"Energy Efficiency in IPPC-installations" Modern Combined Cycle Power Plants – Improvement of a high efficient and clean technology O. Kreyenberg, H. Schütz, H. Friede Siemens PG "Energy Efficiency in IPPC-installations" 21 and 22 October 2004 Vienna

Reference Power Plant Product Overview - Steam Power Plant Agenda Market Drivers Reference Power Plant Product Overview - Steam Power Plant - Combined Cycle Power Plant Reference Power Plant Design Philosophy Design Targets References

* technical warranties (NOx, et. al.), delivery time The Market Conditions Have Changed Dramatically in the Power Industry Over the Last 10 Years Overall Construction Time Efficiency Price Risk Guarantee* Market Conditions Years * technical warranties (NOx, et. al.), delivery time

Life Cycle Cost (LCC) Analysis Parameters influenced by the supplier Parameters Costs Investment costs Financing costs Service life Demolition costs Reduction of specific investment costs Global sourcing Modular design Short delivery times Capital costs Live Cycle Costs Fuel contract conditions Efficiency Fuel Costs High process and component efficiencies Personnel costs Consumables/waste Spare parts Maintenance Optimized level of automation High availability Ease of maintenance Operating costs

Reference Power Plant Product Overview

Components, Islands and Turnkey Our Reference Power Plants are Focused on International Main Market Demand for IPP’s Varioplant 300 300- 450 MW 700 500- 750 MW 900 800- 1000 MW Coal/Oil Customized... of the shelf... Single-Shaft 50 Hz 100, 290, 400 MW Gas/Oil 60 Hz 100, 270, 365 MW Multi-Shaft 50 Hz 200, 580, 800 MW 60 Hz 200, 540, 730 MW Components, Islands and Turnkey Gas/Oil

Multi-Shaft Combined Cycle Power Plant Econopac Arrangement Gas turbine Gas turbine generator Air intake Exhaust gas system Fuel system Electrical package (SFC/SEE) GT - Auxiliaries Fire protection Options

Multi-Shaft Combined Cycle Power Plant Power Island Arrangement Econopac Steam turbine Steam turbine generator incl. SEE Heat recovery steam generator Major pumps Condenser Critical valves ST - Auxiliaries Cycle optimization Fuel gas pre-heater Options

Multi-Shaft Combined Cycle Power Plant Turnkey (Cooling Tower) Power Island Fuel supply systems Cooling systems Water treatment Raw water system Waste water system Tanks Cranes/ hoists Buildings/ structures Fire protection Plant piping/ valves Plant electrical Further options

Multi-Shaft Combined Cycle Power Plant Turnkey with House (Cooling Tower) Power Island Fuel supply systems Cooling systems Water treatment Raw water system Waste water system Tanks Cranes/ hoists Buildings/ structures Fire protection Plant piping/ valves Plant electrical Further options

Reference Power Plant Design Philosophy

Evolution of Combined Cycle Power Plant Efficiency Steam cycle Single pressure Dual pressure Tripple pressure with reheat Net efficiency (%) 60 1160°C — 100 bar 520°C Turbine inlet temp. (ISO) Fuel preheating Life steam pressure Life steam temperature 1250°C 200°C 160 bar 580°C 58 1230°C 130°C 125 bar 565°C 1230°C 130°C 110 bar 550°C 1120°C — 80 bar 520°C 1190°C 200°C 110 bar 540°C 56 1050°C — 75 bar 510°C 54 1000°C — 60 bar 485°C 52 960°C — 50 bar 460°C Fuel gas firing ISO ambient conditions (15°C, 1013 mbar, 60% rel. humidity) Condenser back pressure 0.04 bar 50 48 46 1983/84 1987/88 1990/91 1992/93 1994/95 1996/97 1998/99 2001 2005/06 Year of commissioning Source: Siemens Gas Turbines

Economical Evaluation Factors

Power Output, Efficiency, NOx-Emission and Cooling Air Demand versus Combustion Temperature Boundary conditions: The same technology for blade cooling, combustion chamber cooling and burner. mKL . Ex- haust gas 102% Gas turbine NOX Tcomb. Fuel 2% Heat recovery steam generator Combustion air 80% Combustion chamber NOX Air intake 100% Electricity Generator Cooling air 20% TCool.-air hGUD Steam turbine Circulating water Electricity TIT Generator Condenser 1570°C 1700°C TCombustion

Efficiency Improvements due to Increasing the Number of Pressure Stages Temperature curves in a heat recovery steam generator Efficiency increase D h net [%-points] Temperature [°C] 1-pressure process 2-pressure process 3-pressure process 125 bar/565 °C 28 bar/565 °C 4 bar/235 °C 600 3 500 125 bar/565 °C 29 bar/320 °C 5 bar/200 °C Exhaust gas 400 2 80 bar/540 °C 5 bar/210 °C 300 2.8 200 1 2.1 1.6 100 65 bar/540 °C 54.1% Transfered heat 1-pressure 2-pressure 3-pressure without reheat 3-pressure with reheat

Quick Start up Increases Plant Utilisation Factor... GT at full load/ Bypass System closed Start-up after 8h Shut-down Plant start-up with improved equipment Typical plant start-up Plant Load [MW] ≈ 40 min ≈ 90 min Time

Limiting Values for Flue Gas Emissions

Relationship between turbine inlet temperature and NOx emissions A temperature increase by 70K doubles the NOx- emissions !

Design Targets

One the way to the Technical leadership now tomorrow Efficiency 58%* > 59% TIT** 1230°C 1290°C NOx 25 ppm 9 – 15 ppm * depending on cooling conditions ** turbine inlet temperature Details on additional measures will be presented at a VDI Symposium in Leverkusen 23./24. November 2004

References

Mainz-Wiesbaden, Germany Combined Cycle Power Plant V94 Mainz-Wiesbaden, Germany Combined Cycle Power Plant V94.3A with Steam Extraction Mainz - Wiesbaden (Germany) Concept: Multi Shaft 1+1 V94.3A Output (nat. gas, site) : 1 x 400 MW Efficiency (nat. gas, site): >58,4 %* COD: July 2001 Fuels: Natural Gas (Fuel oil Back up) Contract: EPC TK plus 10 y. S&M

Pulau Seraya, Singapore: 2 CC 1S. V94 Pulau Seraya, Singapore: 2 CC 1S.V94.3A The Most Efficient Plant in SEA Pulau Seraya (Singapore) Concept: Single Shaft 1S.V94.3A Output (nat. gas, site) : 2x 367 MW Efficiency (nat. gas, site): >57.2 % COD: November 2002 Fuels: Natural Gas (Fuel oil Back up) Contract: EPC TK plus 10 y. S&M