1. "Energy Efficiency in IPPC-installations"
Modern Combined Cycle Power Plants – Improvement of a high efficient and clean technology O. Kreyenberg, H. Schütz, H. Friede Siemens PG
"Energy Efficiency in IPPC-installations"
21 and 22 October 2004
Vienna

2. Reference Power Plant Product Overview - Steam Power Plant
Agenda
Market Drivers
Reference Power Plant Product Overview
- Steam Power Plant
- Combined Cycle Power Plant
Reference Power Plant Design Philosophy
Design Targets
References

3. * technical warranties (NOx, et. al.), delivery time
The Market Conditions Have Changed Dramatically in the Power Industry Over the Last 10 Years
Overall Construction Time
Efficiency
Price
Risk Guarantee*
Market Conditions
Years
* technical warranties (NOx, et. al.), delivery time

4. Life Cycle Cost (LCC) Analysis
Parameters influenced
by the supplier
Parameters
Costs
Investment costs
Financing costs
Service life
Demolition costs
Reduction of specific investment costs
Global sourcing
Modular design
Short delivery times
Capital
costs
Live
Cycle
Costs
Fuel contract conditions
Efficiency
Fuel
Costs
High process and
component efficiencies
Personnel costs
Consumables/waste
Spare parts
Maintenance
Optimized level of automation
High availability
Ease of maintenance
Operating
costs

5. Reference Power Plant Product Overview

6. Components, Islands and Turnkey
Our Reference Power Plants are Focused on International Main Market Demand for IPP’s
Varioplant MW MW MW
Coal/Oil
Customized...
of the shelf...
Single-Shaft 50 Hz 100, 290, 400 MW
Gas/Oil
60 Hz 100, 270, 365 MW
Multi-Shaft 50 Hz 200, 580, 800 MW Hz 200, 540, 730 MW
Components, Islands and Turnkey
Gas/Oil

7. Multi-Shaft Combined Cycle Power Plant Econopac Arrangement
Gas turbine
Gas turbine generator
Air intake
Exhaust gas system
Fuel system
Electrical package (SFC/SEE)
GT - Auxiliaries
Fire protection
Options

8. Multi-Shaft Combined Cycle Power Plant Power Island Arrangement
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

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

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

11. Reference Power Plant Design Philosophy

12. Evolution of Combined Cycle Power Plant Efficiency
Steam cycle
Single pressure
Dual pressure
Tripple pressure with reheat
Net efficiency (%) 60
1160°C —
100 bar
520°C
Turbine inlet temp. (ISO)
Fuel preheating
Life steam pressure
Life steam temperature
1250°C
200°C
160 bar
580°C 58
1230°C
130°C
125 bar
565°C
1230°C
130°C
110 bar
550°C
1120°C —
80 bar
520°C
1190°C
200°C
110 bar
540°C 56
1050°C —
75 bar
510°C 54
1000°C —
60 bar
485°C 52
960°C —
50 bar
460°C
Fuel gas firing
ISO ambient conditions
(15°C, 1013 mbar, 60% rel. humidity)
Condenser back pressure 0.04 bar 50 48 46
1983/84
1987/88
1990/91
1992/93
1994/95
1996/97
1998/99
2001
2005/06
Year of commissioning
Source: Siemens Gas Turbines

13. Economical Evaluation Factors

14. Power Output, Efficiency, NOx-Emission and Cooling Air Demand versus Combustion Temperature
Boundary conditions:
The same technology for blade cooling, combustion chamber cooling and burner.
mKL .
Ex-
haust
gas
102%
Gas turbine
NOX
Tcomb.
Fuel 2%
Heat recovery
steam generator
Combustion
air 80%
Combustion
chamber
NOX
Air intake
100%
Electricity
Generator
Cooling air 20%
TCool.-air
hGUD
Steam turbine
Circulating
water
Electricity
TIT
Generator
Condenser
1570°C
1700°C
TCombustion

15. Efficiency Improvements due to Increasing the Number of Pressure Stages
Temperature curves in a heat recovery steam generator
Efficiency increase
D h net
[%-points]
Temperature [°C]
1-pressure process
2-pressure process
3-pressure process
125 bar/565 °C 28 bar/565 °C 4 bar/235 °C
600 3
500
125 bar/565 °C 29 bar/320 °C 5 bar/200 °C
Exhaust gas
400 2
80 bar/540 °C 5 bar/210 °C
300
2.8
200 1
2.1
1.6
100
65 bar/540 °C
54.1%
Transfered heat
1-pressure
2-pressure
3-pressure without reheat
3-pressure
with reheat

16. Quick Start up Increases Plant Utilisation Factor...
GT at full load/ Bypass System closed
Start-up after 8h Shut-down
Plant start-up with
improved equipment
Typical plant start-up
Plant Load [MW]
≈ 40 min
≈ 90 min
Time

17. Limiting Values for Flue Gas Emissions

18. Relationship between turbine inlet temperature and NOx emissions
A temperature increase by 70K doubles the NOx- emissions !

19. Design Targets

20. One the way to the Technical leadership
now tomorrow
Efficiency 58%* > 59%
TIT** °C 1290°C
NOx ppm 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

21. References

22. Mainz-Wiesbaden, Germany Combined Cycle Power Plant V94
Mainz-Wiesbaden, Germany Combined Cycle Power Plant V94.3A with Steam Extraction
Mainz - Wiesbaden (Germany)
Concept: Multi Shaft 1+1 V94.3A
Output (nat. gas, site) : x MW
Efficiency (nat. gas, site): >58,4 %*
COD: July 2001
Fuels: Natural Gas (Fuel oil Back up)
Contract: EPC TK plus 10 y. S&M

23. Pulau Seraya, Singapore: 2 CC 1S. V94
Pulau Seraya, Singapore: 2 CC 1S.V94.3A The Most Efficient Plant in SEA
Pulau Seraya (Singapore)
Concept: Single Shaft 1S.V94.3A
Output (nat. gas, site) : x 367 MW
Efficiency (nat. gas, site): >57.2 %
COD: November 2002
Fuels: Natural Gas (Fuel oil Back up)
Contract: EPC TK plus 10 y. S&M