Work Package 5 focuses on CHP component integration. Siemens Industrial Turbomachinery Ltd leads the work package. The objectives are to share information on RTD activities related to component and systems integration for CHP applications. Workshops are held biannually where participants report activities, results, and plans and discuss new areas of interest and potential collaborations. Topics discussed at workshops include improvements to gas turbines, steam turbines, gas engines and other components as well as the use of biomass and other alternative fuels for CHP applications.

1. Work Package 5
CHP Component Integration
Ulf Linder, Head of Future Technology
Geraldine Roy, Lead Market Analyst
Siemens Industial Turbomachinery Ltd
Work Package 5
CHP Component Integration
Overview of WP5
Objectives
Conclusions
Overview, SIEMENS Industrial Turbomachinery Ltd
Activities within Component Integration for Industrial
Gas Turbines
1

2. What are the benefits of the CHAPNET
Network?
• A focus for the industry to improve its R&D
• A knowledge centre for who is doing what, where
and with whom
• A place to develop new ideas for projects for
– 6th or 7th Framework Programme
– Energy Intelligent Europe Programme
• A strategic platform for identifying needs and
pulling together actors to address these needs
• A place to inform the Commission, Member State
Governments on the requirements of the industry
WorkPackage 5 -Component Integration
RTD Cluster on CHP Component Integration
Objective / Purpose
– To share information on RTD activities on Component Integration
and Systems Integration for CHP.
– EU programmes, and Accession countries
– National programmes
– Industrial activities
– Universities
– To Address the European competency in RTD with regard to
whole CHP systems not individual components
– Evaluate long term possibilities and technologies
2

3. WorkPackage 5 -Component Integration
Workshops Two per year
• Report Activities, Results and Plans
• Discuss and Recommend new activities, areas of interest, and
potential
• 1st Workshop held 28 August 2002 in Lincoln
• 2nd Workshop held 21 February 2003 in Brussels
• 3rd Workshop held 8 May 2003 in Düsseldorf
• 4th Workshop held 17 December 2003 in Brussels
• 5th Workshop held 28 & 29 January 2004, Västerås, Sweden
• 6th Workshop held 26 & 27 May 2004, Barcelona, Spain
• Often combined with WP7 – Cooling & Trigeneration
WorkPackage 5 -Component Integration
Workshops 1-6:
• CAME GT – Clean And more Efficient Gas Turbines
• BIOCOGEN -Biomass Cogeneration Thematic Network
• CHP Sewage Gasification - Sewage sludge gasification for CHP applications
• BAGIT - Biomass and gas integrated CHP technology
• Nedalo - Packaged CHP Systems,
• Linnhoff March - CHP Process and Utility Integration and Optimisation
• Promocell - Fuel Cell Cogeneration
• Hybrid CHP - Hybrid Solar collector CHP system
• OSCOGEN - Optimisation of Cogeneration Systems
• CHP Club - CHP Information, Advice and Networking
• ALSTOM - Using Fuels derived from Biomass and MSW in Industrial Gas Turbine
• SimTech - Thermodynamic simulations software
• CE-IGT - Increase awareness of industrial gas turbines
3

4. WorkPackage 5 -Component Integration
Workshops 1-6:
• ICEHT - Natural gas fuelled SOFCs for cogeneration of elect. & chemicals
• Baxter Eng. Ltd - LG Cable Absorption Chillers
• KKK Ltd - New high speed turbo-generator with “electronic gear”
• Aircogen - Aircogen Activities
• ALSTOM - Current & Potential Gas Turbine Technologies
• Wartsila - Current & Potential Gas Reciprocating Engine Technologies
• ALSTOM - Steam Turbine Technologies
• Dalkia - CHP: A CEM contractors perspective
• TBE - Phosphoric Acid Fuel cells & Digester Gas operation
• ALSTOM - Carbo-V gasification system
• Innogy - Iso-engine
• Farmatic - Cogeneration using Anaerobic Digestion
• Southeast Research Inst. - Gas Engine Research
WorkPackage 5 -Component Integration
Workshops 1-6:
• Gasification of Biomass and Power Generation, TPS
• Gasification and Gas Engine, Wartsila
• Gas turbines Technology Development trends, DDIT
• The Evaporative Gas Turbine demonstration Project, Lund University
• Connecting to the grid, Powerformer Technology, ABB
• Research and Development at Mãlardalens University
• Absorption chillers in Cooling and Tri-generation applications, WEIR Entropie
• Gas Turbines and Chillers Integration, DDIT
• Fogging and High Fogging : ALSTOM´s Experience and Customer Benefits,
ALSTOM Power
• SOFC - Future CHP, Siemens
• Gas engines – Maintenance philosophies, Wärtsilä
• CHP Systems Integration, Tecnicas Reunidas
• Biofuel based CHP production in Sweden and CHP R&D at CEDER (Soria/Spain),
CIEMAT
4

5. Current Technologies,
Topics
• Gas Turbines
• Improvements made to increase both electrical and overall fuel
efficiencies and future potential
• Fuel Flexibility
• Steam Turbines
• Improvements to increase efficiencies and future potential
• Novel features like High speed alternators
• Gas Engines
• Recent developments and future areas for research
» Improved availability
» Fuel flexibility
Current Technologies,
Topics
• Absorption Chillers
• GT Air Inlet Chilling
• Heat recovery
• Use of non-fossil fuels
– Increasing awareness of local, low cost wastes and use of
biomass resources
– Biomass Gasifiers
– Sewage sludge gasification
– Cogeneration using anaerobic digestion
• Plant Modelling and Optimisation
– Engineering solution
– Economics
5

6. The Customer’s Perspective
Topics
• High Reliability
• Of supreme importance in Liberalised Energy Markets
• Unwilling / unable to take technical and commercial risks associated
with new technologies
• Reduced Operating costs
• Lower fuel consumption
• Fuel flexibility
• Reduced maintenance
• Low Capital costs
Future and Emerging
Technologies, Topics
• Fuel Cells
• PEM
• Phosphoric Acid using digester gas
• SOFC
• Complex Cycle Gas Turbines
• Improved Efficiency
• Integration with SOFC
• Isopower Engine
• High efficiency
6

7. INNOGY Isoengine Cycle Diagram
Turbocharger Exhaust
Recuperator
Engine HX Separator
Water Injection
Aux.
Turbo HX Air Cooler Cooler Fuel
LP Air Spray Water
(2 cylinders)
Compressor
Isothermal
Cooler
HP Air
Isobaric
Water
Air-Water (Two-Phase)
Fuel
Combustors
(6 cylinders)
~
Combustion gas Engine Generator
A biogas plant
The simplest biogas plant is a cow...
7

8. Functional scheme of a
biopower station
Cleaned waste air
Deliv. solid residues Crushing Pulper
Pump
Waste gas to biofilter
Heat exchanger
Homogenization Hygienization Digestion
Deliv. liquid residues
Flare
Heat Storage
CHP unit tank
Desulphu-
Electricity
Heat storage Gas storage Drying risation Transport digested substrate
Key figures, Sweden*
• A total energy supply of 615,8 TWh
• 16 % (98,2 TWh) of the energy supply was based on
biofuels.
• Fuel supply for district heating amounted to 55 TWh
of which 33 TWh was based on biofuels
• Biofuel based electricity production amounted to 6,2
TWh (CHP in district heating systems 2,5 TWh and
industrial back pressure 3,7 TWh)
* Facts and figures 2003, ET21:2003, The Swedish Energy Agency
8

9. Activities within Component Integration,
Industrial Gas Turbines, Integration of Chillers
GT-Inlet Chillers,
Future potentials
• The use of absorption chillers
+ Integration with CHP
+ Improved heat rate
- Higher investment
Net Output
60.0
50.0
40.0
Net Output MW
Net Output MW
30.0
Net Output MW, Chiller in operation
20.0
10.0
0.0
-40.0 -30.0 -20.0 -10.0 0.0 10.0 20.0 30.0 40.0 50.0
Ambient Temperature
WorkPackage 5 -Component Integration
After Six WorkShops:
Presentations from;
– Several EU projects (RTD and Thematic Networks)
– Several CHP players -equipment, plant optimisation, concepts
3 Main themes & conclusions:
• Most efficient design not necessarily most economic solution !
» Economics is the key !
• Deregulated market raises issues
– Difficulty launching new technologies with associated technical and
commercial risks
• Fuel flexibility to maximise economic benefits
– Non-standard fuels, i.e. gasification of biomass and wastes
» Avoid disposal costs, Benefit from ‘green energy’ financial
incentives
9

10. Outputs
Suggested RTD areas!
• Further research in both conventional & emerging
technologies, required to improve:
– Reliability
– Fuel flexibility
– Efficiencies
– First costs
• Need for Government to help underwrite Commercial Risks
associated with new technologies
– International competitors receive company and technology
specific funding from concept to commercial demonstration
Work Package 5
CHP Component Integration
Overview of WP5
Objectives
Conclusions
Overview, SIEMENS Industrial Gas Turbines
Activities within Component Integration
for Industrial Gas Turbines
10

11. Integration is a major
challenge
Industrie
Turbinen
Power Generation
KWU AG KWU
AEG Industrial
Applications
Westinghouse
Mannesmann Demag
DemagDelaval
Delaval
I-Segment
ASEA
ABB
BBC ABB
Alstom Alstom
Power
Ruston GEC GEC
Alstom
Alsthom Alsthom
1960 1970 1980 1990 2000 2003
Siemens Gas Turbine product
range
W501G 253 MW
PGF Gas Turbine range
W501F 190 MW
W501D5A 121 MW
V64.3A 67 MW 60HZ
V94.3A 266 MW
V94.2A 182 MW
V94.2 159 MW
V64.3A 67 MW
50HZ
GTX100 43 MW
PGI Gas Turbine range
30 MW
GT10C
GT10B 25 MW
17 MW V94.3A
GT35C
Cyclone 13 MW
Tempest 8 MW
7 MW
Tornado
5 MW Cyclone
Typhoon
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12. Activities within Component Integration,
Industrial Gas Turbines, Gasification
Power from Biomass & Wastes
• Not new technologies
• Many years experience in chemical industry
• Little experience of Biomass Integrated Gasification Combined
Cycle (BIGCC)
• Growing experience using these technologies
• BIGCC concept has been proven at Värnamo, Sweden
Activities within Component Integration,
Industrial Gas Turbines, Gasification
Gasifier Flare
BIGCC Scheme
Fuel
Input
Gas Cooler Hot Gas Filter
Booster
Compressor Gas
Turbine Start-up
fuel store
Steam Turbine
Stack
Air
HRSG Heat
Load
12

13. Activities within Component Integration,
Industrial Gas Turbines, Gasification
Power from Biomass & Wastes
Net efficiency comparison for –Air blown or oxygen-blown
sub-40MW plant
–Atmospheric or pressurised
–Circulating, bubbling or fixed beds
Bio Oil CCGT
Pressurised BIGCC All systems produce different fuel
Atmospheric BIGCC gas compositions and calorific
Atmospheric Gasifier + values !
Gas Engine
CFB
–3.5 to 30MJ/Nm³, 5 to 50% hydrogen
Direct Combustion
•Combustion issues
0 5 10 15 20 25 30 35 40 45
Activities within Component Integration,
Industrial Gas Turbines, Gasification
Potential Future Applications Conclusions
Integrated Agriculture & Biomass-IGCC
• Plants of 5 - 20MW output Use of Gas Turbine-based
schemes could:
• Use waste from main crop to provide
fuel for CHP scheme to heat • Assist in the
greenhouses etc. development of
• Atmospheric or pressurised gasifiers advanced thermal
conversion
• Potentially >35% net efficiency
technologies and eco-
Large scale Biomass-IGCC friendly CHP
• Plants of 20 - 40MW output optimised • Offer high efficiency,
for power generation low emission, carbon
• Atmospheric or pressurised gasifiers neutral power
• Potentially > 40% net efficiency generation from
biomass and waste-
derived fuels
13

14. Activities within Component Integration,
Industrial Gas Turbines, Integration of Chillers
GTX100 Nominal Generator Output vs Inlet Temp
A Typical Gas Turbine Characteristic
Activities within Component Integration,
Industrial Gas Turbines, Integration of Chillers
General description of the system
The system consists of 2 parallel chillers
and 1 common water loop to the air inlet
coil.
The air inlet coil is a part of the air inlet
system
Evaporators
Compressors.
Condensers
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