Alstom-GT11N2_PowerTurbine

8/21/2019 Alstom-GT11N2_PowerTurbine

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Unique in its fuel flexibility and reliability

GT11N2GAS TURBINE

POWER


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Utilities and independent power producers around the world face unprecedented change in theirindustry – deregulation and the resulting intensified competition, stringent emissions legislationand environmental compliance. The challenge is to meet these requirements and still raiseefficiency and productivity to maximise profits.

The feasibility of a power generation project depends not only on the use of cost-effective andreliable mainstream equipment, but also on finding that unique “fit,” which often calls for smaller,highly customisable gas turbines, plus the extensive support a leading equipment manufacturersuch as Alstom Power can offer.

The GT11N2, a market-oriented solutionAlstom developed the GT11N2 to satisfy a market need for a 60 Hz/50 Hz, 115 MW unit powered

by a wide range of fuels. With this high operational flexibility and its rugged design, the GT11N2is suited to a variety of applications, ranging from simple-cycle operation, through industrialco-generation applications, to combined-cycle power generation.

The GT11N2 comes with three types of combustor. The EV (environmental burner) dry low NOxcombustor is suitable for standard natural gas fuels. The LBTU combustor can cope with fuels suchas blast furnace gases with a low heating value (LHV) as low as 2,200 kJ/kg. Finally, the SingleBurner (SB) combustor can burn diesel oil or high hydrogen synthetic fuels with a hydrogencontent of well in excess of 50%.

A solution with a proven track recordSince its introduction in 1989, the heavy-duty GT11N series has established itself as one of themost reliable gas turbines in its class. Today, the GT11N2 fleet boasts 60 units worldwide inoperation in various industrial co-generations, simple or combined-cycle applications. The fleet has

a proven record of high reliability and availability with more than one million fired hours in ambientconditions from - 40°C to + 50°C.

Right technology, right products

Alstom’s gas turbines stand out for their high cost efficiency,

availability and flexibility.

The range covers a wide spectrum of products, including machines

for both the 50 Hz and 60 Hz markets. They can operate either in

simple cycle or combined cycle and are fuelled by natural gas,

medium or low calorific gases or light oil; with on-line fuel switchover capability eliminating dependency on any one fuel.

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NMeeting your demands


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Unique fuel flexibilityThree different combustion systems enable the GT11N2 turbine to be adapted toindividual fuel needs. The LBTU combustor operates on low-calorific gases such

as blast furnace gas without the need for blending higher calorific gases. The EV

combustor offers dry low NOx (DLN) combustion. The Single Burner (SB)

combustor increases power output, even with standard fuels.

Maximum operational flexibility The GT11N2’s high operational flexibility is the result of excellent part loadefficiency and emissions, fuel flexibility, quick reaction to changing load

demands, and customisation to power plant operations.

High reliability/availability The GT11N2 fulfils the highest availability and reliability benchmark criteria,with experience from over 1.5 million fired hours. For simple-cycle operations,

the GT11N2 has achieved an average of 99% start reliability in peaker unitsand over 99% reliability in continuous operating units.

Excellent mxaintainability Exceptional accessibility and a simplified arrangement ensure that maintenance

of the GT11N2 is fast and smooth. The combustor only requires visualinspections between hot gas path inspections. The welded rotor technology

eliminates the need for major overhauls (where the rotor needs to be returned

to the factory for refurbishment).

Low environmental emissionsThe EV burner technology enables Alstom gas turbines to meet the most

stringent environmental requirements. The GT11N2 achieves a dry low NOx

emission level of 25 ppm or less when operating at base load with naturalgas, and 42 ppm with oil (wet). The LBTU combustor has a record of

continuous single-digit NOx emissions.

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GT11N2: the benefits


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Unique fuel flexibilityOur knowledge of fuel usage and extensive operating experience gained in special fuel applicationsover the past 50 years, allow Alstom to offer gas turbines designed to operate on various fuels.

In addition to the standard gas turbine

fuels, natural gas and No. 2 fuel oil, the

GT11N2 can burn special fuels, such

as low-calorific gases from steel mills orwaste gases from chemical processes.

The reason for this unique fuel flexibility

lies in the design of the GT11N2 withits top-mounted silo combustor. This

external combustor design allows

easy adaptation of the GT11N2 to aspecific fuel. Three different combustors

with different burner configurations are

available, depending on the specific

plant requirements.

EV CombustorThis dry low-NOx combustor uses

Alstom’s proven EV (Environmental)

burners for low emissions. The dual-fuel EV burner is designed for gaseous,

as well as liquid fuels and has been

successfully operated for millions of

fired hours in all Alstom Power gas

turbines. The EV combustor is well-

suited to simple and combined-cycle

operation, where low emissions and

high efficiencies are important.

SB CombustorThe Single Burner (SB) combustor with

its single fuel nozzle and large combustion

chamber is extremely well-suited tosimple-cycle peaking applications, where

large water amounts can be safely injected

into the combustor. This increases power

output of the gas turbine by up to 15%

above base load, while keeping NOx

emissions at 25 ppm for gas operation

and 42 ppm for No. 2 fuel oil operation.

LBTU CombustorThe GT11N2 is the biggest gas turbineworldwide capable of base load

operation exclusively burning low-

calorific gases without blending with

higher calorific gases. Safe continuous

operation has been demonstrated for

blast furnace gases with heating values

as low as 2,200 kJ/kg (950 Btu/lb.),

while achieving single digit NOx

emissions. Its rugged design makes the

LBTU combustor the ideal fit for

demanding industrial operation

conditions while burning waste gasesfrom steel mills or chemical processes.


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Key design featuresThe GT11N2 is a rugged, compact gas turbine based on Alstom Power’s proven technologythat was specially developed for demanding service environments. It is specifically designedfor ease of maintenance, easy visual inspections and short hot gas path inspections.

Solid welded rotorAlstom’s maintenance-free gas turbine rotor is a prime

example of the company’s insistence on the highest qualitystandards. Its design – using forged discs welded together –

used in all Alstom gas and steam turbines, has not had a single

weld or disc failure in over 70 years of operation. This single-

element design ensures high rotor stiffness, which is at the root

of the machine’s high reliability and trouble-free operation.

Since the rotor is welded, it has no through-bolts and no risk

of misalignment. Furthermore, re-stacking is not applicable so

the rotor never goes back to the factory for major overhauls.

Reblading and re-balancing are done on-site. In short, a

maintenance-free rotor.

CompressorThe 14-stage compressor with a pressure ratio of 16:1

benefits from a high combined-cycle part-load efficiency

based on compressor turn-down capability. The compressor

variable guide vanes (VGVs) provide a high compressor flow

turn-down capability, allowing process steam conditions to be

maintained from 100% gas turbine output all the way to 40%

gas turbine output.

CombustorThe single, top-mounted, silo combustor allows for easy

access from the top of the engine for direct visual inspectionof the combustor and hot gas path, as well as the first row

of turbine vanes and blades.

Three combustor types are available.

The EV (Environmental burner) dry low NOx combustor is

suitable for standard natural gas fuels, whereas the LBTU

combustor for low calorific value fuels can cope with fuels

such as blast furnace gases with a heating value (LHV) as

low as 2,200 kJ/kg. The Single Burner (SB) combustor is

designed for high output peaking with water or steam

injection.

TurbineThe four-stage turbine is made of materials that are easy to

recondition. The turbine blade losses are minimised thanks

to 3-D designed and air-cooled blades and vanes for the first

two stages. Hence the turbine’s high efficiency.


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Low-calorific gas challenge

In the last 50 years, Alstom has built asignificant number of gas turbines

designed for applications in steel mills

using low-calorific fuels. The operating

experience of these machines exceeds

two million hours. One of these

turbines, installed in 1959 at the

Donawitz plant in Austria, has today

notched up over a quarter of a million

operating hours. Only minor

modifications were needed to adapt an

existing LBTU diffusion burner for this

application. Its design is based on that

of similar burners installed in more than

20 units operating on blast furnace gas.

The two GT11N2 units incommercial operation at Bao Shan,

China, and Mizushima, Japan, have

now accumulated nearly 150,000

fired hours. Operations of these two

power plants have demonstrated

excellent results, confirming the

forecast performance and single-digit

emission levels. With thermal

efficiencies of over 45%, such plants

are a very attractive solution for

industrial users burning waste gases.

The need for reliable, efficient and environmentally friendlysolutions has driven many industrial users to search forbetter ways to burn waste gases from industrial plants inconventional thermal power plants.

Steel mill / blast furnace gas


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Greater flexibility in heat and power

The Alstom power plant conceptAlstom Power has introduced a range of pre-engineered,

modularised combined-cycle power plants, based on

customer requirements and configured for optimal

performance and short installation time. Thanks to this

concept, Alstom can deliver a turnkey power plant at low risk

and reduced overall costs. The modules can be adapted to

specific site conditions and individual customer requirements.

This concept reduces the cost of electricity production as a

result of:

T Pre-engineered solutions that shorten the time from

contract to grid-to-power;

T Higher reliability and availability;

T Full turnkey power plant capability;

T Easy multiplication of blocks;

T Simple and robust design with well-defined quality

standards;

T Substantial modularisation and pre-assembly;T Flexible location of the administration building and

Balance of Plant (BOP) systems.

The KA 11N2-2 combined-cyclepower plantThe KA11N2-2 power plant concept is a truly customised

package designed to provide operational flexibility and reduce

the time from order to reliable commercial operation. This

makes the KA11N2-2 the ideal choice for customers with a

need for a fast increase in electricity and heat.

T Modular multi-shaft arrangement in a ”2 on 1”

configuration;

T Compact floor-mounted arrangement;

T Special options available for high earthquake loads and

high-altitude sites;

T Phased construction option.

KA 11N2-2 for cogenerationThe profitability of a multi-block power plant can often be

significantly enhanced by adding another dimension: heat to

produce HP (high pressure) steam at a reasonable cost and,

possibly, additional district heating can easily compensate for

lower base load plant efficiencies. A single KA11N2-2 block can generate over 430 tons/hr of HP steam.

GT11N2 for repoweringThe compact GT11N2/KA11N2-2 is extremely suitable forrepowering applications. Using the identical gas turbine

island of the KA11N2-2 CCPP makes it easy to adapt toexisting steam turbines. Significant cost reductions are

achieved with two or more GT11N2’s matching one steamturbine.

GT11N2 for simple-cycle peakerThe identical KA11N2-2 compact gas turbine island is alsousable for open cycle peaking needs. High starting reliability,

high maximum power output for a peaking unit, short start-up time, and low initial costs make the GT11N2 an excellentpeaking unit. Several power-increase options are available.


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Termobarranquilla /COLOMBIA

This 750 MW natural gas-fired powerstation, located near Barranquilla on

Columbia’s Atlantic coast, is one of the

largest IPP projects in Latin America. The

power plant consists of two power

blocks: one 450 MW block based on

three GT11N2, and one steam turbineand one 300 MW blocks based on two

GT11N2 and a second steam turbine.The gas turbines are equipped with EV

burners for low NOx emissions without

water or steam injection. This power

plant is one of the cleanest in South

America.

The power plant has started to supply

electricity to the local grid at the

beginning of 1996. The first two units are

currently the leaders of the GT11N2 fleet,with more than 70,000 fired hours each.

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The GT11N2 in action

Bao Shan / CHINABao Steel Corporation of China installed

a GT11N2 unit for operation on LBTUblast furnace gas, a by-product of

the steel-making process. Built in

co-operation with Kawasaki Heavy

Industries, this combined-cycle facility

aligns gas turbine, gas compressor, steam

turbine and turbogenerators on a single

shaft. The gas turbine went in operation

in the first quarter of 1997 and has

accumulated nearly 60,000 fired hours to

date. The plant is designed to provide up

to 150 MW of electrical power and up to

180 tons/hr of steam to the steel mill,

while burning blast furnace gas with a

heating value of 2,200 kJ/kg. The

GT11N2 gas turbine with the LBTUcombustor can burn this gas at very low

emissions.

Burgin / USAThe Burgin power plant, consisting of

five GT11N2 units, is located in MercerCounty, Kentucky, on a 35-acre plot

adjacent to an existing three-unit steam

generating station. The purpose of the

plant is to provide peaking power in the

summer and winter seasons. The power

plant has been designed as an unmanned

facility with minimal connections to the

existing steam units – service water for

plant auxiliaries, de-mineralised water for

NOx control, and a data highway for

remote control of the peaking units.

The first four units started operation

between 1994 and 1996, with a fifth

unit installed in 2001.

GT11N2 fleet has a proven record of high reliability and availability with more than 1.5 millionfired hours. It operates successfully worldwide in various industrial co-generations, simple orcombined-cycle applications.


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Sarnia / CANADAAlstom’s GT11N2 gas turbine

technology is used for the largestco-generation facility in Canada. The

650 MW combined-cycle co-generation

plant in Sarnia, Ontario, owned by

TransAlta Energy Corporation, is

amongst the largest independent power

projects in Canada. The plant generates

electricity and steam from a single

natural gas fuel source using the

combination of gas turbines, heat

recovery steam generators and steam

turbines. Sarnia features the key element

required for an efficient co-generation

project: substantial demand for both

steam and electricity. By efficiently

managing the fuel, the Sarnia Regional

co-generation plant reduces air

emissions associated with energy

production for the Dow Chemical

Canada Inc and Bayer Chemical sites.

Valle de Mexico / MEXICOUnit 4 of the existing Valle de Mexico

thermal power plant has been convertedinto a combined-cycle plant. The

repowering of this unit has increased the

power output from 300 MW to around

550 MW at the design point and during

hybrid operation, providing additional

power to Mexico City. The power plant

has been fully operational since 2002

and was the first combined-cycle plant

in Mexico whose design allows for

operation in pure combined-cycle or

hybrid mode.

Alstom supplied three GT11N2 gasturbines with TOPAIR turbogenerators,

three heat recovery steam generators

(HRSG) and the associated auxiliary

equipment, engineering, the electrical

and control system and a high voltage

switchyard. Alstom was responsible for

site preparation, civil works, erection and

commissioning. Alstom also originally

supplied the existing steam turbine to

Valle de Mexico.

TermoRio / BRAZILTermoRio is a combined-cycle

co-generation power plant located onthe outskirts of Rio de Janeiro. It consists

of three KA11N2-2 combined-cycleblocks. The plant delivers an electrical

power output of more than 1,000 MW

to the grid and 400 tons/hr of high

pressure steam to Petrobras’s Reduc

refinery. It is one of the largest combined

cycle and co-generation power plants in

South America.

The plant was constructed in phases: it

started commercial operation in simple

cycle mode in 2002, less than a year

after placing the order. The whole plant

was complete in 2004. The highly

modularised KA11N2-2 helpedstreamline project execution.


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Alstom Power R&D

We aim for the best utilisation of the Customers’

investment, the earth’s materials and the fuel used, through

efficiency, availability and cost reduction. The increased

environmental concern means that we place a focus on

minimising CO2 emissions through the development of

mitigation and renewable technologies for application in

new and retrofit installations.

The engineering and R&D workforce totals 5,500 people,

of which 4,000 are in engineering and 1,500 in R&D in over

20 R&D centres. There are more than 10 laboratories with

dedicated infrastructure, equipment and testing facilitities.

Alstom Power R&D policy takes a global approach which has

several benefits. First, it puts the work where the expertise is

located. Secondly, it helps to nurture close contacts withuniversities and design institutes that can complement our

in-house efforts. Thirdly, it enables us to stay in touch with

global customers' expectations, anticipate their needs and

lead the technology trends.

Alstom Power works with more than 30 universities worldwide.

We establish close, long-term links with institutions and

professors who are experts in fields which are important to

us, for example, with MIT and Stanford Research Institute on

CO2, Grenoble and Lausanne universities on hydro turbines,

Cologne's DLR on combustion, Oxford University on heat

transfer as well as with engineering institutes in China, India

and Russia.

In the field of international collaboration, Alstom Power has

played a leading role in establishing the European technology

platform for zero emission fossil fuel power generation (ZEP).

The Gas Turbine Test Power PlantThe Gas Turbine Test Power Plant located in Birr,

Switzerland, provides a unique environment for maintaining

Alstom’s competitive advantage through product

improvement, all within the proximity of Alstom's R&D

facility, the gas turbine development department and the

manufacturing facility. The facility is equipped with a dual fuelGT26 and a dual fuel GT8C2 gas turbine, both operating insimple cycle mode dispatching to the Swiss electrical grid.

The shortened feedback loop (in terms of time and distance)

of field experience helps in speeding up design validation

and implementation in Alstom's gas turbine fleet. The Gas

Turbine Test Power Plant, in combination with the Product

Support organization and the GT development department

puts Alstom in a position to insure seamless implementation

of evolutionary product improvements based on the

GT24/GT26 fleet experience.

Alstom Power R&D is market and customer oriented and focuses on creating innovativetechnologies to apply at all stages of our products’ life cycles.

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ALSTOM POWER – SERVICE PORTFOLIO

Full operation O&M

General/daily maintenance o&M

Operation & maintenance support Risk mitigationby dedicatedOEM

Operation &MaintenanceContracts

Service Agreements(LTSA)

PurchaseOrders

Optimization of costs

and performance

o&m

Planned & unplanned maintenance m

Planned outages Support & Consulting

Field Services

Parts

Purchase Order

Alstom Power offers extensive service experience in

power generation. It has a complete range of services from

traditional spare parts supply and field service specialists to

the full operation and maintenance of gas turbine and

combined-cycle power plants. As the Original Equipment

Manufacturer (OEM) we are ideally placed to provide

continuous plant improvement packages, e.g. performance

upgrades, lifetime extensions or emission reduction packages.With over 100 years experience and an installed fleet of more

than 700 GW, Alstom Power’s 200 Local Service Centers

(LSCs), located in 70 countries, are there to provide local

facilities and expertise directly to our customers, powering

your plant performance.

Long-term service contractsAlstom’s long-term service contracts are flexible in scope of

services and equipment covered as well as contract duration

in order to meet your unique business requirements.With traditional purchase order contracts, customers can

purchase spare parts according to their needs. Service

agreements can add outage duration and performance

commitments and fixed prices for parts, services and consulting.

Our portfolio of Operations and Maintenance contracts ranges

from the provision of parts and services for planned maintenance

up to full operation and maintenance of the complete plant.

Our operation experience covers 12 plants and more than 30 gas

turbines of the GT11N2 type with long term service contracts.Such contracts with the OEM benefit from the extensive first-

hand experience gained from site operations and make full use

of the knowledge gained from the complete installed fleet.

With our service contracts, our partners obtain significantly

more value to ensure key requirements (depending upon scope

of supply) are met:

T Predictable operation & maintenance costs

T Reliability and availability

T Heat rate and power output

T Environmentally sound products

T 24 hour / 7 day plant support

Plant Support CenterAlstom’s Plant Support Center (PSC) offers fast, comprehensive

technical support for the whole power plant. The PSC provides

direct access to a global network of technical experts, 24 hours

per day / 7 days per week. Expert support can be provided either

as a hotline for immediate and competent troubleshooting

assistance, or in the form of advanced remote monitoring and

diagnostic services to support your maintenance decisions.

Our PSC services help you to manage operational risks andoptimize plant performance.

Service during operation


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Creating customer valuePlant Integrator™ approach is a fully customised product range

in which customer needs have been systematically analysed and

measured to ensure their optimisation – technically,

economically and ecologically. Alstom deliberately takes acustomer point of view to determine the value of Plant

Integrator™ products. Solutions are optimised to the highest

customer value – the benchmark for all enhancements and

customisation.

Solutions attuned to customer’sinterestThanks to our in-depth system design skills, we are able to

assemble components such that they maximise plant

performance. And, because we can boast a wide range of

components, our system designers can assemble the optimalmatch; this is not possible by simply buying components like

commodities. Indeed, Alstom combines the skills of component

supplier AND architect engineer unrivalled in the industry.

Making a differenceWe bring to the market a superior Plant Integrator™ offering

for thermal power plants:

T Single component packages and control systems, power

islands and complete plants;T Operation and Maintenance services, including long-term

maintenance contracts for all types of equipment and power

plant;

T Retrofit solutions combining our knowledge in the initial

installation with that of Operation and Maintenance

services.

Benefits to customersT Improve cash flow – by achieving lowest costs

T Generate more power

T Increase installation efficiencyT Burn less fuel

T Improve operational flexibility

Plant Integrator™The trademark of Alstom’s uniqueness


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A world leader inclean power generation

Manjung power plant, Malaysia

Alstom Power is a global leader in the world of power generation and sets the benchmark for innovativeand environmentally friendly technologies.

The company designs, manufactures and delivers state-of-

the-art products and systems to the power generation

(gas, coal and hydro power plants) and industrial markets.

In addition, Alstom provides the conventional equipment for

nuclear power plants.

Our objective is to build the cleanest integrated power

solutions for our customers. We supply and integrate all

components of a clean power system, from boilers to air

quality control and energy recovery systems. We also have

extensive experience in retrofitting, upgrading and

modernising existing power plant equipment. We can also

boast unrivalled expertise in project management for all typesand sizes of power generation systems – small to large as

well as single equipment to complete turnkey solutions.

Alstom‘s unique offering brings real value to our customers.

With our innovative plant integration concept, we help

operators to maximise their plant performance, while fully

complying with environmental regulations and obligations.

A world leader

Alstom Power supplies major equipment for

25% of the world‘s installed base, making us:

N°1 in turnkey power plants

N°1 in air quality control systems

N°1 in hydro turbines and generators

N°1 in the number of installed boilers

worldwide

N°1 in installed turbines and generators

for nuclear power plants

N°1 in steam turbine retrofit and integratedretrofit projects


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Expertise in clean power solutionsPlant operators today face multiple challenges in their efforts

to make their plants more competitive, while complying with

the different environmental regulations.

Alstom is delivering clean power solutions now. As the

uncontested leader in clean power generation technologies,

we provide the cleanest integrated power solutions

on the market.

They cover all plants (both existing and new ones), all energy

sources (from fossil fuels to hydro and nuclear), and all

emissions (NOx, SOx, Mercury, particulate matter).

Alstom offers the complete range of products designed to

help power plants to either reduce pollutant and CO2emissions, or to produce clean electricity from the outset.

For example, we deliver new coal-fired power plants with an

advanced supercritical design using proven clean combustionsolutions that are integrated with state-of-the-art emission

controls. Similarly, we improve the thermal and

environmental efficiency of existing power plants by

retrofitting plant components or upgrading the whole system.

Investing in the future of clean powerAlstom is uniquely placed as a plant integrator and full-service

provider to design and manufacture all the components

of a clean power plant, from turbines such as the GT11N2

to turbogenerators, boilers and air quality control systems.

Alstom also invests substantially in the research and

development of new, environmentally friendly power solutions.

Together with partners, universities and customers in Europe

and the United States, we are working on collaborative

projects to develop solutions for pre- and post-combustionCO2 capture and oxy-firing.

Research in actionIn addition to our own R&D efforts to develop new emission

control technologies and improve existing techniques, we are

also involved in a number of public projects and partnerships,

notably in the field of CO2 capture and storage. The CASTOR

project (founded by the European Union) is studying

procedures for post-combustion separation that lower the

cost of CO2 capture and develop an understanding of the long

term storage mechanism. Within the ENCAP programme(founded by the European Union), research is under way to

develop new pre-combustion and post-combustion CO2capture technologies. The “Zero Emission Fossil Fuel Power

Plants” (ZEP) technology platform launched by the European

Commission aims to develop and deploy new competitive

options for zero emission fossil fuel power plants.

Dunkirk combined cycle power plant, France.


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r e e s g r o w n

i n p r o d u c t i o n f o r e s t s u n d e r r e s p o n s i b l e m a n a g e m e n t , a n d s e l e c

t e d r e c y c l e d t h r e e - l a y e r f i b r e s .

Alstom (Switzerland) Ltd

Brown-Boveri Strasse 7CH-5401 Baden

Switzerland

Phone +41 56 205 70 58

Fax +41 56 205 28 88

www.alstom.com

Documents

Alstom-GT11N2_PowerTurbine