Steam Turbines With Biomass Fuel

Steam Turbines in CHP
Applications of Steam Turbines
March, 2010
Girish Rajamani | Siemens Energy Inc.
Typical Steam Turbine Plant

component efficiencies
z Boiler
94.5%
z Piping
99.7%
z Condensing unit
58%
z Turbine
87%
z Gearbox
98%
z Generator
98.8%
Improved by co-generation!
March, 2010
Efficiency
z Conventional electricity only plant 49%

z CHP 75%
z Source: US EPA 2002
z CAPEX ($/kW): $300 - $1000 (size and app dependent) only STG
March, 2010
Fuel flexibility
z Agricultural biomass (beef cattle manure, cotton gin trash,

corn stover, wheat straw, beef meat processing waste, broiler
manure, poultry processing waste, dairy cattle manure, rice
hulls, hog manure, sugarcane bagasse, peanut shells)
z Forest biomass (wood energy crops, pulp and paper waste,
logging residues, lumber mill residues, forest thinning waste)
z Urban biomass (municipal solid waste, construction debris)
z Conventional fuels: coal, natural gas, etc.
March, 2010
Steam turbines in CHP

Recommended Application*
z Baseload and premium power for institutional

buildings/campuses, industrial waste fuels, wood processing,
paper and pulp, other small-scale biomass
z Advantages:
z Large selection of fuels
z Can produce high-quality steam
z Disadvantage:
z Slow start-up time
*Sources: NREL. Gas-Fired Distributed Energy Resource Technology Characterizations. Office of Energy Efficiency and Renewable
Energy (2003), Table 1, page 1-5; U.S. Environmental Protection Agency. Catalogue of CHP Technologies. Combined Heat and
Power Partnership (2002).
March, 2010
Heat Consumers
z Steam for an industrial process

z Space heating
z Water heating
z Space cooling (absorption/adsorption chillers)
z Dehumidification (using desiccant)
March, 2010
Steam turbines in CHP

Backpressure or Condensing
z Backpressure:
z Constant steam demand at baseload operation
z Lower Capital expenditure
z Condensing:
z Higher electrical output
z Higher overall efficiency
z Condensing plant required
z Extraction Condensing
z District Heating Condensing
March, 2010
Sankey diagram
March, 2010
March, 2010
10
Typical CHP Applications

Industry based
z Chemicals:
z 30, 16, 6 bar steam lines (backpressure)
z Sugar:
z Steam line at 2.5 bar (backpressure or extraction)
z Paper:
z Steam lines at 20 bar and 3 bar
z Pulp:
z Steam lines at 12 and 4 bar
March, 2010
11
Biomass Energy Production

Key Factors
z Steam turbines are well suited to medium and large scale industrial applications
where inexpensive fuel (like coal, biomass, wastes, byproduct fuels...)
z Electricity key energy product from biomass,
z Steam turbine biomass plant products
z Electricity
z Condensing turbines (exhaust steam cooled by water from river, from
closed circuit, or by air)
z Combined heat + electricity
z Extraction condensing turbines (extraction steam used in process)
z Backpressure turbines (exhaust steam used for district heating, or in
process)
z Because of relatively high Rankine cycle cost:
z high annual capacity required - high reliability, availability (proven modular
concept, packaging)
z high efficiency of energy conversion required (MRB, customized steam
path)
z low manpower cost (automation)
March, 2010
12
Boost factors
z Efficiency
z High inlet steam temperature, reheating of steam
z Low exhaust pressure
z High turbine speed
z Higher inlet pressure does not bring too much !!!
z Reliability
z Proven concept
z Proven components
z Quality control system including sub-suppliers
z Quantity of produced units
z Automation
z Full remote control
z Suitable supervisory system
March, 2010
13
Pros and Cons
z Proven steam turbine technology
z Higher investment cost
z Low maintenance cost
z Decreasing efficiency with

decreasing size of units
z High reliability (above 98 %)

z Efficiency lower compare to large
fossil units
z High availability (above 97 %)
z Unstable legal conditions in some
countries
z Life time exceeding 200 000
operation hours
March, 2010
14
Singlestage or Multistage Turbines
Low investment cost

Short-time return of investment
MULTISTAGE TURBINES
Suitable for higher enthalpy drop
and higher power output
Good efficiency in wide range of
load (flat characteristic)
Higher investment cost
Medium-time return of
investment
Higher output = higher profit
March, 2010
100
80
internal efficiency (%)
SINGLE-STAGE TURBINES
Suitable for lower enthalpy drop
and lower power output
Lower efficiency in full range of
load
60
40
20
0
0
0,2
0,4
0,6
0,8
flow rate (m actual/m max)
15
16
Economic Potential
z Sensitive to:
z Fuel costs
z Electricity price
z CAPEX
z Subsidies
March, 2010
Example of Biomass Plant

Monopoli, Italy
March, 2010
17
THE FUNCTION PRINCIPLE OF

RECOVERY ISLAND
FIBER LINE
WOOD
DEBARKING
CHIPPING
COOKING
WASHING
DRYING
BLEACHING
BLACK LIQUER
FIBER LINE
INTERNAL
BLACK LIQUER
CIRCULATION
LIME KILN
PULP
BALING
REMISSED WOOD MATERIAL 10 %

COOKING CHEMICALS
5%
WATER 85 %
EVAPORATION PLANT
CAUSTIZATION
WATER
SOAP
Electricity
TALL OIL PLANT

( 50 kg / ADt )
Process steam
BLACK LIQUEOR
WATER CONTENT 15 %
RECOVERY BOILER
FILTRATION
CHIMNEY GAS + FLY SALT
Steam
Turbo Generator
DREG
WOOD ASH
( 5 kg / ADt )
DISSOLVING TANK
Na2so4
Salt
Na2so4
March, 2010
Electrostatic
precipitators
18
Example of CHP Pulp and Paper

mill Wisapower, Finland
Requirements from pulp & paper process
Live Steam: 95 bar/498 C

max 240 kg/s
Process steam lines:
Soot blower and air heater for
recovery boiler at 30 bar
Process steam and preheater
at 12.5 bar
Process steam at 7.0 bar
Process steam and deaerator
at 4 bar
March, 2010
19
Main Components Condensing

Steam turbine
March, 2010
20
10
Package condensing turbine

integral oil system in baseframe and condenser
foundation
condenser
March, 2010
21

condenser
foundation
condenser
March, 2010
22
11

condenser
skid
condensate
pumps
March, 2010
foundation
condenser
23

skid steam
ejector
condenser
skid
condensate
pumps
foundation
condenser
March, 2010
24
12

foundation
turbo set
skid steam
ejector
condenser
skid
condensate
pumps
foundation
condenser
March, 2010
25

foundation
turbo set
skid steam
ejector
condenser
skid
condensate
pumps
foundation
condenser
March, 2010
26
13

base frame
integral oil
system
foundation
turbo set
skid steam
ejector
condenser
skid
condensate
pumps
foundation
condenser
March, 2010
27

steam
turbine
base frame
integral oil
system
foundation
turbo set
skid steam
ejector
condenser
skid
condensate
pumps
foundation
condenser
March, 2010
28
14

steam
turbine
gear box
base frame
integral oil
system
foundation
turbo set
skid steam
ejector
condenser
skid
condensate
pumps
foundation
condenser
March, 2010
29

steam
turbine
equipment
oil system
gear box
base frame
integral oil
system
foundation
turbo set
skid steam
ejector
condenser
skid
condensate
pumps
foundation
condenser
March, 2010
30
15

steam
turbine
generator
equipment
oil system
gear box
base frame
integral oil
system
foundation
turbo set
skid steam
ejector
condenser
skid
condensate
pumps
foundation
condenser
March, 2010
31

steam
turbine
generator
equipment
oil system
gear box
base frame
integral oil
system
foundation
turbo set
skid steam
ejector
condenser
skid
condensate
pumps
foundation
condenser
March, 2010
32
16
Package turbine
Backpressure Turbine
March, 2010
Package turbine
33
SST - 300
foundation
March, 2010
34
17
Package turbine
SST - 300
spring
elements
foundation
March, 2010
Package turbine
35
SST - 300
base frame
spring
elements
March, 2010
foundation
36
18
Package turbine
SST - 300
oil
equipment
base frame
spring
elements
foundation
March, 2010
Package turbine
37
SST - 300
steam
turbine
oil
equipment
base frame
spring
elements
March, 2010
foundation
38
19
Package turbine
SST - 300
steam
turbine
gear box
oil
equipment
base frame
spring
elements
foundation
March, 2010
Package turbine
steam
turbine
39
SST - 300
gear box
generator
oil
equipment
base frame
spring
elements
March, 2010
foundation
40
20
Package turbine
SST - 300
steam
turbine
gear box
generator
gland steam
condenser
oil
equipment
base frame
spring
elements
foundation
March, 2010
Package turbine
steam
turbine
41
SST - 300
gear box
generator
pipe work
gland steam
condenser
oil
equipment
base frame
spring
elements
March, 2010
foundation
42
21
Package turbine
SST - 300
steam
turbine
gear box
generator
pipe work
gland steam
condenser
oil
equipment
base frame
spring
elements
March, 2010
foundation
43
Thank You!
March, 2010
44
22

Steam Turbines With Biomass Fuel

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Steam Turbines With Biomass Fuel

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Steam Turbines in CHP

Applications of Steam Turbines

Girish Rajamani | Siemens Energy Inc.

Typical Steam Turbine Plant

Girish Rajamani | Siemens Energy Inc.

z Conventional electricity only plant 49%

Girish Rajamani | Siemens Energy Inc.

z Agricultural biomass (beef cattle manure, cotton gin trash,

Girish Rajamani | Siemens Energy Inc.

Steam turbines in CHP

z Baseload and premium power for institutional

Girish Rajamani | Siemens Energy Inc.

z Steam for an industrial process

Girish Rajamani | Siemens Energy Inc.

Steam turbines in CHP

Girish Rajamani | Siemens Energy Inc.

Girish Rajamani | Siemens Energy Inc.

Girish Rajamani | Siemens Energy Inc.

Typical CHP Applications

Girish Rajamani | Siemens Energy Inc.

Biomass Energy Production

Girish Rajamani | Siemens Energy Inc.

Pros and Cons

z Proven steam turbine technology

z Higher investment cost

z Low maintenance cost

z Decreasing efficiency with

z High reliability (above 98 %)

Girish Rajamani | Siemens Energy Inc.

Singlestage or Multistage Turbines

Low investment cost

internal efficiency (%)

flow rate (m actual/m max)

Girish Rajamani | Siemens Energy Inc.

Girish Rajamani | Siemens Energy Inc.

Example of Biomass Plant

Girish Rajamani | Siemens Energy Inc.

THE FUNCTION PRINCIPLE OF

REMISSED WOOD MATERIAL 10 %

TALL OIL PLANT

CHIMNEY GAS + FLY SALT

Girish Rajamani | Siemens Energy Inc.

Example of CHP Pulp and Paper

Live Steam: 95 bar/498 C

Girish Rajamani | Siemens Energy Inc.

Main Components Condensing

Girish Rajamani | Siemens Energy Inc.

Package condensing turbine

Girish Rajamani | Siemens Energy Inc.

Package condensing turbine

Girish Rajamani | Siemens Energy Inc.

Package condensing turbine

Package condensing turbine

Girish Rajamani | Siemens Energy Inc.

Package condensing turbine

Girish Rajamani | Siemens Energy Inc.

Package condensing turbine

Girish Rajamani | Siemens Energy Inc.

Package condensing turbine

Girish Rajamani | Siemens Energy Inc.

Package condensing turbine

Girish Rajamani | Siemens Energy Inc.

Package condensing turbine