Thermal and on - Tim Clarke

8/6/2019 Thermal and on - Tim Clarke

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Thermal Power and Cogen Opportunities

Tim Clarke

Head of Power GMR International

March 2011


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Thermal and Cogen for the future

The power of electricity is critical to industrial society, lack of it strangles growth and development,

an abundance creates a plethora of uses

(though some more useful than others!!)

ISLAND POWER 800 MWCombined Cycle Power Project

As most readers know, GDP growth is a

strong predictor of power generationdemand.Eppinger and Smith, Fluor Corp


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Thermal and Cogen for the future

Thermal Power Plants are proven and commercially strong Key parameters of a Thermal Power Project

Market fit Unit size, flexibility, grid issues, fuel diversity, through life costs

Fuel - Coal, Gas, Oil, Biomass

Fuel route Source, transport, commercial position, reliability

Environmental emissions long term effects

Efficiency and reliability technology selection

Conventional steam turbine plant

Gas turbine plant open and closed cycle

Reciprocating engines open and closed cycle

Co Gen increases heat conversion efficiency

Efficiency is critical CCGT gas plant that costs circa $900/kw, over30 years will use

over $9000/kw of gas & emit 73T/kw CO2 costing $1518/kw

Fuel cost is 10x cost of capital, CO2 1.6x

Conventional coal plant that costs circa $2500/kw, over30 years

will use over $8000/kw of coal & emit 151T/kw CO2 costing $3141/kw

Fuel cost is 3.2x cost of capital, CO2 1.3x

RIJNMOND I 820 MW

Combined Cycle Power Project


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Market fit

Thermal power plants offer High reliability, high load factors, predictable output

Cost effective to build and operate

Grid services frequency control, voltage control

Globally traded fuel resources, available and competitively priced long termcontracted positions possible

Contractually robust and financeable internationally

But.....

Environmental impact is significant

Emissions CO2, NOx, Pollutants, Ash

Upstream supply impact

Can require costly capital clean up equipment

SO2 removal, NOx reduction, heavy metal

removal, Ash removal, CO2 removal

Constrained by government regulationROCKSAVAGE 806 MWCombined Cycle Power Project


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Conventional equipment

Source; US EIA

Boiler turbine plant

Efficiency limited by ultimate Rankine cycle efficiency,

the fluid used, the min temperature sink (atmospheric temp) and the highestavailable temperature (material limits)

Focus has been on pushing up temperature and pressure and hence size 1000MW units

Ultra supercitical plant 600+c/300bar, 46% efficiency Advanced 3D turbine design improves conversion efficiency

Modelled flow and heat dynamics tune and optimise the process

Biomass fuel is usually lower CV/high volume, so units smaller andmore conventional and hence lower efficiency

greater proportion of costs in fuel handling Boilers need to be designed for fuel

biomass characteristics vary

CHHATTISGARH 1370 MW

Coal- Fired Power Project


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Gas Turbine

GTs run at higher temperature so offer higher ultimate efficiency

Focus has been on pushing up combustion temperature and henceefficiency F technology 1300c, H technology 1400c

Materials technology is the limit blades, combustors, coatings

Capacity increases with technology, F 290Mw, H 340Mw

Open cycle efficiency of up to 42% - high exhaust gas temperature 600+c

Fuel generally Gas, but oil and Naphtha also used GT life decreases ascontaminants increase

Advanced combustion technology limits Nox emissions that increase ascombustion temperature rises

Combined cycle captures exhaust gas heat in a second, steam cycle Offers efficiency of 58%/400MW F technology, 60% /500MW H technology

Significant cost increase, over open cycle requires

boiler, steam turbine and cooling systems

VEMAGIRI 388 MW Combined

Cycle Power Project


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Integrated Gasification Combined Cycle

IGCC offers opportunity to use lower grade solid fuel (eg coal), to produce

a gas that can be cleaned prior to combustion Widens fuel that can be utilised for CCGT plant

When fully integrated, heat from gasification can be recovered into the steamcycle

Offers high efficiency up to 50%

Very costly to build closer to chemical plant than power plant

IGCC SchematicDiagram

IGCC Puertolano, Spain


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Reciprocating Engines

Large Marine Diesel derived engines Smaller capacity units up to 60MW

Oil or gas fuel

Offer lower capex than CCGT but higher efficiency thanconventional units 46% open cycle, 50% closed cycle

Simple and robust, easier to maintain in less technologicalenvironments

CHENNAI 200MW Diesel

Engine Power Project

Man B&W 2 stroke

50MW Diesel Engine


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Cogeneration

Thermal power plants have to reject heat to the environment,if this heat can be re-used, efficiency rises Co Gen utilises low grade heat from steam condensing

Ideally a co process that takes steam and returns condensed water,quantities matched to plant steam flows from generation

Ideal matches can achieve 80+% - eg paper mills Usually steam take is lower than steam flow, so efficiency

improvement limited 60-80% efficiency common

Cogen needs to be co located heat cannot

be transported long distances

Reduces power plant flexibility

minimum conditions needed to

supply steam to process

Focus has been on matching processesLarge Cogen facility, Elsta, Netherlands


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Emissions clean up

Thermal power plants may require SO2 abatement wet or dry gas clean process

NOx abatement advanced burners & catalytic reduction

Ash abatement Electrostatic precipitators or bag filters

Polutant removal eg heavy metals via activated carbon

and bag filters

CO2 abatement Post combustion CO2 stripping

All processes have high capital

and operating costs

All (except NOx) require disposal

of a waste stream

The better the fuel (eg natural gas),

the lower is the clean up need/cost

CT-121 FGD Plant atStigns Power Station,Denmark


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Conclusion

Thermal power plants offer the lowest capital cost for capacity Through life fuel costs are significant, fuel route and

commercial contracts are critical to success

Emissions must be managed in the local environment

SPALDING 860 MW Combined

Cycle Power Project

LA ROSITA I 780 MW

Combined Cycle Power Project

Thank You


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Thermal Power and Cogen Opportunities

Tim Clarke

Head of Power GMR International

March 2011

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Thermal and on - Tim Clarke