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An Introduction to Gas Turbines

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More complicated to manufacture. Higher Firing Temperatures. More exotic materials ... Manufacturing. Refinery. Hospitals. Universities. Industries using Gas ... – PowerPoint PPT presentation

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Title: An Introduction to Gas Turbines


1
An Introduction to Gas Turbines Microturbines
for DE ApplicationsWorld Energy Technologies
Summit10 11 February 2004
  • Michael Brown Director
  • World Alliance for Decentralized Energy (WADE)
  • michael.brown_at_localpower.org

2
What is Decentralized Energy (DE)?
  • Electricity production at the point of use,
    irrespective of size, fuel or technology
  • High efficiency cogeneration / combined heat and
    power (CHP)
  • Simultaneous production of useful power and heat
    from single fuel source
  • The most efficient use of any fuel
  • Based on gas turbines, microturbines, engines,
    steam turbines, etc
  • On-site renewable energy
  • On-grid and off-grid

3
Origins of the Gas Turbine
  • Concept envisualised at beginning of 20th Century
  • First Industrial Gas Turbine built in 1931 by
    Brown Boveri
  • In late 1930s focus shifted to aircraft
    propulsion
  • Industrial Gas Turbine development continued
    after World War II
  • Robust
  • Compact
  • Ability to operate on gas fuels
  • No external coolant required
  • Size range now 1 100 MWe

4
The Basic Concept simple cycle
5
Typical Cogeneration System
6
Typical Industrial Cogeneration System
7
Gas Turbine Cogeneration Plant
Solar Turbines
8
Gas Turbine Cogeneration Plant
Solar Turbines
9
Gas Turbine Cogeneration Plant
Solar Turbines
10
Principles for Performance Improvement
  • Power output and efficiency can be improved by
  • Increasing the Firing Temperature
  • Greater effect on power output but required
  • New Materials
  • Thermal Barrier Coatings
  • Cooling of hot section components
  • Increasing the Pressure Ratio
  • Greater effect on efficiency but required
  • New materials
  • Improved Aerodynamics

11
Required Developments
  • Market Pressures for
  • Lower Emissions
  • Water or Steam Injection
  • Dry Low Emissions Combustion
  • Fuel Flexibility
  • New combustion and fuel systems
  • New coatings
  • Improved Reliability Availability
  • Longer Component Lives
  • Intelligent Control Systems
  • Condition Monitoring

12
Required Developments
  • Market Pressures for
  • Improved Efficiency
  • Improved individual component efficiencies
  • Tighter tolerances, improved aerodynamics
  • More complicated to manufacture
  • Higher Firing Temperatures
  • More exotic materials
  • Reaching firing temperature limits effectiveness
    of DLE
  • Reduced Costs
  • Increased Power Density
  • Higher firing temperatures new component
    designs
  • More compact turbomachinery with lower component
    costs
  • More highly loaded components

13
The Results of Technology Development
  • Improvements in design have led to
  • Reduced size
  • 13MW gas turbine now needs same package space as
    a 6.5MW gas turbine of 1980
  • Improved Efficiencies
  • 35 electrical efficiency compared to 30 in 1980
  • Reduced Emissions
  • Single digit NOx possible on natural gas
  • Further improvements possible, but incremental

14
Future Possibilities
  • For step change improvements, move to Complex
    Cycle technologies
  • Combined Cycle
  • Recuperated
  • Intercooled Recuperated
  • Integration with high temperature Fuel Cells
  • Solid Oxide or Molten Carbonate
  • Reheat
  • Cheng Cycle
  • Wet Cycles
  • Humid Air Turbine (HAT) Cycles

15
Combined Cycle (Brayton Rankine Cycles)
GAS TURBINE
STEAM TURBINE
16
Combined Cycle
  • Uses GT exhaust gases to produce steam for Steam
    Turbine generator
  • Approximately 40 - 50 additional power
  • 13MW gas turbine gives c.18.5MW in CCGT
    configuration
  • Approximately 15 - 20 points increase in fuel
    efficiency
  • 13MW GT of 35 electrical efficiency gives 50
    efficient CCGT
  • Increased Capital Costs
  • High pressure HRSG, Steam Turbine etc.
  • Increased Space Requirements

17
Recuperation and Intercooling
  • Recuperation
  • Uses exhaust gases to preheat combustion air
  • Improves efficiency for same mass flow, but
    slight power reduction
  • Intercooling
  • Reduces the work required to compress air
  • Increases power output for same mass flow but no
    efficiency gains
  • When combined with recuperation (ICR), improves
    efficiency too
  • Rolls Royce WR21
  • Simple Cycle 13MW 35 efficiency
  • Recuperated 12MW 40 efficiency
  • ICR 15MW 45 efficiency

18
Combined Gas Turbine / Fuel Cell Derivatives
  • Can integrate gas turbines with High Temperature
    Fuel Cells
  • Fuel flexible
  • Increases power density of FC
  • Offers very high electrical efficiencies
  • Concept designs and pilot plant
  • 200kW pilot scheme from NKK/JFE, Japan with 2000
    hrs experience
  • 300kW plant of 57 efficiency under construction
    in USA
  • lt 1MW scheme from Siemens Westinghouse within 2
    -3 years
  • 40MW concept based around WR21 ICR Gas Turbine

19
Gas Turbine Cogeneration - Selection Criteria
20
Heat Recovery Methods
  • Direct Heating
  • Fluid Heating / Hot Water
  • Steam Production
  • Absorption Chilling
  • Preheated Combustion Air

21
Industries using Gas Turbine Cogeneration
  • Food Processing
  • Pharmaceutical
  • Pulp and Paper
  • Manufacturing
  • Refinery
  • Hospitals
  • Universities

22
Cogeneration Economic Factors
  • Need for reliable electric and thermal Energy
  • Facility Heat to Electricity Ratio of 21
  • Electricity Price to Gas Price Ratio of 21
  • Continuous Operation

23
Gas Turbine Summary
  • Simple Cycle designs are approaching their limits
  • Application flexible
  • Complex Cycles offer improved efficiencies and
    higher power densities
  • More complicated designs
  • Danger of becoming application specific
  • Optimum component technologies may differ from
    simple cycle designs
  • Uncertain market conditions
  • Will conditions allow commercialisation of new
    technologies ?

24
Microturbines
  • Small, high-speed generator power plants, 25
    200 kWe
  • One moving part
  • Primarily fuelled with natural gas major biogas
    potential
  • Relatively low capital, OM costs
  • Lower emissions than conventional reciprocating
    engines
  • Several applications
  • Traditional cogeneration, hospitals etc
  • Generation using waste and biofuels
  • Backup power
  • Remote Power for those with Black Start
    capability
  • Peak Shaving.

25
Microturbines the Capstone System
  • 30-60 kW power output
  • Multi-fuel capability
  • High cogen efficiency
  • Low maintenance
  • Low emissions
  • 2-to-100 unit multipacking
  • lt30 kW to 6 MW
  • gt2,500 sold worldwide
  • gt5 million operating hours

26
Inside the Microturbine
Exhaust
Control panel
MicroTurbine
Air inlets
Fuel supply
0-30 0-60 kW400-480 VAC/DC
User connection bay
Digital power controller
27
Deep Inside the Microturbine
  • One moving part
  • No coolants or lubricants
  • Compact and lightweight

28
WADE Key Points
  • Non-profit organisation created June 2002
  • Mission
  • To accelerate the deployment of DE systems
    worldwide
  • WADE is supported by
  • National Cogen/DE organisations including COGEN
    Portugal
  • Cogen/DE companies with international interests
  • Caterpillar, Capstone, Solar Turbines, FuelCell
    Energy, MTU, Marubeni, Primary Energy, Dalkia,
    Wartsila
  • UN agencies
  • National governments (eg US, Norway, Canada)

29
WADE Network of DE Promotional Organisations
2nd (Amsterdam, 2001)
5th (Beijing, 2004
1
st
(Washington, 2000)
3rd (Delhi, 2002)
WADE Network
4th (Rio, 2003)
In train
WADE Annual International Conferences
30
WADE action
  • Documenting DE development and barriers
  • World Survey of Decentralized Energy 2004
  • National DE Surveys China, Brazil
  • Promoting worldwide knowledge
  • Cogeneration On Site Power Journal of
    international DE industry
  • Annual International CHP DE Conferences
    Washington (2000), Amsterdam (2001), Delhi
    (2002), Rio de Janeiro (2003), Beijing (2005).
  • Promoting DE with international agencies, eg
    World Bank institutions and UN agencies
  • Building international network of DE
    organisations
  • Carbon credit development from DE
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