Identifying Technology Barriers In Adapting A State Of The Art Gas Turbine For Igcc Applications And An Experimental Investigation Of Air Extraction Schemes For Igcc Operations Final Report

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 primary objective of the cold flow experiments is to study the effects of air extraction from two sites in a heavy-frame gas turbine: (1) the engine wrapper or manholes and (2) the compressor/combustor prediffuser inlet. The experiments involve a scale model of components of a state-of-the-art, US made gas turbine between the compressor exit and the turbine inlet Specifically, the purpose is to observe and measure how air extraction affects the flow distribution around the combustor cans and the impingement cooling flow rates on transition pieces of the combustor. The experimental data should provide turbine manufacturers the information needed to determine their preferred air extraction site. The secondary objectives for the experiments are as follows: (1) to identify regions with high-pressure losses, (2) to develop a dam base which will validate computational fluid dynamic calculations, and (3) to establish an experimental facility which may be used to assist the US industry in improving the aerodynamic design of nonrotating components of a heavy-frame gas turbine.

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 objective of this program was to develop the technologies required for a fuel flexible (coal derived hydrogen or syngas) gas turbine for IGCC that met DOE turbine performance goals. The overall DOE Advanced Power System goal was to conduct the research and development (R & D) necessary to produce coal-based IGCC power systems with high efficiency, near-zero emissions, and competitive capital cost. To meet this goal, the DOE Fossil Energy Turbine Program had as an interim objective of 2 to 3 percentage points improvement in combined cycle (CC) efficiency. The final goal is 3 to 5 percentage points improvement in CC efficiency above the state of the art for CC turbines in IGCC applications at the time the program started. The efficiency goals were for NOx emissions of less than 2 ppm NOx (@15 % O2). As a result of the technologies developed under this program, the DOE goals were exceeded with a projected 8 point efficiency improvement. In addition, a new combustion technology was conceived of and developed to overcome the challenges of burning hydrogen and achieving the DOE's NOx goal. This report also covers the developments under the ARRA-funded portion of the program that include gas turbine technology advancements for improvement in the efficiency, emissions, and cost performance of gas turbines for industrial applications with carbon capture and sequestration. Example applications could be cement plants, chemical plants, refineries, steel and aluminum plants, manufacturing facilities, etc. The DOE's goal for more than 5 percentage point improvement in efficiency was met with cycle analyses performed for representative IGCC Steel Mill and IGCC Refinery applications. Technologies were developed in this program under the following areas: combustion, larger latter stage buckets, CMC and EBC, advanced materials and coatings, advanced configurations to reduce cooling, sealing and rotor purge flows, turbine aerodynamics, advanced sensors, advancements in first stage hot gas path components, and systems analyses to determine benefits of all previously mentioned technologies to a gas turbine system in an IGCC configuration. This project built on existing gas turbine technology and product developments, and developed and validated the necessary turbine related technologies and sub-systems needed to meet the DOE turbine program goals. The scope of the program did not cover the design and validation of a full-scale prototype machine with the technology advances from this program incorporated. In summary, the DOE goals were met with this program. While the commercial landscape has not resulted in a demand for IGCC gas turbines many of the technologies that were developed over the course of the program are benefiting the US by being applied to new higher efficiency natural gas fueled gas turbines.

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.

The U.S. Department of Energy (DOE) was given a mandate in the 1992 Energy Policy Act (EPACT) to pursue strategies in coal technology that promote a more competitive economy, a cleaner environment, and increased energy security. Coal evaluates DOE's performance and recommends priorities in updating its coal program and responding to EPACT. This volume provides a picture of likely future coal use and associated technology requirements through the year 2040. Based on near-, mid-, and long-term scenarios, the committee presents a framework for DOE to use in identifying R&D strategies and in making detailed assessments of specific programs. Coal offers an overview of coal-related programs and recent budget trends and explores principal issues in future U.S. and foreign coal use. The volume evaluates DOE Fossil Energy R&D programs in such key areas as electric power generation and conversion of coal to clean fuels. Coal will be important to energy policymakers, executives in the power industry and related trade associations, environmental organizations, and researchers.

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.