Diffusion Bonded Heat Exchangers (PCHEs) in Fuel Gas Heating to Improve Efficiency of CCGTs

2014 ◽  
Author(s):  
Dereje Shiferaw ◽  
Robert Broad
Keyword(s):  
Heat Exchanger ◽  
Gas Turbine ◽  
Heat Exchangers ◽  
Capital Expenditure ◽  
Combined Cycle ◽  
Inlet Temperature ◽  
Feed Water ◽  
Compact Heat Exchanger ◽  
Fuel Gas ◽  
Gas Heating

The purpose of this paper is to show how compact heat exchanger technology can offer energy savings and hence cycle efficiency improvements on new and existing gas turbine installations by being utilised for fuel gas heating. After a brief introduction to high temperature compact heat exchanger technology and comparison to traditional equipment, thermodynamic cycle analysis for a combined cycle gas turbine plant (CCGT) is used show the advantages of compact technology over conventional technology, analysing the fuel gas heating, to illustrate the overall savings. A case study is used to demonstrate an increase in net LHV electric efficiency in the range of 0.5 to 1.17 % achievable using high effectiveness compact diffusion bonded heat exchangers in fuel gas heating. Intermediate pressure and high pressure feed water heating is considered for increasing the fuel gas inlet temperature to the combustor. The model is built in Excel and is extended to a capital expenditure overview based on new or a retrofitting in existing plants.

Optimization Concerns for Combined Cycle Power Plants: II — Optimum Fuel Gas Heating

2003 ◽  
Author(s):  
Walter I. Serbetci
Keyword(s):  
Gas Turbine ◽  
Power Output ◽  
Heat Rate ◽  
Combined Cycle ◽  
Hot Water ◽  
Fuel Temperature ◽  
General Electric ◽  
Fuel Gas ◽  
Gas Heating ◽  
Overall Efficiency

As the second study in a sequence of studies conducted on the optimization of combined cycle plants [Ref. 1], this paper presents the effects of fuel gas heating on plant performance and plant economics for various 1×1×1 configurations. First, the theoretical background is presented to explain the effects of fuel gas heating on combustion turbine efficiency and on the overall efficiency of the combined cycle plant. Then, *CycleDeck-Performance Estimator™ and *GateCycle™ computer codes were used to investigate the impact of fuel gas heating on various 1×1×1 configurations. The configurations studied here are: 1) GE CC107FA with three pressure/reheat HRSG and General Electric PG7241(FA) gas turbine (Fig. 1), 2) GE CC106FA with three pressure/reheat HRSG and General Electric PG6101(FA) gas turbine and, 3) GE CC 107EA with three pressure/non-reheat HRSG with General Electric PG7121(EA) gas turbine. In all calculations, natural gas with high methane percentage is used as a typical fuel gas. Hot water from the outlet of IP economizer is used to heat the fuel gas from its supply temperature of 80 °F (27 °C). Heating the fuel gas to target temperatures of 150 °F, 200 °F, 250° F, 300 °F, 350 °F, 375 °F, 400 °F and 425 °F ( 66, 93, 121, 149, 177, 191, 204 and 218 °C), the combustion turbine power output, the combustion turbine heat rate and the plant power output and the corresponding heat rate are determined for each target fuel temperature. For each configuration, the heat transfer surface required to heat the fuel gas to the given target temperatures are also determined and budgetary price quotes are obtained for the fuel gas heaters. As expected, as the fuel temperature is increased, the overall efficiency (therefore the heat rate) improved, however at the expense of some small power output loss. Factoring in the fuel cost savings, the opportunity cost of the power lost, the cost of the various size performance heaters and the incremental auxiliary power consumption (if any), a cost-benefit analysis is carried out and the economically optimum fuel temperature and the corresponding performance heater size are determined for each 1×1×1 configuration.

scholarly journals Experimental Evaluation of Simplified IGCC

1984 ◽  
Author(s):  
M. W. Horner ◽  
J. C. Corman
Keyword(s):  
Gas Turbine ◽  
Pilot Scale ◽  
Combined Cycle ◽  
Experimental Program ◽  
Inlet Temperature ◽  
Fuel System ◽  
Fuel Gas ◽  
Capital Costs ◽  
Coal Gas ◽  
Coal Gasifier

Integrated gasification combined cycle (IGCC) power plants offer the opportunity to burn coal in an environmentally sound manner at a competitive cost of output energy. Advanced simplified IGCC systems have been identified which offer reduced fuel system capital costs and complexity as well as improved thermal efficiency of coal to fuel conversion. These systems, however, must utilize hot gas cleanup devices to remove particulates, alkali metals, and sulfur to permit utilization of the product fuel gas in a gas turbine. Technology and component development are underway to prepare the hot fuel gas cleanup and gas turbine systems for subsequent integration and verification testing at pilot scale. An experimental testing program is underway to address fuel system and gas turbine components technology for a simplified IGCC configuration. Gas turbine nozzle sectors have been adapted for installation in a turbine simulator for development testing. A low-Btu gas combustor installed upstream of the nozzle sectors is utilized to burn a hot coal gas. Modifications have been made to an existing pilot scale coal gasifier to deliver 1000°F low-Btu coal gas to the gas turbine combustor after partial cleanup by a hot cyclone to remove particulate matter carried over from the coal gasifier. The results from this experimental program will resolve technical issues related to corrosion, deposition and erosion phenomena related to fuel quality, turbine inlet temperature, and nozzle metal surface temperature.

scholarly journals The Increasing Role of Heat Exchangers in Gas Turbine Plants

1989 ◽  
Author(s):  
Colin F. McDonald
Keyword(s):  
Heat Exchanger ◽  
Gas Turbine ◽  
Heat Exchangers ◽  
Electrical Power ◽  
Plant Performance ◽  
Simple Cycle ◽  
Inlet Temperature ◽  
Full Spectrum ◽  
Wide Range ◽  
Prime Movers

In the introductory phase of gas turbine deployment for industrial service there was a natural reluctance to incorporate heat exchangers, although some variants included recuperators and intercoolers to enhance performance, since only modest values of compressor and turbine efficiency could be realized. Today, following half a century of intensive development, the situation is quite different, since high turbomachinery efficiencies contribute to attractive levels of performance for contemporary simple cycle plants. Because further aerodynamic advancements are likely to be incremental in nature, significant increase in plant performance can only be realized by either going to higher turbine inlet temperature, or utilizing more complex thermodynamic cycles, or both. It is in the latter two cases that heat exchangers will play an increasing role in the evolutionary advancement of gas turbine plant efficiency. This paper highlights the potential use of heat exchangers for a wide range of gas turbine applications, including industrial prime-movers, electrical power generation, marine service, and perhaps their ultimate use in aircraft propulsion systems. In the last decade, significant heat exchanger technology advancements have been made, to the point where previous impediments (to their widespread acceptance) associated with reliability, have been overcome. It is encouraging that today many proven heat exchanger hardware options are available to gas turbine users, and this will enhance their utilization across the full spectrum of applications, and indeed in the long-term may well make the simple cycle gas turbine obsolete.

Compressor Station Fuel Gas Superheating Using Lube Oil Waste Heat

2004 ◽  
Author(s):  
Katie T. Sell ◽  
Paul R. Langston ◽  
Rene´ H. Mitchell
Keyword(s):  
High Pressure ◽  
Heat Exchanger ◽  
Gas Turbine ◽  
Heat Exchangers ◽  
Waste Heat ◽  
Drop Out ◽  
Compressor Station ◽  
Fuel Gas ◽  
The North ◽  
Gas Compression

Compressor station gas turbine engines require protection from fuel gas liquid drop-out caused by the Joule-Thomson effect when natural gas is let down from transportation line pressure to the burner supply pressure. Indeed, gas turbine manufacturers specify a minimum gas superheat, which requires fuel gas heating at pipeline temperatures experienced in Northern Europe. Conventionally, fuel gas superheating is achieved through the use of either electric or gas fired water bath heaters, which require maintenance, and an external heat source. Meanwhile, waste heat from the turbo-compressor lube oil system is released to atmosphere, typically by air-cooled heat exchangers. Hence, there is an obvious opportunity to protect the gas turbine engine, whilst reducing the amount of heat rejected to the environment. Mechanical integrity is a key operational requirement when combining fuel gas superheating with lube oil cooling in a single heat exchanger. Fuel gas at high pressure must not enter the low pressure lube oil system. High integrity Printed Circuit Heat Exchangers (PCHEs) are ideally suited to this application, as they are diffusion bonded and fully welded heat exchangers. Used extensively in offshore high pressure gas compression trains in the North Sea, PCHEs have demonstrated that they are low maintenance items that are ideal for use in remote unmanned applications, such as those required by gas compression stations. PCHEs are highly compact, reducing space and structural requirements. This allows the exchanger to be installed underneath the compressor, minimizing the visual impact of the heat exchanger. In addition, safety and pressure relief requirements are significantly reduced, a PCHEs do not have a failure mode analogous to tube rupture in shell and tube heat exchangers. National Grid Transco have realized the opportunities of PCHEs and operated them successfully over many years in many of their compression stations throughout the United Kingdom.

Design for the 145-MW Blast Furnace Gas Firing Gas Turbine Combined Cycle Plant

1989 ◽  
Vol 111 (2) ◽  
pp. 218-224 ◽  
Author(s):  
H. Takano ◽  
Y. Kitauchi ◽  
H. Hiura
Keyword(s):  
Blast Furnace ◽  
Gas Turbine ◽  
Large Scale ◽  
Combined Cycle ◽  
Inlet Temperature ◽  
Mixed Gas ◽  
Fuel Gas ◽  
Blast Furnace Gas ◽  
Combined Cycle Plant ◽  
Steel Works

A 145-MW blast furnace gas firing gas turbine combined cycle plant was designed and installed in a steel works in Japan as a repowering unit. A 124-MW large-scale gas turbine with turbine inlet temperature 1150°C (1423 K) was adopted as a core engine for the combined cycle plant. The fuel of this gas turbine is blast furnace gas mixed with coke oven gas. These are byproducts of steel works, and the calorific value of the mixed gas is controlled to be about 1000 kcal/Nm3 (4187 kJ/Nm3). A specially designed multicannular type combustor was developed to burn such a low Btu fuel. The gas turbine, generator, steam turbine, and fuel gas compressor are connected to make a single-shaft configuration. As a result of introducing the gas turbine combined cycle plant, the plant thermal efficiency was above 45 percent (at NET) and the total electricity generation in the works has increased from 243 MW to 317 MW. This paper describes the design features of this combined cycle plant.

Modern opportunities for preparation of ultra-pure water for feeding high-performance boiler plants

2020 ◽  
pp. 74-84
Author(s):  
A.A. Filimonova ◽  
◽  
N.D. Chichirova ◽  
A.A. Chichirov ◽  
A.A. Batalova ◽  
...  
Keyword(s):  
Gas Turbine ◽  
Gas Turbines ◽  
High Performance ◽  
Waste Heat ◽  
Pure Water ◽  
Combined Cycle ◽  
Feed Water ◽  
Operational Characteristics ◽  
Treatment Equipment

The article provides an overview of modern high-performance combined-cycle plants and gas turbine plants with waste heat boilers. The forecast for the introduction of gas turbine equipment at TPPs in the world and in Russia is presented. The classification of gas turbines according to the degree of energy efficiency and operational characteristics is given. Waste heat boilers are characterized in terms of design and associated performance and efficiency. To achieve high operating parameters of gas turbine and boiler equipment, it is necessary to use, among other things, modern water treatment equipment. The article discusses modern effective technologies, the leading place among which is occupied by membrane, and especially baromembrane methods of preparing feed water-waste heat boilers. At the same time, the ion exchange technology remains one of the most demanded at TPPs in the Russian Federation.

Externally-Fired Combined Cycle Repowering of Existing Steam Plants

1993 ◽  
Author(s):  
Christian L. Vandervort ◽  
Mohammed R. Bary ◽  
Larry E. Stoddard ◽  
Steven T. Higgins
Keyword(s):  
Heat Exchanger ◽  
Steam Turbine ◽  
Gas Turbine ◽  
High Efficiency ◽  
Low Cost ◽  
Operating Experience ◽  
Capital Cost ◽  
Combined Cycle ◽  
Plant Design ◽  
Generating Capacity

The Externally-Fired Combined Cycle (EFCC) is an attractive emerging technology for powering high efficiency combined gas and steam turbine cycles with coal or other ash bearing fuels. The key near-term market for the EFCC is likely to be repowering of existing coal fueled power generation units. Repowering with an EFCC system offers utilities the ability to improve efficiency of existing plants by 25 to 60 percent, while doubling generating capacity. Repowering can be accomplished at a capital cost half that of a new facility of similar capacity. Furthermore, the EFCC concept does not require complex chemical processes, and is therefore very compatible with existing utility operating experience. In the EFCC, the heat input to the gas turbine is supplied indirectly through a ceramic heat exchanger. The heat exchanger, coupled with an atmospheric coal combustor and auxiliary components, replaces the conventional gas turbine combustor. Addition of a steam bottoming plant and exhaust cleanup system completes the combined cycle. A conceptual design has been developed for EFCC repowering of an existing reference plant which operates with a 48 MW steam turbine at a net plant efficiency of 25 percent. The repowered plant design uses a General Electric LM6000 gas turbine package in the EFCC power island. Topping the existing steam plant with the coal fueled EFCC improves efficiency to nearly 40 percent. The capital cost of this upgrade is 1,090/kW. When combined with the high efficiency, the low cost of coal, and low operation and maintenance costs, the resulting cost of electricity is competitive for base load generation.

Gas Turbine Combined Cycle With CO2-Capture Using Auto-Thermal Reforming of Natural Gas

2000 ◽  
Author(s):  
Thormod Andersen ◽  
Hanne M. Kvamsdal ◽  
Olav Bolland
Keyword(s):  
Natural Gas ◽  
Gas Turbine ◽  
Process Integration ◽  
Combined Cycle ◽  
Co2 Removal ◽  
Gas Turbine Combustor ◽  
Chemical Absorption ◽  
Fuel Gas ◽  
The Impact ◽  
Water Gas

A concept for capturing and sequestering CO2 from a natural gas fired combined cycle power plant is presented. The present approach is to decarbonise the fuel prior to combustion by reforming natural gas, producing a hydrogen-rich fuel. The reforming process consists of an air-blown pressurised auto-thermal reformer that produces a gas containing H2, CO and a small fraction of CH4 as combustible components. The gas is then led through a water gas shift reactor, where the equilibrium of CO and H2O is shifted towards CO2 and H2. The CO2 is then captured from the resulting gas by chemical absorption. The gas turbine of this system is then fed with a fuel gas containing approximately 50% H2. In order to achieve acceptable level of fuel-to-electricity conversion efficiency, this kind of process is attractive because of the possibility of process integration between the combined cycle and the reforming process. A comparison is made between a “standard” combined cycle and the current process with CO2-removal. This study also comprise an investigation of using a lower pressure level in the reforming section than in the gas turbine combustor and the impact of reduced steam/carbon ratio in the main reformer. The impact on gas turbine operation because of massive air bleed and the use of a hydrogen rich fuel is discussed.

Advanced and Transformational Hydrogen Turbines for Integrated Gasification Combined Cycles

2016 ◽  
Author(s):  
Walter W. Shelton ◽  
Robin W. Ames ◽  
Richard A. Dennis ◽  
Charles W. White ◽  
John E. Plunkett ◽  
...  
Keyword(s):  
Gas Turbine ◽  
Carbon Capture ◽  
Combined Cycle ◽  
Plant Performance ◽  
System Level ◽  
Inlet Temperature ◽  
Air Cooling ◽  
Reference Case ◽  
Advanced Technologies ◽  
Integrated Gasification

The U.S. Department of Energy’s (DOE) provides a worldwide leadership role in the development of advanced fossil fuel-based energy conversion technologies, with a focus on electric power generation with carbon capture and storage (CCS). As part of DOE’s Office of Fossil Energy, the National Energy Technology Laboratory (NETL) implements research, development, and demonstration (RD&D) programs that address the challenges of reducing greenhouse gas emissions. To meet these challenges, NETL evaluates advanced power cycles that will maximize system efficiency and performance, while minimizing CO2 emissions and the costs of CCS. NETL’s Hydrogen Turbine Program has sponsored numerous R&D projects in support of Advanced Hydrogen Turbines (AHT). Turbine systems and components targeted for development include combustor technology, materials research, enhanced cooling technology, coatings development, and more. The R&D builds on existing gas turbine technologies and is intended to develop and test the component technologies and subsystems needed to validate the ability to meet the Turbine Program goals. These technologies are key components of AHTs, which enable overall plant efficiency and cost of electricity (COE) improvements relative to an F-frame turbine-based Integrated Gasification Combined Cycle (IGCC) reference plant equipped with carbon capture (today’s state-of-the-art). This work has also provided the basis for estimating future IGCC plant performance based on a Transformational Hydrogen Turbine (THT) with a higher turbine inlet temperature, enhanced material capabilities, reduced air cooling and leakage, and higher pressure ratios than the AHT. IGCC cases from using system-level AHT and THT gas turbine models were developed for comparisons with an F-frame turbine-based IGCC reference case and for an IGCC pathway study. The IGCC pathway is presented in which the reference case (i.e. includes F-frame turbine) is sequentially-modified through the incorporation of advanced technologies. Advanced technologies are considered to be either 2nd Generation or Transformational, if they are anticipated to be ready for demonstration by 2025 and 2030, respectively. The current results included the THT, additional potential transformational technologies related to IGCC plant sections (e.g. air separation, gasification, gas cleanup, carbon capture, NOx reduction) are being considered by NETL and are topics for inclusion in future reports.

scholarly journals Analytical and Experimental Investigation of a Plate Fin Heat Exchanger at Cryogenics Temperature

2021 ◽  
Vol 39 (4) ◽  
pp. 1225-1235
Author(s):  
Ajay K. Gupta ◽  
Manoj Kumar ◽  
Ranjit K. Sahoo ◽  
Sunil K. Sarangi
Keyword(s):  
Heat Exchanger ◽  
Pressure Drop ◽  
Mass Flow Rate ◽  
Mass Flow ◽  
Flow Rate ◽  
Heat Exchangers ◽  
Cryogenic Temperature ◽  
Operating Conditions ◽  
Inlet Temperature ◽  
Compact Size

Plate-fin heat exchangers provide a broad range of applications in many cryogenic industries for liquefaction and separation of gasses because of their excellent technical advantages such as high effectiveness, compact size, etc. Correlations are available for the design of a plate-fin heat exchanger, but experimental investigations are few at cryogenic temperature. In the present study, a cryogenic heat exchanger test setup has been designed and fabricated to investigate the performance of plate-fin heat exchanger at cryogenic temperature. Major parameters (Colburn factor, Friction factor, etc.) that affect the performance of plate-fin heat exchangers are provided concisely. The effect of mass flow rate and inlet temperature on the effectiveness and pressure drop of the heat exchanger are investigated. It is observed that with an increase in mass flow rate effectiveness and pressure drop increases. The present setup emphasis the systematic procedure to perform the experiment based on cryogenic operating conditions and represent its uncertainties level.

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