FT8 TwinPac

The 54 MW
Cogeneration Plant in Rheinberg
 In November 1996
a Cogeneration Plant was commis-
sioned at SOLVAY ALKALI GmbH in
Rheinberg / Germany.
MAN Turbomaschinen AG GHH
BORSIG (MAN TURBO) in Ober-
hausen, Germany, supplied Europe’s
first FT8 TwinPac gas turbine installati-
on with 54 MW power rating. The over-
all plant concept was jointly developed
by SOLVAY and MAN TURBO.
Products from the SOLVAY Rheinberg
plant include the salt-based chemicals
soda ash, chlorine and PVC.
Energy costs for the production of
these feedstock materials are very high,
with a demand for both electrical ener-
gy and process steam.
2
An ideal CHP application The FT8 TwinPac has increased the
The gas turbine unit is provided with power generation capacity by 40 MW
down-stream waste-heat recovery while maintaining the same process
steam generators which replace a steam production rate, hence achieving
coal-fired boiler giving 100 t/h steam an excellent plant utilization factor.
production which had been in service
since 1961 and whose operating per-
mit had expired after approx. 260,000
service hours. Shutdown of the original
coal-fired boiler has reduced the output
of electrical energy from the existing
backpressure steam turbines by
approx. 14 MW.
Integration of gas turbine The two waste-heat recovery boilers
package into existing feed a total of 84 t/h of 12 bar steam to
power station the process and to a MAN TURBO
extraction condensing steam turbine. In
addition, some 200 t/h of feedwater are
preheated from 105 °C to 170 °C.
A basic prerequisite for the project was
that both operating costs and capital
outlay should be optimized on the
basis of the technical input require-
ments.

Obviously aeroderivative gas turbines

Live steam pressure 12 bar were the best choice for this applicati-
Live steam temperature 260 °C on of a combined heat and power
Live steam mass flow 70 t/h generation process. These gas turbines
Extraction pressure 1.8 bar have the highest electric efficiency in
Outlet pressure 0.07 bar the power range 25 to 50 MW with
Turbine speed 5,400 rpm exhaust temperatures around 450 °C.
Power at terminals 12,280 kW Therefore they are particularly suited for
cogeneration processes requiring hot
1 MAN TURBO steam turbine water or process steam with tempera-
tures of less than 400 °C.

The selected site provided an excellent

infrastructure for a low-cost installation,
i.e. a natural gas long-distance pipeline
with a pressure of approx. 45 bar, a
transformer station, and the necessary
2 Flow diagram of the power station process-steam piping were already
located in the immediate vicinity of the
gas turbine facility. In a purpose-built
pressure reduction station, the fuel
gas pressure is reduced to 32 bar.

The existing water treatment plant is

of a sufficient capacity to provide fully
demineralized water (approx. 5 m³ per
hour) needed by the gas turbines to
reduce their NOx emissions. As cooling
water is not available on site, the lube
oil systems of the gas turbines and
generator are of air-cooled type, and
the generator itself is also provided with
open circuit direct air cooling.

3
 FT8-30 TwinPac The core element of the plant is the The FT8 gas turbine consists of a gas
FT8-30 TwinPac gas turbine unit. In this generator and a free-running power tur-
facility, two FT8 aeroderivative gas turbi- bine. The gas generator has been deri-
nes, each rated for an electric power out- ved from the latest version of the most
put of 27 MW, are directly connected to successfull aeroengine in commercial
a centrally located synchronous gene- service, the JT8D-219 of Pratt &
rator. This particular FT8 arrangement Whitney.
was chosen for the first time in Europe.
Twin-Pac Award For power generation with grid fre-
Twin-Pac Award
Pratt & Whittney's FT8 TwinPac, quencies of 50 Hz or 60 Hz, 4-stage
a novel package with a gas power turbine designs are available
Pratt & Whitney's
turbine FT8 of
at each end TwinPac
a with design speeds of 3,000 or
has earned thegenerator,
double-ended company 3,600 rpm for CW and CCW rotation.
Frost and Sullivan's
has earned 2000
the company This makes the FT8 the only gas turbi-
Market Engineering
Frost and Sullivan'sProduct
2000 ne in this power range which is suitable
Differentiation Innovation
Market Engineering Award.
Product for coupling to the generator without
Differentiation Innovation Award. the need for a gearbox.
MAN TURBO's partner, Pratt &
Whitney, has already accumulated per- The basic TwinPac concept was fully
tinent experience of long years' stan- implemented at the SOLVAY Rheinberg
ding in the U.S. with TwinPac units in installation, with separate auxiliaries,
incorporating the FT8 and the earlier ancillaries and control systems provi-
FT4 gas turbines. ded for each gas turbine and each boi-
ler. In consequence, every gas turbine
More than 1,100 FT4 gas turbines were or boiler can be shut down for mainten-
built, of which a large number are ope- ance or repair work, whilst the second
rated in a TwinPac configuration. unit is kept in operation.

3 TwinPac facility Rheinberg

4
Overrunning clutches
Overrunning clutches are provided on
both sides of the generator to permit
the gas turbines to be used from each
other independently, thus providing
maximum flexibility. These clutches,
type 170T, were delivered by SSS-
Gears, Sunbury/Great Britain.

Referring to Synchronized Self-

Switching, the term SSS describes the
clutch operating mode. As soon as
there is the same input and output
speed, the teeth of the clutch are auto-
matically engaged axially with precise
alignment of tooth and flute.

On engagement, the driving torque is

transmitted from the gas turbine to the
generator. The clutch is disengaged
again when the input speed drops
below the output speed. Engagement 4 FT8 industrial gas turbine

or disengagement itself is without tor-

que transmission, and therefore virtually
without any wear. When engaged, the
power loss per clutch is a mere 50 kW.

Future expansion Synchronous condensing

In applications where power demand mode
grows gradually, the FT8 TwinPac con- Another option of the FT8 TwinPac
cept offers the option of future expansi- when fitted with overrunning clutches is
on. Initially just one gas turbine can be to run the generator as a synchronous
coupled to a generator rated for twice condenser. This feature is however not
the power output ("1/2 TwinPac"), and used in the SOLVAY plant. In this ope-
another FT8 may be added at a later rating mode, the generator is uncou-
stage. The generator efficiency is kept pled from the driver and provides reac-
Elements of basic
SSS Clutch
A Pawl
almost constant in the 50-100% power tive power to the electricity grid.
B Clutch Teeth E Input Shaft
C
D
Sliding Component
Helical Splines
F Output Clutch Ring
G Ratchet Teeth range. Thus, the power station can be Mechanical losses are overcome by tap-
adapted to growing requirements. ping electric power from the grid.

5 SSS clutch

5
 Simple operation and
control
Operation of the gas turbine unit is per-
formed under remote control from the
central control room of the SOLVAY
Power Station. Additionally, all opera-
ting and control functions are available
from the local control building beside
the gas turbine.
The SOLVAY Power Station personnel
were prepared for their task of opera-
ting the first gas turbine package at
Rheinberg both during commissioning
of the unit and in a special training
course held by MAN TURBO.
Waste-heat recovery steam
generators without supple-
ment firing
Each FT8 gas turbine is fitted with a
waste-heat recovery boiler without
supplementary firing. The natural con-
vection boilers are of horizontal con-
struction. Each boiler is fitted in a self-
supporting structure, and comprises
the following main modules: inlet duct,
superheater module, evaporator modu-
le including boiler drum, hotwater eco-
nomizer module, and outlet duct.
The waste-heat recovery steam gener-
ators are rated for a gas turbine star-
ting ramp of approx. 10 MW/min after
synchronization. Operation is without a
bypass. This reduced the capital outlay
without any limitation on functionality.
Very low operating costs
The TwinPac concept offers the merit
of high efficiency over a wide load ran-
ge. The FT8 TwinPac gas turbine ope-
rates in the load-sharing mode in the
range between full load and 50% load
(corresponding to 54 or 27 MW,
respectively). If power requirements
drop below the half-load level, one of
the gas turbines can be shut down,
which of course means a basic ad-
vantage over other gas turbines in the
50 MW power class.
The fuel utilization rate in the combined
heat and power generation process
exceeds 80%.
Further factors determining the opera-
ting costs are the availability of the
plant as well as the maintenance and
repair costs. Compared to a single gas
turbine of the same total power rating,
the TwinPac facility is distinguished by
a higher availability of half its power out-
put. For the industrial operator of
power stations, such a TwinPac facility
thus assures a higher reliability in the
supply of both electric power and pro-
cess heat.

A full-service concept offers the possi-

bility of using rental equipment for the
duration of a complete major overhaul,
so as to minimize downtime periods.

40
1)
FT8 TwinPac >30%
Electric Efficiency (ISO) [%]

35

>30%
30

Heavy-duty gas turbine

25 50 MW power class
(typical data)
20

15
1)
Water injection for NOx reduction
10 6 Advantage of efficiency
0 10 20 30 40 50 60
Electric Power (ISO) [MW]

6
Low capital outlay oxide emissions are roughly halved;
To reduce the capital outlay required for dust or sulphur dioxide is not emitted
for
the the facility,
facility, the the
plantplant concept
concept andand its at all by a gas turbine unit, as compa-
its arrangement
arrangement was was optimized
optimized by by
desig- red to a coal-fired boiler.
designing
ning the GT thepackage
gas turbine packageinstal-
for outdoor for The enclosures are built for noise emis-
outdoor
lation oninstallation
a "greenfield" on asite.
"greenfield"
No cost sions as low as 70 dB(A) SPL at 1 m.
site. The gas turbine
was incurred acoustic
for a machine enclosu-
house buil- The described cogeneration plant
res
ding. each
Thehave their ownenclosures
GT acoustic crane system each achieves a high electric efficiency over
for
have rapid
theirexchange
own crane of system
the gasfor turbine
rapid a wide load range with a good fuel utili-
components
exchange of the during
GT scheduled
components over- zation rate. High availability and flexible
hauls.
during scheduled overhauls. operation are fully satisfied, whilst mee-
The GT ancilliaries were each accom- ting the economic and ecological
The
modated packaged TwinPac
in separate configuration
housings directly demands made today on modern ener-
clearly
linked to reduces
the GTthe capital outlay in
enclosures. gy supply facilities for industry.
comparison
The packaged with two individual
TwinPac engines
configuration
of the same
clearly reduces totalthepower
capital rating.
outlayCost
in
savings
comparison werewith mainly
twoobtained
individualbyengines
having to a coal-fired steam power station. The cogeneration plant achieves a
to install
of the samejust total
one generator
power rating. withCost
ancilla- Nitric oxide emissions are roughly hal- high electric efficiency over a wide load
ries
savings and were
unit transformer.
mainly obtained by having ved; dust or sulphur dioxide is not range with an excellent fuel utilization
to install just one generator with ancilla- emitted at all by a gas turbine unit, as rate. High availability and flexible opera-
Investment
ries and unitcosts were also distinctly
transformer. compared to a coal-fired boiler. tion are fully satisfied, whilst meeting
lowered
Investment through
coststhe weredescribed design
also distinctly The enclosures are built for noise emis- the economic and ecological demands
of the two
lowered waste-heat
through recovery design
the described steam sions as low as 70 dB(A) SPL at 1 m. made today on modern energy supply
generators. The pre-fabrication
of the two waste-heat recovery of steamcom- facilities for industry.
plete boiler modules
generators. of course reduced
The pre-fabrication of com-
assembly
plete boilerand erection
modules of times
courseatreduced
site,
with
assemblya favourable impact
and erection on costs.
times at site,
with a favourable impact on costs. Technical data
With the chosen plant concept all the
technical pre-requisites were met, lea- Cogeneration process
ding to a specific total investment cost Application: base load (>8400 h/a)
of approx. Euro 460 per kW of installed Fuel utilization rate: > 80%
electric power.
Emissions effectively redu- Gas turbine
Emission
ced reduction Type: FT8-30 TwinPac
In terms of pollutant emissions, a dis- Manufacturer: MAN Turbomaschinen AG
tinct reduction has been achieved by GHH BORSIG/ Pratt & Whitney
the new cogeneration facility at Fuel: natural gas
SOLVAY's Rheinberg Works in compa- Electric power: 54 MW
rison with the previous coal-fired boiler Efficiency: 38,3% (at full and half load)
installation. Carbon-dioxide emissions Exhaust temperature: 460 °C
3
are reduced by approx. 90,000 Emissions: NOx <120 mg/Nm (15% O2, dry)
3
Carbon-dioxide
tons/annum dueemissions to the useare reduced
of gas fuel. CO <10 mg/ Nm (15% O2, dry)
by
When approx.
making 90,000 tons per
an overall year due to
assessment with water injection
the use ofthe
including gasadditional
fuel. When making
electric poweran
overall
generation assessment
capacity,including the addi-
this reduction can Waste-heat recovery boiler
tional
be equatedelectrictopower generation
a reduction capaci-
of 370,000 Steam production rate: 2 x 42 t/h (12 bar, 240 °C)
ty,
tons this reduction
per year when cancompared
be equated to toa Feedwater preheating: 2 x 100 t/h (105/170 °C)
370,000
coal-firedtons steam perpower
year when compared
station. Nitric Stack temperature: <120 °C

7
MAN Turbomaschinen AG
GHH BORSIG
Steinbrinkstrasse 1
46145 Oberhausen / Germany
Phone +49. 208. 6 92-01
Fax +49. 208. 6 92-20 19
www.manturbo.com
MAN Turbomaschinen AG
GHH BORSIG
Egellsstrasse 21
13507 Berlin / Germany
Phone +49. 30. 440 402
0
Fax +49. 30. 440 402
2000
In the interests of technical progress,
subject to change without notice.
Printed in Germany.
August 2001
TURBO 944 e 08013 ba

MAN Turbomaschinen AG MAN Turbomacchine S.r.l.

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