OP16: Small fuel flexible Gas Turbines for Decentralized

power generation China Gpower, Shanghai, 2014-04-09

Regine Mowill
Marketing Director
OPRA PROPRIETARY INFORMATION
Outline of today’s presentation
Benefits of Distributed Energy
Cleaner onsite power generation

Market drivers for gas turbine driven onsite power

Introduction to OPRA Turbines

History

OP16 Markets and applications

Key technologies: OP16 gas turbine & OP16 combustion technology

Reference projects
Examples from the field

Summary and conclusions

OPRA PROPRIETARY INFORMATION

Smog can be a thing of the past
A fog so thick and polluted it left thousands dead, London in 1952. The smoke-like pollution
was so toxic it was reported to have choked cows to death in the fields.
Clean Air Acts of 1956 and 1968. Acts banned emissions of black
smoke and decreed residents of urban areas and operators of
factories must convert to smokeless fuels. UK 1952,
People were given time to adapt to the new rules, and fogs Clean Air Act
continued to be smoky after the Act of 1956 was passed. In
1962, for example, 750 Londoners died as a result of a fog, but 1956 & 1968
nothing on the scale of the 1952 Great Smog has ever occurred
again.

This kind of smog has now become a thing of the past, thanks
partly to pollution legislation and also to modern developments,
such as the widespread use of central heating.

Canned air for sale in China as smog returns

Chen Guangbiao, whose
wealth is valued at $740
million according to the
China 2013
Hurun Report, sells his
cans of air for five yuan
each.

OPRA PROPRIETARY INFORMATION

Distributed Energy can improve air quality and increase
availability of power
China is a large country with diverse resources, regions and sizes of cities
Locally available fuels / energy resources (incl Solar, wind, gas, hydro, geo thermal
etc)

Utilization of waste gases

Energy Efficiency (CHP)

Energy conservation

Minimize grid losses

Lower investment costs and quicker to install compared to centralized power

Diverisfy energy mix and increase availability of power

Reach remote locations

Enable own power production and increase security of supply

Incremental changes also help

OPRA PROPRIETARY INFORMATION

Key market drivers for gas turbine driven onsite power
Shale gas and increasing gas abundance
Lower long term gas prices ( world wide)

Greater availability (world wide)

On-site power generation / Decentralized power generation

Energy security / Lack of grid / grid reliability issues: esp. for critical operations incl.
oil & gas production, hospitals, 24/7 factory production, data centers

Energy efficiency: cogeneration / trigeneration

New fuel sources (liquid / gas)

Bio fuels

waste fuels : industrial waste, municipal waste, gas flaring from oil and gas fields

Environmental policies: air pollution, mitigating climate change

Renewables on the grid increasing need for peak shaving

OPRA PROPRIETARY INFORMATION

Mission statement

OPRA aims to become the world’s leading

provider of on-site gas turbine driven energy
solutions in the 0.5 – 10.0 MW power range

OPRA PROPRIETARY INFORMATION

Executive summary

OPRA was established in the Netherlands in 1991

After initial R & D and technology demonstration, the OP16

gas turbine was commercialized in 2005.

The 2 MW range OP16 gas turbine is unique in that it

combines robustness and simplicity with high performance
and fuel flexibility

OPRA has demonstrated market success for oil & gas as well
as industrial and commercial CHP applications

OPRA has sold more than 80 gas turbines over the last
five years

The OP16 has accumulated more than 1,5 million

operating hours worldwide

OPRA is ISO 9001, DNV according to API standards, and

GHOST certified

OPRA PROPRIETARY INFORMATION

OPRA has valuable sales references world wide

TEEKAY
The 1.9 MW OP16 gas turbine engine combines
the best of simplicity and high performance
6.7:1 ratio Dual-fuel & low emissions
Reduction compressor combustors (4)
gear

High-efficiency radial
turbine
Bearings
in cold part
of engine

ELECTRIC EFF. 26%

8.7 kg/s
EXHAUST FLOW
19.2 lb/sec
EXHAUST GAS TEMP. 570ºC / 1063ºF
ROTOR SPEED 26,000 rpm
40,000 hours
TBO
AND 3000 starts

OPRA PROPRIETARY INFORMATION

The OP16 Rotor Module: the robust heart of the engine

 Overhung rotor with bearings in the cold

section of turbine
 Single stage 6.7:1 compression
 Single stage turbine
 Virtually no lube oil consumption
 Robustness and long life
 High resistance to FOD*
 High efficiency (~90%)
 No blade cooling

* Foreign Object Damage

OPRA PROPRIETARY INFORMATION
Increasing demand to burn alternative fuels

Increased demand from customer to burn alternative fuels

Environmentally friendly

More cost-effective operation

Utilize fuels that are locally available

Dual fuel / bi fuel for operational flexibility

OPRA PROPRIETARY INFORMATION

Fuel flexibility - Broad range of fuels gas turbines can handle

OPRA PROPRIETARY INFORMATION

OP16 combustor systems
Conventional combustor
Diffusion flame
Film cooling
Dual fuel operation
Switch under full load operation

DLN combustor
Dry low emission (<25 ppmv NOx)
Pre-mixed flame
Impingement cooling
Gas 38-50 MJ/kg

Low calorific fuel combustor

Diffusion flame
Impingement cooling
About 5 times larger volume
Specially designed for low calorific fuels

OPRA PROPRIETARY INFORMATION

The low-calorific fuel combustor fits on the engine
without the need to extend the overall package
About 5 times larger combustor volume is required

Can handle liquid and gaseous fuels with LHV

down to 6 MJ/kg (150 btu/scf )

The low-calorific combustor (left) and OP16 with low-calorific combustor

the conventional combustor (right)

OPRA PROPRIETARY INFORMATION

Fully containerized system is compact and low weight

Power output: 1.8 Mwe

4 – 5 MWt
Compact: 20 ft ISO container
Low weight: <20 tons
Clean: Ultra Low NOx
Quiet: 70-85 dB at 1 meter
Reliable: TBO* 40,000 hours
Low maintenance cost

*Time Between Overhaul

The OP16 can be used for a wide range of onsite
power applications

Industrial Commercial
Co-/tri-generation Hotels
Process Data centers
Ceramics, paper Hospitals

OP16 markets

Oil & Gas Waste to power

Offshore Landfill gas
Onshore VOC destruction
Floaters Flare gas utilization

OPRA PROPRIETARY INFORMATION

OP16 is highly suitable for CHP applications with only 3%
losses
100% Fuel

3%
26% Losses
Electrical 71%
energy High grade thermal
energy
The OP16 has lower losses than piston engines

OP16 Reciprocating
100% Fuel Engine 100% Fuel

3% 9% 27%
26% Losses 27%
Losses 37% LOW grade
Electrical MEDIUM grade
71% thermal energy
energy Electrical energy thermal energy
HIGH grade
thermal energy
OPRA is uniquely competitive where a high degree of thermal
energy is required in addition to electrical power
Competitive landscape, CHP market

High Industrial
Thermal Energy Requirement

Light
Industrial

Commercial

Micro
GT
Low Residential
0 1 2 3 4 5 6
Electric Power (MW)
Small-scale onsite gas turbine power generation

Independent power generation

Peak shaving
The exhaust heat can be utilized leading to high
overall fuel efficiency (CHP)
Can utilize fuels that are locally available

OPRA PROPRIETARY INFORMATION

Page 20
Example of onsite power and heat generation for an
industrial process

Isotonic drink manufacturer in Indonesia

24/7 production line
Issues with the grid stability
2 OP16-3A units installed connected to 1 HRSG
1.5 MWe each
6 tons of steam per hour each
Steam required for sterilizing the water bottles
Dual fuel where liquid fuel is used as back-up
to ensure continuous operation

OPRA PROPRIETARY INFORMATION

Example from operation on associated gas

Flare gas is a challenging fuel

High content of sulphur
Heavy hydrocarbons
Variation of fuel composition
Remote oil field in Russia
The OP16 fleet has operated more than 500,000 hours on flare gas
Sulphur content up to 4%
2 units have operated more than 50,000 hours each without overhaul

OPRA PROPRIETARY INFORMATION

Example for flexible operation on syngas

Turbine Model: OP16-3A / upgrade to 3C

Application: Electricity, Drying
Location: Netherlands.

A gas turbine was desired that could operate on both

syngas and natural gas.

The special low calorific combustor and dual fuel system of 1 OP16 for gypsum
the OP16-3C gas turbine enables 24/7 continuous operation plasterboard manufacturer
on any ratio of syngas / natural gas.

In other words, the OP16-3C gas turbine can operate on

100% syngas, 100% natural gas or any combination of
these gases, without losing performance.

OPRA PROPRIETARY INFORMATION

Operation on syngas derived from solid municipal waste
Power production via gasification of solid waste has gained
importance.
Traditionally, syngas is utilized via steam/organic rankine cycles to
produce power with 13-20% efficiency. The waste to power
industry is challenged to increase the efficiency and utilize syngas
on combustion turbines/engines without expensive fuel cleaning.
The syngas is produced from the municipal un-sorted solid
waste (ultra-low heating value of 150BTU/scf, containing
impurities and condensables.) The OP16 gas turbine can operate
on this fuel to produce 1.8MWe with 25% electrical efficiency. In
addition, the gas turbine exhaust when coupled to an ORC cycle,
obtainins a combined cycle efficiency of 37%.
Plant operates 24/7 and delivers all the power output to the
national grid.
Possibility of dual- and bi-fuel operation. The former refers to
switching between gas and liquid fuels and the latter refers to
simultaneous operation on gas and liquid fuels. Since the
availability of the alternative fuels changes over time these types
of operation modes are becoming more important.
6 OPRA units providing power to the Winter Olympics
CHP at a Cigarette Factory in Germany
Heat and Power for a Starch factory in Germany
2 OP16’s providing CHP solutions for energy drink plant
Direct heat and power at a ceramics factory
1 OPRA unit at an Offset Plate factory

NG BASIC DESIGN
900 oC

Liqu
gen NG Sol
900 oC
vents
Gas turbine
560 oC

blast off 40-80 oC 390 oC Com 25 barg

bus
tor
600 oC
gen
steam 60 barg

160 oC
180 oC condensate
SCR

ECO

stack
ECO
damper
hot water
90 oC 135 oC
1 OPRA unit at an optics and thermal imaging plant
2 OPRA units at an oil field above the polar circle
3 OPRA units on an FPSO in Brazil
3 OPRA units for an oil field in the North Sea
7 OPRA units at natural gas field
1 OPRA unit on an offshore gas field
Summary: More focus on flexible power generation
Smaller gas turbines are suitable for decentralized power production

Increasing demand for decentralized/onsite power generation using alternative /

waste fuels

Operational flexibility: Dual fuel, bi-fuel, 1 min start-up

”Off-grid” remote locations

Energy security

Cost savings and environmental benefits

OPRA has demonstrated product reliability during operation on contaminated

fuels such as sour well-head gas

OPRA has developed a combustor that can handle fuels with

heating values : 6-25 MJ/Nm3 (150-640 btu/scf )

OPRA PROPRIETARY INFORMATION
Thank you for your attention!

For further information: Regine Mowill, Marketing Director: [email protected]

www.opraturbines.com
OPRA PROPRIETARY INFORMATION