PowerGen Europe, Vienna, Austria, June 4 - 06, 2013
The SCC5-8000H 1S Lausward Block F: ”The First
CHP to Extract 300MWth of District Heating from a
Single Power Plant Unit in
Combined Cycle Operation”
Michael Baum, Sales Manager GT Power Plants
Copyright © Siemens AG, 2013. All rights reserved.
PowerGen Europe in Vienna, Austria, June 4 - 6, 2013
Introduction
The strive for efficient use of primary energy combined with reducing the greenhouse gases (GHG) is
a key element in the EU-Policy for decarbonization.
The energy sector is expected to offer a high potential for contributing to the aim of the EU to reduce
the CO2 emissions by 20 – 25% in comparison with the 1990 value.
Electrical energy is not only considered as a key enabler of decarbonization (e.g. use of electric cars
instead of fuel driven vehicles), but also as a major driver for keeping industrialization within Europe
at high level by the EU-policy makers.
After the Fukushima nuclear disaster Germany has decided to abandon nuclear power plant technology by 2022 and enforce its Energy Transition. Driven by the introduction of a variety of subsidies for
renewable energy sources, Germany has seen a rise in the installation of Photovoltaic and Wind plants,
which already exceeded the projected figures by far. This in consequence has led to additional financial burdens and increase in electricity prices for consumers. Therefore, the German government is
searching for ways to restructure the built-out of renewables to achieve a better balance between renewable built-out and improving the power grid, without substantially loosing speed in the Energy
Transition “Energiewende”.
Besides the fact that Germany has achieved its CO2 aims defined in the Kyoto protocol, the CO2emissions generated by its power industry have continuously risen over the last two years. The reasons
for that can be mainly attributed to the very low Carbon prices and the rise of shale gas in the US and
subsequently to the decreased coal prices on the world market. This resulted in extended usage hours
of coal fired power plants due to the decreased marginal costs of these generation facilities. Combined
Cycle Power Plants (CCPP) are, therefore, under substantial economic pressure. This leads to the conclusion that only those CCPPs with a high efficiency and flexible operation characteristics will have a
positive business case in the future, provided that the current market conditions prevail.
It is yet to be seen if the shale gas boom will have a long-lasting downward effect on the worldwide
gas and oil prices. Irrespective thereof, natural gas will remain one of the important and widely available primary energy sources to be used in power generation for the next decades to come.
For the EU-policy makers, keeping the energy infrastructure at internationally competitive level in
terms of prices and greenhouse gas emissions will be of vital importance to maintain not only the
prosperity of its member states, but also to ensure the achievement of environmental goals.
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How the Combined Cycle Power Plants can play an important role in reducing CO2 footprint of the
energy industry will be explained in the next chapters.
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Europe’s Road to Decarbonization, part 1
In its roadmap for moving to a competitive low carbon economy in 2050 1 the European Commission
has reconfirmed several strategies to achieve substantial reduction in greenhouse gases (see Figure 1
below).
Europe‘s Road to Decarbonization
EU – Policy for 2050
EU Policies for
Decarbonization
-The EU Emission Trading
Scheme
- The legislation to promote RES
- The legislation to promote
Combined Heat and Power
generation (CHP)
- The legislation to promote the
energy efficiency of buildings
such as the “Directive on the
Energy
Source: COMMUNICATION FROM THE COMMISSION
TO THE EUROPEAN PARLIAMENT, THE COUNCIL, THE EUROPEAN
ECONOMIC AND SOCIAL COMMITTEE AND THE COMMITTEE OF THE
REGIONS
A Roadmap for moving to a competitive low carbon economy in 2050
…is currently on track due to effects of financial crisis, but future reductions
require substantial efforts
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Vienna, June 5th, 2013
Michael Baum @ PowerGen Europe
Figure 1: EU-Policy for Decarbonization
Among those policies are the promotion of Renewable Energy Sources (RES) and the legislation to
promote Combined Heat and Power (CHP) 2 .
The rise of RES has resulted in additional economical and technological challenges, with the first being closely connected to the payment of subsidies and the subsequent effects on the electricity prices.
The latter – the technological challenges – are concerned with the integration especially of large centralized RES into the power grid, with the constraints to grid overloading and grid frequency stability
problems and in the future the usage/implementation of storage capacities to make efficient use of the
excess of renewable energy feed-in.
1
EU – Communication from the Commission to the European Parliament, the Council, the European Economic and Social Committee and
the Committee of the Regions, A Roadmap for moving to a competitive low carbon economy in 2050, COM(2011) 112 final, Brussels,
8.3.2011
2
Directive on the promotion of cogeneration based on a useful heat demand in the internal energy market and amending Directive
92/62/EEC, officially 2004/8/EC
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PowerGen Europe in Vienna, Austria, June 4 - 6, 2013
The anticipated future power generation mix as shown for an exemplary week in June 2020 (see Figure 2) indicates that due to the fluctuating feed-in of RES, substantial load gradients need to be mastered by the non-renewable fleet.
We need flexible plants in the future:
Power Generation Scenario 2020 (Germany)
Typical Summer Week (June 2020)
residual load [MW]
High wind day
20.000
15.000
10.000
5.000
Load ramps:
Average: 52 MW/min
Max.: 181 MW/min
Min.: 0,467 MW/min
Peaks
≥9h
≥6h
≥10h
≥8h
≥11h
0
-5.000
Overload
-10.000
0 1
3
5
7
9
11
13
15
17
19
21
23
25
time [h]
Peak
4 GW
≥ 6h
≥ 11h
2 GW
2 GW
1 GW
2 GW
≥ 8h
≥ 9h
6 GW
≥ 10h
100% daily start-stop
Germany 2020: Up to 100% of the non-renewable fleet requires daily start-stop operation,
load ramps of about 200 MW/min to be covered
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Vienna, June 5th, 2013
Michael Baum @ PowerGen Europe
Figure 2: Effect of RES on non-renewable fleet
In order to summarize this section, it can be stated that not only efficiency in terms of fuel, but also
flexibility will be a main driver for power plant operations and developments in the future.
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Combined Heat and Power
Based upon the EU Combined Heat and Power legislation, Germany has introduced its CHPlegislation “KWK Gesetz” in 2009, which was revised in 2012 to further promote CHP and achieve
25% of power generation from the CHP-Plants (see Figure 3 below).
Combined Heat and Power in EU 24 / Germany
• German Government creates pre-conditions for CHP
promotion by „KWK Gesetz 2009 / 2012”
Consequences and Figures for high Efficient Combined
Cycle Power Plants > 2MW (KWKG 2012)
• Increase of promotion for CHP from
1.8 ct/kWh up to actual 2.1 ct/kWh KWK-Power
GER:
ca.12% Aim: 25%
in 2020
• Abolition of the max. promotion period of time (6 years) and
introduction of a promotion limit of “30,000 full load operating
hours”
• Introduction of promotion mechanism for heat- and cooling
storage
Amendment of „Kraft-Wärme-Kopplungsgesetz“ 2012
supports also the application of large CHP
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Source: http://www.dbresearch.de/PROD/DBR_INTERNET_DE-PROD/PROD0000000000221415.PDF
Speicher:DB-Research2008_KWK-Eckpfeiler-des-IEKP_16p.pdf
Michael Baum @ PowerGen Europe
Figure 3: Short Overview of Germany’s CHP - Legislation
With the latest revision of the CHP-legislation, the subsidy was increased from 1.8 to 2.1ct/kWh
CHP-Power. Furthermore, the subsidy receipt period was flexibilized to 30.000 Full Load Operating
Hours (FLOH), instead of the formerly limit of 6 years/ 30.000 (FLOH). For most CHP this will extend the subsidy receipt period beyond 6 years.
Considering the current low spark spread for CCPP in Germany, only CCPPs with CHP are likely to
demonstrate a positive business case due to the available subsidies for CHP-Power. For example, the
subsidies may reach up to EUR 200 Million for a CCPP with 270MWth district heating.
Also, the introduction of subsidies for cold and heating storages may have a positive impact on the
success of CHP plants, given that the storages will add value to the operational flexibility of CCPPs,
e.g. the heating storage can be loaded when the CCPP is running in low load operation (little power
demand) and the storage can be unloaded in times of peak power prices, with the CCPP preferably
running in pure condensing mode to obtain maximum benefits from the power market.
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PowerGen Europe in Vienna, Austria, June 4 - 6, 2013
The success of CHP with CCPP, not only in Germany, will depend upon a series of factors, including:
1. Economic concerns, such as the market structure and prices for natural gas and
electricity (spark spread).
2. The future of the EU Emission Trading System (ETS).
3. The availability of heat sinks (district heating or process steam requirements).
4. The investment in infrastructure to bring the “heat” to its consumers, e.g. builtout of district heating networks.
5. Competitiveness of other power generation technologies, especially the
traditional “substitutes” , e.g. coal fired power plants.
There is no doubt that CCPPs with and without CHP are and will be key corner stones of the future
energy mix, but its immediate advance to substitute coal fired power plants is hampered by the overall
economic situation.
Therefore short-term developments in CCPP technology will focus on effective integration of CHP
requirements.
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PowerGen Europe in Vienna, Austria, June 4 - 6, 2013
CCPP with Combined Heat and Power Technology (CHP)
The Combined Heat and Power Technology are largely driven by the process demands, e.g. district
heating applications or process steam extraction.
Virtually each CHP Plant is customized to provide the most benefit in terms of:

Satisfying the process parameters to the extent possible, without using back-up facilities or
add-ons, such as duct firing

Reaching a high fuel utilization factor (a value above 80% is an indication for a good CHPquality)

Minimizing the power loss factor, which provides an indication about the quantity of electricity “lost” due to the extracted steam not taking part in the electricity generation process
With an increase in steam export to a district heating system or to process plants, the fuel utilization
factor increases but the net electrical efficiency decreases due to the “lost” steam, as shown in
Figure 4:
SCC5-8000H 1S optimized for combined heat and power
achieves over 80% fuel utilization
1 stage steam extraction
Fuel utilization factor,  [%]
Electrical efficiency,  [%]
3 stage steam extraction
 = Fuel utilization factor
+20%-pt.
 = Elec. efficiency
Thermal to electrical power ratio [%]
=
Heat power + elec. Power
Fuel power
=
Elec. power output
Fuel power
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Vienna, June 5th, 2013
Michael Baum @ PowerGen Europe
Figure 4: Interdependency between Fuel utilization and Electrical efficiency
As could be seen above, an increase in fuel utilization for district heating applications, can be achieved
by using an innovative multiple steam extraction. This is due to the fact that the multiple steam extraction can be fine-tuned to account for the most important load cases.
Obviously, the extraction stages correspond to steam-extraction-points within the water-steam-cycle of
the power plant. The typical extraction points are shown in the Figure 5 below.
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PowerGen Europe in Vienna, Austria, June 4 - 6, 2013
Combined Heat and Power with CC Power Plants
in Single-Shaft Configuration by Siemens…
Heat Recovery Steam Generator
LP Steam
Additional Heating
LP
Loop in the HRSG
Fuel utilization factor ca. 85%
(Based on
district
heating)
(Based
on 270MWth
270 MWth
district
heating)
LP Main Steam
HP Main Steam
IP
HP
Cross-over pipe
Gas Turbine Generator
Steam
Turbine
Exhaust Gas
Cold Reheat
Cold Reheat
= Possible extractions for district heating
Hot Reheat
LP Turbine
Condensate
… the combination of standardization and customizing
for the full benefit of the owner and operator
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Vienna, June 5th, 2013
Michael Baum @ PowerGen Europe
Figure 5: Steam extraction points in water-steam-cycle
For district heating applications lower calorific steam should be used to minimize power losses. This
may result in extracting steam from the low-pressure section of the steam turbine for this kind of application. For process steam applications, the steam extraction points must be selected to ensure the
necessary physical properties of steam: pressure and temperature.
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The SCC5-8000H 1S Lausward Block F, Düsseldorf / Germany
Düsseldorf’s local utility, Stadtwerke Düsseldorf (SWD), is running an extensive district heating network on both sides of the Rhine river.
With its three generation centers Flingern, Garath, and Lausward, SWD provides yearly approx.
1.4Mill. MWth of district heating power over its 200km network to its customers.
In future SWD wants to use its district heating upgrade potential by increasing the system capacity by
15MWth/a 3 .
For its project SCC5-8000H 1S Lausward Block F, SWD was looking for state-of-the-art power plant
technology to ensure SWD’s competitiveness on the market, by increasing its share of self produced
electricity and to produce district heating at lowest costs.
Siemens met those requirements by offering the SCC5-8000H 1S based upon its high efficient gas
turbine SGT5-8000H. The gas turbine is arranged in a single-shaft configuration combined with a
steam turbine SST5-5000 which is equipped with three steam extraction points as shown in Figure 6
below.
District Heating Applications, Example SCC5-8000H 1S
Steam extraction from cross-over pipe
Steam extraction from side of LP-turbine
Steam Turbine design modified to support highest efficient steam extraction
at very low electricity losses
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Michael Baum @ PowerGen Europe
Figure 6: Steam extraction points in water-steam-cycle, SCC5-8000H 1S Lausward Block F
Using these steam extraction points, the power loss factor is as low as 0.16 for the important load case
of 150MWth district heating.
3
„Attraktive Effizienz“, ZfK March 2013, page 14
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PowerGen Europe in Vienna, Austria, June 4 - 6, 2013
The power plant can extract in total 300MWth, which is approx. 75% of the maximum district heating
demand of Düsseldorf. No further auxiliaries such as duct firing are needed to achieve this outstanding
performance, especially in respect to eco-friendliness and security of supply.
By using the 3 stage steam extraction layout, the most efficient way to balance steam export with district heating demand is achieved without the need for quenching high calorific steam from other upstream steam extraction sources.
This means that with increased district heating demand, the steam is extracted accordingly from the
relevant sources, e.g. for a low to medium heating demand, only extraction from the LP section of the
steam turbine is used. With increased heating demand, further steam is extracted from the cross-overpipe between the IP and LP Section of the steam turbine. Subsequently at full district heating load,
most of the steam is taken from the latter source.
This high level of steam extraction results in a fuel utilization factor of approx. 85%, meaning that
85% of the fuel is converted into heat and power. This demonstrates the high quality of the CHP process.
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Another outstanding feature of the SCC5-8000H 1S Lausward Block F is the achievement of over
61% Net Electrical Efficiency by using the state-of-the-art water-steam-cycle features, such as 600°C
life steam temperature and the Benson ® design for the Heat Recovery Generation System
(see Figure 7 below).
Innovative design features and proven technologies
enable SCC5-8000H 1S to reach η > 60%
HRSG: BensonTM
3Pr/RH 600 °C/170 bar
Steam Turb.: SST5-5000
Gas Turbine: SGT5-8000H
Combined HP/IP
Dual flow LP
HP: 170 bar / 600 °C
IP: 35 bar / 600 °C
LP: 5 bar / 300 °C
Generator: SGen5-3000W
Water cooled stator winding
Hydrogen cooled rotor winding
MICALASTIC® Stator insulation
World class efficiency
Two main levers to reach highest efficiency
Gas Turbine
■ Increased pressure ratio
■ Increased turbine inlet temperature
combined with cooling air optimization
■ Improved component efficiencies
Water/Steam Cycle
■ Fuel preheating of 215 °C
■ Advanced water/steam cycle (up to
600 °C) with BensonTM HRSG
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Vienna, June 5th, 2013
Michael Baum @ PowerGen Europe
Figure 7: Design Features SCC5-8000H 1S Lausward Block F
Based upon this high efficiency, SCC5-8000H 1S Lausward Block F will keep its competitive advantage in Germany’s Merit-Order system.
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The road to decarbonization, part 2
Obviously, an increase in efficiency and a high fuel utilization factor results in low specific CO2 emissions per electrical kilowatt-hour produced.
Based upon Siemens’ SGT5-8000H, the SCC5-8000H 1S produces specific CO2-emissions as low as
325g CO2/kWh net.
ECONOMICS:
Highest fuel efficiency in CHP Plant by Siemens
Lausward
Düsseldorf
SCC5-8000H 1S
Customer
Stadtwerke
Düsseldorf
Total el. Power Output 596 MW
Plant efficiency
>61 %
ST Type
SST5-5000
Generator Type
SGen5-3000W
Date of contract
05 / 2012
1st comm. operation
end 2015
Special features
 District heating 300 MW th
 85 % fuel efficiency
 CO2- Emissions less than 325 g/kWh
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Michael Baum @ PowerGen Europe
Figure 8: Summary Design Features of SCC5-8000H 1S Lausward Block F
This exceptionally low value in comparison with coal fired power plants results from a change to relatively low carbon fuel (natural gas) and from the higher power plant efficiency.
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The following Figure 9 summarizes this aspect.
Siemens high efficient H-class CCPP solution
enables significant CO2 emissions reduction
Spezifische CO2 - Emissionen verschiedener
Kraftwerkstypen
kg/kWhel, netto
1
0,94
0,73
0,8
0,6
η≈ 43%
η≈ 46%
η≈ 60 - 61%
0,33
0,4
kg/kWhel +
kWhth, netto
CO2 savings:
5 Mill tons/year/
1100 MW*
0,15
0,2
0
Lignite Plant,
State-of-the-Art
(*)
Hard Coal Plant,
State-of-the-Art
per 1100 MW unit power output and 7500 operation hours/a
CCPP
SCC5-8000H
CCPP
SCC5-8000H
with CHP
(300MWth)
η= Netto Efficiency
Quelle: Umweltbundesamt: klimaschutz und Versorgungssicherheit – Entwicklung einer nachhaltigen Stromversorgung, Climate Change 13/2009, Dessau-Roßlau 2009
~ 115 - 175% CO2 emission reduction due to lower carbon content of natural gas and
higher efficiency with our SCC5-8000H
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Michael Baum @ PowerGen Europe
Figure 9: Specific CO2 Emissions per Power Plant Type (fossil fuel)
The SCC5-8000H 1S Lausward Block F will produce approx. one-third of the CO2 emissions of one
state-of-the-art lignite plant. Comparing total emissions by using a typical lignite plant size of
1100MW, this results in yearly CO2 savings of 5 Mill. tons.
If the comparison is extended by including the maximum district heating production of 300MWth then
the CO2 savings are even greater.
Therefore, the SCC5-8000H 1S with CHP are the most preferable fossil plant solution to meet the
ambitious EU CO2 limits.
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Summary
Energy efficiency and the fuel switch from coal to natural gas are the key elements to reduce the CO2
footprint of the energy industry. The latest generation of CCPPs already achieves an efficiency level
beyond 60% and is therefore the most efficient fossil fired power plants. But there are still ways to
increase the energy efficiency of a CCPP even further by implementing e.g. combined heat and power
capabilities (CHP). Stadtwerke Duesseldorf and Siemens signed the contract to start building the
Lausward CHP plant in July 2012, providing a contribution in meeting the city’s climate and CHP
targets set by the state and German governments. In addition to the outstanding, “world record” efficiency level over 61% net in condensing mode operation, the Lausward CHP plant can export up to
300MWth to the local district heating network. No further auxiliaries such as duct firing are needed to
achieve this outstanding performance, especially in respect to eco-friendliness and security of supply.
The configuration provides the most efficient way to extract steam to the district heating system corresponding ideally to the respective load demand and will set a landmark for future power generation in
Germany and elsewhere.It emphasizes the central role of CHP engine as part of the German energy
transition (Energiewende) debate. Based on Siemens experience with the H-class design this paper
presented the outperforming advantages of the Lausward CHP Block F in regard to heat extraction,
fuel utilization of approx. 85%, and the optimized cycle design selected to reduce electricity losses at
extraction point to a minimum.
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Permission for use
The content of this paper is copyrighted by Siemens and is licensed to PowerGen Europe for publication and distribution only. Any inquiries regarding permission to use the content of this paper, in
whole or in part, for any purpose must be addressed to Siemens directly.
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