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Oct.

21, 2004

Modern Combined Cycle Power Plants Improvement of a high efficient and clean technology

Power Generation

Authors: Schtz, Kreyenberg, Friede SPG

Agenda

Market Drivers Market Drivers Reference Power Plant Product Overview Reference Power Plant Product Overview Steam Power Plant -- Steam Power Plant Combined Cycle Power Plant -- Combined Cycle Power Plant Reference Power Plant Design Philosophy Reference Power Plant Design Philosophy Design Targets Design Targets References References
Oct. 21, 2004

Modern Combined Cycle Power Plants Improvement of a high efficient and clean technology

Power Generation

Authors: Schtz, Kreyenberg, Friede SPG

The Market Conditions Have Changed Dramatically in the Power Industry Over the Last 10 Years

Market Conditions

Efficiency Risk Guarantee*

Overall Construction Time Price

Years
* technical warranties (NOx, et. al.), delivery time
Oct. 21, 2004

Modern Combined Cycle Power Plants Improvement of a high efficient and clean technology

Power Generation

Authors: Schtz, Kreyenberg, Friede SPG

Life Cycle Cost (LCC) Analysis

Parameters
Investment costs Financing costs Service life Demolition costs Fuel contract conditions Efficiency Personnel costs Consumables/waste Spare parts Maintenance

Costs

Parameters influenced by the supplier


Reduction of specific investment costs Global sourcing

Capital costs

Fuel Costs

Live Cycle Costs

Modular design Short delivery times High process and component efficiencies Optimized level of automation High availability Ease of maintenance

Operating costs

Oct. 21, 2004

Modern Combined Cycle Power Plants Improvement of a high efficient and clean technology

Power Generation

Authors: Schtz, Kreyenberg, Friede SPG

Reference Power Plant Product Overview


Oct. 21, 2004

Modern Combined Cycle Power Plants Improvement of a high efficient and clean technology

Power Generation

Authors: Schtz, Kreyenberg, Friede SPG

Our Reference Power Plants are Focused on International Main Market Demand for IPPs Varioplant 300 300- 450 MW 700 500- 750 MW 900 800- 1000 MW Coal/Oil

Customized... Customized...

of the shelf... of the shelf...

Components, Islands Components, Islands and Turnkey and Turnkey Gas/Oil


50 Hz 60 Hz
Oct. 21, 2004

Gas/Oil
Multi-Shaft 60 Hz 50 Hz

-Shaft

100, 290, 400 MW 100, 270, 365 MW

200, 580, 80 200, 540, 730 MW


Power Generation 6
Authors: Schtz, Kreyenberg, Friede SPG

Modern Combined Cycle Power Plants Improvement of a high efficient and clean technology

Multi-Shaft Combined Cycle Power Plant Econopac Arrangement

ECONOPAC
Gas turbine Gas turbine generator Air intake Exhaust gas system Fuel system Electrical package (SFC/SEE) GT - Auxiliaries Fire protection Options
Oct. 21, 2004

Modern Combined Cycle Power Plants Improvement of a high efficient and clean technology

Power Generation

Authors: Schtz, Kreyenberg, Friede SPG

Multi-Shaft Combined Cycle Power Plant Power Island Arrangement

POWER ISLAND
Econopac Steam turbine Steam turbine generator incl. SEE Heat recovery steam generator Major pumps Condenser Critical valves ST - Auxiliaries Cycle optimization Fuel gas pre-heater Options
Oct. 21, 2004

Modern Combined Cycle Power Plants Improvement of a high efficient and clean technology

Power Generation

Authors: Schtz, Kreyenberg, Friede SPG

Oct. 21, 2004

Modern Combined Cycle Power Plants Improvement of a high efficient and clean technology

Power Generation

Authors: Schtz, Kreyenberg, Friede SPG

Multi-Shaft Combined Cycle Power Plant Turnkey (Cooling Tower)

TURNKEY
Power Island Fuel supply systems Cooling systems Water treatment Raw water system Waste water system Tanks Cranes/ hoists Buildings/ structures Fire protection Plant piping/ valves Plant electrical Further options
Oct. 21, 2004

Modern Combined Cycle Power Plants Improvement of a high efficient and clean technology

Power Generation 10
Authors: Schtz, Kreyenberg, Friede SPG

Multi-Shaft Combined Cycle Power Plant Turnkey with House (Cooling Tower)

TURNKEY
Power Island Fuel supply systems Cooling systems Water treatment Raw water system Waste water system Tanks Cranes/ hoists Buildings/ structures Fire protection Plant piping/ valves Plant electrical Further options
Oct. 21, 2004

Modern Combined Cycle Power Plants Improvement of a high efficient and clean technology

Power Generation 11
Authors: Schtz, Kreyenberg, Friede SPG

Evolution of Combined Cycle Power Plant Efficiency

Steam cycle Single pressure


60 58 56 54 52 50 48 46 960C 50 bar 460C 1983/84 1000C 60 bar 485C 1050C 75 bar 510C Net efficiency (%) 1120C 80 bar 520C

Dual pressure
1160C 100 bar 520C

Tripple pressure with reheat


Turbine inlet temp. (ISO) Fuel preheating Life steam pressure Life steam temperature

1190C 200C 110 bar 540C

1230C 130C 110 bar 550C

1250C 1230C 200C 130C 160 bar 125 bar 580C 565C

Fuel gas firing ISO ambient conditions (15C, 1013 mbar, 60% rel. humidity) Condenser back pressure 0.04 bar 1990/91 1992/93 1994/95 1996/97 1998/99 2001 2005/06 Year of commissioning

1987/88

Source: Siemens Gas Turbines

Oct. 21, 2004

Modern Combined Cycle Power Plants Improvement of a high efficient and clean technology

Power Generation 12
Authors: Schtz, Kreyenberg, Friede SPG

Economical Evaluation Factors


Evaluation Factors (price related)

(at 1 %targeted Internal Rate of Return for additional investm 2 ent)

Power Output
0 0.2 0.4 0.6 0.8 1.0

0.55 mill / MW 06 mill / MW 7.1 mill / / %-point 98 mill %-point


0 4 6 8 10 12

Efficiency Lead Time


0 0.5 1 1,5 2

2.5 mill / / month 09 mill month 2.7 mill / / %-point 26 mill %-point
0 1 2 3 4

Availability

Boundary Conditions
Power Output Efficiency Load Regime Electricity Price Fuel Price
Oct. 21, 2004

397 MW 57.00 % Base Load (7000hr/a) 37 / MWh (escalation 1% /a) 3.9 / GJ (escalation 1% /a)

Lead Time Overall Project Costs Debt/ equity ratio Income Tax Operating Period

24 22 months 185 mill 70 / 30 35 % 20 years


Power Generation 13
Authors: Schtz, Kreyenberg, Friede SPG

Modern Combined Cycle Power Plants Improvement of a high efficient and clean technology

Power Output, Efficiency, NOx-Emission and Cooling Air Demand versus Combustion Temperature
Boundary conditions: Boundary conditions: The same technology for The same technology for blade cooling, combustion blade cooling, combustion chamber cooling and chamber cooling and burner. burner.

Gas turbine
Tcom. b Fuel 2% Combustion air 80% Air intake 100% Cooling air 20% Combustion chamber

Exhaust gas 102%

. mKL

NOX

Heat recovery steam generator

NOX
Electricity Generator TCool.-air

Steam turbine

Electricity

GD U

Circulating water Condenser Generator

TIT
1570C 1700C TCmustion ob

Oct. 21, 2004

Modern Combined Cycle Power Plants Improvement of a high efficient and clean technology

Power Generation 14
Authors: Schtz, Kreyenberg, Friede SPG

Efficiency Improvements due to Increasing the Number of Pressure Stages

Temperature curves in a heat recovery steam generator


net [%-points] 3

Efficiency increase

Temperature [C] 600 500 400 300 200 100 0 Transfered heat

1-pressure process 2-pressure process 3-pressure process

125 bar/565 C 28 bar/565 C 4 bar/235 C 125 bar/565 C 29 bar/320 C 5 bar/200 C

Exhaust gas 2
80 bar/540 C 5 bar/210 C

2.8 1
65 bar/540 C

2.1 1.6 54.1% 1-pressure 2-pressure 3-pressure without reheat 3-pressure with reheat

Oct. 21, 2004

Modern Combined Cycle Power Plants Improvement of a high efficient and clean technology

Power Generation 15
Authors: Schtz, Kreyenberg, Friede SPG

Quick Start up Increases Plant Utilisation Factor...


GT at full load/ Bypass System closed

Start-up after 8h Shut-down


400 350

Plant Load [MW]

Plant start-up with Plant start-up with improved equipment improved equipment

Typical plant start-up Typical plant start-up

300 250 200 150 100 50 0

40 min

90 min

Time
Power Generation 16
Authors: Schtz, Kreyenberg, Friede SPG

Oct. 21, 2004

Modern Combined Cycle Power Plants Improvement of a high efficient and clean technology

Limiting Values for Flue Gas Emissions

Oct. 21, 2004

Modern Combined Cycle Power Plants Improvement of a high efficient and clean technology

Power Generation 17
Authors: Schtz, Kreyenberg, Friede SPG

Relationship between turbine inlet temperature and NOx emissions

2,5

2,0

1,5 NOx* 1,0 0,5 0,0 1220 1230 1240 1250 1260 1270 1280 1290 1300 1310 Temperatur in C

A temperature increase by 70K doubles the NOx- emissions !


Modern Combined Cycle Power Plants Improvement of a high efficient and clean technology
Power Generation 18
Authors: Schtz, Kreyenberg, Friede SPG

Oct. 21, 2004

Design Targets

Oct. 21, 2004

Modern Combined Cycle Power Plants Improvement of a high efficient and clean technology

Power Generation 19
Authors: Schtz, Kreyenberg, Friede SPG

One the way to the Technical leadership

now Efficiency TIT** NOx 58%* 1230C 25 ppm

tomorrow > 59% 1290C 9 15 ppm

* depending on cooling conditions ** turbine inlet temperature Details on additional measures will be presented at a VDI Symposium in Leverkusen 23./24. November 2004
Oct. 21, 2004

Modern Combined Cycle Power Plants Improvement of a high efficient and clean technology

Power Generation 20
Authors: Schtz, Kreyenberg, Friede SPG

References

Oct. 21, 2004

Modern Combined Cycle Power Plants Improvement of a high efficient and clean technology

Power Generation 21
Authors: Schtz, Kreyenberg, Friede SPG

Mainz-Wiesbaden, Germany Combined Cycle Power Plant V94.3A with Steam Extraction

Mainz - -Wiesbaden (Germany) Mainz Wiesbaden (Germany) Concept: Multi Shaft 1+1 V94.3A Concept: Multi Shaft 1+1 V94.3A Output (nat. gas, site) : : 11xx400 MW Output (nat. gas, site) 400 MW Efficiency (nat. gas, site): : >58,4 %* Efficiency (nat. gas, site) >58,4 %* COD: July 2001 COD: July 2001 Fuels: Natural Gas (Fuel oil Back up) Fuels: Natural Gas (Fuel oil Back up) Contract: EPC TK plus 10 y. S&M Contract: EPC TK plus 10 y. S&M
Oct. 21, 2004

Modern Combined Cycle Power Plants Improvement of a high efficient and clean technology

Power Generation 22
Authors: Schtz, Kreyenberg, Friede SPG

Pulau Seraya, Singapore: 2 CC 1S.V94.3A The Most Efficient Plant in SEA

Oct. 21, 2004

Modern Combined Cycle Power Plants Improvement of a high efficient and clean technology

Pulau Seraya (Singapore) Pulau Seraya (Singapore) Concept: Single Shaft 1S.V94.3A Concept: Single Shaft 1S.V94.3A Output (nat. gas, site) : : 2x 367 MW Output (nat. gas, site) 2x 367 MW Efficiency (nat. gas, site): : >57.2 % Efficiency (nat. gas, site) >57.2 % COD: November 2002 COD: November 2002 Fuels: Natural Gas (Fuel oil Back up) Fuels: Natural Gas (Fuel oil Back up) Contract: EPC TK plus 10 y. S&M Contract: EPC TK plus 10 y. S&M
Power Generation 23
Authors: Schtz, Kreyenberg, Friede SPG