Raising the Efficiency of Gas-Fired Power Plants and CCPP. GEA Heat Exchangers

Transcription

1 Raising the Efficiency of Gas-Fired Power Plants and CCPP

2 Content 1 2 Double-Tube Safety Gas Preheater Technology Basics (Equipment/Technology) Detection Successful Application Basic reasons for installation of DTSHX 3 Application: CCPP in Northern Italy Facts Flow charts/pictures Details on heaters Reasons to choose a DTSHX Advantages Savings by heaters 4 Summary 2

3 DTSHX - Gas Preheater Technology Basics - Equipment double-tube cross-section hot water outlet hot water inlet leakage switch gas inlet gas outlet leakage space 3

4 DTSHX - Gas Preheater Technology Basics - Detection Normal operation Inner tube failure Outer tube failure 4

5 DTSHX - Gas Preheater Technology Basics - Patented Safety Leakage Switch Installation Example 5 Normal operation status without failure Rupture disc broken: optical and electrical indication of failure

6 Successful Application Basic Reasons for Installation of DTSHX Increasing of efficiency No bypass necessary Intermediate cycle avoided Easy monitoring of heat exchanger No immediate shutdown after tube leakage Lower consumption costs Low installation costs and minimum space required Less assembly area, higher thermal efficiency Inspection on site and during operation Highest possible operation reliability 6

7 Facts 7

8 Flow Charts Start up position fuel gas external supply -aux. steam - GPRS GT GT ST start up heater Normal operation feedwater from steam turbine stand by feedwater from steam turbine GPRS feedwater from steam turbine GPRS GT GT ST Joule Thompson heater performance heater 8 0 C 35 C 53 C 55 C 100 C

9 Installation performance heater Joule Thompson heaters start up heater 9

10 Details on Heater - Start Up Heater Heat duty: KW Steam (12 bar abs.) cooling down from 250 C, condensing at 190 C and subcooling to 85 C 10,000 kg/h (13,589 scm/h) natural gas at max. 65 bar abs. heating up from 0 C to 55 C 10

11 Details on Fuel Gas Heater - Joule Thompson Heater Heat duty: KW Feed water (22 bar abs.) cooling down from C to C 19,640 kg/h (26,688 scm/h) natural gas at max. 65 bar abs. heating up from 0 C to 53 C 11

12 Details on Gas Heater - Performance Heater Heat duty: KW Feed water (22 bar abs.) cooling down from C to C 9,820 kg/h (13,344 scm/h) natural gas at min. 28 bar abs. heating up from min. 35 C to 100 C 12

13 Reasons to Choose a DTSHX as a Start Up Heater Steam available externally from the production process No additional investments needed, e.g. for electrical heater or external boiler Solution cheaper compared to other opportunities, e.g. as for electrical heaters No external energy needed (due to energy of steam was brought to natural gas which raised the efficiency of gas turbine process) Gas pressure higher than steam pressure but without risk due to double tube safety technology Leak can be easily detected and alarm signal can be supplied to monitoring system Only in DTSHX two gaseous media can be combined (steam and natural gas) without risk of being mixed even at malfunction 13

14 Savings by Heaters - Start Up Heater Savings of fuel gas % Annual savings of gas 352,456 scm Nominal Power of GT 45,000 KW Efficiency improvement % 14

15 Reasons to Choose DTSHX as a Joule Thompson Heater Gas Wasser- Wärmeübertrager gas M house heating M L T Gasvorwärmer ex-area L T Gas pressure regulation system: gas preheating with traditional safety device house heating ex-area gas Bisherige Ausführung der P P Gasvorwärmung Gebäude- Heizung M Ex-Bereich T Gas pressure regulation system: gas preheating with GEA R&G DTSHX 15

16 Savings by Heaters - Joule Thompson Heater Savings of fuel gas % Annual savings of gas 670,261 scm Nominal Power of GT 45,000 KW Efficiency improvement % 16

17 Reasons to Choose DTSHX as a Performance Heater Safe use of different heat sources, independent from their pressure and temperature, higher safety with a simplified system Heating up of gas even with waste heat like lube oil, steam or condensate Use of additional energy (e.g. electric heaters or separate boilers) avoided No need for a scrubber in front of gas turbine No bypass necessary in front of gas turbine No intermediate shutdown of turbine after tube leakage Reduction of gas consumption, lower CO2 emission Available for all sizes of gas turbines 17

18 Savings by Heaters - Performance Gas Heater Savings of fuel gas % Annual savings of gas 357,840 scm Nominal Power of GT 45,000 KW Efficiency improvement % 18

19 Summary Overall Savings Efficiency improvement for the CCPP start up heater 0.12 % Joule Thompson heater 0.05 % performance heater 0.11 % if all three DTSHX are in operation 0.28 % Annual savings of gas for the CCPP start up heater Joule Thompson heater performance heater if all three DTSHX are in operation 352,456 scm 670,261 scm 357,840 scm + 357,840 scm (for two gas turbines!) 1,738,397 scm Monetary savings per annum 400,000 EUR (without start up heater) 19

20 Summary Overall Savings (continued) Savings in Green House Gas (if Joule Thompson heater and performance heater are in operation): 1, , to CO 2 20 Euro/t: 38,000 EUR Grand total in savings: 438,000 EUR (578,160 US$, exchange rate: 1.32) ROI < 1 year 20

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