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Title: Systems Study for Improving Gas Turbine Performance for Coal/IGCC Application

Abstract

This study identifies vital gas turbine (GT) parameters and quantifies their influence in meeting the DOE Turbine Program overall Integrated Gasification Combined Cycle (IGCC) plant goals of 50% net HHV efficiency, $1000/kW capital cost, and low emissions. The project analytically evaluates GE advanced F class air cooled technology level gas turbine conceptual cycle designs and determines their influence on IGCC plant level performance including impact of Carbon capture. This report summarizes the work accomplished in each of the following six Tasks. Task 1.0--Overall IGCC Plant Level Requirements Identification: Plant level requirements were identified, and compared with DOE's IGCC Goal of achieving 50% Net HHV Efficiency and $1000/KW by the Year 2008, through use of a Six Sigma Quality Functional Deployment (QFD) Tool. This analysis resulted in 7 GT System Level Parameters as the most significant. Task 2.0--Requirements Prioritization/Flow-Down to GT Subsystem Level: GT requirements were identified, analyzed and prioritized relative to achieving plant level goals, and compared with the flow down of power island goals through use of a Six Sigma QFD Tool. This analysis resulted in 11 GT Cycle Design Parameters being selected as the most significant. Task 3.0--IGCC Conceptual System Analysis: A Baseline IGCC Plant configuration was chosen,more » and an IGCC simulation analysis model was constructed, validated against published performance data and then optimized by including air extraction heat recovery and GE steam turbine model. Baseline IGCC based on GE 207FA+e gas turbine combined cycle has net HHV efficiency of 40.5% and net output nominally of 526 Megawatts at NOx emission level of 15 ppmvd{at}15% corrected O2. 18 advanced F technology GT cycle design options were developed to provide performance targets with increased output and/or efficiency with low NOx emissions. Task 4.0--Gas Turbine Cycle Options vs. Requirements Evaluation: Influence coefficients on 4 key IGCC plant level parameters (IGCC Net Efficiency, IGCC Net Output, GT Output, NOx Emissions) of 11 GT identified cycle parameters were determined. Results indicate that IGCC net efficiency HHV gains up to 2.8 pts (40.5% to 43.3%) and IGCC net output gains up to 35% are possible due to improvements in GT technology alone with single digit NOx emission levels. Task 5.0--Recommendations for GT Technical Improvements: A trade off analysis was conducted utilizing the performance results of 18 gas turbine (GT) conceptual designs, and three most promising GT candidates are recommended. A roadmap for turbine technology development is proposed for future coal based IGCC power plants. Task 6.0--Determine Carbon Capture Impact on IGCC Plant Level Performance: A gas turbine performance model for high Hydrogen fuel gas turbine was created and integrated to an IGCC system performance model, which also included newly created models for moisturized syngas, gas shift and CO2 removal subsystems. This performance model was analyzed for two gas turbine technology based subsystems each with two Carbon removal design options of 85% and 88% respectively. The results show larger IGCC performance penalty for gas turbine designs with higher firing temperature and higher Carbon removal.« less

Authors:
Publication Date:
Research Org.:
General Electric Company
Sponsoring Org.:
USDOE
OSTI Identifier:
889755
DOE Contract Number:
FC26-03NT41889
Resource Type:
Technical Report
Country of Publication:
United States
Language:
English
Subject:
01 COAL, LIGNITE, AND PEAT; 08 HYDROGEN; CAPITALIZED COST; CARBON; COAL; COMBINED CYCLES; CONFIGURATION; EFFICIENCY; FUNCTIONALS; GAS TURBINES; GASIFICATION; HEAT RECOVERY; HYDROGEN FUELS; POWER PLANTS; REMOVAL; SIMULATION; STEAM TURBINES; TARGETS; TURBINES

Citation Formats

Ashok K. Anand. Systems Study for Improving Gas Turbine Performance for Coal/IGCC Application. United States: N. p., 2005. Web. doi:10.2172/889755.
Ashok K. Anand. Systems Study for Improving Gas Turbine Performance for Coal/IGCC Application. United States. doi:10.2172/889755.
Ashok K. Anand. Fri . "Systems Study for Improving Gas Turbine Performance for Coal/IGCC Application". United States. doi:10.2172/889755. https://www.osti.gov/servlets/purl/889755.
@article{osti_889755,
title = {Systems Study for Improving Gas Turbine Performance for Coal/IGCC Application},
author = {Ashok K. Anand},
abstractNote = {This study identifies vital gas turbine (GT) parameters and quantifies their influence in meeting the DOE Turbine Program overall Integrated Gasification Combined Cycle (IGCC) plant goals of 50% net HHV efficiency, $1000/kW capital cost, and low emissions. The project analytically evaluates GE advanced F class air cooled technology level gas turbine conceptual cycle designs and determines their influence on IGCC plant level performance including impact of Carbon capture. This report summarizes the work accomplished in each of the following six Tasks. Task 1.0--Overall IGCC Plant Level Requirements Identification: Plant level requirements were identified, and compared with DOE's IGCC Goal of achieving 50% Net HHV Efficiency and $1000/KW by the Year 2008, through use of a Six Sigma Quality Functional Deployment (QFD) Tool. This analysis resulted in 7 GT System Level Parameters as the most significant. Task 2.0--Requirements Prioritization/Flow-Down to GT Subsystem Level: GT requirements were identified, analyzed and prioritized relative to achieving plant level goals, and compared with the flow down of power island goals through use of a Six Sigma QFD Tool. This analysis resulted in 11 GT Cycle Design Parameters being selected as the most significant. Task 3.0--IGCC Conceptual System Analysis: A Baseline IGCC Plant configuration was chosen, and an IGCC simulation analysis model was constructed, validated against published performance data and then optimized by including air extraction heat recovery and GE steam turbine model. Baseline IGCC based on GE 207FA+e gas turbine combined cycle has net HHV efficiency of 40.5% and net output nominally of 526 Megawatts at NOx emission level of 15 ppmvd{at}15% corrected O2. 18 advanced F technology GT cycle design options were developed to provide performance targets with increased output and/or efficiency with low NOx emissions. Task 4.0--Gas Turbine Cycle Options vs. Requirements Evaluation: Influence coefficients on 4 key IGCC plant level parameters (IGCC Net Efficiency, IGCC Net Output, GT Output, NOx Emissions) of 11 GT identified cycle parameters were determined. Results indicate that IGCC net efficiency HHV gains up to 2.8 pts (40.5% to 43.3%) and IGCC net output gains up to 35% are possible due to improvements in GT technology alone with single digit NOx emission levels. Task 5.0--Recommendations for GT Technical Improvements: A trade off analysis was conducted utilizing the performance results of 18 gas turbine (GT) conceptual designs, and three most promising GT candidates are recommended. A roadmap for turbine technology development is proposed for future coal based IGCC power plants. Task 6.0--Determine Carbon Capture Impact on IGCC Plant Level Performance: A gas turbine performance model for high Hydrogen fuel gas turbine was created and integrated to an IGCC system performance model, which also included newly created models for moisturized syngas, gas shift and CO2 removal subsystems. This performance model was analyzed for two gas turbine technology based subsystems each with two Carbon removal design options of 85% and 88% respectively. The results show larger IGCC performance penalty for gas turbine designs with higher firing temperature and higher Carbon removal.},
doi = {10.2172/889755},
journal = {},
number = ,
volume = ,
place = {United States},
year = {Fri Dec 16 00:00:00 EST 2005},
month = {Fri Dec 16 00:00:00 EST 2005}
}

Technical Report:

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  • This appendix is a compilation of work done to predict overall cycle performance from gasifier to generator terminals. A spreadsheet has been generated for each case to show flows within a cycle. The spreadsheet shows gaseous or solid composition of flow, temperature of flow, quantity of flow, and heat heat content of flow. Prediction of steam and gas turbine performance was obtained by the computer program GTPro. Outputs of all runs for each combined cycle reviewed has been added to this appendix. A process schematic displaying all flows predicted through GTPro and the spreadsheet is also added to this appendix.more » The numbered bubbles on the schematic correspond to columns on the top headings of the spreadsheet.« less
  • The ''Enabling & Information Technology To Increase RAM for Advanced Powerplants'' program, by DOE request, has been re-directed, de-scoped to two tasks, shortened to a 2-year period of performance, and refocused to develop, validate and accelerate the commercial use of enabling materials technologies and sensors for Coal IGCC powerplants. The new program has been re-titled as ''Enabling Technology for Monitoring & Predicting Gas Turbine Health & Performance in IGCC Powerplants'' to better match the new scope. This technical progress report summarizes the work accomplished in the reporting period April 1, 2004 to August 31, 2004 on the revised Re-Directed andmore » De-Scoped program activity. The program Tasks are: Task 1--IGCC Environmental Impact on high Temperature Materials: This first materials task has been refocused to address Coal IGCC environmental impacts on high temperature materials use in gas turbines and remains in the program. This task will screen material performance and quantify the effects of high temperature erosion and corrosion of hot gas path materials in Coal IGCC applications. The materials of interest will include those in current service as well as advanced, high-performance alloys and coatings. Task 2--Material In-Service Health Monitoring: This second task develops and demonstrates new sensor technologies to determine the in-service health of advanced technology Coal IGCC powerplants, and remains in the program with a reduced scope. Its focus is now on only two critical sensor need areas for advanced Coal IGCC gas turbines: (1) Fuel Quality Sensor for detection of fuel impurities that could lead to rapid component degradation, and a Fuel Heating Value Sensor to rapidly determine the fuel heating value for more precise control of the gas turbine, and (2) Infra-Red Pyrometer to continuously measure the temperature of gas turbine buckets, nozzles, and combustor hardware.« less
  • The January, 1988 draft topical report, entitled An Assessment of Off-Design Particle Control Performance on Direct Coal-Fired Gas Turbine Systems'' (Ref.1.1), identified the need to assess potential trade-offs in turbine aerodynamic and thermodynamic design which may offer improvements in the performance, operational and maintenance characteristics of open-cycle, direct coal-fired, combustion gas turbines. In this second of a series of three topical reports, an assessment of the technical options posed by the above trade-offs is presented. The assessment is based on the current status of gas turbine technology. Several industry and university experts were contacted to contribute to the study. Literaturemore » sources and theoretical considerations are used only to provide additional background and insight to the technology involved.« less
  • The January, 1988 draft topical report, entitled ``An Assessment of Off-Design Particle Control Performance on Direct Coal-Fired Gas Turbine Systems`` [Ref.1.1], identified the need to assess potential trade-offs in turbine aerodynamic and thermodynamic design which may offer improvements in the performance, operational and maintenance characteristics of open-cycle, direct coal-fired, combustion gas turbines. In this second of a series of three topical reports, an assessment of the technical options posed by the above trade-offs is presented. The assessment is based on the current status of gas turbine technology. Several industry and university experts were contacted to contribute to the study. Literaturemore » sources and theoretical considerations are used only to provide additional background and insight to the technology involved.« less