Block: Forum Title:

3 Natural Gas & Renewables F18 - Monetizing Under-utilized Gas Resources (GTL, LNG)
YOU CAN PLACE YOUR PHOTO HERE

Poster Title:

Integration of CCGT Plant and LNG Terminal

Author:

Augusto Bulte Proposal Manager - LNG & Power Projects

Author Biography

Augusto Bulte has a MSc degree in Marine Engineering and a PhD in Chemical Engineering. He has 12 years experience in power and LNG projects and has been proposal manager of Foster Wheeler Iberias commercial department since 2003. He has previously held the positions of mechanical engineer and project engineer at Foster Wheeler. Augusto has experience in gas turbines for CCPP with Alstom Power, and gas engines for cogeneration services with Jenbacher.

Forum Title:

F18 - Monetizing Under-utilized Gas Resources (GTL, LNG)

Poster Title:

Integration of CCGT Plant and LNG Terminal

Abstract

A recent Foster Wheeler study indicated that process integration of cold energy recovery from an LNG terminal has the potential to provide a highly reliable and operable combined cycle gas turbine facility with enhanced economics. This presentation covers integration opportunities targeting thermal processes, particularly, the utilization of cold process fluids from LNG regasification to increase the electrical energy production of a CCGT plant. As the chiller system will be in operation 7,000 hours per year, the economic analysis shows a gain of around US$40 million per year in the case study, indicating a simple pay back of the installation in one year.

Introduction
A recent Foster Wheeler study indicated that process integration of cold energy recovery from an LNG terminal has the potential to provide a highly reliable and operable combined cycle gas turbine facility with enhanced economics This presentation covers integration opportunities targeting thermal processes, particularly, the utilization of cold process fluids from LNG regasification to increase the electrical energy production of a CCGT plant

Gas Turbine Power Augmentation

Filter House Combustor airin Turbine Compressor I t k Air

Steam Expansion Effect

Intercooling Effect

Evaporative Cooling Effect

Water Injection Plane

Gas turbines are air-based engines, with operating efficiencies directly sensitive to ambient conditions An evaporative cooler, fogging systems or chillers/coolers, can provide an increase in system power All these system modifications have inherently low installation and operational costs and provide a high return on investment especially for locations with relatively high ambient temperatures

Gas Turbine Power Augmentation

Evaporative Cooler
Filter House Combustor airin Turbine Compressor

Droplet Separator Evaporative Cooler

The major components of an evaporative cooler are

The evaporative cooler media (cellulose or fibreglass) A water distribution manifold A water sump tank with low pressure recycle pump A droplet separator

Water evaporates before entering the compressor and air is cooled down before inlet The cooler media and the droplet separator produce a pressure drop between 1.5 and 3 mbar, and require an axial extension of the filter house

Gas Turbine Power Augmentation

Fogging System
Filter House Combustor airin Turbine Compressor

Fogging Nozzles

Fogging systems increase gas turbine power similar to an evaporative cooler The major components of a fogging unit are
The nozzle rack with nozzles The high pressure pump skid including a control unit and a valve skid A water drain system for the air intake and the intake manifold

Gas Turbine Power Augmentation

Chiller
Filter House Combustor airin Turbine Compressor

Droplet Separator Chiller

An air intake chiller system consists of a heat exchanger, which is located in the air intake downstream of the filter The chillers are usually installed in the gas turbine air intake, downstream of the air filter, together with a droplet separator to take out water droplets from condensation of humid air due to the temperature drop. The heat exchanger and the droplet separator produce a pressure drop of about 5 mbar, and require an axial extension of the filter-house

LNG Terminal Integration

S&T vaporizers have been considered to integrate the LNG Plant with the CCGT plant In the estimate study, the Chicago Power & Process Vaporizer and the Reli Vaporizer (next slide) were considered

LNG Terminal Integration

Reli Vaporizer

LNG Terminal Integration

12C GAS TURBINE

Compressor

AIR FILTER & CHILLER

(SIMILAR FOR EACH GAS TURBINE. EIGHT IN TOTAL)

BYPASS (ONLY TO COMPENSATE DIFFERENCES)

SEAWATER INLET GAS TURBINE 2C

Compressor

12C WATER/GLYCOL SOLUTION HEATER

AIR FILTER & CHILLER

SEAWATER OUTLET

2C LNG VAPORIZER LNG GAS EXPANSION VESSEL

12C

WATER/GLYCOL SOLUTION PUMPS

The proposed integration scheme is based upon generation of heat for the LNG process from a water/glycol solution in special vaporizers (shell & tube type). Consequently, a chilled water/glycol solution stream can be circulated to the power plant LNG terminal disturbances must be minimized. Regasification heat is used mostly in the CCGT plant, but if ambient conditions will not permit, two options are available:
Use of conventional seawater vaporizers instead of the shell & tube type Use of shell & tube type vaporizer, and use of plate heat exchangers to heat the water/glycol

Daily Mean Dry Temperature

Yearly Temperature Profile
45.0 40.0 35.0 30.0 25.0 20.0 15.0 10.0 5.0 0.0 May-05 Mar-05 Apr-05 Aug-05 Sep-05 Nov-05 Dec-05 Jan-05 Feb-05 Jun-05 Oct-05 Jul-05

T [C]

Historical Relative Humidity

Yearly Relative Humidity Profile
100.0 90.0 80.0 70.0 60.0 50.0 40.0 30.0 20.0 10.0 0.0 May-05 Mar-05 Aug-05 Sep-05 Nov-05 Apr-05 Jan-05 Feb-05 Jun-05 Oct-05 Jul-05 Dec-05

Relative Humidity [%

Yearly Wet Bulb Temperature

Yearly Wet Bulb Temperature Profile
40.0 35.0 30.0 25.0 20.0 15.0 10.0 5.0 0.0 May-05 Apr-05 Aug-05 Nov-05 Mar-05 Feb-05 Jul-05 Dec-05 Jan-05 Jun-05 Sep-05 Oct-05

T [C]

Yearly Air Dew Point

Yearly Air Dew Point Profile
40.0 35.0 30.0 25.0 20.0 15.0 10.0 5.0 0.0 May-05 Mar-05 Nov-05 Apr-05 Aug-05 Dec-05 Feb-05 Sep-05 Jan-05 Jun-05 Oct-05 Jul-05

T [C]

Power Augmentation
GT Power vs Inlet Pressure Drop
Power vs Air Inlet Pressure Drop
Power Correction Factor 1.005 1.000 0.995 0.990 0.985 0.980 0 2 4 6 8 10 Pressure Drop [mbar]
The correction curves have been adjusted by linear correlation for pressure drop variations and non-linear correlation for temperature changes. These formulae are used in the later calculations.

y = -1.532E-03x + 1.000E+00

Power Augmentation
Heat Rate vs Inlet Pressure Drop
Heat Rate vs Air Inlet Pressure Drop
1.006 Heat Rate Correction Factor 1.005 1.004 1.003 1.002 1.001 1.000 0.999 0 2 4 6 8 10 Pressure Drop [mbar] y = 5.444E-04x + 1.000E+00

Power Augmentation
GT Power vs Air Inlet Temperature
Power vs Air Inlet Temperature
Power Correction Factor 1.100 1.050 1.000 0.950 0.900 0.850 0.800 0 10 20 30 40 50 Inlet Temperature [C] y = 6.124E-07x 3 + 1.252E-06x 2 - 7.214E-03x + 1.106E+00

Power Augmentation
Heat Rate vs Air Inlet Temperature
Heat Rate vs Air Inlet Temperature
y = -3.519E-08x 3 + 6.392E-06x 2 + 1.646E-03x + 9.741E-01 1.060 1.050 1.040 1.030 1.020 1.010 1.000 0.990 0.980 0.970 0 10 20 30 40 50 Inlet Temperature [C] Heat Rate Correction Factor

Power Production
The gas turbine power production varies according to the ambient conditions. The power production of the eight gas turbines is shown below:

Yearly Gas Turbines Power (without chiller)

1900.0 1850.0 1800.0 1750.0 1700.0 1650.0 1600.0 1550.0 1500.0 May-05 Aug-05 Mar-05 Apr-05 Sep-05 Nov-05 Feb-05 Jan-05 Jun-05 Oct-05 Jul-05 Dec-05

POWER [MW]

Power Production
If the chiller is installed in each gas turbine air inlet, the power will be modified as shown below:

Yearly Gas Turbines Power (with chiller)

230.0 180.0 130.0 80.0 DELTA POWER [MW] 1870.0 POWER [MW] 1850.0 1830.0 1810.0 1790.0

Power

Power
1770.0 May-05 Feb-05 Sep-05 Nov-05 Aug-05 Mar-05 Apr-05 Jun-05 Jan-05 Oct-05 Jul-05 Dec-05

30.0 -20.0

Indicated power considers the gas turbine power production minus electric consumption because of water/glycol solution pumping.

Power Production
On the other hand, the heat rate is affected as shown below:

Yearly Gas Turbine Heat Rate (with chiller)

DELTA HEAT RATE [kJ/kWh] 10320.0 HEAT RATE [kJ/kWh] 10300.0 10280.0 10260.0 10240.0 10220.0 10200.0 May-05 Mar-05 Apr-05 Aug-05 Jul-05 Jan-05 Feb-05 Jun-05

Heat Rate

100.0 0.0 -100.0 -200.0 -300.0

heat Rate
Sep-05 Nov-05 Oct-05 Dec-05

-400.0 -500.0

Overall gas turbine power production would increase, largely during hot weather, while during cold weather it would decrease as no significant air inlet temperature drop could be obtained and a chiller would act as an air restriction (pressure drop at air inlet).

Economics
Overall Profit due to Power Augmentation [MM $/year]: 104.92 83.84 89.83 83.84 77.85 71.86 Overall Expense due to Heat Rate Augmentation [MM $/year]: 37.14 29.68 31.80 29.68 27.56 25.44

Operating Hours per year

Net Profit [MM $/year]:

8,760 7,000 7,500 7,000 6,500 6,000

67.78 54.16 58.03 54.16 50.29 46.42

Heat rate effect has been evaluated in comparison with power augmentation. Net profit (margin) considers income from power augmentation and expense because of fuel consumption increase.

Economics
Chiller Pressure Drop Sensitivity
Operating Hours per year Overall Profit due to Power Augmentation [MM $/year]: 92.90 74.24 79.54 74.24 68.93 63.63 Overall Expense due to Heat Rate Augmentation [MM $/year]: 33.36 26.66 28.56 26.66 24.76 22.85 Net Profit [MM $/year]:

8,760 7,000 7,500 7,000 6,500 6,000

59.54 47.58 50.97 47.58 44.18 40.78

The economic evaluation has been performed for a pressure drop of 10 mbar

Economics
Chiller Pressure Drop Sensitivity
Operating Hours per year Overall Profit due to Power Augmentation [MM $/year]: 80.88 64.63 69.25 64.63 60.02 55.40 Overall Expense due to Heat Rate Augmentation [MM $/year]: 29.55 23.62 25.30 23.62 21.93 20.24 Net Profit [MM $/year]:

8,760 7,000 7,500 7,000 6,500 6,000

51.33 41.02 43.95 41.02 38.09 35.16

Similarly to before, the economic evaluation has been performed for a pressure drop of 15 mbar

Economics
Wet Bulb Temperature Sensitivity
Operating Hours per year Overall Profit due to Power Augmentation [MM $/year]: 125.62 100.38 107.55 100.38 93.21 86.04 Overall Expense due to Heat Rate Augmentation [MM $/year]: 44.57 35.62 38.16 35.62 33.07 30.53 Net Profit [MM $/year]:

8,760 7,000 7,500 7,000 6,500 6,000

81.05 64.76 69.39 64.76 60.14 55.51

An economic evaluation has been performed for a wet bulb temperature of 8C

Economics
Wet Bulb Temperature Sensitivity
Operating Hours per year Overall Profit due to Power Augmentation [MM $/year]: 84.80 67.76 72.60 67.76 62.92 58.08 Overall Expense due to Heat Rate Augmentation [MM $/year]: 29.91 23.90 25.61 23.90 22.19 20.49 Net Profit [MM $/year]:

8,760 7,000 7,500 7,000 6,500 6,000

54.89 43.86 46.99 43.86 40.73 37.59

Similarly, an economic evaluation has been performed for a wet bulb temperature of 12C

Conclusions
Study results indicate that process integration of cold energy recovery from an LNG terminal in a power plant has the potential to provide a highly reliable and operable facility with enhanced economics Utilizing a very conservative assessment for a retrofit with known and unknown elements of constructability risk (additional structural support, piping, pump costs, etc) a CAPEX deduct of $10.5 MM was estimated, allowing a conservative potential investment gain ranging from $30 MM to $43 MM This potential profit margin projects a simple pay back of the installation in the range of 1 to 1.5 years

Thank you. Any questions?

Augusto Bulte Proposal Manager - LNG & Power Projects Foster Wheeler Iberia augusto_bulte@fwiberia.fwc.com www.fwc.com