Microturbines 2004-03-25 Rolf Gabrielsson, Volvo Aero ... 1.pdf · Microturbine lecture 2005-04-21, ... Volvo / ABB KTT150 MK I Turbec T100 Car GT ... Rolf Gabrielsson Microturbines,

Microturbines

2005-04-21Rolf Gabrielsson, Volvo Aero Corporation

Section 1

Microturbine lecture 2005-04-21, Rolf Gabrielsson

Microturbines, Section 1

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Gas Turbine Applications

• Aero

• Industry

•Power

•Combined Heat and Power, CHP

•Mechanical drive for pumps and compressors

• Marine

• Automotive

• Microturbines



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Gas Turbine - Civil aircraft



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Solar Mercury 50

Click here to enlarge image

Ref.: Solar Turbines



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Marine Gas Turbine



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Small Gas Turbine development line1960- Sven-Olof Kronogård works at Volvo with the S-tank and a

Volvo gas turbine project for the tank

1970-Turbokonsult founded by Professor Kronogård

1974-United Turbine founded by Kronogård and AB Volvo

1972-1984 Automotive gas turbine for cars, KTT 150 MK1

1984-1987 Development of GT110 for Volvo Cars

1990-1992 Development of HSG 40

1994-1995 Development of VT100

1998 Turbec was established to develop T100

LPP combustor

New company Volvo / ABB

Turbec T100KTT150 MK ICar GT (1972-1984)

GT 110 with LPP Car GT (1984-1987)

HSG 40 Volvo / ABB / Vattenfall

VT 100for ECB/ ECT

1970 1975 1980 1985 1991970 1975 1980 1985 1990 1995 20000 1995 2000Ref.:Lars Sundin, Volvo Aero Presentation 10-11 July 2003 Brussels



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Volvo experience in automotive Gas Turbines

KTT 150 Mk I developed 1972-1984

Automotive GT for cars.

Power 100 hp

3-shaft design with patented KTT transmission system

Conventional combustor

Rotary ceramic heat exchanger

Demonstrated in cars from 1977 including the first car ever with ceramic HP turbine

One car in daily use to gain experience

Ref.:Lars Sundin, Volvo Aero Presentation 10-11 July 2003 Brussels



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KTT MK II / GT110

• Developed 1985-1987

• Automotive GT for cars.

• Power 115 kW (155 hp)

• 2-shaft with ceramic HP turbine

• Low emission combustor (LPP)

• Rotary ceramic heat exchanger

• Design with low parasitic losses




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Volvo Environmental Concept Vehicles

VT40 for ECC (Environmental Concept Car)

VT100 for ECT/ECB (Truck and Bus)

Series Hybrid Drive lines

Combined Gas Turbine and High Speed Generator

1-shaft Regenerative Engine




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Volvo Environmental Concept Vehicles




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The Power Module of T100 microturbine

Very few moving parts




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T100 installed in a boiler room




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Gas TurbinesTypical conditions

Pressure TIT Combustor inlet temp.

Bar °C °C Industrial, Combined and simple cycle 10-40 -> 1500 300 - 650

Recuperated < 10 ->1300 600 - 800Aero 20-40 ->1600 450-650

Automotive / Microturbines 4-6 1000-1350 600-900



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Gas Turbine Design Features Related to Output Capacity

Ref.: ”Advanced Microturbine Systems”, US DoE, March 2000, www.eere.energy.gov



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Microturbine system



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Microturbine characteristics

• Electricity power output 25 – 500 kW• Market:

- Distributed generation - Standby power - Combined Heat and Power generation (CHP) - Direct mechanical drive for air conditioning system

• Simplified design for mass production- Radial flow compressors- Low pressure ratios defined by single – or possibly two-stage compression- Minimal use of vane rotor cooling- Use of materials that are amendable to low cost production

• Recuperation of exhaust heat for air preheating - Electrical efficiency 25–30%• Very high shaft rotational speed (>40 000 rpm)• Direct drive high-frequency alternator



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Comparison: Microturbine - Gas Engine

Microturbine Gas Engine• Number of mowing parts + -• Package size + -• Electric efficiency = =• Fuel utilization = =• Emissions NOx, CO, HC + -• Noise, vibrations + -• Fuel flexibility + -• Opportunity to utilize waste fuel + -



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Microturbine Cycles



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Microturbine Cycles

ηel (%) ηtot (%) • Simple cycle, metallic < 20

• Recuperated, metallic 25-30ceramic 40

• Inter-cooled Recuperated (ICR) >40

• Combined cycle with Organic > 40Rankine Cycle (ORC)

• CHP, metallic 80



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Recuperated Gas Turbine Efficiency and Specific Power

v.s. Turbine inlet temperature (TIT) and Pressure Ratio (Π)



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System studiesFuture microturbines or automotive gas turbines

Intercooling a regenerative gas turbine

36,00%

38,00%

40,00%

42,00%

44,00%

46,00%

150 200 250 300 350

Specific Power (kWs/kg)

Ther

mal

eff

icie

ncy

RC 1000C

RC 1250C

IRC 1000C

IRC 1250C

π=4

5

6

7Recuperated

IRC

More advanced cycles

Intercooling of recuperated gas turbines

Bottoming cycles

Increased temperature

Ceramics

Cooling concepts for small components




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Turbec MicroturbineCombined Heat and Power (CHP) System

High efficiency

Low emissions levels

Performance at ISO-conditions

Net electrical output: 100 kW

Net electrical efficiency: 30%

Net total efficiency: 80% (at 50 oCWRT)

Noise level: 70 dBA at 1 meter

Emissions, 15% O2

NOx: < 15 ppmv

CO: < 15 ppmv

UHC: < 10 ppmv

1. Generator

2. Inlet air

3. Combustion chamber

4. Air to Recuperator

5. Compressor

6. Turbine

7. Recuperator

8. Exhaust gases

9. Heat exchanger

Ref.: Turbec datasheet



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Compressor



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Compressor

Typical characteristics:

• Radial flow compressors

• Low pressure ratios defined by single – or possibly two-stage compression

• Materials that are amendable to low cost production

• Very high shaft rotational speed (>40 000 rpm)



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Compressor diagram

46.2

62.3

74.4

84.4

92.5

98.5

104.5

nredV = 112.6 * 103 min-1

η isV = 0.78

0.77

0.76

0.75

0.73

0.70

0.70

0.65

0.65

0.60

1,0

1,4

1,8

2,2

2,6

3,0

3,4

3,8

4,2

0,04 0,08 0,12 0,16 0,20 0,24 0,28 0,32 0,36 0,40 0,44 0,48 0,52 0,56

Pressure Ratio, Π

Air mass flow



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Component developmentCompressors

Development steps

Inverse design method

Parametric design

Introduction of 3D viscous CFD

Compressor Pressure ratio

Efficiency Method Year

KTT 150 MK1 5.1 75% Inverse design 1976 HSG 40 v1 3.5 75% Inverse design 1991 HSG 40 v2 4.0 77% Parametric/Streamline 1993 VT600 9.2 77% Parametric/Streamline 1992 VT100/T100 4.4 77% Parametric/Streamline 1994 T100 prot 4.6 80% Parametric/3D CFD 2002

Polytropic efficiency development

84,5%85,0%85,5%86,0%86,5%87,0%87,5%88,0%88,5%

1970 1975 1980 1985 1990 1995 2000 2005

Development Year

Poly

trop

ic e

ffici

ency




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Combustor



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Combustor development

Gas turbine with conventional combustor

•Typical NOx emission = 150 ppm @15%O2

LowNOx Combustor

•Typical NOx emission = 25 --> 9 ppm@15%O2



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Gas Turbine combustor design

Diffusion combustor LowNOx combustor



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Emission trends - NOx

Large Gas Turbines

•California: NOx < 3 ppm

Microturbines -Distributed generation

•State of the art: 15 ppm

•US Dept. of Energy goal: NOx < 7 ppm



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Volvo Aero / Turbec Combustor developmentEmissions at 100% load and 15% O2

Engine Fuel

NOx CO

Type of combustor

T100 Natural gas <15 ppm <15 ppm LPP T100 Petroleum gas,

Propane 95% <10 ppm <10 ppm LPP

T100 Petroleum gas, Propane/butane 20/80

<10 ppm <10 ppm LPP

T100 Landfill gas (HLHV≈19 MJ/kg)

<12 ppm <5 ppm LPP

T100 Methanol <10 ppm <5 ppm LPP VT100 Ethanol (E85) <20 ppm <40 ppm LPP T100 Kerosene <10 ppm <15 ppm LPP VT40/T100 Diesel <10 ppm <15 ppm LPP VT4400DLE <25 ppm <15 ppm LPP VT4400 Low Calorific Fuel

(HLHV≈5 MJ/kg, no NH3) <9 ppm <20 ppm Diffusion

Lean Premixed Prevaporizedcombustor system

Original development for the automotive GT 110

Multi fuel capability

Used in Turbec T100



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Ingersoll-Rand 250 kWe PowerWorks Combustor

Ref.: Jim Kesseli Presentation at the IGTI Turbo Expo June 18 2003, Atlanta USA



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Honda Microturbine Combustor

Ref.: Koichi Shinmura Presentation at the IGTI Turbo Expo, June 18 2003, Atlanta, USA



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Capstone C60 Microturbine

Ref.: Capstone Product Datasheet

Combustion Chamber

Turbine

Fuel Injector

Recuperator



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Catalytic Combustor



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High Temperature Catalytic CombustorProject AGATA, Complete reaction in the catalyst section

Diesel fuel Catalyst outlet temperature 1350°C



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Catalytica• Hybrid catalytic combustor

• Catayst section + Post catalyst zone

NOx emissions as low as 2.5 ppm.



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Ref.: Kawasaki Gas Turbines, Datasheet



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Turbine



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Volvo Aero / Turbec Component developmentTurbines

Axial turbinesBLISK designsIntroduction of 3D ”Compound Lean”

Radial turbinesIn-house developed inverse design

method3D Stress&CFD for optimal trade-

offs Performance-Life

T100 PerformanceExpansion ratio 489% total-totalDiameter 175 mm

Ref.:Lars Sundin, Volvo Aero, Presentation 10-11 July 2003 Brussels



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Microturbines - Turbine material

Today standard material

• Ni-based materials • Example: MAR-M247, max temperature 1050 °C• Turbine Inlet Temperature today: approx. 950 - 1000 °C• Thermal Barrier Coating, TBC, will increase service life

Future ceramic materials

• Si3N4• Turbine Inlet Temperature 1350°C



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Heat exchanger



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Heat exchangers• Key component for microturbines• Accounts for about half heat input

Regenerator - Automotive application

Recuperator - Microturbine application

Ref.: Bowman Power




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Regenerator

+• High efficiency• Compact and low weight• Suitable for ceramics• Can be used for high temperatures

-• Difficult to seal - lifing problems• Leakage problems

• 5% leakage will reduce power with > 12.5%• 5% leakage will reduce system efficiency by >4%-units• Leakage means reduced engine life due to increasing hot parts

temperature. Ex.: Increased combustor liner temperature



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Recuperator

+• Reliable and durable• Close to zero leakage

-• Reduced efficiency, approx. 90%• Can be bulky• More complex piping can mean increased weight• Increased volume and exposed area require improved insulation - or

innovative design



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Alternative recuperator developmentDevelopment of a recuperator for

volume production in RecuperatorSvenska AB.

Stamped plates

Laser welded

Modularised

Performance according to specification (Efficiency~90% at dp/p<4.5 %)

First full size prototype tested for ~4500 h Ref.:Lars Sundin, Volvo Aero Presentation 10-11 July 2003 Brussels



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Recuperators - Annular design

Honda Microturbine

Ref.: Koichi Shinmura Presentation at the IGTI Turbo Expo, June 18 2003, Atlanta, USA

Capstone Microturbine

Ref.: Capstone Product Datasheet



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Recuperator materials

Metallic materials

• Type 347 stainless steel - Today standard materialMax temperature (exhaust): 1200F = 650°C

• Inconel - Advanced materialMax temperature (exhaust): 1500F = 820°C

Ceramics• >1600F = 870°C



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Ceramic materials



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Ceramic componentsDevelopment of ceramic turbine

components started 1981

Turbine wheel from ASEA CERAMA tested in a car 1982

Several components including combustor, inlet scroll and turbine developed for the GT110 gas turbine

GT110 demonstrated reliable at 1250 ºC 1987

European AGATA project developed

Ceramic radial turbine

Ceramic recuperator

Ceramic catalytic combustor




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Ceramic development in Japan and USA

Japan - MITI (Ministry of International Trade and Industry)- Kyocera

USA: - DoE (Department of Energy)- ORNL- Honeywell



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Specification:•Combustor inlet temperature: 935°C

•Turbine inlet temperature, TIT: 1350°C

•Cycle efficiency: 42%



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Ceramic Turbine

Ref.: Jim Kesseli et al, presentation at the IGTI Turbo Expo June 18 2003, Atlanta USA



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AGATACeramic Heat Exchanger with casing and seals



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AGATACordierite Ceramic Heat Exchanger Matrix



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Power Electronics



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Power Electronics

Generator

• High speed alternator permanent magnet rotor inside the stator. The generator produce a high frequency AC (Alternating currency)

Rectifier

• Rectify to DC (Direct currency)

Converter

• Converts to 50 or 60 Hz AC, 400 – 480 V

Documents

Microturbines 2004-03-25 Rolf Gabrielsson, Volvo Aero ... 1.pdf · Microturbine lecture 2005-04-21, ... Volvo / ABB KTT150 MK I Turbec T100 Car GT ... Rolf Gabrielsson Microturbines,