microturbines - kth | energiteknik

Microturbines

2005-04-21Rolf Gabrielsson, Volvo Aero Corporation

Section 2

Microturbine lecture, section 2, 2005-04-21, Rolf Gabrielsson

Microturbines, section 2

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Operators on the microturbine market

Manufacturers/ CapstoneCommercial Bowman

Ingersoll-RandElliottTurbec

Research / General ElectricDevelopment Honda

Solar TurbinesUnited Technology, UTC (partnership with Capstone)



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Capstone C60 Microturbine System

Microturbine Generator Capstone C60 Microturbine System

Ref.: Capstone Product Datasheet



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Ref.: US Dept of Energy, www.eere.energy.gov/microturbines/projects.html



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T100 installed in a boiler room

Turbec Microturbine



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Turbec Microturbine

Ref.; Turbec datasheet, www.turbec.com



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Turbec T100 CHP biogas package

Following on from their early success with T100 biogas installations, NewEnCo, the UK Turbecdistributor, exhibited at the Chartered Institute of Waste Management annual conference and exhibition at Torbay in the second week in June 2003.The T100 attracted significant interest in this sector, primarily for landfill gas applications.The unit sets new standards for emissions from landfill gas generation and is promoted by NewEnCoas ‘best available technology’.



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B o w m a n M ic ro tu rb in e

F e a tu re s

T h e B P S s ys te m s o ffe r th e fo llo w in g s ta n d a rd a n d o p tio n a l fe a tu re s : •R e c u p e ra te d o r s im p le c yc le M ic ro tu rb in e G e n e ra to r •P re -e n g in e e re d c o m p a c t P a c k a g e •G a s fu e l c a p a b ility •A lte rn a te fu e ls : D ie s e l a n d K e ro s e n e (O p tio n a l) •L o w E m is s io n s •H ig h o p e ra tio n a l fle x ib ility a llo w in g b o th 'H e a t o r P o w e r d e m a n d fo llo w in g ' •L o w a c o u s tic n o is e le v e l •L o w te m p e ra tu re h o t w a te r o u tp u t (9 0 d e g re e s C .) •C a p a b ility to p ro d u ce h ig h p re s s u re h o t w a te r •C a p a b ility fo r s te a m p ro d u c tio n •P o w e r o u tp u t w ith u t il ity n e tw o rk in te rfa c e fo r g r id c o n n e c tio n (O p tio n ) •P o w e r o u tp u t fo r s ta n d a lo n e o p e ra tio n (O p tio n ) •P e a k s h a v in g a n d lo a d fo llo w in g (O p tio n s ) •R e m o te c o n tro l a n d m o n ito r in g (O p tio n s ) •D a ta lo g g in g (O p tio n s )

S e e B o w m a n B ro c h u re P D F

S e e B o w m a n s p e c s h e e t P D F

M ic ro tu rb in e E n g in e s T h e s e v e ry s m a ll h ig h s p e e d g a s tu rb in e e n g in e s a re s im p le ra d ia l d e s ig n s , c lo s e r in c o n c e p t to lo w c o s t tu rb o c h a rg e rs th a n th e m o re c o m p le x a x ia l d e s ig n s o f la rg e in d u s tr ia l e n g in e s , w h ic h a re o fte n d e r iv e d fro m a e ro e n g in e s . C o n s e rv a tiv e o p e ra tin g te m p e ra tu re s e lim in a te th e n e e d to u s e h ig h c o s t s o p h is tic a te d m a te r ia ls , w h ic h to g e th e r w ith th e ir s im p lic ity is c o n d u c iv e to lo w c o s t w h e n p ro d u c e d in v o lu m e .

In c o m p a ris o n w ith re c ip ro c a tin g e n g in e s , th e y a ttra c t lo w e r m a in te n a n ce c o s ts , p ro d u ce lo w e r v ib ra tio n , lo w e r e m is s io n s a n d a re m o re c o m p a c t, m a k in g th e m th e id e a l e n g in e c h o ic e fo r c o g e n e ra tio n a n d C H P s ys te m s .

T u rb o A lte rn a to rs A c o n v e n tio n a l s m a ll g a s tu rb in e g e n e ra to r s e t c o n s is ts o f a h ig h s p e e d tu rb in e (e .g . 5 0 k rp m ) c o u p le d to a lo w s p e e d e le c tr ic a l m a c h in e (e .g . 3 k rp m ) th ro u g h a re d u c tio n g e a rb o x . H o w e v e r, th e p o w e r o u tp u t o f a n e le c tr ic a l m a c h in e is p ro p o rtio n a l to s p e e d . C o n s e q u e n tly , if th e e le c tr ic a l m a c h in e (a lte rn a to r) is ru n a t tu rb in e s p e e d it is s o s m a ll th a t it c a n b e in te g ra te d in to th e e n g in e o n th e s a m e s h a ft a s th e tu rb o m a c h in e ry fo rm in g a c o m p a c t h ig h s p e e d g e n e ra to r o r T u rb o A lte rn a to r. T h e g e a rb o x is n o lo n g e r re q u ire d a n d th e a lte rn a to r a ls o a c ts a s a s ta rte r m o to r to fu rth e r re d u ce th e s iz e o f th e g e n e ra to r s e t.

T h e B P S d e fin it io n o f a M T G is w h e re a h ig h s p e e d g e n e ra to r is u s e d a n d ru n s a t tu rb in e s p e e d o n a s in g le o r m u lti-s h a ft s ys te m . T h e p r im a ry p o w e r ra n g e fo r th is T u rb o A lte rn a to r te c h n o lo g y is 2 5 kW to 5 0 0 kW . H o w e v e r, fo r c e rta in a p p lic a tio n s it is e x p e c te d to b e u se d d o w n to a fe w k W a n d p o s s ib ly u p to a fe w M W .

B P S f irs t s ys te m s c o v e r th e ra n g e 2 5 kW to 1 1 5 kW , w ith s ys te m s u p to 2 M W p la n n e d fo r la te r d e v e lo p m e n t.

S e e T u rb o A lte rn a to r s p e c s h e e t P D F

R e c u p e ra to rs D u ra b le h e a t e x c h a n g e rs o f h ig h e ffe c tiv ity a n d lo w c o s t a re n e e d e d to in c re a se th e e ffic ie n c y o f g a s tu rb in e s to th e le v e ls n e e d e d to c o m p e te w ith re c ip ro c a tin g e n g in e b a se d p o w e r g e n e ra tio n s ys te m s . T h e ir fu n c tio n is to p re h e a t th e a ir u s e d in th e c o m b u s tio n p ro ce s s a n d th e re b y re d u c e th e a m o u n t o f fu e l u s e d to re a c h o p e ra tin g te m p e ra tu re .

T h e B P S re c u p e ra to r is a p r im a ry s u rfa c e typ e , m a n u fa c tu re d fro m s ta in le s s s te e l fo r lo n g life . W ith a n e ffe c tiv ity o f a b o u t 9 0 % , th e fu e l c o n s u m p tio n o f th e m ic ro tu rb in e e n g in e is a p p ro x im a te ly h a lv e d , d o u b lin g th e M T G e ffic ie n c y fro m 1 5 % to a b o u t 3 0 % .

P o w e r C o n d it io n e rs T h e e le c tr ic a l o u tp u t fre q u e n c y o f a T u rb o A lte rn a to r is typ ic a lly 1 0 0 0 to 3 0 0 0 H z a n d m u s t b e c o n v e rte d to 5 0 o r 6 0 H z . A m ic ro p ro c e s so r c o n tro lle d P o w e r C o n d itio n e r c a rr ie s o u t th e fre q u e n c y c o n v e rs io n , a n d o th e r p o w e r c o n d itio n in g a n d u til ity c o n n e c tio n fu n c tio n s , to p ro v id e e le c tr ic a l p o w e r o f a p p ro p ria te q u a lity a n d fe a tu re s . T h e P o w e r C o n d itio n e r c o n tro ls o u tp u t fre q u e n c y in d e p e n d e n t o f tu rb in e s p e e d a n d fa c ilita te s th e v a ria tio n o f s p e e d w ith lo a d to s a v e fu e l.

T h e B P S P o w e r C o n d itio n e r is d e s ig n e d in h o u se a n d p ro v id e s th e fu n c tio n a lity to a llo w th e M T G to o p e ra te in p a ra lle l w ith th e u til ity s u p p ly (G r id c o n n e c te d ) in E x p o rt o r L o a d F o llo w in g m o d e , o r a s a s ta n d a lo n e s ys te m ( Is la n d M o d e ). In te g ra te d e n g in e c o n tro l a n d m a n a g e m e n t c a p a b ility to g e th e r w ith re m o te c o n tro l a n d m o n ito r in g is a fu rth e r fe a tu re o f th is m o d u le .

Bowman Microturbines



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ELLIOTT Microturbine

Ref.: ELLIOTT datasheet



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Ingersoll-Rand MicroturbinePowerWorks 70 kW and 250 kW

•70 and 250kWe

•Electrical efficiency 29-30% LHV at ISO

•Low emissions with natural gas

•NOx< 9 ppm, CO< 9 ppm @15% O2

Ref.: Ingelson-Rand , IGTI Microturbine session , June 16, 2003, Atlanta, USA



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GE Microturbine system

Ref.: Karl Sheldon presentation at the IGTI Turbo Expo June 18 2003, Atlanta USA



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Alternative fuels for microturbines

• Natural gas - Standard fuel, but increasing price in the US

• Propane

• Medium Calorific Value gas (MCV) Example: Landfill gas and Sewage gas

• Diesel, kerosine

• Methanol, Ethanol



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Microturbine systems / users• Distributed power generation

Example: - Industrial applications to boost electric power reliability- Remote locations

• Standby powerExample: - Restaurants, Hospitals

• Combined Heat and Power generation (CHP)Example: - Commercial buildings (el and heat)

- Hospitals (el and steam)- Residential buildings (el and heat)

• Mechanical drive for air conditioning systems

• Power generation from alternative fuelsExample: - Landfill gas and Sewage gas

• Hybrid systems. Fuel cell - microturbine



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Ref.: Capstone Product Datasheet



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Ref.: Rob Brandon, CANMET Energy Technology Centre, presentation at the IGTI Turbo Expo June 18 2003, Atlanta USA



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Microturbines today

• Around 3 000 units shipped (as of Nov 2002):

• Capstone: >80% of market share. 30 and 60 kW (develops 200 kW). 2 400 units shipped

• Bowman: 80 kW. 125 units shipped• Ingersoll-Rand: 70 kW (develop 250 kW). 80 units shipped• Turbec: 100 kW. 150 units shipped• Elliott: 80 kW. 125 units shipped

• Cost about 1000 $/kW

• Electric efficiency 27 – 31%

• NOx < 25 ppm (some < 9 ppm)



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Microturbine market 2003

• 2003-2004 sales next to zero

However:

• Experiences of power interruptions (black-outs) led to new market for ”high grade” power capable of supporting the ”digital world” Willing to pay a premium for reliable, uninterrupted power.

• Green energy production certificates



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Ref.: Forecast International, C. E. Opdyke, D. J.Franus “The World Gas Turbine Industry. Production Trends and Key Factors 2002-2011



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Microturbines - Design Trends

• Single shaft engines, 100 – 400 kW

• Air bearings

• Lean premix, low emission combustors

• High efficiency componentshigher turbine outlet temperature (650 732°C - Solar Turbines)

or higher Turbine Inlet Temperature (UTC). Both these temperature raises imply advanced materials such as ceramics



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US Department of Energy, DoEAdvanced Microturbine program

6-year program 2000 – 2006 of $60 Million

Focus for the next generation:

• Fuel-to-electricity conversion efficiency of at least 40%• NOx-levels below 7 ppm (for natural gas)• System cost < 500 $US/kW• Cost of electricity that are competitive with the alternatives for market

applications• 11 000 hours of reliable operations between major overhauls and service life of

at least 45 000 hours• Options for using multiple fuels, including diesel, ethanol, landfill gas and bio-

fuels

The five participating manufacturers that have been chosen for this program are Capstone, General Electric (GE), Ingersoll-Rand, Solar Turbines and United Technology (UTC)

microturbines - kth | energiteknik

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