An Introduction to Gas Turbines & Microturbines for DE Applications

World Energy Technologies Summit 10 11 February 2004

Michael Brown Director World Alliance for Decentralized Energy (WADE) michael.brown@localpower.org

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

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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

The Basic Concept simple cycle

EXHAUST GAS

Typical Cogeneration System

Typical Industrial Cogeneration System

EXHAUST BYPASS SILENCER AIR INLET FILTER GENERATOR

EXHAUST SILENCER DIVERTER VALVE

HEAT RECOVERY STEAM GENERATOR (HRSG) GAS TURBINE SUPPLEMENTARY BURNER

PROCESS STEAM

Gas Turbine Cogeneration Plant

Pulp and Paper Pulp and Paper

Solar Turbines

Gas Turbine Cogeneration Plant

Hospitals Hospitals
Solar Turbines

Gas Turbine Cogeneration Plant

Pharmaceutical Pharmaceutical
Solar Turbines

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

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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

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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

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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

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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

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Combined Cycle (Brayton & Rankine Cycles)

GAS TURBINE

STEAM TURBINE

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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

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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

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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 < 1MW scheme from Siemens Westinghouse within 2 -3 years 40MW concept based around WR21 ICR Gas Turbine

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Gas Turbine Cogeneration - Selection Criteria

PROCESS HEAT, MWt

Stand Alone Process Heat (Package Boiler)

6:1 Process Heat-to-Power Ratio

Gas Turbine with Cogeneration or STAC

2:1

Recip or Gas Turbine with Low Grade Heat Recovery or STAC 1:1 STAC System or Combined-Cycle with Back Pressure or Extraction Steam Turbine ELECTRIC LOAD, MWe
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Heat Recovery Methods Direct Heating Fluid Heating / Hot Water

Steam Production
Absorption Chilling Preheated Combustion Air

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

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Cogeneration Economic Factors Need for reliable electric and thermal Energy Facility Heat to Electricity Ratio of 2:1

Electricity Price to Gas Price Ratio of 2:1

Continuous Operation

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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 ?

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Microturbines
Small, high-speed generator power plants, 25 200 kWe One moving part Primarily fuelled with natural gas; major biogas potential Relatively low capital, O&M 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.

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Microturbines the Capstone System

30-60 kW power output Multi-fuel capability High cogen efficiency Low maintenance Low emissions 2-to-100 unit multipacking
<30 kW to 6 MW

>2,500 sold worldwide >5 million operating hours

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Inside the Microturbine

Exhaust Control panel MicroTurbine Air inlets Fuel supply

0-30; 0-60 kW 400-480 VAC/DC User connection bay Digital power controller
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Deep Inside the Microturbine

Cooling fins

One moving part No coolants or lubricants Compact and lightweight

Exhaust output Recuperator Air intake Fuel injector Combustion chamber

Generator

Compressor

Air bearings
Turbine

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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)

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WADE Network of DE Promotional Organisations

2nd (Amsterdam, 2001) 1st (Washington, 2000)

5th (Beijing, 2004

3rd (Delhi, 2002)

WADE Network
4th (Rio, 2003)

In train WADE Annual International Conferences

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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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