Enabling Technology For Monitoring Predicting Gas Turbine Health Performance In Coal Igcc Powerplants

The ''Enabling & Information Technology To Increase RAM for Advanced Powerplants'' program, by DOE request, has been re-directed, de-scoped to two tasks, shortened to a 2-year period of performance, and refocused to develop, validate and accelerate the commercial use of enabling materials technologies and sensors for Coal IGCC powerplants. The new program has been re-titled as ''Enabling Technology for Monitoring & Predicting Gas Turbine Health & Performance in IGCC Powerplants'' to better match the new scope. This technical progress report summarizes the work accomplished in the reporting period April 1, 2004 to August 31, 2004 on the revised Re-Directed and De-Scoped program activity. The program Tasks are: Task 1--IGCC Environmental Impact on high Temperature Materials: This first materials task has been refocused to address Coal IGCC environmental impacts on high temperature materials use in gas turbines and remains in the program. This task will screen material performance and quantify the effects of high temperature erosion and corrosion of hot gas path materials in Coal IGCC applications. The materials of interest will include those in current service as well as advanced, high-performance alloys and coatings. Task 2--Material In-Service Health Monitoring: This second task develops and demonstrates new sensor technologies to determine the in-service health of advanced technology Coal IGCC powerplants, and remains in the program with a reduced scope. Its focus is now on only two critical sensor need areas for advanced Coal IGCC gas turbines: (1) Fuel Quality Sensor for detection of fuel impurities that could lead to rapid component degradation, and a Fuel Heating Value Sensor to rapidly determine the fuel heating value for more precise control of the gas turbine, and (2) Infra-Red Pyrometer to continuously measure the temperature of gas turbine buckets, nozzles, and combustor hardware.

The ''Enabling & Information Technology To Increase RAM for Advanced Powerplants'' program, by DOE request, was re-directed, de-scoped to two tasks, shortened to a 2-year period of performance, and refocused to develop, validate and accelerate the commercial use of enabling materials technologies and sensors for coal/IGCC powerplants. The new program was re-titled ''Enabling Technology for Monitoring & Predicting Gas Turbine Health & Performance in IGCC Powerplants''. This final report summarizes the work accomplished from March 1, 2003 to March 31, 2004 on the four original tasks, and the work accomplished from April 1, 2004 to July 30, 2005 on the two re-directed tasks. The program Tasks are summarized below: Task 1--IGCC Environmental Impact on high Temperature Materials: The first task was refocused to address IGCC environmental impacts on high temperature materials used in gas turbines. This task screened material performance and quantified the effects of high temperature erosion and corrosion of hot gas path materials in coal/IGCC applications. The materials of interest included those in current service as well as advanced, high-performance alloys and coatings. Task 2--Material In-Service Health Monitoring: The second task was reduced in scope to demonstrate new technologies to determine the inservice health of advanced technology coal/IGCC powerplants. The task focused on two critical sensing needs for advanced coal/IGCC gas turbines: (1) Fuel Quality Sensor to rapidly determine the fuel heating value for more precise control of the gas turbine, and detection of fuel impurities that could lead to rapid component degradation. (2) Infra-Red Pyrometer to continuously measure the temperature of gas turbine buckets, nozzles, and combustor hardware. Task 3--Advanced Methods for Combustion Monitoring and Control: The third task was originally to develop and validate advanced monitoring and control methods for coal/IGCC gas turbine combustion systems. This task was refocused to address pre-mixed combustion phenomenon for IGCC applications. The work effort on this task was shifted to another joint GE Energy/DOE-NETL program investigation, High Hydrogen Pre-mixer Designs, as of April 1, 2004. Task 4--Information Technology (IT) Integration: The fourth task was originally to demonstrate Information Technology (IT) tools for advanced technology coal/IGCC powerplant condition assessment and condition based maintenance. The task focused on development of GateCycle. software to model complete-plant IGCC systems, and the Universal On-Site Monitor (UOSM) to collect and integrate data from multiple condition monitoring applications at a power plant. The work on this task was stopped as of April 1, 2004.

This study identifies vital gas turbine (GT) parameters and quantifies their influence in meeting the DOE Turbine Program overall Integrated Gasification Combined Cycle (IGCC) plant goals of 50% net HHV efficiency, $1000/kW capital cost, and low emissions. The project analytically evaluates GE advanced F class air cooled technology level gas turbine conceptual cycle designs and determines their influence on IGCC plant level performance including impact of Carbon capture. This report summarizes the work accomplished in each of the following six Tasks. Task 1.0--Overall IGCC Plant Level Requirements Identification: Plant level requirements were identified, and compared with DOE's IGCC Goal of achieving 50% Net HHV Efficiency and $1000/KW by the Year 2008, through use of a Six Sigma Quality Functional Deployment (QFD) Tool. This analysis resulted in 7 GT System Level Parameters as the most significant. Task 2.0--Requirements Prioritization/Flow-Down to GT Subsystem Level: GT requirements were identified, analyzed and prioritized relative to achieving plant level goals, and compared with the flow down of power island goals through use of a Six Sigma QFD Tool. This analysis resulted in 11 GT Cycle Design Parameters being selected as the most significant. Task 3.0--IGCC Conceptual System Analysis: A Baseline IGCC Plant configuration was chosen, and an IGCC simulation analysis model was constructed, validated against published performance data and then optimized by including air extraction heat recovery and GE steam turbine model. Baseline IGCC based on GE 207FA+e gas turbine combined cycle has net HHV efficiency of 40.5% and net output nominally of 526 Megawatts at NOx emission level of 15 ppmvd@15% corrected O2. 18 advanced F technology GT cycle design options were developed to provide performance targets with increased output and/or efficiency with low NOx emissions. Task 4.0--Gas Turbine Cycle Options vs. Requirements Evaluation: Influence coefficients on 4 key IGCC plant level parameters (IGCC Net Efficiency, IGCC Net Output, GT Output, NOx Emissions) of 11 GT identified cycle parameters were determined. Results indicate that IGCC net efficiency HHV gains up to 2.8 pts (40.5% to 43.3%) and IGCC net output gains up to 35% are possible due to improvements in GT technology alone with single digit NOx emission levels. Task 5.0--Recommendations for GT Technical Improvements: A trade off analysis was conducted utilizing the performance results of 18 gas turbine (GT) conceptual designs, and three most promising GT candidates are recommended. A roadmap for turbine technology development is proposed for future coal based IGCC power plants. Task 6.0--Determine Carbon Capture Impact on IGCC Plant Level Performance: A gas turbine performance model for high Hydrogen fuel gas turbine was created and integrated to an IGCC system performance model, which also included newly created models for moisturized syngas, gas shift and CO2 removal subsystems. This performance model was analyzed for two gas turbine technology based subsystems each with two Carbon removal design options of 85% and 88% respectively. The results show larger IGCC performance penalty for gas turbine designs with higher firing temperature and higher Carbon removal.

The primary objective of the Phase I ERDA High-Temperature Turbine Technology (HTTT) Program was to provide a ''Program and System Definition'' of the three-phase program which would culminate in the testing of a Technology Readiness Vehicle (TRV) at the end of a six-year period. The TRV is designed for use in a combined cycle using coal-derived fuels at a firing temperature of 2600°F; growth capability to 3000°F is projected. The Phase I results reported are based on a 2600°F gas turbine burning coal-derived fuels. The following major areas are covered: overall plant design descriptions; systems design descriptions; turbine subsystem design; combustor design; phase II proposed program; and phase III proposed program. Details regarding final results of each of these areas are presented. It is concluded that the water-cooled gas turbine in combined cycle has been shown to be capable of extremely attractive levels of performance, both in terms of efficiency and specific output. Coupled with the ability to tolerate a wide range of coal-derived fuels with minimum fuel treatment, an extremely attractive system is presented for the generation of electric power. Future technology development of the high-firing-temperature water-cooled gas turbine is expected to result in the commercial introduction of this concept in combined cycles by the late 1980's or early 1990's.

This appendix is a compilation of work done to predict overall cycle performance from gasifier to generator terminals. A spreadsheet has been generated for each case to show flows within a cycle. The spreadsheet shows gaseous or solid composition of flow, temperature of flow, quantity of flow, and heat heat content of flow. Prediction of steam and gas turbine performance was obtained by the computer program GTPro. Outputs of all runs for each combined cycle reviewed has been added to this appendix. A process schematic displaying all flows predicted through GTPro and the spreadsheet is also added to this appendix. The numbered bubbles on the schematic correspond to columns on the top headings of the spreadsheet.

As a technology in early commercial phase, research work is needed to provide evaluation of the effects of alternative designs and technology advances and provide guidelines for development direction of Integrated Gasification Combined Cycle (IGCC) technology in future. The objective of this study is to evaluate the potential pay-offs as well as risks of technological infeasibility for IGCC systems and to provide insight regarding desired strategies for the future development of advanced IGCC systems. Texaco gasifier process is widely used in power generation. A process simulation model for a base Texaco gasifier-based IGCC system, including performance (e.g., efficiency), emissions, and cost, was implemented in the ASPEN Plus. To find out the implications of the effects of coal compositions on IGCC plant, Illinois No. 6, Pittsburgh No. 8, and West Kentucky coal are selected for comparison. The effects of the most advanced Frame 7H and the current widely used Frame 7F gas turbine combined cycles on IGCC system were evaluated. The IGCC system based on 7H gas turbine (IGCC-7H) has higher efficiency, lower CO2 emission, and lower cost of electricity than the 7FA based system (IGCC-7FA). A simplified spreadsheet model is developed to estimate performance of gas turbine combined cycle. This study implicated the ability to do desktop simulations to support policy analysis. Uncertainty analysis is implemented to evaluate risks associated with IGCC systems, i.e., there is about 80% probability that the uncertain results of the efficiency of IGCC-7FA are lower than the deterministic result. The IGCC-7H system is superior to IGCC-7FA despite the uncertainty of inputs. Gasifier carbon conversion and project uncertainty are identified as the key uncertain inputs. The effects of different integration methods of air separation unit (ASU) and gas turbine are evaluated. The results indicate that the integrated IGCC design has higher efficiency and lower cost than nonintegrated design.

Under contracted work with Morgantown Energy Technology Center, Clemson University, the prime contractor, and General Electric (GE) and CRSS, the subcontractors, made a comprehensive study in the first phase of research to investigate the technology barriers of integrating a coal gasification process with a hot gas cleanup scheme and the state-of-the-art industrial gas turbine, the GE MS-7001F. This effort focused on (1) establishing analytical tools necessary for modeling combustion phenomenon and emissions in gas turbine combustors operating on multiple species coal gas, (2) estimates the overall performance of the GE MS-7001F combined cycle plant, (3) evaluating material issues in the hot gas path, (4) examining the flow and temperature fields when air extraction takes place at both the compressor exit and at the manhole adjacent to the combustor, and (5) examining the combustion/cooling limitations of such a gas turbine by using 3-D numerical simulation of a MS-7001F combustor operated with gasified coal. In the second phase of this contract, a 35% cool flow model was built similar to GE's MS-7001F gas turbine for mapping the flow region between the compressor exit and the expander inlet. The model included sufficient details, such as the combustor's transition pieces, the fuel nozzles, and the supporting struts. Four cases were studied: the first with a base line flow field of a GE 7001F without air extraction; the second with a GE 7001F with air extraction; and the third and fourth with a GE 7001F using a Griffith diffuser to replace the straight wall diffuser and operating without air extraction and with extraction, respectively.

The objective of the US Department of Energy High-Temperature Turbine Technology (DOE-HTTT) program is to bring to technology readiness a high-temperature (2600/sup 0/F to 3000/sup 0/F firing temperature) turbine within a 6- to 10-year duration, Phase II has addressed the performance of component design and technology testing in critical areas to confirm the design concepts identified in the earlier Phase I program. Based on the testing and support studies completed under Phase II, this report describes the updated turbine subsystem design for a coal-derived gas fuel (low-Btu gas) operation at 2600/sup 0/F turbine firing temperature. A commercial IGCC plant configuration would contain four gas turbines. These gas turbines utilize an existing axial flow compressor from the GE product line MS6001 machine. A complete description of the Primary Reference Design-Overall Plant Design Description has been developed and has been documented. Trends in overall plant performance improvement at higher pressure ratio and higher firing temperature are shown. It should be noted that the effect of pressure ratio on efficiency is significally enhanced at higher firing temperatures. It is shown that any improvement in overall plant thermal efficiency reflects about the same level of gain in Cost of Electricity (COE). The IGCC concepts are shown to be competitive in both performance and cost at current and near-term gas turbine firing temperatures of 1985/sup 0/F to 2100/sup 0/F. The savings that can be accumulated over a thirty-year plant life for a water-cooled gas turbine in an IGCC plant as compared to a state-of-the-art coal-fired steam plant are estimated. A total of $500 million over the life of a 1000 MW plant is projected. Also, this IGCC power plant has significant environmental advantages over equivalent coal-fired steam power plants.