Steam Power Systems Product Catalog - GE Power

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STEAM POWER SYSTEMS PRODUCT CATALOG

Delivering highly efficient and cleaner power generation The availability and affordability of coal makes it a critical fuel in a world that is striving to meet the energy needs of tomorrow. Coal and oil fired power plants are well positioned to deliver additional capacity to growing regions of the world as long as we use our best technology to lessen the related environmental impact. If anyone is up for the challenge, we are. At GE’s Steam Power Systems we use our unrivalled expertise every day to help customers get tailored systems that stand the test of time, while continually driving improved efficiency and performance benchmarks. We offer customers exceptional flexibility. From a single component to a full power plant — our broad range of products covers a large scope of applications and a wide range of fuels including coal, lignite, anthracite and petcoke. We put over 100 years of steam power expertise to work, generating power that is reliable, efficient, easy to integrate and operate. Our customers can count on us to help them deliver as much energy as possible, to the greatest number of people, in the most efficient way. Our relationship goes beyond the technology or our team of experts; it’s a partnership based on a shared commitment to make sustainable power possible for people around the world, and right around the corner.

© 2015, General Electric Company and/or its affiliates. GE Proprietary Information. All Rights Reserved. No part of this document may be reproduced, transmitted, stored in a retrieval system nor translated into any human or computer language, in any form or by any means, electronic, mechanical, magnetic, optical, manual, or otherwise, without the prior written permission of the General Electric Company or its concerned affiliate.

CONTENTS Industry Overview. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 Key Differentiators. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

Technology Leadership. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

The Plant Integrator Approach. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

Standardized/Pre-Engineered Solutions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

Flexible Offerings. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 Power Plant Components. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20

Information contained in this document is indicative only. No representation or warranty is given or should be relied on that it is complete or correct or will apply to any particular project. This will depend on the technical and commercial circumstances. It is provided without liability and is subject to change without notice.

Boilers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20

Steam Turbines. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34

Generators. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46

Air Quality Control Systems. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58

CO2 Capture Solutions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78

Powering the World

STEAM POWER SYSTEMS PRODUCT CATALOG I Global Overview

COAL POWER Industry Overview Capacity Additions

An Essential Role in the Global Power Mix Coal power is the most mature and the most common power generation technology in the world. With 2,550 GW of installed capacity providing 41 percent of the global electricity supply, coal serves as the reliable, cost-effective and durable baseload power source to utility scale networks.

Installed Base (GW) Electricity Generated (TWh)

41%

7%

23%

30%

Total Worldwide

2,550

400

1,440

1,855

6,245 GW

42%

11%

21%

26%

10,000

2,550

5,050

6,050

Coal

Nuclear

Gas

23,650 TWh

Other * Source Alstom, Status end of 2014

Coal Power Market for the Next 10 Years

25%

of all future power capacity additions will be coalor oil-fired steam power plants

95%

of the global demand will come from fast-growing economies in India, China, Asia, the Middle East and Africa

Market Drivers • Affordable energy • Available and reliable supply • Fuel flexibility • Emissions regulations

Highly efficient power generation from coal and oil 2

Russia 173

Europe (ind. Turkey)

5%

North America Latin America

15% 40%

Coal resources are broadly distributed around the globe and are often locally available. At current consumption rates coal reserves should last for centuries. The use of coal for power generation can also offer energy security by reducing dependence on more restricted fuel supplies.

Coal Reserves

Europe 48 NAM 270

Oceania

China 126

Russia and CIS

RoA 12

Middle East and Africa Asia (exd. China and India)

35%

India China

The demand for new coal power plants in the next 10 years will come predominantly from the prospering emerging regions of the world.

India 62 Bituminous Sub-bituminous Lignite NOTE: Reserve figures in trillions tonnes

LAM 18 Africa 55 Oceania 85

Widely dispersed and abundant coal resources provide a highly secure supply for coal power generation.

Reducing Emissions to Mitigate Global Environmental Concerns GE’s Steam Power Systems is an industry leader in cleaner power generation from coal and oil. Stringent regulations to limit emissions have been deployed, revised and reinforced for decades. The U.S. and parts of Europe have strict emission regulations in place, while China has implemented, and India is developing, environmental control strategies to cope with booming development of their coal-based industries. With more than 80 years of experience providing Air Quality Control Systems (AQCS), GE has the expertise, technology and extended product portfolio to reduce gaseous emissions from coal (or oil) combustion and meet today’s most stringent emission requirements. To reduce CO2 emissions, GE is contributing on two major fronts. First, GE has designed, installed and commissioned many of the highest efficiency coal and oil plants in the world, which not only optimize the operating costs (reduced fuel consumption per MW produced) but also reduce the CO2 emitted per MW produced. Second, GE has developed and industrially tested CO2 Capture solutions which are fully ready for large-scale deployment.

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STEAM POWER SYSTEMS PRODUCT CATALOG I Technology Leadership

Key Differentiators

TECHNOLOGY LEADERSHIP GE has the expertise and resources to meet specific customer needs with a portfolio of products covering commonly used fuels for power generation. With fossil fuel power plants likely to continue as the main providers of global power generation, the efficient and reliable conversion of fuel into electricity will remain critically important.

At GE, we are always working to lower fuel consumption and emissions by increasing power plant efficiency. Our advanced power plants use ultra-supercritical technology. Other improvements in power plant efficiency include: • Double-reheat technology • Cold end advancement • Flue gas heat recovery systems To optimize the thermodynamic cycle, we have enhanced the design of each component to improve overall efficiency of the plant. Future developments from GE include advanced USC (>700°C) technology and pre-drying technology for high-moisture lignite.

GE’s Advanced USC Developments Change in overall plant net efficiency (relative)

Efficiency Increase

+11.3%

Today

Our products deliver high operational flexibility to accommodate the growing requirements of power generation from renewables.

To lower the impact of power generation to the environment, our AQCS products enable power plants to conform to today’s strict environmental standards for air emission levels.

Experience derived from a huge installed fleet helps us to continually improve our products and increase their operational reliability. Our products and designs deliver high availability and easy maintenance for:

In addition, we have developed a portfolio of technologies for CO2 capture that includes pre- and post-combustion processes suitable for new builds as well as the retrofit of existing plants.

• Reduced life-cycle costs in the power station

+8.7%

Delivering High Efficiency Coal Power to Our Customers Globally

+6.7% +6.0% +4.0%

Baseline 170 bar 540°C 540°C

240 bar 565°C 565°C

Sub-critical

Supercritical

260 bar 600°C 600°C

275 bar 600°C 620°C

Ultra-Supercritical

World’s

Our cleaner combustion technologies:

FIRST

• Cover a large spectrum of fuels, from bituminous to lignite coals to oil and gas, heavy residues, biomass, and others

300 bar 600°C 620/620°C

350 bar 700°C 720°C

Double reheat

700+°C

• 912 MW USC, Germany: greater than 46 percent net efficiency •9 11 MW USC with CHP, Germany: flexible energy production (electricity + district heating + railway power) resulting in fuel utilization up to 70 percent efficiency

USC

50 YEARS OF OPERATION At Eddystone Plant Philadelphia, PA USA

• Have experience with the most difficult fuels (e.g. Oil Shale, VRO, high-moisture, etc.)

202,000

MWe or 313 boilers installed

using USC technology

4

Emissions Reduction

• Shorter planned outages

Proven Fuel Expertise

• Are designed to remain insensitive to variations in fuel composition

Operational Flexibility and Reliability

• 1,080 MW USC, Malaysia: the first USC 1,000 MW-class plants in Southeast Asia. Efficiency over 43 percent (at local cooling temperatures)

36% of our steam turbines

in the last 10 years

are USC

912 MW USC, Germany

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STEAM POWER SYSTEMS PRODUCT CATALOG I Plant Integrator Approach

Key Differentiators

PLANT INTEGRATOR* APPROACH Our Plant Integrator approach is based on our ability to combine GE’s components and auxiliary equipment into fully enhanced and integrated systems. The return of experience from manufacturing, construction, commissioning and operation results in a systematic continuous improvement of GE’s components and standardized/pre-engineered solutions. This leads to improved performance, as well as cost and delivery time reduction of our offering to our key markets and helps our customers achieve and exceed their objectives.

Unique Integration Capabilities • Broad in-house product portfolio – all major plant components jointly developed to work as one unit • Demonstrated high efficiency plants meeting local requirements • Flexible offerings – from single OEM components up to full turnkey power plants • Global flue gas chain management from boiler to stack – controlled emission footprint

Extensive Execution Experience • 100 years of experience – in building steam power plants, making GE a global leader >100 GW installed integrated power >200 integrated projects executed globally • Attuned to the local codes/standards

Continuous Improvement – Via Focus and Extensive Return of Experience Key Market Segments (local customer requirements)

Integrated Execution (overall performance responsibility)

Integration (added value)

Standardized/ Pre-Engineered Solutions (focused product development)

Sustainable customer value and excellence in project execution

Flexible Offerings (improved components and integrated solutions)

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STEAM POWER SYSTEMS PRODUCT CATALOG I Standardized/Pre-Engineered Solutions

Key Differentiators

STANDARDIZED/PRE-ENGINEERED SOLUTIONS GE has a systematic approach to developing standardized and pre-engineered components and power plant designs, while keeping sufficient flexibility to meet our customers’ needs. This approach enables us to improve the manufacturing, assembly, construction, commissioning, operation and maintenance of the power plant, which results in improved reliability and availability of our offerings.

Integrated Steam Platforms (ISP)

Integrated Steam Platform • Designed for local requirements • Can consist of pre-engineered solutions of the following offerings

Turnkey

For each major segment of the market, GE has created a pre-engineered plant approach which delivers solutions matching the specific needs coupled with competitive cycle times during offering and execution phases. These Integrated Steam Platforms (ISP) make extensive use of standardization and design-to-cost, while still maintaining sufficient flexibility to meet individual project requirements. The benefits of this approach to our clients are multifold: • Built-in flexibility: to address most of the site and project specific conditions (fuels, codes and standards, cooling media, emission limits) • Improved quality: Re-use of proven solutions and design principles combined with continuous improvement, systematic return-of-experience, and lessons learned from tendering, engineering and execution • Improved health and safety: Safer to construct and safer to operate • Reduced delivery times: Quicker response to customer requests during the tender phase, and reduced construction and commissioning time • Operation and maintenance: Faster to maintain, leading to improved availability • Emissions Regulations: Each ISP is capable of meeting today’s most stringent local, regional or global emissions requirements

Power Block

Turbine Island

i.PP

(Integrated Power Package)

Stand-Alone

Components

Global Product Standardization Initiatives Boiler Island • Standardized steel structure designs, components and piping sizes • Standardized heating surface components across power output range

Turbine Island • Globalized design by freezing positions and dimensions with specific variants • Increased design commonality

Steam Turbines • Global modular approach of the steam turbine frames with standardized interfaces • Flexibility in the steam path design

ISP

Europe 900

Asia 660

Asia 1100

India 660

India 800

Fuel Type

Domestic/Imported Bituminous and Sub-Bituminous Coal





Gross Power Output (MW)

900

660

1100

660

800

Water/Steam Cycle1

Ultrasupercritical

Ultrasupercritical

Ultrasupercritical

Ultrasupercritical

Ultrasupercritical

Live Steam Pressure (bar)

≤ 294

≤ 294

≤ 294

≤ 294

≤ 294

Live Steam Temperature (°C)2

≤ 605

≤ 605

≤ 605

≤ 605

≤ 605

Hot Reheat Temperature (°C)3

≤ 623

≤ 623

≤ 623

≤ 623

≤ 623

Net Plant Efficiency (%)3

≤ 46.3

≤ 43.5

≤ 43.5

≤ 43.0

≤ 43.0

Boiler Type (typical)

Tower

Two-Pass

Two-Pass

Two-Pass

Two-Pass

Cooling Technology

direct / cooling tower





Vacuum Pressure (mbar)

20 - 30

60 - 80

60 - 80

70 - 100

70 - 100

Number of preheaters

9

8

8

8

8

Feedwater pump drive (typical)

motor

motor / turbine

turbine

turbine

turbine

2

1 State-of-the-art steam technology today; 2 Steam parameters at boiler outlet, typical values; 3 Efficiency values based on LHV basis and typical regional vacuum pressure. Values in table indicate pre-engineered solutions to meet local requirements, adaptions foreseen on project basis

8

Generator • Standardized and reliable product families related to cooling technologies • Common technologies, manufacturing processes, tools and materials

Air Quality Control Systems (AQCS) • Standardized components, processes and tools • Parametric designs for flexibility to meet environmental requirements

GE’s Integrated Steam Platforms (ISP) for today’s competitive environment … and a sustainable future 9

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STEAM POWER SYSTEMS PRODUCT CATALOG I Flexible Offerings

FLEXIBLE OFFERINGS Freedom to Fulfill Individual Customer Requirements

GE applies the concept of flexible offerings across our portfolio, allowing our customers to select from a portfolio of products and systems that meet their specific requirements, while maintaining the key benefits of standardization and pre-engineering processes. In addition, GE’s Plant Integrator* approach can deliver added value across the full range of offerings.

Integrated Offerings - Flexible Scope From the basic engineering of our core components in our Integrated Power Package (i.PP) to the full turnkey plant, GE can address all customer needs.

COMPONENTS

INTEGRATED POWER PACKAGE

TURBINE ISLAND

POWER BLOCK

FULL TURNKEY PLANTS

PLANT INTEGRATOR*

Integrated Offerings - Flexible Output From individual components to the full turnkey plant, GE provides integrated offerings for power output from 100 MW to 1,200 MW across a wide range of fuels for steam power generation. Boiler Types

Power Output Range (MW)

Pulverized Coal (PC) Circulating Fluidized Bed (CFB) Heavy Fuel Oil (HFO)

10

300–1,200 MW 100–660 MW 400–800 MW

The OEM with the full in-house product capability from conceptualization to final design 11

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Flexible Offerings

INTEGRATED POWER PACKAGE (i.PP) Whether you are a power plant owner or an EPC contractor, sourcing the main power generation equipment for your new build is the most important decision you will make. GE’s Integrated Power Package (i.PP) supplies our customers with our world-class boilers, and turbines, all of which have been conceptualized to operate as one unit, allowing us to provide excellent performance and power output. With our flexible offerings concept, customers can add additional GE equipment, providing them with enhanced quality and performance.

Basic i.PP Offering Boiler (core parts): (all pressure parts, the firing system, mills) Steam Turbine, Generator, AQCS (optional)

+

Saudi Arabia 5 x 620 MW Integrated Power Package (i.PP) Product 620 MW supercritical heavy fuel oil (HFO) and gas-fired (dual fuel) power plant Scope Integrated Power Package (i.PP) including AQCS — Boiler, steam turbine, generator — Electrostatic precipitators and flue gas desulfurization system — Basic engineering of the power block — Advisory and site services — Commissioning Benefits • Overall performance and emission guarantees (power output, heat rate, emissions) • Steam extracton for desalination

Saudi Arabia’s first supercritical power plant to run on HFO

Integration

(basic engineering and functional specifications for power block)

+

Overall Performance Guarantee (power output, heat rate, emissions)

Integrated Power Packages – ideal solution for competitive EPC contractors Contributes to 90 percent of the plant performance, using just the core OEM components 12

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Flexible Offerings

TURBINE ISLAND The turbine island is one of the most critical parts of the power plant, and of prime importance is the integration of key parameters and interfaces among the auxiliary components and steam water cycle. With proven equipment and systems, the plant is able to consistently deliver the desired output throughout the product’s life cycle. GE’s flexible offering allows for excellent layout of the turbine hall, providing significant savings in construction and labor costs.

Scope of Offering Steam Turbine, Generator, Heat Exchangers

+

Balance of Turbine Island

India 7 x 660 MW SC Turbine Islands Product 660 MW Turbine Island Scope • Steam turbine and auxiliary equipment • Generator and auxiliary equipment • Condensate system • Feed water system • Control, protection and instrumentation • Construction and commissioning Benefits Integrated and enhanced systems meeting Indian requirements

(feedwater pumps or turbines, piping, valves, control systems)

+

Integration, Construction and Commissioning, O&M

+

Overall Performance Guarantee (power output, heat rate)

Providing critical OEM steam turbine, generator and enhanced water steam cycle interfaces 14

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Flexible Offerings

POWER BLOCK One of the most complicated and critical challenges of integration in a plant is the power block. The power block consists of the power plant’s critical equipment including boiler, steam turbine, generator, air quality control systems and associated auxiliary systems. Integration is key to plant performance over its lifetime and provides a quicker and lower risk return on investment. However, successful integration requires a global footprint and world-class EPC capabilities. GE’s competitive power block offering is based on our extensive global experience integrating key components with varied scope of supply and our proven solutions.

Scope of Offering Full Boiler Island, Full Turbine Island AQCS Equipment (optional)

+

Poland 2 x 930 MW USC Power Block Product 930 MW coal-fired, ultra-supercritical power plant Scope • Boiler island including FGD and ESP • Turbine island including turbine hall equipment • Balance of Power Block (BoPB) • Construction and commissioning support Benefits • High efficiency (approximately 45.5 percent) • Meets stringent European emissions regulation: sulfur dioxide (SOx), nitrogen oxides (NOx) and particulate matter

Poland’s largest coal-fired power plant

Balance of Power Block

(service systems: cooling water, compressed air, HVAC, fire fighting, electrical building and transformers)

+


+


Design and integration of all critical equipment and systems at the power plant level 16

Germany 1 x 912 MW USC Power Block Product 912 MW coal-fired, ultra-supercritical power plant Scope Full turnkey power block Benefits • Overall net plant efficiency of more than 46 percent (greater than 58 percent with district heating) • Meets stringent European emissions regulation: — CO2 < 740 g/kWh — CO and NOx < 100 mg/Nm3

One of the highest efficiency steam power plants in the world

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Flexible Offerings

FULL TURNKEY PLANT Today’s plant owners and power operators know that it takes more than selecting a set of high efficiency components to achieve advanced economic and technical goals. In order to maximize long-term returns on investment, it takes a company like GE, with extensive experience and world-class EPC capabilities – such as project management, logistics, and construction management. GE’s range of capabilities in design and integration of steam power plant solutions gives us a unique perspective that allows us to analyze the entire plant over its full life cycle as an integrated system.

Scope of Offering Full Power Block

+

Malaysia 2 x 1,080 MW USC Coal Plant Product 1,080 MW coal-fired, ultra-supercritical power plant Scope Turnkey EPC contract with consortium partner Benefits • Additional capacity to meet strong demand in fast-growing economy • Continued relationship between customer and GE following successful supply of three previous units

Malaysia’s first ultra-supercritical coal-fired units

Balance of Plant

(water intake, polishing unit, stack, cooling tower, fuel systems, coal/ash handling, switchyard)

+


+


Providing the full GE advantage with enhanced economics, shorter lead times, extended performance and reduced O&M costs over the life cycle of the plant 18

Poland 1 x 858 MW USC Lignite Plant Product 858 MW coal-fired, ultra-supercritical power plant Scope Full turnkey steam power plant Benefits • Higher efficiency (close to 42 percent) • Lower emissions of sulfur dioxide (SOx) and nitrogen oxides (NOx)

Poland’s largest and most efficient lignite-fired plant

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STEAM POWER SYSTEMS PRODUCT CATALOG I Boilers

BOILERS Portfolio and Overview GE’s boiler technology has a heritage of more than 100 years, and our installed base of utility boilers makes up about 30 percent of all boilers installed or under construction worldwide. As an industry leading supplier of efficient, flexible and reliable boilers for power generation, GE offers both two-pass and tower designs that can burn a wide range of hard coals, lignite, and oil/gas, and offers circulating fluidized bed boilers for both conventional and difficult-to-burn fuels.

Two-Pass Lignite B Lignite A Subbit. C Subbit. B Subbit. A

Full Boiler Product Portfolio

Bit. High Vol. C Tower Boiler

CFB Boiler

COAL

Two-Pass Boiler

Tower

Bit. High Vol. B Bit. High Vol. A Bit. Med. Vol. Bit. Low Vol. Semi-Anthracite Anthracite Meta-Anthracite

OIL

Heavy Fuel Oil Vacuum Residual Oil

• Most commonly used technology • Specialized for oil and gas firing • Faster construction with simultaneous construction on both passes • Simple roof penetration

• Up to 1,350 MWe • Up to 605°C/623°C/300 bar*

• Especially designed to burn high moisture lignite • Simple and reliable design • Faster startup • Smaller footprint

• Up to 660 MWe for lignite, higher for hard coal • Up to 605°C/623°C/285 bar* • Suited to low-grade fuels • Can simultaneously burn different fuels • No need for SCR and WFGD • Higher reliability with modular design

* SHO temperature/RH temperature/SHO pressure

Flexible Scope of Supply

Natural Gas GAS

• Bituminous, sub-bituminous • Lignite A and B

• Anthracite through lignite A and B • Opportunity fuels: petroleum coke, biomass, waste coal, oil shale, etc.

Coke Oven Gas Blast Furnace Gas

OPPTY. FUEL

TYPICAL FUELS

• Up to 1,350 MWe • Up to 605°C/623°C/300 bar*

FEATURES/ ADVANTAGES

• Bituminous, sub-bituminous • Lignite A • Oil and gas

CAPACITY

Crude Oil

Biomass Oil Shale Petcoke

CFB

Unparalleled Fuel Expertise Our knowledge of fuels and combustion, a core GE competence, is derived from our extensive laboratory and field experience. With these technologies, our customers can burn a wide spectrum of fuels, from high-rank coals to low-rank coal wastes, and from oil and natural gas to opportunity fuels such as petroleum coke, biomass and oil shale. With our leading technologies and a globally proven product portfolio, GE provides excellent fuel firing flexibility that can lower the cost of electricity for our customers.

Waste Coal

Co-firing in limited amounts Tower boiler is capable of oil and gas firing if requested by the customer.

Efficient, flexible, reliable steam generation

GE has a full range of boiler offerings, from boiler to complete boiler island configurations, depending on our customers’ specific project needs. 20

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BOILERS Portfolio and Overview Tangential Firing System

Industry Leader in Supercritical and High Efficiency

GE introduced the tangential firing system in 1927. Fuel and air are injected through windboxes from the corners of the furnace, aimed tangent to an imaginary circle in the center of the furnace. This creates a single rotating flame envelope (vortex) that produces a uniform and consistent heat profile across the furnace walls over the operating load range. Due to aerodynamics, the fuel and air are mixed throughout the furnace, resulting in high efficiency combustion. Tangential firing also provides the following advantages for GE’s two-pass and tower boiler designs:

GE led the industry in developing supercritical steam generation technology, and is an industry leader in today’s high efficiency ultra-supercritical technology. Our expertise in thermal, hydraulic, and material sciences has led to boiler designs that offer tremendous improvements in steam parameters. Advanced tangential firing systems can lower exhaust gas emissions, providing an additional benefit as countries seek to lower emissions.

• Low primary NOx emissions for decreased SCR catalyst volume, reagent use, and maintenance requirements • Efficient use of furnace volume, resulting in reduced slagging tendency and soot-blowing frequency

High Efficiency

GE’s ultra-supercritical boilers contribute to cycle efficiencies of 42 to 45 percent on an HHV basis (44 to 47 percent LHV basis), significantly reducing both fuel and emission control costs for our customers.

Extensive Experience and Reference

To date, GE has directly supplied more than 116,000 MW of supercritical/ultra supercritical boilers worldwide, and has licensed and trained other companies to install an additional 140,000 MW.

• Excellent flame stability for increased unit turndown and a wider latitude for fuel property variation

Continuous Development

• Tilting capability resulting in no attemperation for reheat temperature controls

•U ltra-supercritical circulating fluidized bed (USC CFB): With our world-class experience in ultra-supercritical pulverized coal boilers and expertise in the design of CFB firing, GE has developed highly efficient ultra-supercritical CFB technology, which provides reliable and fuel-flexible power generation with a lower CO2 footprint.

GE continues to invest significantly in research and development dedicated to improving our high efficiency power generation equipment.

• Double reheat (DRH): GE has supplied double reheat boilers for more than 50 years, and today we offer USC double reheat configurations for both tower and two-pass boiler designs. • Advanced ultra-supercritical (A-USC): GE is in collaboration with various groups in Europe (700°C) and the U.S. (760°C) for A-USC steam cycle development.

Efficiency Improvement with Increasing Steam Conditions 375/730/760 (5,400/1,330/1,400) 375/700/720 (5,400/1,300/1,325)

Steam conditions in bar/ºC/ºC (psi/ºF/ºF)

275/600/620 (4,000/1,100/1,150) R&D ongoing USA USC Materials Consortium & EC AD 700 Project (Ni-base)

275/580/600 (4,000/1,075/1,100)

240/540/565 (3,500/1,000/1,050) 167/540/540 (2,400/1,000/1,000)

ADVANCED USC ULTRA-SUPERCRITICAL (USC) SUPERCRITICAL

SUBCRITICAL 1960

22

1980

2000

2020

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BOILERS Portfolio and Overview

Ultra-supercritical CFB 660 MWe for lignite B, higher for hard coal • Ultra-supercritical 285 bar, 605°C/623°C (MS/RH) • More than three points increased net plant efficiency relative to subcritical • Six percent reduction of CO2 footprint • Inherent low NOx emission with our air staging • L ow SO2 emission without backend treatment • Designed for reliability: — Well-tested material for pressure parts with many years of onsite experience — Multiple fuel feeders and ash extraction ports — Standardized modules that allow changing outputs, fuels and steam temperatures Typical emissions: mg/Nm3 @ 6% O2 dg

ppm

lb/mm Btu

NOx

150

75

0.12

SOx

200

70

0.16

Emissions

With no additional flue gas treatment as SCR and WFGD

Typical lignite analyses used for sizing the 660 MW CFB-firing system Lignite B

India

Malaysia

Turkey

Germany

Poland

Hungary

Indonesia

Moisture (%)

58

50

46

60

46

48

55

Ash (%)

6

8

13

5

11

20

4

VM daf basis (%)

54

51

51

54

56

65

59

Sulfur (%)

0.5

0.4

2.0

0.2

0.4

1.5

0.1

HHV af basis (mBtu/lb)

4.2

4.7

5.6

4.3

5.9

4.4

4.8

LHV ar (Mcal/kg)

1.8

2.1

2.3

1.8

2.5

1.6

2.1

24

Cleaner, efficient, flexible, reliable, steam generation for all type of fuels 25

Powering the World


TWO-PASS BOILERS

Furnace and Convective Passes, Tilting Tangential Firing System, Experience Firing Fuels from All Over the Globe

GE’s two-pass boiler is the workhorse of the power industry, generating steam for today’s large-scale global power projects (up to 1,350 MWe) at pressures and temperatures that can reach the service limits of contemporary materials. Radiant pendant surfaces are located above the furnace, and convective surfaces are arranged horizontally in the second pass. The two-pass configuration results in an efficient furnace height and a lower cost of construction. Our patented tilting tangential firing system accommodates the large spectrum of fuels found across the globe (multiple grades of coal, oil, gas, heavy residues, biomass and other opportunity fuels), and is a leader in primary emissions control.

Coal-fired Two Pass

Fuel

Oil and Gas-fired Two Pass

Coal-fired Two Pass

Oil and Gas–fired Two Pass

• Bituminous

•O il (Heavy Fuel Oil, No. 2 Oil, No. 6 Oil, Crude Oil etc.)

• Sub-bituminous

Flexible and Reliable • High cycle efficiencies at ultra-supercritical conditions reaching 44 to 47 percent on an LHV basis (42 to 45 percent HHV basis), meaning less fuel consumption and cleaner operation •L ow primary NOx emissions using advanced tangential firing systems and effective overfire air arrangements, resulting in less SCR catalyst material and less reagent consumption • Outstanding operational flexibility for temperature control, grid code requirements, sliding pressure capability, and load cycling

Steam Cycle

• Lignite A

•G as (Natural Gas, Coke Oven Gas, Blast Furnace Gas etc.)

• Ultra-supercritical

• Supercritical

• Supercritical

• Subcritical

• Subcritical Size (MWe)

• Subcritical ≤ 800


• USC/SC ≤ 1,350

• SC ≤ 1,000

Superheater Outlet Steam Pressure (bar)

• ≤ 300

• ≤ 250

Superheater Steam Temperature (°C)

• ≤ 605

• ≤ 565

Reheater Steam Temperature (°C)

• ≤ 623

• ≤ 565

Design Features

• Tangential firing system


• Fuel and air staging


• Tilting burners

• Tilting burners

• Vertical and spiral wall designs

• Spiral wall designs

•R educed construction time and cost using advanced construction techniques and standard component design and fabrication

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TOWER BOILERS

Simple and Reliable Design, Expertise for High Moisture Lignite Firing

GE originally introduced the tower boiler design in the mid-20th century to utilize high moisture lignite in Europe. Since then, thanks to its advantages – and positive feedback from customers – the tower boiler has become the predominant design for coal-fired power generation in Europe, according to the EN Codes & Standards. With standardization and modularization, tower boiler equipment can be sourced and constructed cost-effectively around the globe while meeting high quality standards.

Flexible and Reliable

Hard Coal Fired Tower

Fuel

• High cycle efficiencies at ultra-supercritical conditions reaching 44 to 47 percent on an LHV basis (42 to 45 percent HHV basis), meaning less fuel consumption and reduced emissions • Low primary NOx emissions using advanced tangential firing systems and effective overfire air arrangements, resulting in less SCR catalyst material and less reagent consumption • Outstanding operational flexibility to support a stable grid • Reliable plant operation enhanced by fully drainable heating surfaces, resulting in faster startup periods and reduced stresses in pressure part

Expertise in High Moisture Lignite Firing •S pecialized firing system to burn all types of lignite with over 80 years of experience

Hard Coal Fired Tower

Lignite Fired Tower

• Bituminous

• Lignite B

• Sub-bituminous • Lignite A Steam Cycle

• High steam parameters with successful utilization of T24 material

Lignite Fired Tower

• Ultra Supercritical

• Ultra-supercritical

• Supercritical

• Supercritical

• Subcritical

• Subcritical



• USC/SC ≤ 1350

• USC/SC ≤ 1,100


• ≤ 300

• ≤ 300


• ≤ 605

• ≤ 605


• ≤ 623

• ≤ 613

Design Features





• Tilting burners



• Expert firing system for lignites

Size (MWe)

• Integrated with advanced beater wheel mill providing efficient operation and maintenance

Furnace gas resuction ducts

Large furnace

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Beater wheel mills

Mills arranged around furnace

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Powering the World


CFB BOILERS Combination of Fuel Flexibility and Low Emissions

During the past two decades, circulating fluidized bed (CFB) technology has demonstrated its ability to efficiently utilize a wide variety of fuels – including fuels with high ash, high moisture, high sulfur, low volatiles, and low heating value that are unsuitable for other firing systems – while meeting stringent stack emission limits. This unique combination of fuel flexibility and low emissions has led to the development and growth of CFB technology in power generation. • Efficient Combustion A wide range of fuels can be burned efficiently, including low-grade and difficult-to-burn fuels such as anthracite, lignite, petroleum coke, oil shale, discarded coal and biomass. • Fuel Flexibility Several different fuels can be fired in the same boiler within a wide range of mixing rates. • Low inherent NOx emissions at 50-200 mg/Nm3 —R elatively low and uniform furnace temperatures of approximately 850°C to 900°C — Air staging in the lower furnace through the introduction of primary air and secondary air at appropriate levels —U niformly distributed fuel and air due to intense mixing inside the bed of solids in the furnace — Isothermal conditions in the circulating solid loop due to the positive impact of highly efficient cyclones — Selective non-catalytic reduction (SNCR) systems can be added, leading to even lower NOx emissions • Low SO2 emissions with 95 to 98 percent sulfur removal — Injection of prepared and dried limestone in the furnace — Potentially inherent capture by the fuel-bound calcium — Dry scrubber NID* achieving 98 percent sulfur removal while reducing limestone consumption — Just-In-Time (JIT*) system for limestone drying and crushing available for direct limestone feeding

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Dual-Grate Arrangement

Three-Bay Arrangement

Dual-Grate Arrangement

Three-Bay Arrangement

Design for specific requirements

Most common CFB design

Advanced Supercritical CFB

Advanced Supercritical CFB Large-sized CFB firing system

Fuel

Entire range of fuels, including opportunity fuels such as petroleum coke, biomass, waste coal, oil shale, etc.

Steam Cycle

• Subcritical

• Subcritical

• Ultra Supercritical • Supercritical

Size (MWe)

• 350

• 100 – 350

• 660 for lignite B • Higher for hard coal


• ≤ 175

• ≤ 175

• ≤ 285


• ≤ 565

• ≤ 565

• ≤ 605


• ≤ 565

• ≤ 565

• ≤ 623

Design Features

• Four cyclones • Double grates • External beds

• Up to three cyclones in line • Single grate • In-furnace panels • Steam cooled cyclones

• Modular concept • Standardized modules • Up to 8 cyclones • Steam cooled cyclones • Double fluidizing grates • External beds • In-furnace box columns • In-furnace U-shaped panels

• CFB/NID integrated technology • SNCR in-house injection grid • JIT limestone feed system

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MILLS Complete Range of Technology to Meet Low Emission, High Efficiency and Fuel Flexibility Demands

For nearly 100 years – ever since pulverized coal combustion was adapted for power generation – GE has been a leader in coal mill technology for the power industry. That leadership continues today with the world’s largest fleet of installed power milling equipment. Licenses for our milling technology can be found in all coal-powered regions of the world. Pulverizing solid fuel to powder enables its drying and transport for combustion in large furnace sizes. Fine grinding increases the fuel exposed surface area while simultaneously drying and controlling its distribution. These are integral steps to efficient, low emissions combustion which are optimized together with boiler thermal performance. We design and continuously develop a complete range of milling technology that includes vertical spindle bowl mills and beater wheel mills, with classifier options to match our customers’ efficiency and fuel flexibility demands. Our mill and classifier portfolio can process all fuels commonly used for power generation and fuel blends, while maintaining excellent combustion efficiency under lowemission conditions with reduced power consumption and maintenance requirements. • Demonstrated reliable operation • Wide fuel range capability, with the ability to handle all solid fuels suitable for power generation, from anthracite to lignite B • Enhanced operational flexibility, handling fuel blends, transient operation, and load ramping, while supporting emissions compliance

Bowl Mills – SM type

Bowl Mills – HP type

Beater Wheel Mills – Type S, V, SV

Bowl Mills – HP Type

Bowl Mills – SM Type

Beater Wheel Mills – Type S, V, SV

Capacity Range (t/h)

• 18 to 170

• 12 to 170

• 44 to 170 (diam. ≤ 4.4m)

Classifier

• Static or dynamic

• Static, dynamic and combined

• Box type (static)

Loading

• Spring (hydraulic option)

• Hydraulic (spring option)

• Speed control for operational flexibility

Coal

• Bituminous/sub-bituminous • Lignite A

• Bituminous/sub-bituminous • Lignite A • Anthracite • Petroleum coke

•V arious types of lignite with moisture from 25 to 70 percent and ash content up to 35 percent

Design Features

• Interchangeable components • Removable gearbox • External spring loading • Tilt-out journals • Simple fabricated design • Adaptable arrangements • Extended life moving parts

• Interchangeable components • Removable gearbox • External spring loading • Tilt-out journals • Simple fabricated design • Adaptable arrangements • Extended life moving parts

• Optimized performance designs • Modular heavy duty design • Unique maintenance concept • Easy access to wear parts • Pre-beater design available • Insensitive to sudden load changes • Compliance with European standards

• Reduced capital, labor, maintenance, and operating costs: — Simple modular design that keeps capital and construction costs low — Interchangeable modular components that reduce inventory costs and repair cycle time — Unique construction concepts that allow mill installation without welding for reduced labor costs

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STEAM POWER SYSTEMS PRODUCT CATALOG I Steam Turbines

STEAM TURBINES Portfolio and Overview Power and Performance A world leader in the development and application of steam turbine technology, GE has supplied more than 30 percent of the world’s installed steam turbine capacity, totaling more than 930 GW of power production capability to date in operation. For more than a century, we have consolidated the best available technology from numerous suppliers into a single platform that supports our advanced, innovative, efficient and reliable turbine solutions.

Products

GE’s steam turbine platform offers a broad product portfolio that accommodates a wide range of site conditions, operational needs, advanced steam cycles, and applications. In fossil-fired steam plants, our steam turbines offer class-leading ultra-supercritical steam parameters.

REHEAT Up to 300bar (4351psi) Up to 600°C (1112°F)

GE ST-D1050

Up to 54.0.% ST efficiency


GE ST-D850

Up to 49.0% ST efficiency

Experienced and Available


GE ST-D650



GE ST-A650


NON-REHEAT Up to 140bar (2031psi) Up to 565°C (1049°F)

GE ST-D250


NON-REHEAT Up to 140bar (2031psi) Up to 565°C (1049°F)

GE ST-A200


A systematic evolutionary platform approach that incorporates best practices and technology gains based on years of practical experience forms the backbone of GE’s coordinated product portfolio. Our highly qualified and specialized engineering centers and factories – in key marketplaces around the world – enable us to provide this exceptional portfolio of steam turbine products.

Advanced Technology Increased Efficiency

• Continuous improvements to the water steam cycle are supported by our broad rear stage portfolio.

High Availability and Reliability

• Our advanced 3D blading platform helps enhance the load grade and customize the flow path for projectspecific conditions and increased performance.

• Our long-term testing program validates material behavior to help ensure high reliability of our steam turbine components.

Evolutionary Platform Approach

Enhanced Operational Flexibility

• The application of proven design principles to all module types and sizes helps achieve higher reliability. • Operational feedback is systematically applied across GE’s entire modular turbine product portfolio to enhance customer value.

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100

200

300

400

500

600

700

800

900

1000 1100 1200

• Advanced lifetime assessment procedures reduce maintenance and increase turbine availability.

• Advanced fracture mechanic methods provide reliable lifetime assessment of the steam turbine components and increased cycling capabilities. • An enhanced blade groove design reduces thermal stresses for increased rotor life.

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STEAM TURBINES Portfolio and Overview

Key Technical Features Welded Rotors

Introduced in 1930, our welded rotor technology has stood the test of time with no ruptures reported in our large diameter rotors – manufactured by welding together separate smaller forgings. This beneficial design allows for: • Appropriate forging material selection, based on temperature level at each section of the turbine • Stress reduction during thermal transients for faster and more frequent load cycling capability • Better access for ultra-sonic testing equipment – translating to higher reliability

Shrink Ring Design

Our shrink ring design allows for a rotationally symmetric inner casing resulting in: • Reduced distortions while clearances are maintained during operation – providing sustained higher efficiency • A more compact design with smaller wall thicknesses for flexible load cycling and faster startup times

Single Bearing Design

Our multi-casing turbines have a single bearing between each turbine section for: • Avoidance of load shifting for higher reliability • Efficient shaft alignment for reduced construction time • Shorter overall turbine shaft length for lower building costs

LP Large Last Stage Blades

Our enhanced last stage blade portfolio offers: • Dense staggered last stage blade sizes for project-specific cold-end conditions and increased efficiency • A robust design with stress-enhanced grooves and blade attachments for higher reliability Blade size for 50 Hz and 60 Hz 50 Hz/60 Hz

33” (50 Hz)

Design

Free-standing

33” (50 Hz)

37”/30”

Snubber

Material

41”/34”

41”/34”

Free-standing Steel

45”/38”

49”/42”

Snubber and Shroud Titanium

Advanced Blading

Innovative blading technology is apparent in our: • Modern, three-dimensional profile design that results in higher efficiency • High pressure (HP), intermediate pressure (IP), and low pressure (LP) front stage blades that are milled from a single forging for excellent mechanical integrity and higher reliability

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D1050, D850, D650, AND A650 STEAM TURBINES Modular Steam Turbine Platform for High Efficiency

GE’s D-Series is a modular product platform for utility reheat steam turbines in the 100 to 1,200 MW power output range. Our modular concept governs all engineering and manufacturing processes, and results in reduced construction and commissioning times, higher reliability, and excellent efficiency. To enhance performance, the steam path is always adapted to the specific project requirements.

D1050: 400-1200 MW output Up to 54 percent steam turbine efficiency

The extensive LP last stage blade portfolio for 50 Hz and 60 Hz models offers rear stage sizes from 30 inches up to 49 inches. The number and size of LP turbines can be tailored to specific site conditions. The D1050 steam turbine configuration can have up to five casings.

Designed for Efficiency and Reliability • The D-Series are designed for main inlet conditions up to 600°C (1112°F) and 300 bar (4351 psi) and reheat temperatures up to 620°C (1148°F). • HP turbines can be equipped with a second main steam injection system by means of integrated overload valves. This method provides additional load reserve in cases of sudden steps in power demand. • Startup valves (TAL) help ensure a safe and trip-free runback from full load to house load after load rejection.

D850: 200-1000 MW output Up to 49 percent steam turbine efficiency

• HP, IP, and valve units are shipped fully assembled enabling shorter installation time on site. The LP turbine is dispatched in pre-assembled lots for easier handling and reduced construction time on site. • Skid mounted lube and control oil systems with pre-assembled pumps, filters, valves, and interconnecting piping are available for all turbine sizes. • Sleeved rotor couplings help ensure durable shaft alignment and smoother operation.

D650: 200-700 MW output Up to 47.5 percent steam turbine efficiency

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D1050, D850, D650, AND A650 STEAM TURBINES Modular Steam Turbine Platform for High Efficiency

Technical Data D1050

D850

D650

A650

Main Steam

Up to 300bar (4351psi) Up to 600°C (1112°F)




Reheat Temperature

Up to 620°C (1148°F)

Up to 585°C (1085°F)

Up to 565°C (1049°F)

Up to 565°C (1049°F)

Frequency

50 Hz and 60 Hz

50 Hz and 60 Hz

50 Hz and 60 Hz

50 Hz and 60 Hz

Output

≤ 1200 MW

≤ 1000 MW

≤ 700 MW

≤ 300 MW

Steam Turbine Efficiency

Up to 54%

Up to 49%

Up to 47.5%

Up to 47.5%

Maximum Backpressure

0.35 bar (10.34 inHg) (0.7 bar (20.67 inHg) with special high back pressure rear stages)

Control Concept

Sliding pressure mode Hybrid mode with or without overload valve

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Sliding pressure mode Fixed pressure mode

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Powering the World


D250 STEAM TURBINE Platform with Enhanced Design Flexibility

Decades of experience have shaped GE’s D250 platform into an innovative selection of pre-engineered sections and modules that offer flexibility. Available with downward exhaust options, the D250 platform can be integrated into any plant configuration. With its full modular design, the D250 platform can be tailored to meet our customers’ specific project requirements in a double casing arrangement. Turbines with a rear stage size up to 41 inches are completely shop assembled and shipped directly to the site to reduce construction time. The reuse of standard sections and the consequent application of an experience return process supports continuous product design improvements and results in the high reliability of the D250 platform.

Versatile and Robust Design • The D250 platform is designed for main steam inlet conditions up to 565°C (1049°F) and 140 bar (2031 psi). • A single or reverse flow steam path controls axial thrust and axial thermal expansion to help ensure high reliability.

D250 Platform Technical Data Main Steam

140 bar (2031 psi), 565°C (1049°F)

Frequency

50 Hz and 60 Hz

Output

≤ 300 MW


Up to 40.5%



Control Concept

Sliding pressure mode Fixed pressure mode (control stage) Hybrid mode

• Double flow LP turbines meet project specific back pressure requirements. • Flexible heat extractions can be arranged along the steam path to extract the steam at exactly the pressure that is needed.

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A200 STEAM TURBINE Multiple Steam Extractions, Flexible Arrangement Concept

GE’s A200 non-reheat steam turbines provide cogeneration of power steam in an flexible and compact design for either 50 Hz or 60 Hz application. Our fully modular concept combines HP, IP, and LP sections to deliver high efficiency and process steam supply. Available with a single casing, A200 steam turbines have internally and externally controlled flow extractions to tap steam at any point along the steam path at the desired flow and pressure conditions. Arrangement options are available with axial exhausts.

Compact and Flexible • The A200 turbine is designed for main steam inlet conditions up to 565°C (1049°F) and 140 bar (2031 psi). • For added flexibility, the A200 steam turbine is available as a single casing solution with a single flow LP section or as double casing solution with a two-flow LP section.

A200 Turbine Technical Data Main Steam

140 bar (2031 psi), 565°C (1049°F)

• Turbine cylinders are shipped fully assembled to reduce site work and construction time.

Frequency

50 Hz and 60 Hz

• An extensive LP blades portfolio allows a customized rear stage selection to fit all ambient conditions and achieve higher efficiency steam cycles.

Output

≤ 300 MW


Up to 40.5%



Control Concept

Sliding pressure mode Fixed pressure mode (control stage) Hybrid mode

• A flexible arrangement of steam extraction nozzles along the blade path helps extract steam for project-specific conditions. • Design solutions for internally controlled steam extractions are available. Adaptive stage technology is used to control low pressure steam extractions, while intersections with dedicated valves are appropriate for higher pressures.

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STEAM POWER SYSTEMS PRODUCT CATALOG I Generators

GENERATOR Portfolio and Overview GE’s generators are experienced and reliable machines that offer high technical performances. Our generators have successfully operated in more than 2,000 projects worldwide, providing different power output levels and cooling media depending on customer need. Designed to help lower plant investment costs, our generators enhance operation and limit maintenance costs.

Product Families •G IGATOP 2-pole (hydrogen-water-cooled) generators are GE’s enhanced solution for coal power plant applications. This generator has operated in more than 100 projects since 1973. A power plant in the Netherlands has the world’s most powerful generator (1,113 MW) running in a coal power plant. • TOPGAS (hydrogen-cooled) generators are high-efficiency machines. The high power output of this product family provides a cost-effective alternative to conventional hydrogen-water-cooled machines that are commonly used for similar high power output levels. • TOPAIR (air-cooled) generators are precise and robust machines offering high power output and efficiency. This machine can be used in many different applications. • TOPACK (air-cooled) generators are ideal for applications demanding simple, packaged and ready-to-install generators. There are more than 1,500 machines installed worldwide.

Product

510–1,400 MW

TOPGAS Hydrogen-cooled TOPAIR Air-cooled TOPACK Air-cooled

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400–830 MW 70–430 MW 30–170 MW

Technologies Bring Added Value GE’s generators use technologies and contain features that save time and money for the end customer. Based on many years of proven experience and continuous feedback from our customers, these technologies often are shared among different product families, as shown in the following three examples.

Tubes in Stainless Steel for Stator-Winding Cooling Used on GIGATOP 2-pole generator • The cooling tubes in the stator winding of GE’s GIGATOP 2-pole generator are made of stainless steel, so they can’t corrode, and the risk of clogging leading to an unplanned forced outage is eliminated. GE is the only manufacturer to offer this feature. Self-Retightening End-Winding Support Used on TOPAIR, TOPGAS and GIGATOP 2-pole generators

Power Output Range (MW)

GIGATOP 2-pole Hydrogen-water-cooled

GE’s generators are designed to meet all relevant standards, regulations and grid codes that may apply in specific 50 Hz and 60 Hz countries. Machines are designed according to IEC and IEEE standards and are designed for temperature rises of class 130 (B). The insulation, using either DURITENAX or MICADUR* tape (depending on the product family), fulfills thermal class 155 (F). We perform quality tests and inspections during manufacturing, delivery, construction and commissioning of the machines to help ensure high quality and conformance with our customers’ needs.

• GE’s generators have a self-retightening end-winding support, which allows thermal expansion of the bars while simultaneously tightening the winding in radial and tangential directions. This system saves maintenance time for the generator end user, avoids forced outages, and increases plant availability on the grid. Concave-Convex Wedges Used on TOPAIR, TOPGAS and GIGATOP 2-pole generators • The concave-convex wedges used in GE’s generators have a unique design that sustains pressure on the stator bars. This constant pressure prevents radial movements of the winding, avoiding a forced outage from insulation breakdown while cutting maintenance hours and increasing plant availability.

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GENERATOR

Portfolio and Overview

GE’s generators have additional design features that enhance technical performance and reduce maintenance costs: • Roebel bars in the stator winding reduce losses and heighten efficiency. • The MICADUR* insulation system is a well-proven insulation tape that helps ensure high reliability. • Laminated press-plates and low-loss core laminations enhance efficiency. The following table summarizes the availability of features within each product family. GIGATOP 2-pole

TOPGAS

TOPAIR

TOPACK

P

P

P

P

MICADUR VPI

MICADUR VPI

MICADUR VPI

DURITENAX Resin Rich

Concave-convex wedges for reliability and short maintenance time

P

P

P

Ripple Spring System

nhanced stator core design for E low losses and maintenance

P

P

P

P

nhanced seal oil system for E low hydrogen losses and high efficiency

Triple-circuit Seal Oil System

Single-circuit Seal Oil System

—

—

Hydrogen and water

Hydrogen

Air

Air

P

P

—

—

tator end-winding support for S short maintenance time nhanced stator bars insulation E for reliable operation

Enhanced cooling system for high efficiency Skid-mounted auxiliaries that save time on site

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GIGATOP 2-POLE GENERATOR Reliable Hydrogen-Cooled Generator

High-tech Features for Best Performance The hydrogen- and water-cooled GIGATOP 2-pole generator is used for coal power plants, nuclear fullspeed turbines, and gas power plants and can be found in 100 systems since 1973. Flexible in design, each machine fits the end user’s power needs with high efficiency. The GIGATOP 2-pole generator has proven to be highly reliable. For example, a unit in the U.S. boasted 607 days of uninterrupted operation before a scheduled shutdown. Based on technology pioneered in the 1970s, the GIGATOP 2-pole generator is constantly improved with continuous feedback from operational experience worldwide. Designed for both rail and road transport, the generator has only a small number of individual parts, which translates into shorter delivery and faster installation time.

Features: • High power output levels. For example, the GIGATOP 2-pole generator in the operation in Leibstadt (Switzerland) nuclear plant at 1,190 MW. • Efficient and flexible. The cooling system sustains a high level of efficiency and has a unique design of press plates for higher reactive power and stabilization in case of grid disturbance.

Frequency

50 Hz

60 Hz

Power Factor

0.8 to 0.9

0.85

Apparent Power

590 MVA to 1400 MVA

510 MVA to 1120 MVA

Efficiency

Up to 99%

Up to 98.9%

Terminal Voltage

18 kV to 27 kV

22 kV to 26 kV

Reliability1 1

99.996%

Average reliability calculated according to standard IEEE-762 from measurements collected over nine GIGATOP 2-pole units between 1990 and 2012 by the independent company Strategic Power System

• Robust and reliable design. The design takes into account normal operation and transcients. • Continuously evolving technology. The first GIGATOP 2-pole generator was developed in the 1970s and has evolved continuously ever since, based on feedback collected from operating experience.

Success Story

Applications: • GIGATOP 2-pole generator is well-suited for the nuclear full-speed Turbine Generator package. • GIGATOP 2-pole generator represents more than 100 units installed, and its design combines high efficiency, high reliability and optimized maintenance efforts for the benefit of our customers.

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First 1,000 MW Coal Plant in China from GE

Since the rail network in China has narrow tunnel profiles and load restrictions, a specific GIGATOP 2-pole generator was designed to fulfill all of China’s specific technical and rail transportation requirements for dimensions and weight.

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TOPGAS GENERATOR Best-in-Class Hydrogen-Cooled Generator

TOPGAS hydrogen-cooled generators benefit from a strong heritage of technology and extensive operational feedback. The TOPGAS power output range is a cost-effective alternative to bigger and more complex hydrogen-water-cooled generators. Today’s TOPGAS generator power output range goes beyond 710 MVA (ca. 600 MW), so the generator can be installed in power plants that generally would require more complex hydrogen-water-cooled generators, such as conventional 660 MW coal power plants. By offering a lower investment cost and higher efficiency than conventional hydrogen-water-cooled generators, the TOPGAS generator reduces electricity costs and emissions.

Features • L ower investment cost, derived from the high power rating and the generator’s efficiency. TOPGAS machines are a cost-effective alternative to more complex hydrogenwater-cooled generators that normally are used for similar power output levels •E xcellent 99.7 percent reliability, based on measurements collected from 34 TOPGAS units between 1998 and 2012

Frequency

50 Hz

60 Hz

Power Factor

0.8

0.85

Apparent Power

400 MVA to 830 MVA

450 MVA to 615 MVA

Efficiency

Up to 98.9%

Up to 99%

18 kV to 23 kV

19 kV to 23 kV

Terminal Voltage Reliability 1

1

99.715%

verage reliability calculated according to Standard IEEE-762 from measurements collected from 34 TOPGAS units between A 1998 and 2012 by the independent company Strategic Power System.

•H igh efficiency of around 99 percent, mainly because of the enhanced winding and hydrogen cooling system • Easy to maintain, thanks to specific design features of the stator bar wedging and stator end-winding support parts

Success Story TOPGAS in High Cyclic Operation

A TOPGAS unit in a 400 MW gas-fired combined cycle plant, powering a Japanese steel production facility, has been operating reliably in daily start-stop mode since September 2002, accumulating more than 2,050 starts and more than 48,000 operating hours.

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TOPAIR GENERATOR Precise and Robust Air-Cooled Generator

The most powerful air-cooled generator in operation today, GE’s TOPAIR unit has accumulated worldwide operational experience from more than 570 installations. It is a robust machine providing high reliability and maintainability. TOPAIR air-cooled generators have a power output range that usually is found in larger and less cost-effective hydrogen-cooled generators. This is the result of continuous, evolutionary development that has pushed the limits of power output while enhancing efficiency and controlling investment costs. At the same time, it is simple and easy to operate and maintain. The flexible TOPAIR, because of its short production time (parallel manufacture of stator and casing, pre-assembly, and ease of transport), is a generator that can be up and running quickly. This reduces construction and commissioning time and accelerates plant revenue flow. TOPAIR units are available in standardized sizes, with different capabilities and performances.

Features • Cost advantage due to high power rating and efficiency, over hydrogen-cooled generators • Continuous improvement from the latest advanced technology, including enhanced power range and efficiency at limited product cost

Frequency

50 Hz

60 Hz

Power Factor

0.8

0.85

Apparent Power

70 MVA to 430 MVA

80 MVA to 360 MVA

Efficiency

Up to 98.9%

Up to 98.8%

Terminal Voltage

11.5 kV to 22 kV

13.8 kV to 22 kV

Reliability1 1

99.911%

verage reliability calculated according to Standard IEEE-762 from measurements collected from 304 TOPAIR units between A 1990 and 2012 by the independent company Strategic Power System.

• Proven operational flexibility from demonstrated robustness and reliability over many years in all operation modes • Extensive worldwide operational experience with more than 570 units installed worldwide

Success Story TOPAIR Working in a Tough Environment

More than 200 TOPAIR generators have been installed in the Middle East, where their durability and robustness are tested to the limit by extreme operating conditions. For example, 32 TOPAIR units have been operating in Saudi Arabia since 1978. Bahrain is host to the world’s largest air-cooled generator, which has been operating since 1999 and has accumulated more than a million operating hours.

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TOPACK GENERATOR Packaged Air-Cooled Generator

The air-cooled TOPACK generator is remarkable for its breadth of customer advantages and its accumulated experience. The packaged TOPACK solution comes complete with all necessary electrical equipment, saving our customers time, effort and money. Compact and modular, based on standardized manufacturing processes, a TOPACK generator quickly gives our customers exactly what they need. It is delivered as a single unit that is ready to install, simple to integrate into the power plant, and easy to maintain. The TOPACK generator is highly reliable, with a wide power range that is versatile enough to handle all kinds of applications – indoor or outdoor and in a variety of climates. TOPACK generators are available in standardized sizes, with different capabilities and performances.

Features • Fully packaged generator that comes complete with all electrical systems • Reliable and robust product, with more than 1,300 installations worldwide and proven in many different environments

Frequency

50 Hz

60 Hz

Power Factor

0.8

0.85

Apparent Power

35 MVA to 200 MVA

35 MVA to 200 MVA

Efficiency

Up to 98.7%

Up to 98.6%

Terminal Voltage

11 kV to 15 kV

13.8 kV

• Compact size and easy maintenance for quick and easy transportation and installation

Success Story Extreme Operating Conditions

A refinery in Kazakhstan is located at one of the largest oil field in the world and faces extreme ambient temperatures reaching -36°C. Two TOPACK units are installed there to produce electrical power and these machines have operated reliably for more than 10 years.

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Powering the World

STEAM POWER SYSTEMS PRODUCT CATALOG I Air Quality Control Systems

AIR QUALITY CONTROL SYSTEMS (AQCS) Portfolio and Overview Pioneer in Air Quality Control for Power and Industrial Applications We have provided our customers with advanced Air Quality Control Systems (AQCS) for more than 80 years. GE’s expertise, technology and comprehensive product portfolio enable our customers to comply with today’s stringent emission regulations for particulate and gaseous pollutants emitted from power plants and industrial operations. Our high quality and cost-effective equipment and services can be adapted to our customers’ needs.

More than 80 years of experience providing advanced emission controls At GE, we: • Help our customers determine the best combination of technologies for their specific site requirements • Offer a range of products to comply with today’s stringent emissions regulations

Our Success:

500 GW

5,000

• Deliver a variety of AQCS on an engineering, procurement and construction (EPC) or engineering and procurement (EP) basis

In Power Applications

Units in Industrial Applications

• Offer a variety of solutions to upgrade our customers’ existing equipment with our latest innovations for improved performance and/or lower operating costs

• Provide after-sales services including spare parts, inspection and remote monitoring

Russia and CIS Power Industry

13 GW 80 Systems

Europe Power Industry

North America Power Industry

160 GW 360 Systems

113 GW 1,600 Systems

Asia Power Industry

98 GW 1,800 Systems

India Middle East and Africa Power Industry

40 GW 160 Systems

Power Industry

50 GW 700 Systems

Latin America Power Industry

7 GW 230 Systems

Oceania Power Industry

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20 GW 120 Systems

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AIR QUALITY CONTROL SYSTEMS (AQCS) Portfolio and Overview Customized Offerings

Innovative Products and Technologies

With GE, customers receive a wealth of air quality control know-how. For new built and upgrade and retrofit of existing AQCS, we offer on-demand solutions tailored to meet our customers’ requirements, including partial or full scope as described below:

Since 1983, our technology center in Växjö, Sweden – one of the largest in the world in the field of environmental control solutions – has been at the forefront of advanced research and development for air quality and CO2 control solutions. Focusing on technology innovation and product validation, it has test halls for pilot operations and flow modeling, an analytical laboratory specializing in particle and environmental analyses, an instrument workshop, high voltage facilities for ESP electrical testing (SIR, T/R sets), and a mechanical workshop for pilot equipment manufacturing.

• Engineering. GE offers advanced air pollution control engineering, from process and equipment design to construction, operations and maintenance. • Equipment supply. Our comprehensive AQCS portfolio of products covers a broad range of pollutants with industry leading technology with a single process or a combination to cover the entire flue gas chain. This gives customers the flexibility to address complex interactions between components and processes. • Construction and commissioning. We offers: — Construction management — Commissioning management — Construction and commissioning advisory services • Inspection and maintenance. We provide these services for our own fleet and/or other AQCS solutions.

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PARTICULATE CONTROL Dry and Wet Electrostatic Precipitators (ESPs)

Electrostatic precipitators (ESPs) represent a very large installed base worldwide in terms of particulate emission control, and GE offers a wide range of robust, cost effective and reliable ESP designs for a variety of applications. Backed by decades of experience on an extended range of fuel combinations and industrial applications, our solutions cater to increasingly strict regulations at a lower life cycle cost. We offer:

Dry ESP Parameter

Number

• Spiral and rigid designs of emitting electrodes, tumbling hammer and electric impact rapping systems

Applications

Power-Boilers and Heaters, Industry1

Power Capacity (MW)

10 to 1300

Gas Temperatures (°C)

70 – 400

• Flexible layout and modular designs suited to the site

Gas Flow Rate (m3/s)

15 – 2000

Dust Loading at ESP inlet (g/Nm3)

0.2 – 100 g/Nm3; for SDA 600 g/Nm3; for NID 1800 g/Nm3

Emission at ESP outlet (mg/Nm3)

10 – 200 (exceptional 1000 for ESP as precollector), filterable PM only

PM Removal Efficiency

Up to 99.95%

Availability

Up to 98%

• Integrated ESP control systems, including the latest generation EPIC intelligent controller and the ProMo tool for enhanced ESP performance • Switch Integrated Rectifiers (SIR) as an alternative to Transformer/Rectifier (T/R) sets for increased power input, lower power consumption and improved particulate removal efficiency. Ideal for performance enhancement of existing ESPs.

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Industry- Cement: Kiln, Mills, Cooler; Iron & Steel: Sintering, Pelletization, Sponge Iron Kiln, Cast House, Stock House; Biomass fired boilers; Waste to Energy plants; Pulp & Paper: Recovery Boiler, Lime Kiln; Non-Ferrous- Smelter, Converter; Oil & Gas: FCCU et. al.

Wet ESP Parameter

Number

Applications

Power-Boilers, Heaters, Synthesis Gas and Industry2

• Proven particulate matter removal for power and industry applications

Gas Temperatures (°C)

Up to 70 C , Saturated Gas

Gas Flow Rate (m3/s)

15 – 2000

• Less than 10 mg/Nm3 emissions

Dust Loading at ESP inlet (g/Nm3)

Up to 1.2

• More than 237 GW installed in power generation and 70-plus years of experience

PM Emission at ESP outlet (mg/Nm3)

0.5, filterable PM only

SO3 Emission (ppm)

99 achieved

Load Range (% MCR)

20 -100

Load Range (% MCR)

20 - 100

HCl Removal Rate (%)

> 99

• Approximately 58 GW installed capacity

Seawater Temperature Inlet to Absorber (°C)

4 - 45

HF Removal Rate (%)

> 99

• Flexible absorber performance with controllability of the SO2 removal rate

Alkalinity – Minimum (mmol/l)

1.2

Reagent

Limestone, lime or sodium

• Improved performance control through patented sulfite analyzer

pH Seawater Inlet (minimum)

7.7

GE’s Flowpac WFGD is designed for unit sizes up to 360 MW. In this turbulent bed absorber, flue gas passes through limestone slurry. It is targeted for applications with fuels having medium to high sulfur content and requiring increased SO2 and SO3 removal efficiency. In addition, it is well suited for varying fuel conditions.

Key Features

• Fuel flexibility for all types of fuel (including heavy fuel oil) with sulfur content up to 4.5 percent for WFGD-OST and up to 6 percent for Flowpac WFGD • Lower power consumption with lower emissions of particulates and aerosols

Sea Water FGD (SWFGD) Technology GE’s SWFGD is a unique no by-product SO2 removal solution. Thanks to more than 40 years of experience in SWFGD technology for power generation and industry applications, we are one of the leading providers of SWFGD for power generation and industry applications.

Key Features • An economical desulfurization solution for plants in coastal areas • Approximately 51 GW in operation or under construction for a variety of applications and a wide range of fuels

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Success Story In 2015, we successfully commissioned our SWFGD solution at a leading coal-fired power plant in Malaysia. It is the first 1,000 MW plant in Malaysia and the single largest unit in Southeast Asia. The SWFGD system lowers SOx emissions over a wide load range, helping the plant meet its environmental responsibilities.

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NOx CONTROL Selective Catalytic Reduction (SCR)

GE’s Selective Catalytic Reduction (SCR) technology controls nitrogen oxides (NOx) formed in combustion processes. With more than 30 years of experience with SCR technology for power generation and industry applications, GE’s lower cost DeNOx solutions help customers reach their requested performance levels. High NOx reduction rates and system reliability make our flexible and compact SCR technology the choice for post combustion NOx control.

SCR Parameter

Typical Information

Reactor Size

3,200,000 acfm, 5,400,000 m3/h

Fuel Type

Gas, fuel oil, orimulsion, pet coke, biofuel (virgin wood or peat), coal

Reactor Position

High dust SCR for power plants and CHP plants; tail end SCR for waste incinerators

Reactor Flow Direction

Key Features

• Coal applications: vertical down • Oil applications: vertical up or vertical down • Gas applications: vertical up or vertical down and horizontal

Cleaning Method

Soot blower using steam or compressed air, sonic air horns, air sweepers

• More than 48 GW installed with more than 80 installations

NOx Removal Efficiency

Up to 95%

• Up to 95 percent NOx removal, low ammonia slip (less than 2 ppm)

NH3 Slip

2 vppvd @ 3% O2

Operation Temperature

570-815°F, 300-435°C for coal/oil 450-850°F, 230-435°C for gas

NOx Inlet Concentration

2050 mg/Nm3

O2

1% minimum

SO2

3,500 ppm

SO2/ SO3 Conversion

0.5 - 2.0%

Ash Load

35,000 mg/Nm3

Reagent Type

Anhydrous ammonia, aqueous ammonia, urea

• Proprietary IsoSwirl* mixing technology and specific ammonia injection grid design for improved performances •P artnerships with leading catalyst suppliers •D esign tailored to existing site conditions for reduced outage time

SCR on a steam power plant

Success Story In July 2008, GE’s technology was chosen by the main power producer in Portugal to retrofit four SCR units at a power plant in southern Portugal. These SCR units are designed for 81 percent NOx removal efficiency and use heated ammonia solution as the reagent and a vanadium/titanium honeycomb catalyst. With these SCR units, Portugal has become one of the few countries in Europe to have equipped all of its coal-fired plants with systems to control both SOx (sulfur oxides) and NOx, thus meeting European Union emission targets.

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SMALL SIZE AQCS Smartline Solutions

With the knowledge gained from our more than 80 years of experience designing larger sized units, GE has developed the Smartline range of products to cater to smaller-sized applications such as district heating, small power units, thermic fluid heaters, lime kilns, foundries, and metallurgical plants. Key features of our Smartline solutions include:

FABPAC

• Standard and modular designs, which can be pre-assembled • Easily transportable • Lower cost and simple installation

Dust Loading at FF inlet (g/Nm3)

2 – 100

Emission at FF outlet (mg/Nm3)

5 - 50, filterable PM only

Availability (%)

Up to 99%

Gas Temperatures (°C) Gas Flow Rate

70 - 250

(m3/h)

Dust Loading at

Up to 170,000

FF inlet (g/Nm3)

1 – 50

Emission at FF outlet (mg/Nm3)

Up to 20, filterable PM only

Availability (%)

Up to 98%

Micro-NID*

ELPAC ESPs for Particulate Control The ELPAC ESP adapts the benefits developed on large units to a smaller scale. Key features include: covered service room on top, flat bottom with scraper conveyor, Switch Integrated Rectifiers (SIR), efficient construction for easy access, and large gas flow range with one module (7000-170,000 m3/hr).

Maximum gas temperature at inlet (°C) Outlet Emission Limit, HCl

(mg/Nm3)

Outlet Emission Limit, HF (mg/Nm3) Outlet Emission Limit, SO2

(mg/Nm3)

Outlet Emission Limit, Particulate (mg/Nm3) Outlet Emission Limit, Hg

(mg/Nm3)

Outlet Emission Limit, Dioxin (ng/Nm3)

Micro-NID* Technology for Dry Desulfurization

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25 - 200 Up to 250,000

ELPAC

FABPAC Fabric Filters for Particulate Control These standardized and modular fabric filters can help our customers lower operational cost and footprint and reduce site installation time. Our patented Optipow* cleaning valves together with EFFIC controllers provide longer bag life and lower compressed air consumption. FABPAC filters are available in four standardized sizes with various bag lengths and bag materials.

and Multi-pollutant Control Due to its simple design, our advanced dry desulfurization technology is also available for small-scale applications. With more stringent regulations being progressively extended to smaller units, this type of application is expected to be widely deployed in the coming years.

Gas Temperatures (°C) Gas Flow Rate (m3/h)

Maximum Gas Flow rate 1

(Nm3/h)

200 2 0.3 5 5 0.03 0.05 10 0001

For higher gas flow rates, standard NID will apply.

Success Story GE supplied two ELPAC ESPs on a 4 MW boiler and an 8 MW boiler that were firing bio-fuels such as forest residues and wood chips at a CHP project in Norway. Designed for an emission guarantee of 50 mg/Nm3, these ESPs were delivered to the customer within five months and installed in just four weeks. Both units are performing well and achieving emissions lower than what was guaranteed.

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OTHER AQCS SOLUTIONS Mercury, VOC, Zero Liquid Discharge

In addition to addressing the most common pollutants, such as particulate matter, SOx and NOx, GE offers solutions for capturing other pollutants. Mercury The Filsorption* system uses activated carbon injection upstream of a standard primary or secondary particulate control system. The Mer-Cure* system uses a proprietary approach injection of sorbent upstream of the air preheaters, for faster oxidation under higher temperatures. • More than 25 years and 29 GW installed

MERCURY CONTROL Filsorption* for Power (typical)

ZERO LIQUID DISCHARGE SDE* for Power (typical)

Parameter

Number

Parameter

Number

Fuel

Boiler flue gas

Evaporation Rate (m3/h)

5 - 35

Activated carbon or activated lignite coke and/or non-carbon sorbents

Wastewater TDS (mg/l)

Up to 140,000

Reagent

Wastewater TSS (%)

Up to 20

Optional depending on the halogen content in the coal

Gas Flow Rate (Nm3/h)

Up to 175,000

Max Inlet Temperature (°C)

400

Removal Efficiency (%)

Up to 92

Load Range per Module (%)

30 - 100

Temperature (°C)

200

Availability (%)

Up to 97

PAC Addition Rate (kg/106 Nm3/h)

50 - 200

Bromine Injection

• More than two million hours of reliable operation Volatile Organic Compounds (VOC) For VOC mitigation, GE provides thermal oxidizers and regenerative thermal oxidizers – mature technologies that have been sold for many decades. Zero Liquid Discharge (ZLD) Additionally, GE offers our Spray Dryer Evaporator (SDE*) solution for plants operating WFGD technologies to achieve Zero Liquid Discharge (ZLD). Our simple and cost effective SDE technology uses hot flue gas to evaporate waste water. The dissolved or suspended solids are collected in existing particulate removal equipment. With the addition of lime to condition the waste water feed stream, acid gases in the flue gas can be captured as an added benefit.

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VOC CONTROL Thermal Oxidizer Parameter

Number

Gas Flow Rate (Nm3/sec) VOC Concentration (% of LEL)

Regenerative Thermal Oxidizer Parameter

Number

0.2 – 20

Gas Flow Rate (Nm3/sec)

0.5 – 50

0 – 25

VOC Concentration (% of LEL)

0 – 25

Load Range (%)

33 – 100

Load Range (%)

33 – 100

Dust Load (mg/Nm3 wg)

Max 2.0

Dust Load (mg/Nm3 wg)

Max 2.0

Operating Temperature (°C)

760 – 900

Operating Temperature (°C)

815 – 1,000

Oxygen content in Process Gas (%)

10 – 21

Oxygen content in Process Gas (%)

8 – 21

VOC Destruction Efficiency – Applicable for VOC Content Between 1000 ppm and 25% LEL (%)

Max. 99.5

VOC Destruction Efficiency – Applicable for VOC Content Between 1000 ppm and 25% LEL (%)

Up to 95 - 99.5

VOC Emission Applicable for VOC content below 1000 ppm (ppm)

Min. 5

VOC Emission Applicable for VOC content below 1000 ppm (ppm)

Down to 5 - 50

Availability (%)

Up to 98

Availability (%)

Up to 98

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SOLUTIONS FOR EXISTING AQCS Plant operators today face various challenges such as cost reduction, compliance with more stringent environmental regulations, and the need for improved plant flexibility. With an understanding of these challenges, GE uses our knowledge of AQCS technology and continues to innovate, offering a full range of:

Solutions for performance improvement of existing AQCS Equipment – GE & Other OEMs

• Upgrades and retrofit solutions for our customers’ existing AQCS equipment • Services and parts for operation and maintenance Some of our key solutions for enhancing performance of existing AQCS include: • High-frequency power supplies - switch integration rectifiers (SIRs) for ESPs •E missions and energy optimization algorithms, like EPOQ software, for various AQCS equipment types • Advanced control systems - EPIC for ESP and EFFIC for fabric filters • Superior diagnosis using ProMo software SIR Technology Our SIR technology combines a transformer/high voltage rectifier (T/R) and a control system for energizing and controlling ESPs in one compact integrated unit. With an integrated rapping control and EPOQ software for pulse optimization, the SIR controller takes the ESP’s performance to the next level.

Key Features • Suitable for installation on new or existing ESPs from GE and also other OEMs • More than 3,500 SIR units in operation around the world; solution developed in the 1990s • Reduces up to 70 percent particulate emissions compared to conventional technology, and emission levels reduced down to below 20 mg/Nm3, when required • Determines top power consumption

Sulfite Analyzer for WFGD Our new patented solution provides real-time measurement and control of the sulfite concentration in the slurry, allowing for reduced power consumption from the blower. Designed to cope with harsh environments in heavy industrial applications, our Sulfite Analyzer can be installed in the existing slurry slip stream with no need for an outage or process alteration.

Product

Equipment

Functionality

Key Benefits

SIR

ESP

ESP Power Supply

Emission & energy optimization

EPIC

ESP

TR Controller

Emission & energy optimization

ERIC

ESP

Rapper Controller

Control of electric impact rappers

EFFIC

FF

FF Controller

Air consumption & bag life enhancement

Optipow

FF

Pulse Valve

Superior pulsing performance for bag cleaning

ProMo4

ESP/FF/FGD

Monitoring & Control Software

Performance tuning & analytical tool, remote connectivity

ETU

ESP/FF/FGD

Human Machine Interface

Hand-held unit for controller settings, input & display

PCETU/PCMTU

ESP/FF/FGD

Human Machine Interface

PC-based unit for controller settings, input & display

IM300

ESP/FF/FGD

Protocol Convertor

Flaktbus to ethernet converter

AGDMS

ESP

Gas Distribution(GD) Measurement Tool

Robotic device for automated gd measurement

Ammonia Injection Skid

ESP

Ammonia Injection in Flue Gas Stream

Performance improvement of esp using ammonia injection

Switch Integrated Rectifiers (SIR) Model Sizes Available HV Power Supply Input (3-phase rectifier) Operating Temperature Size (w x d x h) Weight Dielectric Type

50 Hz 60 Hz

SIR4 120 kW 70 kV – 1700 mA, 85 kV – 1400 mA, 100 kV – 1200 mA 400 V - 196A, 500V - 157 A 480 V -163 A, 575 V - 136A -40ºC to +40ºC max 50ºC with reduced output current

SIR4 102 kW 70 kV - 1500 mA, 85 kV - 1200 mA 380 V - 180A, 400 V - 175A 480 V - 146 A -25ºC to +40ºC max 50ºC (122ºF) with reduced output current 45ºC with nominal output for 480 V, 60 Hz

845 x 1300 x 1210 mm (33,3 x 51,2 x 47,6 in) 450 - 500 kg Mineral Transformer Oil Nynas Nytro 10XN, vacuum degasified

Success Story A Brazilian customer replaced its conventional T/R sets with new high frequency power supplies (SIR) and control systems (EPIC). Emissions at the stack were reduced from 80 mg/Nm3 to 40 mg/N m3. Furthermore, the reliability of the equipment improved significantly, as did system life.

• Avoids cost-intensive retrofit • Suitable for ESPs in power and industrial applications, such as cement and pulp & paper 76

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AQCS FOR INDUSTRY Solutions for Industrial Applications Products

GE’s advanced Air Quality Control Systems are also used in a variety of industrial applications, including iron and steel, cement, waste-to-energy, biomass, pulp and paper and non-ferrous metals. At GE we address pollutants such as particulates, SOx, NOx, acid compounds, heavy metals, dioxin and furans. Additionally, we have developed special products to mitigate emissions such as HAPs (Hazardous Air Pollutants), VOCs (Volatile Organic Compounds) and H2S.

Key Benefits

APPLICATION

Oil & Gas

Waste To Energy

• Technically reliable and cost-effective solutions • Product expertise leading to solutions that meet customer requirements • Waste to energy: tailored and efficient solutions to help meet the most stringent emission requirements to both air and water, and at the same time recover valuable energy

Iron & Steel

• Pulp and paper: advanced ESP and fabric filter technology applied worldwide for emission compliance • Iron, steel and non-ferrous: primary and secondary steelmaking (coking plants, sintering plants,ore beneficiation, pig iron production, oxygen steel plants, electric arc furnaces, rolling mills) as well as smelting furnaces and converters for various non-ferrous productions • Petrochemicals-oil and gas: allowing the petroleum and refining industry to conform to strict emission limits while processing a broad feedstock slate

Cement

Aluminum

Non-Ferrous Metal

Pulp and Paper

Pulp & Paper Biomass

• Cement: single source for cement industry for multipollutant emission control with proven technologies such as FF, ESP and FGD systems

NonFerrous

Waste to Energy

8 Industries Covered

Particulate Particulate DeSOx-FF -ESP DFGD

DeSOxWFGD/ SWFGD P P P P P P P

DeNOxSCR

VOC- TO / RTO / KemPAK

Mercury Mercure / Filsorption

FCCU Boilers/Heaters Tank farms/Odour/Flares Captive Power Sour Gas Incineration Catalyst Recovery Unit SRU/TGTU

P P P P P P

P P P P P P P

P P P P P P P

Incinerators

P

P

P

P

Iron Ore Sintering Iron Ore Pelletization Sponge Iron Kiln Stock House Ventillation Cast House Ventillation Auxiliary Dedusting Induction Furnace Electric Arc Furnace Blast Furnace Boilers/ Captive Power Plant Cement Kiln Cement Mill Clinker Cooler Coal Mill Auxiliary Dedusting Boilers/ Captive Power Plant Soda Recovery Boiler Lime Kiln Boilers/Heaters Smelter Converter Auxiliary Dedusting

P P

P P P P P P

P P P

P P

P P

P P

P P

P

P

P

P

P

P

P P P

P

P

P P P P P P P P P P P P P P

P

P P P P P P P P P P P P P P

P P P P

P P

P

P

P

Iron/Steel

Success Story A leading cement manufacturer in India decided to expand its cement plant in the Indian state of Rajasthan. The manufacturer chose our AQCS equipment including Raw Mill Kiln Reverse air bag house, Clinker Cooler ESP, and Coal Mill fabric filter, all of which are designed for emissions of 30 mg/Nm3. The equipment was successfully commissioned along with the entire plant in 2015.

Biomass

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Petrochemicals Oil and Gas

Cement

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STEAM POWER SYSTEMS PRODUCT CATALOG I CO 2 Capture Solutions

CO2 CAPTURE SOLUTIONS (CCS) Building a Low Carbon Future

As a leader in the development of both cleaner coal technologies and Air Quality Control Systems, GE is at the forefront in the development of carbon capture technologies. With an intensive research and development program, we have designed and constructed 13 CO2 Capture Solutions (CCS) demonstration projects around the world, and these technologies are ready for large-scale implementation. Given the variety of plant types and fuel combinations in operation today, GE’s portfolio of technologies provides our customers with solutions that take into account many variables, including installation costs, overall plant efficiencies, and operation and maintenance costs. Our CCS technologies offer both postcombustion and oxy-combustion solutions for applications covering new build plants and the existing installed base. Additionally, our post combustion technologies can be scaled down for industrial flue gas from sources such as steel mills, cement factories, refineries and chemical plants. We are also developing secondgeneration technologies such as Regenerative Calcium Cycle (RCC) and Chemical Looping Combustion (CLC).

• All types of offerings for oxy- and post-combustion technologies • Most comprehensive pilot/ demo portfolio • Reliable technologies, ready for scale-up

What We Offer Our CCS services range from concept engineering and feasibility studies to plant commissioning. Our full scope of solutions includes design, equipment supply, installation, power block system integration, CO2 capture and processing equipment, and the full power plant. We make sure our customers have everything they need, including cost control, quality control, health and safety and O&M training.

Key Demonstration Projects Oxy-Combustion • 30 MWth, Germany (lignite) • 30 MWth, France (gas) • Boiler Simulation Facility, 15 MWth, U.S. (coal) • Mobile GPU Unit

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Post-Combustion Advanced Amines Process • 5 MWth, France (coal) • 2 MWth, U.S. (coal)

Post-Combustion Chilled Ammonia Process • 5 MWth, Sweden (oil) • 40 MWth, Norway (gas & FCC flue gas) • 58 MWe, U.S. (coal) • 5 MWth, U.S. (coal)

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Nitrogen

ASU Air Separation Unit

OXY-COMBUSTION CO2 CAPTURE

oxy-Boiler

FGC GPU Gas ESP/Bag FGD Flue Processing Unit Filter Desulphurization Gas Dust Condenser elimination

Coal Mill

Oxy-combustion consists of burning fossil fuels in a mixture of pure oxygen and re-circulated flue gas, resulting in CO2-rich flue gas (free of nitrogen, contrary to conventional air-fired power plants). The pure oxygen is supplied by a cryogenic air separation unit (ASU).

Key Benefits • Reliable and robust process • Adaptable to most boiler and fuel types with the potential for rapid scale up, even up to the 1,000 MWe range

CO2 Storage

Oxy-combustion Target (estimated future commercial)

Status (today’s offering)

Boiler Type

Two-pass, tower

Two-pass

Fuel

• Bituminous, sub-bituminous • Lignite • Oil, gas • Biomass (part load)

• Bituminous, sub-bituminous • Biomass (part load)

Size

Up to 1,350 MWe

Up to 448 MWe

Steam Condition

• Ultra-supercritical • Up to 605°C/623°C/300 bar

• Ultra-supercritical • Up to 605°C/623°C/279 bar

• Operational flexibility options • Available for retrofit to existing power plants • Integrated GE approach, providing both technical and economical benefits The oxy-combustion boiler has been under development for more than a decade, starting with research and the subsequent establishment of a laboratory pilot in the 1990s. GE has been at the forefront of oxy-combustion development, and we:

Gas Processing Unit

• developed the first oxy pilot plant at a site in Germany

Parameters

Target (estimated future commercial)


• demonstrated the entire oxy-technology chain including a gas processing unit in the boiler simulation facility located in Windsor, Connecticut, USA.

Temperature (°C)

20 – 100

20 – 100

Pressure (bars)

1

1

Flow Rate (t/h)

1,400

Up to 875

C02 Vol (% dry basis)

70 – 95

70 – 95

H2O Vol (%)

2 – 25

2 – 25

N2 Vol (% dry basis)

2–5

2–5

O2 Vol (% dry basis)

20 – 50

20 – 50

C02 Capture Rate(%)

90

90

GE is also developing the gas processing unit (GPU), which is designed to further treat and process the flue gas downstream of the oxy-boiler, delivering CO2 at the required specification. As part of the validation program, a mobile pilot unit was built for testing under multiple oxy configurations.

C02 Product Specification and Conditions

Oxy-combustion, a flexible technology for all types of fuel 82

Temperature (°C)

As Required

As Required

Pressure (bars)

As Required

As Required

Flow Rate (t/h)

Up to 600

Up to 276

C02 (mol-%)

> 95 – >99 Depending on Need

> 95 – >99 Depending on Need

H2O (mol-ppm)

As Required

As Required

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POST COMBUSTION CO2 CAPTURE Chilled Ammonia Process (CAP)

CO2 Storage

The chilled ammonia process (CAP) is a proprietary technology being developed by GE. Field validation tests have successfully demonstrated more than 99.9 percent pure CO2 product quality at 90 percent capture rates on combustion flue gas originating from oil, gas, and coal fuels. CAP features include:

CO2 Absorption Flue Gas Cooling/ conditioning

CO2 Regeneration

• High CO2 product purity • CO2 capture process tolerant to oxygen and flue gas impurities • Stable reagent, no degradation or emission of trace contaminants

CAP

• Low-cost, globally available reagent

Parameters

• Ability to use low ambient conditions to further reduce the energy consumption of the process

Flue Gas Inlet Conditions

• Integrated approach from GE, providing both economic and technical benefits

Temperature (°C)

45 – 100

45 – 100

Pressure (bara)

1

1

Environmentally benign in terms of emissions, CAP is a chemical absorption process using an ammonium-based aqueous solvent. The flue gas is contacted with chemical solvent – forming ammonium bicarbonate, ammonium carbonate and ammonium carbamate. The chemical reactions are reversible, and raising the temperature and the pressure of the reaction products reverses the capture reactions, releasing CO2 and allowing the solvent to be regenerated and returned to the process.

Flow Rate (t/h)

Up to 3,000

Up to 1,150


4 – 16

4 – 16

H2O Vol (%)

5 – 10

5 – 10


70

70


2–6

2–6

C02 Capture Rate (%)

Up to 90

Up to 90

CAP technology can be applied to various types of power plants such as coal, gas and biomass, as well as a vast range of industrial processes emitting CO2. The technology uses ammonia for the solvent, which is a globally available, low-cost commodity chemical with excellent thermal and chemical properties.

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CO2 Product Specification and Conditions Temperature (°C)

As Required

As Required

Pressure (bara)

As Required

As Required

Flow Rate (t/h)

Up to 800

10 – 200

C02 (mol-%)

Up to 99.9

Up to 99.9

H2O (mol-ppm)

As Required

As Required

NOTE: Regenerator pressure at 20 bara

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POST COMBUSTION CO2 CAPTURE Advanced Amine Process (AAP)

CO2 Storage

Amine-based carbon capture processes have been proven for decades in natural gas and syngas purification. Our Advanced Amine Process (AAP) applied to flue gases was developed jointly with Dow Chemical Company. Some key benefits of this process include:

CO2 Absorption Flue Gas Cooling/ conditioning

CO2 Regeneration

• More energy efficient capture and compression of the CO2 product • Designed for stringent emissions mitigation and control • Less solvent degradation than Monoethanolamine (MEA), leading to lower chemical consumption and lower production of effluents and waste

AAP Parameters



• Adaptable to new and installed base for both coal- and gas-fired plants

Flue Gas Inlet Conditions

• Higher tolerance against oxygen and trace contaminants

Temperature (°C)

30 – 100

30 – 100

Pressure (bara)

1

1

Flow Rate (t/h)

Up to 4,000

Up to 1,150


3 – 15

4 – 15

H2O Vol (%)

5 – 30

5 – 30


70 – 90

70 – 90


3 – 10

3 – 10

C02 Capture Rate (%)

Up to 90

Up to 90

The flue gas is bound with the chemical solvent – Advanced Amine – which binds selectively to the flue gas CO2. Raising the temperature reverses the capture reaction, releasing CO2 and allowing the solvent to be recycled. The technology has been demonstrated successfully in the field at 90 percent capture rates. Based on the low physical solubility of N2 and O2 in aqueous amines, CO2 product purity is greater than 99.5 percent after CO2 compression and dehydration. The highly selective reaction with CO2 is an important advantage of any alkaline scrubbing process and distinguishes this process from the results obtained from physical solvents, membranes or adsorbents.

CO2 Product Specification and Conditions Temperature (°C)

As Required

As Required

Pressure (bara)

As Required

As Required

Flow Rate (t/h)

Up to 800

12.5 – 230

C02 (mol-%)

> 99.5 – 99.9

> 99.5 – 99.9

H2O (mol-ppm)

As Required

As Required

Optimization of a well-known process for a new application 86

87

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GEA31876 (08/2015)