OP16: Small fuel flexible Gas Turbines for Decentralized
power generation China Gpower, Shanghai, 2014-04-09
Regine Mowill
Marketing Director
OPRA PROPRIETARY INFORMATION
Outline of today’s presentation
Benefits of Distributed Energy
Cleaner onsite power generation
Market drivers for gas turbine driven onsite power
Introduction to OPRA Turbines
History
OP16 Markets and applications
Key technologies: OP16 gas turbine & OP16 combustion technology
Reference projects
Examples from the field
Summary and conclusions
OPRA PROPRIETARY INFORMATION
Smog can be a thing of the past
A fog so thick and polluted it left thousands dead, London in 1952. The smoke-like pollution
was so toxic it was reported to have choked cows to death in the fields.
Clean Air Acts of 1956 and 1968. Acts banned emissions of black
smoke and decreed residents of urban areas and operators of
factories must convert to smokeless fuels. UK 1952,
People were given time to adapt to the new rules, and fogs Clean Air Act
continued to be smoky after the Act of 1956 was passed. In
1962, for example, 750 Londoners died as a result of a fog, but 1956 & 1968
nothing on the scale of the 1952 Great Smog has ever occurred
again.
This kind of smog has now become a thing of the past, thanks
partly to pollution legislation and also to modern developments,
such as the widespread use of central heating.
Canned air for sale in China as smog returns
Chen Guangbiao, whose
wealth is valued at $740
million according to the
China 2013
Hurun Report, sells his
cans of air for five yuan
each.
OPRA PROPRIETARY INFORMATION
Distributed Energy can improve air quality and increase
availability of power
China is a large country with diverse resources, regions and sizes of cities
Locally available fuels / energy resources (incl Solar, wind, gas, hydro, geo thermal
etc)
Utilization of waste gases
Energy Efficiency (CHP)
Energy conservation
Minimize grid losses
Lower investment costs and quicker to install compared to centralized power
Diverisfy energy mix and increase availability of power
Reach remote locations
Enable own power production and increase security of supply
Incremental changes also help
OPRA PROPRIETARY INFORMATION
Key market drivers for gas turbine driven onsite power
Shale gas and increasing gas abundance
Lower long term gas prices ( world wide)
Greater availability (world wide)
On-site power generation / Decentralized power generation
Energy security / Lack of grid / grid reliability issues: esp. for critical operations incl.
oil & gas production, hospitals, 24/7 factory production, data centers
Energy efficiency: cogeneration / trigeneration
New fuel sources (liquid / gas)
Bio fuels
waste fuels : industrial waste, municipal waste, gas flaring from oil and gas fields
Environmental policies: air pollution, mitigating climate change
Renewables on the grid increasing need for peak shaving
OPRA PROPRIETARY INFORMATION
Mission statement
OPRA aims to become the world’s leading
provider of on-site gas turbine driven energy
solutions in the 0.5 – 10.0 MW power range
OPRA PROPRIETARY INFORMATION
Executive summary
OPRA was established in the Netherlands in 1991
After initial R & D and technology demonstration, the OP16
gas turbine was commercialized in 2005.
The 2 MW range OP16 gas turbine is unique in that it
combines robustness and simplicity with high performance
and fuel flexibility
OPRA has demonstrated market success for oil & gas as well
as industrial and commercial CHP applications
OPRA has sold more than 80 gas turbines over the last
five years
The OP16 has accumulated more than 1,5 million
operating hours worldwide
OPRA is ISO 9001, DNV according to API standards, and
GHOST certified
OPRA PROPRIETARY INFORMATION
OPRA has valuable sales references world wide
TEEKAY
The 1.9 MW OP16 gas turbine engine combines
the best of simplicity and high performance
6.7:1 ratio Dual-fuel & low emissions
Reduction compressor combustors (4)
gear
High-efficiency radial
turbine
Bearings
in cold part
of engine
ELECTRIC EFF. 26%
8.7 kg/s
EXHAUST FLOW
19.2 lb/sec
EXHAUST GAS TEMP. 570ºC / 1063ºF
ROTOR SPEED 26,000 rpm
40,000 hours
TBO
AND 3000 starts
OPRA PROPRIETARY INFORMATION
The OP16 Rotor Module: the robust heart of the engine
Overhung rotor with bearings in the cold
section of turbine
Single stage 6.7:1 compression
Single stage turbine
Virtually no lube oil consumption
Robustness and long life
High resistance to FOD*
High efficiency (~90%)
No blade cooling
* Foreign Object Damage
OPRA PROPRIETARY INFORMATION
Increasing demand to burn alternative fuels
Increased demand from customer to burn alternative fuels
Environmentally friendly
More cost-effective operation
Utilize fuels that are locally available
Dual fuel / bi fuel for operational flexibility
OPRA PROPRIETARY INFORMATION
Fuel flexibility - Broad range of fuels gas turbines can handle
OPRA PROPRIETARY INFORMATION
OP16 combustor systems
Conventional combustor
Diffusion flame
Film cooling
Dual fuel operation
Switch under full load operation
DLN combustor
Dry low emission (<25 ppmv NOx)
Pre-mixed flame
Impingement cooling
Gas 38-50 MJ/kg
Low calorific fuel combustor
Diffusion flame
Impingement cooling
About 5 times larger volume
Specially designed for low calorific fuels
OPRA PROPRIETARY INFORMATION
The low-calorific fuel combustor fits on the engine
without the need to extend the overall package
About 5 times larger combustor volume is required
Can handle liquid and gaseous fuels with LHV
down to 6 MJ/kg (150 btu/scf )
The low-calorific combustor (left) and OP16 with low-calorific combustor
the conventional combustor (right)
OPRA PROPRIETARY INFORMATION
Fully containerized system is compact and low weight
Power output: 1.8 Mwe
4 – 5 MWt
Compact: 20 ft ISO container
Low weight: <20 tons
Clean: Ultra Low NOx
Quiet: 70-85 dB at 1 meter
Reliable: TBO* 40,000 hours
Low maintenance cost
*Time Between Overhaul
The OP16 can be used for a wide range of onsite
power applications
Industrial Commercial
Co-/tri-generation Hotels
Process Data centers
Ceramics, paper Hospitals
OP16 markets
Oil & Gas Waste to power
Offshore Landfill gas
Onshore VOC destruction
Floaters Flare gas utilization
OPRA PROPRIETARY INFORMATION
OP16 is highly suitable for CHP applications with only 3%
losses
100% Fuel
3%
26% Losses
Electrical 71%
energy High grade thermal
energy
The OP16 has lower losses than piston engines
OP16 Reciprocating
100% Fuel Engine 100% Fuel
3% 9% 27%
26% Losses 27%
Losses 37% LOW grade
Electrical MEDIUM grade
71% thermal energy
energy Electrical energy thermal energy
HIGH grade
thermal energy
OPRA is uniquely competitive where a high degree of thermal
energy is required in addition to electrical power
Competitive landscape, CHP market
High Industrial
Thermal Energy Requirement
Light
Industrial
Commercial
Micro
GT
Low Residential
0 1 2 3 4 5 6
Electric Power (MW)
Small-scale onsite gas turbine power generation
Independent power generation
Peak shaving
The exhaust heat can be utilized leading to high
overall fuel efficiency (CHP)
Can utilize fuels that are locally available
OPRA PROPRIETARY INFORMATION
Page 20
Example of onsite power and heat generation for an
industrial process
Isotonic drink manufacturer in Indonesia
24/7 production line
Issues with the grid stability
2 OP16-3A units installed connected to 1 HRSG
1.5 MWe each
6 tons of steam per hour each
Steam required for sterilizing the water bottles
Dual fuel where liquid fuel is used as back-up
to ensure continuous operation
OPRA PROPRIETARY INFORMATION
Example from operation on associated gas
Flare gas is a challenging fuel
High content of sulphur
Heavy hydrocarbons
Variation of fuel composition
Remote oil field in Russia
The OP16 fleet has operated more than 500,000 hours on flare gas
Sulphur content up to 4%
2 units have operated more than 50,000 hours each without overhaul
OPRA PROPRIETARY INFORMATION
Example for flexible operation on syngas
Turbine Model: OP16-3A / upgrade to 3C
Application: Electricity, Drying
Location: Netherlands.
A gas turbine was desired that could operate on both
syngas and natural gas.
The special low calorific combustor and dual fuel system of 1 OP16 for gypsum
the OP16-3C gas turbine enables 24/7 continuous operation plasterboard manufacturer
on any ratio of syngas / natural gas.
In other words, the OP16-3C gas turbine can operate on
100% syngas, 100% natural gas or any combination of
these gases, without losing performance.
OPRA PROPRIETARY INFORMATION
Operation on syngas derived from solid municipal waste
Power production via gasification of solid waste has gained
importance.
Traditionally, syngas is utilized via steam/organic rankine cycles to
produce power with 13-20% efficiency. The waste to power
industry is challenged to increase the efficiency and utilize syngas
on combustion turbines/engines without expensive fuel cleaning.
The syngas is produced from the municipal un-sorted solid
waste (ultra-low heating value of 150BTU/scf, containing
impurities and condensables.) The OP16 gas turbine can operate
on this fuel to produce 1.8MWe with 25% electrical efficiency. In
addition, the gas turbine exhaust when coupled to an ORC cycle,
obtainins a combined cycle efficiency of 37%.
Plant operates 24/7 and delivers all the power output to the
national grid.
Possibility of dual- and bi-fuel operation. The former refers to
switching between gas and liquid fuels and the latter refers to
simultaneous operation on gas and liquid fuels. Since the
availability of the alternative fuels changes over time these types
of operation modes are becoming more important.
6 OPRA units providing power to the Winter Olympics
CHP at a Cigarette Factory in Germany
Heat and Power for a Starch factory in Germany
2 OP16’s providing CHP solutions for energy drink plant
Direct heat and power at a ceramics factory
1 OPRA unit at an Offset Plate factory
NG BASIC DESIGN
900 oC
Liqu
gen NG Sol
900 oC
vents
Gas turbine
560 oC
blast off 40-80 oC 390 oC Com 25 barg
bus
tor
600 oC
gen
steam 60 barg
160 oC
180 oC condensate
SCR
ECO
stack
ECO
damper
hot water
90 oC 135 oC
1 OPRA unit at an optics and thermal imaging plant
2 OPRA units at an oil field above the polar circle
3 OPRA units on an FPSO in Brazil
3 OPRA units for an oil field in the North Sea
7 OPRA units at natural gas field
1 OPRA unit on an offshore gas field
Summary: More focus on flexible power generation
Smaller gas turbines are suitable for decentralized power production
Increasing demand for decentralized/onsite power generation using alternative /
waste fuels
Operational flexibility: Dual fuel, bi-fuel, 1 min start-up
”Off-grid” remote locations
Energy security
Cost savings and environmental benefits
OPRA has demonstrated product reliability during operation on contaminated
fuels such as sour well-head gas
OPRA has developed a combustor that can handle fuels with
heating values : 6-25 MJ/Nm3 (150-640 btu/scf )
OPRA PROPRIETARY INFORMATION
Thank you for your attention!
For further information: Regine Mowill, Marketing Director: [email protected]
www.opraturbines.com
OPRA PROPRIETARY INFORMATION
