Sustainable Thermal Energy Management Conference 2010

Operation Window and Part-Load

Performance Study of
a Syngas Fired Gas Turbine

Fen He, Zheng Li, Pei Liu, Linwei Ma, Efstratios N. Pistikopoulos
Tsinghua University, China Imperial College London, UK

November 2-3, 2010

Introduction

With the rapid development of coal gasification, growing interest in using
syngas (mostly CO+H2) as gas turbine fuel

Challenges to gas turbine due to fuel switch from natural gas (NG) to syngas
 to identify operation window in wide load range

Concept of fuel dilution and air bleed/integration

N2 from Undiluted syngas fuel

ASU (LHV: 11~12MJ/kg) Features of dilution & air bleed
Diluted syngas
Mixing of syngas with N2 (diluent) for
(LHV: 5~8MJ/kg) 1. Combustion control
2. NOx control
3. Power enhancement

Dilution increases mismatch of turbo-
machinery components

Standard solution: air bleed for use in
ASU  GT Integration

25~30% integration degree requires
Air Exhaust gas
approximately 5~7% air bleed ratio

2
Gas turbine model and key parameters
A general model for a typical E-class gas turbine Flame temp. Tflame
Fuel
Fuel
Definition
Compressor
Variable Inlet
ASU
Guide Vane
VIGV Cooling air
Air bleed

G Compressor

Surge margin

Compressor
outlet temp.
TK2
Coolling air
Air Exhaust

Turbine inlet temp. TIT Turbine blade temp. Tbl Exhaust temp. TAT
3
Assumption and fuel specification

Baseline: gas turbine with natural gas full load @ ISO ambient condition
Output Pressure Turbine inlet Turbine exhaust Exhaust mass
Net efficiency (%)
(MW) ratio temperature (oC) temperature (oC) flow (kg/s)
166.5 17.6 1100 524 533 35.7

Results are referred to as deviation from the baseline to facilitate the comparison

Air bleed ratio: 0 % , 5 %, 10 %

Fuel specification
No. 1 No. 2 No. 3 No. 4
Undiluted CO-rich Diluted CO-rich Undiluted H2-rich Diluted H2-rich
N2 (Vol.%) 6.22 39.65 6.23 52.08
CO2 (Vol.%) 1.01 0.65 1.13 0.58
H2O (Vol.%) 0.15 0.10 0.44 0.22
CH4 (Vol.%) 0.03 0.02 0.03 0.02
H2 (Vol.%) 30.87 19.87 87.77 44.85
CO (Vol.%) 61.72 39.72 4.40 2.25

LHV(kJ/kg) 12397 7000 42212 7000

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Basic part-load control concept

Maximum TAT
Temperature
TAT Temperature
TAT Temperature

5
 Baseline analysis: natural gas operation
Turbine blade temperature & exhaust temperature
Close VIGV  Inlet air mass flow ↘  Hot gas mass flow↘
↘  Pressure ratio↘
↘
Operation Window (natural gas)
ISO Ambient Condition

50
T
bl a
de
CO
Pressure ratio↘
↘  TAT ↗
25 NS
TR
0 RA
IN
TIT C
ONT
ROL
AIN  Turbine outlet overheat
ST
 Derate TIT temperature
erature [oC]

N
-25 CO
T
TA
-50
Change in Flame Tempe

-75 Coolant flow almost unchanged

-100
 Cooling air to hot gas ratio↗
↗
-125

-150
 Blade temperature ↘
-175

-200 Active operation constraints

Close VIGV
-225
Tblade,max ≤ Tblade,ref TATmax ≤ TATref + 30° C
-250

-275
40 50 60 70 80 90 100 110 120 130 140 150 160 170
Power Output [MW]

0.2 0.3 0.4 0.5 0.6 0.7 0.8 0.9 1

Load

6
 Baseline analysis: natural gas operation
NG operation window & compressor surge margin
Gas turbine is operated along the upper boundary of the operation window.

Operation Window (Natural gas, ISO condition)

50 15% SURGE MARGIN T IGV=0
bl CO GT Operation Line

ed Pressure Ratio
NS 1.2 IGV=5
T RA IGV=10
0 T IT C IN
ONT IGV=20
N ROL
erature [C]

RAI 1
T
-50 O NS
IGV=30
C
T
TA
Change in flame tempe

Compr. Reduce
0.8
-100 Surge Line

0.6
-150
Close VIGV TIT/TAT = Constant

IN
D

A
SE

TR
LO

-200
EN

0.5 0.6 0.7 0.8 0.9 1 71.1

NS
VC

OP

Reduced Massflow
CO
VI G

-250
VIG

TK

40 60 80 100 120 140 160

Power output [MW]
 Syngas fired gas turbine
Diluted CO-rich syngas without air bleed
Operation window is significantly smaller due to constraints of turbine blade temp.
Operation Window (diluted syngas)
LHV = 7000 kJ/kg = 7166 kJ/m3, Air bleed ratio = 0%
1.3
50 IGV=0
AIN SU 1.2
GT Operation Line
TR RG IGV=5

d Pressure Ratio
S
CON E
LI IGV=10
0 T NE 1.1
TA
erature [C]

T IGV=20
8% SURGE bl 1
CO
MARGIN LINE NS IGV=30
-50 TIT C 0.9
O NTR T RA
OL

Compr. Reduced
Change in flame tempe

IN 0.8
Surge Line
-100 0.7

0.6
-150

RAIN
0.5 NG Reference
D
SE

0.4
ONST
0.5 0.6 0.7 0.8 0.9 1 1.1
LO

-200
N

Reduced Massflow
PE
VC

8
TK2 C
VO
VIG

-250
VIG

80 100 120 140 160 180 200 220

Power output [MW]
 Impact of air bleed
Diluted CO-rich syngas with air bleed

Air bleed ratio ↗  Surge margin ↗, blade temperature ↘ , power↘↘
 High TAT in a wider range, benefits bottoming steam cycle
Air bleed ratio 5% Air bleed ratio 10 %
Operation Window (diluted syngas) Operation Window (diluted syngas)
LHV = 7000 kJ/kg = 7166 kJ/m3, Air bleed ratio = 5 % LHV = 7000 kJ/kg = 7166 kJ/m3, Air bleed ratio = 10 %
50 50
8% SURGE MARGIN LINE
15% SURGE MARGIN LINE
T T
bl bl CO
0 CO 0
NS
Change in flame temperature [[C]

NS

Change in flame temperature [[C]

IN T TR
TRA TIT C
ONT
RA AI
S IN N TIT C N
-50 N ROL -50 AI ONT
CO TR ROL
TA
T
ONS
C
T
-100 -100 TA

D
-150

SE
-150

LO
IN

IN
ED

VC
RA

RA
OS

-200 -200
ST

VIG

ST
N
CL

N
PE

PE
ON

ON
V

VO

VO
VIG

2C

2C
-250 -250
VIG

VIG
TK

TK
60 80 100 120 140 160 180 200 40 60 80 100 120 140 160 180
Power output [MW] Power output [MW]

9
 Impact of air bleed
Undiluted CO-rich syngas

A larger operation window is observed compared with fuel dilution
 Less dilution benefits the gas turbine operation

Smaller air bleed ratio is required to further improve the operation window
Air bleed ratio 0% Air bleed ratio 5%
Operation Window (undiluted syngas) Operation Window (undiluted syngas)
LHV = 12397 kJ/kg = 11137 kJ/m3, Air bleed ratio = 0% LHV = 12387 kJ/kg = 11137 kJ/m3, Air bleed ratio = 5 %
50 8% 50 T
T SU
SURGE MARGIN bl
CO
bl CO RG NS
IN NS E TR
0 TRA TR
AI
N
M
AR 0 TIT C AI
NS
GI ONT N
Change in flame temperature [C]]

Change in flame temperature [C]]

O TIT N ROL
C CO NTR N
TA
T O L RAI
-50 -50 T
NS
CO
T
-100 -100 TA

D
-150

SE
-150
AIN

LO
ED

IN
VC
STR
OS

A
-200

TR
-200
N

VIG
CL

N
ON
PE

NS
PE
V

VO

2C

CO
VIG

VO
-250
VIG

TK

-250

2
VIG

TK
60 80 100 120 140 160 180 40 60 80 100 120 140 160
Power Output [MW] Power output [MW]

10
H2-rich syngas fired gas turbine
Undiluted, without air bleed

If advanced combustion technology is available for undiluted H2-riched SG, air
bleed would not be needed.
Operation Window (undiluted H2 riched syngas)
LHV = 42212 kJ/kg = 10031 kJ/m3, Air bleed ratio = 0 %
50 SURGE MARGIN
T
bl CO
0 NS
T RA
Change in flame temperature [C]

N TIT C IN
RAI ONT
ROL
-50 T
NS
CO
T
-100 TA

-150

IN
RA
D
SE

-200

ST
LO

ON
PE
VC

2C
VO

-250
VIG

TK
VIG

60 80 100 120 140 160 180

Power output [MW] 11
 H2-rich syngas fired gas turbine
Diluted, with & without air bleed

The operation with diluted H2-rich syngas is more critical than CO rich syngas

H2-content ↗  Fuel heating value ↗  to reach the same diluted LHV, dilution ↗
 hot gas mass flow ↗  blade temp.↗ ↗ pressure ratio ↗  surge margin ↘

Operation Window (diluted H2 riched syngas) Operation Window (diluted H2 riched syngas)
LHV = 7000 kJ/kg = 5129 kJ/m3, Air bleed ratio = 0% LHV = 7000 kJ/kg = 5129 kJ/m3, Air bleed ratio = 5 %
50 50
Tb C
l ON
STR
AIN
0 0 8% SURGE MARGIN
SU

C]
C]

Change in flame temperature [C

Change in flame temperature [C

RG
E
LIN
N
AI E
-50 STR TIT
CON -50
N TRO N
CO L AI TIT
CON
TA
T
STR TRO
N L
-100 -100 CO
Tb T
TA
l
C
O
N
ST
R
-150 -150
A
IN
A IN
ST R

IN
D
SE

ED
-200

A
-200
ON

TR
LO

OS
N

2C

S
VC

PE

N
CL

ON
PE
VO

TK
VIG

VO

2C
VIG
-250 -250
VIG

VIG

TK
80 100 120 140 160 180 200 220 240 260 60 80 100 120 140 160 180 200 220
Power output [MW] Power output [MW]

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Conclusions

Active constraints of a conventional GT fired with syngas are:
 insufficient cooling of turbine blade, and
 decreased compressor surge margin

The lower the syngas heating value,
 the further GT operation points depart from baseline, and
 the lower the GT firing temperature

Operation with diluted H2-rich syngas is more critical than with CO-rich
syngas.

Air bleed and less dilution are beneficial for improving GT working
conditions in the current range of investigation.

Thank you for your attention! Any questions?

E-mail: lz-dte@tsinghua.edu.cn

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