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MAN Diesel & Turbo Schweiz AG OSS / BroC 13.06.2012CAES 2 Technology
Second Generation Compressed Air Energy Storage
The Technology Geared Up For Europe's Renewable Energy GrowthDr. M. Nakhamkin Christian BrotelEnergy Storage and Power, LLC (ES&P) MAN Diesel & Turbo (MDT)
MAN Diesel & Turbo BroC, OSS CAES 2 Technology 13 June 2012
© MAN Diesel & Turbo Schweiz AG 2012 - All rights reserved.All Data and Information contained in this document is provided without liability for information purposes only,explicitly non-binding and is subject to change without notice. No representation or warranty is given or to beimplied as to the completeness of information or fitness for any particular purpose.Reproduction, use or disclosure to third parties, without express written authority, is strictly prohibited.
MAN Diesel & Turbo BroC, OSS CAES 2 Technology 13 June 2012
Agenda
2
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6
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CAES2 Performance Characteristics for 440 MW / 227 MW and 17MW plants
Products used for CAES plants
CAES2 Plants performance and operational flexibility to meet renewables and smart grid requirements
Renewable Energies and Compressed Air Energy Storage
1 MDT & ESPC Company Introduction
7 Conclusion
5 Cost estimates and economics
MAN Diesel & Turbo BroC, OSS CAES 2 Technology 13 June 2012
MAN Diesel & Turbo ProductsTurbomachinery
Compressors and turbines for all industrial applicationsSingle machines and complete machinery trainsAxial and radial compressors, screw and gear-type compressors for volume flows up to 1.5 million m³/h and pressures up to 1,000 barGas and steam turbines for power generation or mechanical drive applications with outputs up to 51 MW (Gas Turbines) and up to 160 MW (Steam / Air Turbines)Industrial Expanders for energy recovery with outputs up to 35 MWChemical reactors and apparatuses
MAN Diesel & Turbo BroC, OSS CAES 2 Technology 13 June 2012
Energy Storage and Power
MAN Diesel & Turbo BroC, OSS CAES 2 Technology 13 June 2012
Renewable EnergiesFuture Outlook
1 Mtoe is the amount of energy released by burning one ton of crude oil, approximately 42 GJ
MAN Diesel & Turbo BroC, OSS CAES 2 Technology 13 June 2012
Energy StoragePower Industry Challenges
Industry Demand
Fluctuations
Primary Energies
Price Volatility
Renewables
Intermittency
Transmission Grid
Congestion
Baseload Arbitrage Reduce Price sensivity Enhanced Value Higher Distribution
Improved Balance
To handle the increasing intermittent renewable power generation and the resulting volatility of electricity prices, a significant amount
of energy storage capacity will be required.
MAN Diesel & Turbo BroC, OSS CAES 2 Technology 13 June 2012
Energy StorageRange of available Technologies
Available Storage Technologies Estimated Storage Costs
MAN Diesel & Turbo BroC, OSS CAES 2 Technology 13 June 2012
Energy StorageExisting CAES 1 Plants
Huntorf (1978) Germany
McIntosh (1991)USA
Turbine Power / Discharge time Old 290 MW / 2 hrsNew 320 MW / ~3 hrs
110 MW / 24 hrs
Compression Power / Charging time 60 MW / 8 hrs 50 MW / 38 hrs
Power ratio 0.19 0.45
Charge / Discharge time Ratio 2.7 1.6
Cavern Pressure 46 – 72 bara 45 – 74 bara
EfficiencyHeat Rate
42%6700 BTU/kWh
(without heat Recuperator)
54%4100 BTU/kWh
(with heat recuperator)
AvailabilityReliabilityStart-up reliability
90 %97 %95 %
90 %97 %95 %
Cavern 2 x 150’000 m3 (Salt Cavern) 538’000 m3 (Salt Cavern)
MAN Diesel & Turbo BroC, OSS CAES 2 Technology 13 June 2012
ES&P Developed and Optimized the AES’s 110MW CAES Plant Conducted Technical Supervision of the Project Execution
Gibbs & Hill / Herbert Delivered Project on EPC basis
FuelAftercooler
Compressors (50 MW)
LP HP
Expanders (110 MW)
HP IP-2 IP-1 LP LP HP
Intercoolers
SSS Clutches
Underground Storage Cavern: A Solution Mined Salt
Motor/Generator
Recuperator
Heat Rate 4100 Btu/kWhEnergy Ratio 0.81 KWh in/out
Exhaust Stack
Salt Cavern Air Storage:Depth 1500 ft
Volume = 22MCF
Pressure = 650 psi
Existing CAES 1 PlantsSchematic for AEC CAES Plant
MAN Diesel & Turbo BroC, OSS CAES 2 Technology 13 June 2012
CAES 1 plants are based on a complicated Combustion Turbine Thermal Cycle withunique and first of its kind components.
Casing arrangement of components along the single shaft leads to muchcomplicated train rotor dynamics and start-up sequence.First of the kind components engineered for the site specific CAES Plant:• Uniquely Developed HP combustors operating at variable airflow (for AEC at 800
psia and 1000F supplied by AIT UK)• Uniquely Developed LP combustors operating at variable airflow (for AEC at 200
psia and 1600F supplied by AIT UK)• HP Steam Turbine converted into expander and integrated with the HP
combustor• The industrial expander with increased TIT from 1350F to 1500 F that required
the first time applied by DR nozzles cooling• Expansion Cycle operating at constant inlet pressure only (Throttling of Cavern
Pressure necessary leading to efficiency losses)Longer switch-over from Compression mode to expansion mode and vice-versaNo scalability of the concept, the 1st Gen plants/components were built for the SiteSpecific Data
Compressed Air Energy StorageLessons learned from CAES 1
ESPC Developed, Optimized and Specified The Unique and Customized the 110 MW CAES Plant Based on AEC Specific Conditions
MAN Diesel & Turbo BroC, OSS CAES 2 Technology 13 June 2012
Compressed Air Energy Storage440 MW CAES 2 Plant Layout
Exhaust Stack
Low PressureCompressors
High PressureCompressors
Air Turbines
Gas Turbine
Recuperator
GT Air intake
Switchyard
Cooling System
MAN Diesel & Turbo BroC, OSS CAES 2 Technology 13 June 2012
CAES 2440 MW plant based on GE 7FA Gas Turbine
440 MW CAES2 Plant Concept withInlet Chilling Power Augmentation
420 MW CAES2 Plant Concept withAir Injection Power Augmentation
MAN Diesel & Turbo BroC, OSS CAES 2 Technology 13 June 2012
235 MW CAES2 Plant Concept withInlet Chilling Power Augmentation
CAES 2235 MW Plant based on GE 7EA Gas Turbine
227 MW CAES2 Plant Concept withAir Injection Power Augmentation
MAN Diesel & Turbo BroC, OSS CAES 2 Technology 13 June 2012
CAES 217 MW plant with Above Ground Storage based on MAN Diesel & Turbo GT6-2 Gas Turbine
17.2 MW CAES2 Plant Concept with Air Injection Power Augmentation
and duct burner(1500-650 psia)
16.9 MW CAES2 Plant Concept with Humidification and Humid Air
Injection(1500-800 psia)
MAN Diesel & Turbo BroC, OSS CAES 2 Technology 13 June 2012
17.2 MW CAES2 Plant Concept with Multiple Expanders / Sliding
Pressure Operation (1500-800 psia)
17.2 MW CAES2 Plant Concept with Multiple Expanders / Sliding
Pressure Operation (800-530 psia)
CAES 217 MW plant with Above Ground Storage based on MAN Diesel & Turbo GT6-2 Gas Turbine
MAN Diesel & Turbo BroC, OSS CAES 2 Technology 13 June 2012
CAES 217 MW – 2 hours CAES plant with Above Ground Storage based on Gas Pipeline Technology
MAN Diesel & Turbo BroC, OSS CAES 2 Technology 13 June 2012
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Energy Ratio %
of Full Load
Heat Rate %
of Full Load
Total Plant Load %
Heat Rate & Energy Ratio vs Load (GE 7B CAES IC)
Expander 100‐0% Air Injection 100‐0% GT 100‐60%
Heat Rate & Energy Ratio vs. Load
CAES 2Heat Rate and Energy Ratio at Part Loads
MAN Diesel & Turbo BroC, OSS CAES 2 Technology 13 June 2012
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Plant Load, %
Time, minutes
CAES2 Cold Startup with Synchronized Expander
Bottoming Cycle Gas Turbine Total Plant
Gas Turbine Synchronized
Bottoming Cycle Power Gas Turbine
Power
Total PlantPower
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Total P
lant Pow
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Time, seconds
CAES2 Load Control During Plant Operation / Regulation
Total Plant Power
CAES 2Start-up and load dynamic response
Load FollowingCAES2 Startup with Synchronized Expander
High Ramping ratesEmergency and Fast Start Capability
MAN Diesel & Turbo BroC, OSS CAES 2 Technology 13 June 2012
CAES2 vs. Batteries, Pumped Hydro Performance and Capital Cost Estimate
Parameters Batteries PumpedHydro
440 MWCAES2
with below ground storage
235 MW CAES2
with below ground storage
17 MW CAES2
with above ground storage
Total Power, MW 10-20 500 440 180 17
Storage Hours 4 10 10 10 4
Estimated Specific Capital Costs, $/kW 2800 2500 - 4000 900 1000 1200
Estimated Capital Costs, $/kWh 400-600 250-400 85-90 85-90 400-450
MAN Diesel & Turbo BroC, OSS CAES 2 Technology 13 June 2012
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Compressed Air Energy StorageProduct Requirements & Matrix
MAN Diesel & Turbo BroC, OSS CAES 2 Technology 13 June 2012
Standardized Turbomachinery In different sizes ...
... standardized, but highly flexible
... suits all client and site-specific requirements
Standardized Auxiliary Systems
GEARBOXES
OIL SYSTEM
PIPING
AUXILIARIES
Frame Sizes
Rotors
Impellers
Bearings
Shaft seals
INTEGRATED
COOLERS
CAES 2 - Product Matrix & RequirementsStandardized line of Compressors
MAN Diesel & Turbo BroC, OSS CAES 2 Technology 13 June 2012
CAES 2 - Product Matrix & RequirementsStandardized line of CompressorsCompressor General Arrangement
MAN Diesel & Turbo BroC, OSS CAES 2 Technology 13 June 2012
CAES 2 - Product Matrix & Requirements GT Combination with Air Turbine
GE 7EA Net Output (base) 81 MW Max Air Turbine Power
+ + = 240 MW
Air Turbine will be mainly selected based upon the selected Gas Turbine (Heat Source)
GE LM 6000 Net Output (base) 43 MW
+ = 102 MW
MAN THM1304-15
Net Output (base) 12.2 MW
= 26 MW
MAN GT6 Net Output (base) 6.2 MW
= 17 MW
MAN Diesel & Turbo BroC, OSS CAES 2 Technology 13 June 2012
CAES 2 is based on a simple and reliable concept and on the utilization of standard“off-the-shelf” components with significant operational, maintenance and spare partsexpertise. It provides wide range of capacities from 10MW to 500 MWCAES 2 projects have design flexibility and operational advantages optimized for sitespecific conditions, renewable/smart grid operational terms and for customereconomical benefits:
low specific capital costs of app. 900-1200 $/kWlower heat rates – 3800 Btu/kWh, and energy ratios – 0.7-0.8Regulation/Load control – app. 60% of the total MW (the bottoming cycle) can bechanged within 10-15 sec.Synchronous reserve start-up - app. 60% of total MW will be delivered in 1-2 min.Combustion turbines with dry low emission (DLE) combustors have lowemissions which are further diluted on a per kWh-out basis by the green powergenerated by the expanders.
CAES 2 has a limited technical risk, a moderate investment costs, it provides afeasible technological solution today.Projects will be delivered jointly by MAN D&T and ES&P who are involved, on aWorldwide basis, in CAES 2 Technology and projects since more that three decades.
CAES 2Conclusion
MAN Diesel & Turbo BroC, OSS CAES 2 Technology 13 June 2012
All data provided in this document is non-binding.
This data serves informational purposes only and is especially not guaranteed in any way. Depending on the
subsequent specific individual projects, the relevant data may be subject to changes and will be assessed and determined individually for each project. This will depend
on the particular characteristics of each individual project, especially specific site and operational conditions.
MAN Diesel & Turbo BroC, OSS CAES 2 Technology 13 June 2012
Backup Slides
MAN Diesel & Turbo BroC, OSS CAES 2 Technology 13 June 2012
Compressed Air Energy StorageCAES 2 Key Benefits
Key features at a glance:CAES 2 is based on a simple concept based on Standardized ComponentsFast Start Capability for both generation and compression modesHigh ramping ratesHigh turn-down ratiosHighly flexible Operation Concept. It can provide several ancillary services on Generation and Distribution levels:
Arbitrage, Frequency Regulation, Spinning Reserve, Balancing EnergyRenewables ramp smoothing, capacity firmingGrid Support, Congestion, Capital Deferral, Black Start / Black Grid supportSynchronous Condensing mode (power factor and voltage regulation)
No switch-over time losses from Compression to Expansion or vice versaLow EmissionsLow Capital investment due to optimization based on standard components Fully defined maintenance costsCAES 2 Total Cost of Ownership shall be evaluated for period over 20+ years
MAN Diesel & Turbo BroC, OSS CAES 2 Technology 13 June 2012
MDT Cooperation with ESPC on CAES2 technology forover 3 years• Providing Compressors and expanders proposals for several projects
MDT is working with various Utilities on a Worldwide basis on CAES projects in various study and developmentstages
CAES Norton (USA) 2001 Engineering Study Contract• Isotherm - Radial Compressor Train, using Dr. M. Nakhamkin patent
110MW CAES plant - Alabama Plant 1988• Sumbmitted proposals for Compressors with higher efficiency and
lower costs
Soyland * CAES Project (USA) Decatur, Illinois 1981 • Axial – Radial Compressor Train• Conceptually engineered by Gibson&Hill/Dr. M. Nakhamkin
CAES Plant Huntorf (Germany) 1976• Supplied Axial – Radial Compressor Train
* Awarded contract hasbeen cancelled during
detail engineering.
CAES2MDT CAES Technology Experience
Since more than three decades, MAN Diesel & Turbo is involved in CAES projects on aworldwide basis and has developed a substantial experience in CAES Projects and allcomponents associated with the CAES Technology
MAN Diesel & Turbo BroC, OSS CAES 2 Technology 13 June 2012
ES&P patented the First and the Second Generation of the CAES Technologies
DOE co-sponsor NYSEG/PGE CAES projects based on CAES2 Proposals
ES&P is working with various Utilities on a Worldwide basis on CAES projects in variousstudy and development stages
110MW CAES plant - Alabama Plant 1988• ESPC conducted the optimization and conceptual engineering of the project• ESPC was conducting technical supervision of the project execution including:
• Supervision of the turbomachinery development by Dresser Rand• Supervision of the HP combustors development by AIT• Development of the test procedures• Supervised performance guarantee tests and issued the Test Report
• Under contract with EPRI, ESPC recorded key plant parameters during 1991-1994 -three years after theproject commercialization, and issued “ Value Engineering” Report
CAES Norton (USA) 2001 using Dr. M. Nakhamkin Patent to replace the HP Combustor
Soyland CAES Project (USA)* Decatur, Illinois 1981• Conceptually engineered by G&H/Dr. M. Nakhamkin
CAES2ES&P CAES Technology Experience
* Awarded contract hasbeen cancelled during
detail engineering.