The way forward for gasoline generators and hydrogen are intricately intertwined. Fuel turbine producers know that they want their tools to be able to function on increased ranges of hydrogen as electrolysis expertise advances, manufacturing tasks come on-line, and clear hydrogen turns into extra available to assist end-users decarbonize their energy techniques.
In Might 2023, the U.S. Environmental Safety Company (EPA) proposed 5 separate actions beneath Part 111 of the Clear Air Act addressing greenhouse gasoline (GHG) emissions from fossil fuel-fired electrical producing models. Among the many actions have been proposed emission tips for GHG emissions from the “largest, most often operated present stationary combustion generators” and a solicitation for feedback on approaches for emission tips for GHG emissions for the rest of the present combustion turbine class.
Throughout the 181-page proposed rule printed within the Federal Register is a greatest system of emission discount (BSER) pathway that may require the co-firing of 30% (by quantity) low-GHG hydrogen in baseload gasoline turbine models by 2032, ramping as much as 96% by quantity by 2038. Whereas EPA Administrator Michael Regan on Feb. 29, 2024, indicated the company would drop necessities protecting present pure gasoline–fired energy vegetation in its last Part 111 GHG rule, which is predicted to be printed in April 2024, gasoline turbine unique tools producers (OEMs) perceive that creating larger hydrogen co-firing capabilities of their gasoline generators stays a crucial want, as it’s attainable such necessities might be stipulated sooner or later sooner or later.
Moreover, GHG laws will not be solely a U.S. precedence. Many different international locations are additionally engaged on measures to decarbonize their vitality techniques and will impose laws that OEMs might want to assist plant homeowners meet. Due to this fact, analysis and improvement (R&D) on superior combustion techniques permitting as much as 100% firing of hydrogen in gasoline generators is a aim for nearly all the main gasoline turbine OEMs.
Hydrogen Provides Anticipated to Develop
In January, consultants from Siemens Vitality, Mitsubishi Energy, and GE Vernova, amongst others, gathered on stage at POWERGEN Worldwide in New Orleans, Louisiana, for a Mega Session titled “The Decarbonization Journey for Dispatchable Fuel Generators—2032 and Past.” Bobby Noble, program supervisor for Fuel Turbine R&D with EPRI, moderated the session, which included shows given by Jason Jermark, vp—World Companies Operations, Fuel Companies, Siemens Vitality; Ben Thomas, senior supervisor, Hydrogen Manufacturing Engineering, Mitsubishi Energy Americas; and Jeff Goldmeer, World Hydrogen Worth Chain Chief, GE Vernova.
Noble started the session by explaining how laws are behind not less than a few of the actions OEMs are taking. In Jermark’s presentation, whereas not disagreeing with Noble, he took it a step additional by noting how tax credit score adjustments and the Inflation Discount Act (IRA) within the U.S., and carbon tax developments in Europe and Asia, are additionally resulting in expanded curiosity in hydrogen.
“Hydrogen supplies a pleasant various to present gasoline sources, particularly pure gasoline,” Jermark mentioned. “It’s very versatile. It’s very considerable. Now we have expertise utilizing it. And, we’re capable of successfully present it’s attainable to make use of it in quite a lot of methods. For instance, Siemens Vitality on the co-firing entrance, it’s not well-known throughout the trade, however we’ve been utilizing hydrogen in varied functions for over 4 a long time now.”
But, when the subject of co-firing comes up, Jermark mentioned, the “elephant within the room” revolves round provide. He prompt that just a few years in the past he was skeptical that sufficient hydrogen might be produced to have a significant influence on the ability technology sector, however after seeing the pace at which manufacturing capabilities are altering, he sees how vital hydrogen might be sooner or later.
“The variety of tasks which were introduced globally elevated by about four-fold in the previous couple of years and proceed to speed up,” he mentioned. Particular to Siemens Vitality’s capabilities, Jermark referred to a brand new gigawatt electrolyzer manufacturing facility in Berlin that was formally inaugurated final November. Siemens Vitality and Air Liquide anticipate a ramp-up to not less than three gigawatts by 2025 with potential for extra. The corporate estimates that with three gigawatts of put in electrolysis capability, a mean of 300,000 metric tons of inexperienced hydrogen will be produced per yr when operated with renewable energies.
Electrolysis Know-how
The Berlin manufacturing facility will produce stacks based mostly on proton alternate membrane (PEM) expertise, which Siemens Vitality says is especially good at following intermittent renewable vitality provide. In Europe, quite a few low-carbon and renewable large-scale hydrogen tasks are already beneath improvement. One, the Air Liquide Normand’Hy 200-MW electrolyzer challenge, is beneath development close to Port-Jérôme, France. The Normand’Hy challenge is predicted to be one of many first tasks equipped with tools from the Berlin facility. Siemens Vitality can be engaged on a number of different large-scale electrolyzer tasks, reminiscent of Kassø in Denmark and FlagshipONE in Sweden, which can each present hydrogen not less than partly for the synthesis of e-fuels for transport.
In the meantime, Mitsubishi Energy is creating different hydrogen manufacturing applied sciences, together with strong oxide electrolysis cells (SOEC), anion alternate membrane (AEM) water electrolyzers, and next-generation turquoise-hydrogen manufacturing expertise that produces hydrogen with out emitting CO2 by the pyrolysis of methane into hydrogen and strong carbon. Mitsubishi Energy is creating these basic applied sciences on the firm’s Nagasaki Carbon Impartial Park, and plans to realize commercialization following hydrogen manufacturing validation at its Takasago Hydrogen Park.
Mitsubishi Energy has an extended historical past of validating its gasoline turbine expertise in an indication plant, generally known as T-Level, at its Takasago Equipment Works facility, situated about 50 kilometers west of Kobe, Japan. The hydrogen park was not too long ago added to the positioning; it entered full-scale operation in September 2023. Mitsubishi Energy mentioned the park “goals to enhance product reliability by the validation of hydrogen co-firing and 100% hydrogen firing of gasoline generators, whereas additionally implementing successive enlargement with the introduction of next-generation hydrogen manufacturing applied sciences.”
Takasago Hydrogen Park (Determine 1) is split into sections in keeping with three hydrogen-related features: hydrogen manufacturing, storage, and utilization. Within the manufacturing space, an alkaline electrolyzer manufactured by HydrogenPro AS of Norway with a hydrogen manufacturing capability of 1,100 regular cubic meters per hour (Nm3/hr), which Mitsubishi Energy mentioned was the best on the planet when it entered service, is operational. The hydrogen produced is saved in tools with a complete capability of 39,000 Nm3.
1. Mitsubishi Energy says Takasago Hydrogen Park is the world’s first built-in hydrogen validation facility. It’s divided into three sections: hydrogen manufacturing, storage, and utilization. Courtesy: Mitsubishi Energy
Finish-Customers Want Superior Know-how
As hydrogen availability expands, gasoline turbine homeowners are beginning to demand the flexibleness to make use of it in various levels (Determine 2). “The trade is totally asking for: ‘We wish models to have the ability to burn hydrogen. We need to ensure that they’re future-proof. We need to present that we even have the tangible actual capabilities to do that,’ ” Jermark mentioned. “In the event you look throughout our whole product portfolio of gasoline generators—it’s round 20 totally different merchandise that we help at the moment—and every one in every of them has some facet of hydrogen co-firing—both improvement, rig testing, discipline testing—that’s both in progress or happening.”
2. The 830-MW Excessive Desert mixed cycle energy plant in San Bernardino County, California, not too long ago accomplished FX efficiency upgrades and superior ultra-low-NOx (ULN) combustor upgrades on its three Siemens Vitality SGT6-5000F gasoline generators. The ULN combustor modifications enable for the utilization of hydrogen as a gasoline supply sooner or later. Courtesy: Siemens Vitality
And the curiosity is international. “We’re not seeing, essentially, geographic pockets of developments, and buyer push and curiosity,” famous Jermark. “It’s actually taking place around the globe.”
Mitsubishi Energy has plans to function a business unit on as much as 30% hydrogen very quickly. That’s why the validation of 30% hydrogen co-firing on the T-Level 2 mixed cycle energy plant validation facility in 2023 was so vital. The testing was executed with a Mitsubishi Energy JAC large-frame gasoline turbine (450-MW class). “We introduced 30% hydrogen by quantity late final yr, the place we ran on a 1,650-degree-Celsius firing temperature within the gasoline turbine,” said Thomas.
The Pioneering ACES Venture
The primary challenge Mitsubishi Energy’s validation work helps is the Superior Clear Vitality Storage (ACES) challenge in Delta, Utah. “We’re going to be operating hydrogen in a business unit subsequent yr—2025,” Thomas proclaimed, in reference to the ACES challenge. “This challenge is actual. It’s taking place. It’s going into sizzling commissioning and the salt caverns are being solution-mined proper now.”
The ACES hub has been designed to transform about 220 MW of renewable vitality to 100 tonnes per day of inexperienced hydrogen, which can then be saved in two huge salt caverns succesful upon startup of storing greater than 300 GWh of dispatchable clear vitality. The hub will help the Intermountain Energy Venture (IPP) Renewed challenge (Determine 3).
3. In June and July 2023, Mitsubishi Energy delivered two M501JAC advanced-class gasoline generators to the Intermountain Energy Venture Renewed challenge, which is beneath development in Utah. Courtesy: Mitsubishi Energy
IPP initially included two coal-fired models with a mixed capability of 1,900 MW. The IPP Renewed challenge includes the retirement of the present coal-fueled models; development of an 840-MW hydrogen-capable gasoline turbine mixed cycle energy plant; modernization of IPP’s Southern Transmission System linking IPP to Southern California; and the event of hydrogen manufacturing and long-term storage capabilities. As soon as completed, IPP will use renewable vitality–powered electrolysis to supply hydrogen, storing it in underground salt caverns to be used as gasoline within the gasoline generators. The models will initially run on a mix of 30% inexperienced hydrogen and 70% pure gasoline, incrementally increasing to 100% inexperienced hydrogen by 2045.
But, whereas the need for hydrogen-burning functionality could also be common, Thomas mentioned there is no such thing as a one-size-fits-all resolution. He prompt decarbonization plans in Texas, New England, the Southeast, and the Western U.S. are all very various. “Actually, it’s so regional. It’s so nuanced. Each location has totally different wants,” he mentioned.
With the necessity rising, Mitsubishi Energy has additional hydrogen validations deliberate within the not-too-distant future. For instance, the corporate mentioned it should use an H-25 gasoline turbine (40-MW class) that had been beforehand put in for compressor driving on the combustion check facility in Takasago for 100% hydrogen firing validation later this yr.
GE Vernova Additionally Makes Progress
In 2022, GE Vernova proved the flexibility to keep up stack emissions compliance for NOx, CO, and ammonia limits at regular state working circumstances with hydrogen gasoline mixing ranges of as much as 44% by quantity. The work was executed in collaboration with the New York Energy Authority (NYPA), EPRI, Sargent & Lundy, Contemporary Meadow Energy, and Airgas, an Air Liquide firm. The challenge, accomplished at NYPA’s Brentwood Energy Station on Lengthy Island in Suffolk County, New York, gained a POWER Prime Plant Award in 2023.
The Brentwood web site (Determine 4) has a GE LM6000 PC gasoline turbine, which was commissioned in 2001 and makes use of a single annular combustor (SAC) combustion system. For greater than 20 years, GE has made incremental reliability and efficiency enhancements to the LM6000, and the corporate continues to promote this engine configuration for brand new unit installations at the moment. All check outcomes from the NYPA demonstration are additionally relevant to new LM6000 gasoline generators with comparable combustion configurations, GE Vernova mentioned.
4. The New York Energy Authority (NYPA) and a group of collaborators, which included GE Vernova and others, performed profitable gasoline mixing checks starting from 5% to 44% (by quantity) hydrogen on the Brentwood Energy Station on Lengthy Island in New York. NYPA mentioned this cutting-edge analysis supplies crucial insights into the potential for mixing clear hydrogen and pure gasoline. Courtesy: NYPA
The gasoline mixing ranged from 5% to 44% (by quantity) hydrogen. The mix vary was based mostly on a suggestion by GE Vernova and was chosen based mostly on a number of components, together with the aptitude of the engine on the web site, the quantity of hydrogen obtainable, and web site circumstances.
With elevated hydrogen blends, gasoline turbine NOx emissions for diffusion-style combustors, reminiscent of these on the Brentwood web site, could also be increased in comparison with pure gasoline as a result of hydrogen’s adiabatic flame temperature is increased. The NOx emissions restrict on the Brentwood web site is 2.5 components per million (ppm) on the stack. Through the testing, the group was capable of preserve emissions inside present allow ranges because of the LM6000’s SAC water-injected combustor and selective catalytic discount (SCR) system.
GE Vernova mentioned it felt comfy working the LM6000 on hydrogen blends based mostly on the in depth fleet expertise of its present portfolio of aeroderivative and heavy-duty gasoline generators working on fuels with hydrogen content material above 50% (by quantity) and, in a single case, with fuels that comprise as much as 94% (by quantity) hydrogen. Nonetheless, the corporate mentioned for future checks utilizing increased hydrogen blends, websites might have to improve SCR techniques and/or water injection techniques to permit for increased water flows with a purpose to preserve stack emissions much like these obtained when firing on pure gasoline.
Concurrent Advances Wanted
In Goldmeer’s presentation, he identified an attention-grabbing improvement happening within the land down beneath. “In the event you haven’t paid consideration to what’s occurred in Australia with coal coming offline and large quantities of photo voltaic, they’ve huge wants for peaking,” he mentioned. But, the federal government is dedicated to decreasing emissions, and a few combustion turbine homeowners are turning to hydrogen in consequence.
Goldmeer referenced a 200-plus-MW easy cycle F-class peaker plant in Australia that has dedicated to burning 1% to five% hydrogen by subsequent yr. “What’s loopy is at 5% hydrogen for the variety of hours they’ll run, that’s roughly 200,000 kilograms of hydrogen a yr. That’s extra hydrogen on an annual foundation than Australia makes at the moment for clear hydrogen,” he mentioned. Constructing the infrastructure and provide chain to help the motion towards clear hydrogen gained’t be straightforward. “This isn’t the rooster or the egg, that is the rooster and the egg concurrently,” exclaimed Goldmeer.
“Australia is simply such a pivotal market as a result of the social license to creating new energy vegetation actually requires a pathway to decarbonization. And, in lots of instances, which means having the ability to show pathways to decarbonize with hydrogen,” Goldmeer defined.
As one other instance in Australia, Goldmeer talked about a plant beneath improvement that may have 12 aeroderivative models. The combustion generators are at present able to working on 35% hydrogen. “The power to run on increased ranges of hydrogen is not going to be restricted by the gasoline generators, as a result of we pledge to do upgrades over time. It’s the availability chain. How do you produce that a lot clear hydrogen and what’s the price level and the way do you get it there?” he requested. These are all vital questions that have to be answered, maybe sooner, slightly than later.
—Aaron Larson is POWER’s govt editor.