ARABAL 2011 MUSCAT, OMAN

Gulf Smelters Large Potlines supplied by large high efficiency

CCGT power plants Risks and Benefits of a Grid Connection
Page No.1
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CCGT Using Large F Class GT Units -
Benefits

Low Capex / kW Installed typically US$650 US$700
per kW in the Gulf.
High Efficiency - typically 55% (LHV basis) above ~90%
load and reduced fuel cost.
Well proven technology.
Low Emissions NOx ~ 15 - 25 ppmv (30 - 50 mg/M
3
)
CO ~ 25 ppmv.
Short Construction Schedule, typically 30 -36 months for 4
GT Unit CCGT Plant.
Page No.2
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Gulf Aluminium Smelter Potline Size Growth

Page No.3
2005 - ALBA Potline 5 1x 336 pots 505 MW
2009 - Sohar Aluminium 1 x 360 pots 560 MW
2011 - Qatalum 2 x 352 pots 2 x 500 MW
2011 - Emal 1 2 x 378 pots 2 x 600 MW
2015 Sohar Aluminium 1 x 460 pots > 800 MW
MW values shown are for the potline power only
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Matching the Power Plant to the Smelter

Page No.4
F Class 50 Hz GTs have ISO ratings (15 Deg C &1013 mbara) between
250 - 280 MW with typical Gulf Summer ratings (45 Deg C & 1000 mbara)
between 210 - 235 MW.
In CCGT operation each GT will produce an additional 50% output from
HRSG that supplies a steam turbine (ST).
F Class GTs therefore effectively produce 315 350 MW in CCGT
operation in a Gulf Summer.
To allow for maintenance, a minimum of N+1 GT Units must be installed,
where N is the number of GT Units operating to meet the Smelter power
demand.
To minimise capital cost, no more than N+1 GT Units should be installed.
To achieve high efficiency the GTs should operate at ! 90% power output.
Therefore, for an assumed Smelter power demand of 900 MW, a minimum
of four (4) F Class GTs must be installed.
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E Class F Class
No of GT Units Installed 6 / 7 4
No of GT Units Running to Supply Smelter 5 / 6 3
LHV Efficiency 48% 55%
Annual Fuel Consumption MMBtu 54.4 million 47.5 million
Annual Fuel Cost @ US$ 1.5 /MMBtu $81.6 million $71.2 million
Annual NOx Emissions - tonnes 3700 - 4100 2800
Capital Cost - US$ millions $835/$920m $850/$940m

Comparison of CCGT Plant Using
F and E Class GT Units to supply an
assumed 900 MW Smelter Load

Page No.5
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Reliability & Security of Smelter Power Supply
In House Power Generation
Page No.6
Aluminium Smelters need a very secure and reliable power supply.
In house power generation alone cannot meet this requirement unless
adequate standby generation is installed.
A single standby GT is not sufficient see table below.
____________________________________________________________
Assumed GT Availability 93%, Unavailability 7%
No of GTs Installed 7 6 5 4
No of GTs operating to meet 6 5 4 3
Smelter Power Demand
Reliability of Power Supply 91.9% 93.9% 95.8% 97.3%
_____________________________________________________________



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Reliability & Security of Smelter Power Supply
Grid Connection

Page No.7
Connection to the local HV Electrical Grid provides standby generation
capacity and improves the reliability and security of the smelter power
supply.
Capacity of Grid Inter-connector should at least match the output of 1
GT and its associated ST this achieves a 99.8% reliable power
supply with the a 3 out of 4 GT operating scenario.
Two (2) Grid inter-connectors increase the reliability of the power
supply to 99.99% (< 1 hour unavailability of full power supply per year)
Capital cost of a Grid Connection is much lower than the cost of
installing additional GT Unit(s)


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Grid Connection - Benefits to Smelter

Page No.8
Provides start-up power for the Smelter & its power plant.
Provides power during maintenance and forced outages of
gas turbines (GT) or steam turbines (ST).
Provides spinning reserve generation that instantaneously
(within 5 secs) allows power import in the event of a trip of a
Smelter GT or ST Unit.
Allows the Smelter GT Units to operate at > 90% output and
hence at high efficiency.
Helps maintain the Smelter electrical system frequency and
voltage.


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Smelter Connection - Benefits to Grid

Page No.9
Provides a large steady load throughout the year that helps
stabilise Grid voltage and frequency, particularly during the
low load Gulf Winter period.
Provides spare generating capacity that can be made
available to the Grid during the peak load Gulf Summer
period.
Provides short term (1 minute to 1 hour) frequency support to
the Grid by de-loading the potline.
Smelter is a large customer and a potential source of
significant revenue to the Grid.



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Grid Connection Risks to Smelter

Page No.10
Trips of Grid generating units will affect Smelter electrical
system frequency and may reduce power to the potline.
Electrical faults on the Grid network may affect Smelter
electrical system voltage and power supply to the potline.
Grid has a primary responsibility to maintain the security and
integrity of its own system, not to support the Smelter.
Grid may therefore disconnect if it considers the Smelter power
system is having a significant negative impact on the Grid.
Disconnection from Grid may result in instability of the Smelter
power system resulting in a power black-out.



Page No.11



Smelter Electrical System Instability following Disconnection from Grid
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Risks to Grid of Connection to Smelter

Page No.12
Potline trip causing a sudden very large power flow into the
Grid resulting in a rapid increase in grid frequency and the
trip of Grid generating units.
Trip of a large Smelter generating unit causing a significant
fall in Grid frequency and resultant load shedding.
Electrical faults on the Smelter electrical network that affect
Grid system voltage and stability.




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Risk Mitigation
by Smelter to Protect the Grid (1)
Page No.13
Ensure a potline trip causes a matching rapid reduction in Smelter
generation
Smelter power reduction must occur within ~ <250 ms to avoid rapid
increase in Grid frequency.
GT governor/load control is not fast enough hard wired trip of GT and ST
HV circuit breakers from potline trip system is required.
Pre-selection of which GTs and STs to disconnect is required.
Pre-selection scheme becomes more complex as more generating units
and potlines are included.






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Risk Mitigation by Smelter
to Protect the Grid (2)
Page No.14
Automatic disconnection from the Grid if a potline trip occurs
AND high frequency is detected at the Grid Connection point.
High grid frequency allied with a potline trip indicates the primary
protection method described on the previous slide has failed to operate
correctly.
If a large Smelter generating unit trips, deload the potline
using the high speed tap-changers of the rectiformers until
Grid frequency recovers.
Pre-selection of which potline to deload may be required in a multi
potline Smelter.





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Risk Mitigation
to Protect the Smelter
Page No.15
A Minimum of two Grid inter-connectors each rated to at least
match the output of 1 GT and its associated ST.
Grid Connection Agreement should include
A clear communication protocol between Grid Despatch and Smelter
power plant Operations.
A clear set of operating instructions that specify under what
circumstances and with how much warning the Grid can disconnect the
Smelter.
Smelter must develop and maintain good relationships at all
levels with Grid personnel.



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Summary
Page No.16
There are significant Financial and Operational Benefits to the
Smelter of connecting to the Grid.
There are Benefits to the Grid of a connection to the Smelter,
but the associated Risks can be significant.
Smelter must appreciate the obligations of the Grid to its other
Customers and take mitigation measure to ensure the Risks
posed by Smelter connection to the grid are minimised.
Good working relationships and communication at all levels
between the Smelter and the Grid is essential to ensure that, in
the event of a serious power system disturbance, the security
of the Smelter potline power supply is not jeopardised.



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