. Apply a DLE / DLN (Dry Low NOx) emission reduction retrofit 5. Apply a SCR (Selective Catalytic Reduction) emission reduction retrofit 6. Apply an ASI (Advanced Steam Injection) emission reduction retrofit

13 Benefits, concerns & bottom line of each option to deal with the IED - 1 Option 1: Stop your gas turbine operation before January 1, 2016 (or 2020) Benefits: * No investments required for further NOx emission reduction Concerns: * Another source for electricity and/or heat required Bottom line: * Good option when electricity and/or heat are no longer required or can be arranged in another way at lower costs

14 Benefits, concerns & bottom line of each option to deal with the IED - 2 Option 2: Keep operating after January 1, 2016 (or 2020) without investing in emission reduction Benefits: * No investments required for further NOx emission reduction Concerns: * In this case owners and/or plant managers of gas turbines are intentionally not complying with the IED. These owners and/or plant managers may face the risk of becoming personally liable for intentionally not complying with current legal requirements Bottom line: * Not an option from a corporate or managerial perspective

15 Benefits, concerns & bottom line of each option to deal with the IED - 3 Option 3: Apply a DLE / DLN (Dry Low Nox) retrofit Benefits: * Compliance with the IED Concerns: * A very substantial investment required * Requires structural additional maintenance (and maintenance costs) * Works at full load but not so good at part loads Bottom line: * Good option when you can afford it and operate mainly on full load

16 Benefits, concerns & bottom line of each option to deal with the IED - 4 Option 4: Apply a SCR (Selective Catalytic Reduction) retrofit Benefits: * Compliance with the IED Concerns: * SCR systems need a complete renewal every five years * SCR requires a constant supply of ammonia for the emission reduction process * SCR works at full load but not so good at part loads Bottom line: * Good option when you have no other choice and operate mainly on full load

17 Benefits, concerns & bottom line of each option to deal with the IED - 5 Option 5: Apply an ASI (Advanced Steam Injection) retrofit. Benefits: * Compliance with the IED * Reduction in fuel costs at similar power output * Reduction in maintenance (and maintenance costs) * Works at all loads (full load and part loads) Concerns: * Turbine needs a steam system capable of supplying sufficient overheated steam for fuel injection * No ASI reference site in Europe yet, currently only installed and operational in the USA Bottom line: Good option when your gas turbine is already fitted with steam injection and operates at all loads (full load and part loads)

18 A closer look at Advanced Steam Injection (ASI) emission reduction - 1 The three common types of steam injection for gas turbines: * Pre-mix steam * Direct steam * On-board pre-mix steam ASI is the advanced version of the traditional pre-mix steam injection. ASI works by running an engine on a > 98% homogenous gaseous mix of steam and fuel to realize a cleaner, more effective and more efficient combustion process at a lower temperature. ASI lowers the heat rate of a gas turbine and therefore limits the formation of NOx and CO during the combustion process rather than removing these chemicals from the combustor exhaust after they have been formed.

19 A closer look at Advanced Steam Injection (ASI) emission reduction - 2 Shape and size of an ASI flame compared with a regular flame and with a steam injection flame.

20 A closer look at Advanced Steam Injection (ASI) emission reduction - 3 Four graphics comparing the variations between no steam and the ASI NOx emission reduction system 1 : CH4 2 : Temperature 3 : NOx 4 : CO

21 ASI NOx emission reduction a LM2500 case study LM2500PE Standard WLE DLE ASI Power output / kw Heat rate / kwh Efficiency / % 38,8 35,6 35,4 39,6 NOx level / ppm CO2 per year / tons CO2 reduction / tons (relative to WLE) Source: the article 1.8 : 1 steam to fuel ratio reduces NOx output of LM2500 to 5 ppm by Victor de Biasi in the May-June 2009 edition of Gas Turbine World. Bottom line: test data verify that NOx levels are reduced at relatively low steam-to-fuel injection ratio s independently of load while increasing power and improving efficiency.

22 Examples of specially designed and patented ASI hardware - 1 ASI turbine enclosure piping Fuel line Steam line Flow meter Check valve Mixer

23 Examples of specially designed and patented ASI hardware - 2 Steam manifold and flexible connectors

24 Examples of specially designed and patented ASI hardware - 3 Flexible connectors and specially designed ASI fuel nozzles flexible connectors Specially designed ASI fuel nozzles

25 Examples of specially designed and patented ASI hardware - 4 Differences between ASI fuel nozzles & GE fuel nozzles (regular and STIG)

26 Examples of specially designed and patented ASI hardware - 5 X-ray showing location of CRV in ASI fuel nozzle for GE LM2500 CRV

27 ASI NOx emission reduction retrofits available for Europe ASI NOx emission reduction retrofits already installed and operational in the USA: * GE LM2500 * GE Frame 6B & Frame 7EA * RR 501 ASI NOx emission reduction retrofits available for Europe: * GE LM1600, LM2500 and LM6000 * GE Frame 5, Frame 6B and Frame 9E * RR 501, Avon, RB 211 and Trent

28 Considerations for decision making about IED compliance Considerations for decision making about IED compliance of existing older gas turbines: - ASI is a NOx and CO reduction retrofit for existing older gas turbines - ASI reduces NOx and CO below the new IED emission limits - ASI works at all loads (full load and part loads) - ASI lowers the fuel costs (or raises the power output) of gas turbines - ASI improves the efficiency of gas turbines - ASI reduces the heat rate of gas turbines - ASI supports lifetime extension of gas turbines - ASI is a more robust and more reliable technology than DLE / DLN or SCR - ASI requires less maintenance (and less maintenance costs) than DLE / DLN or SCR - ASI installation costs are lower than DLE or SCR installation costs (with existing steam injection) - ASI is a future proof solution, realize further NOx reductions by mixing more steam into the fuel

29 Summary For owners and operators of an older gas turbine in Europe there are at least three NOx emission reduction technologies available to achieve compliance with the IED: DLE / DLN (Dry Low NOx) SCR (Selective Catalytic Reduction) ASI (Advanced Steam Injection) For owners and operators of an older gas turbine in Europe that is already fitted with a properly dimensioned steam injection system an ASI NOx reduction retrofit will most likely be: the most effective, the most cost effective, the most reliable and the most sustainable solution to comply with the IED as of January 1, 2016 (or 2020)

30 Questions? Questions?

31 Thank you for your attention Thank you for your attention