Microturbines

2005-04-21
Rolf Gabrielsson, Volvo Aero Corporation
Section 1

Microturbines, Section 1

Gas Turbine Applications

Aero
Industry
Power
Combined Heat and Power, CHP
Mechanical drive for pumps and
compressors
Marine
Automotive
Microturbines
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Microturbines, Section 1

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Microturbines, Section 1

Gas Turbine - Civil aircraft

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Microturbines, Section 1

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Microturbines, Section 1

Solar Mercury 50

Click here to enlarge image

Ref.: Solar Turbines

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Microturbines, Section 1

Marine Gas Turbine

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Microturbines, Section 1

Small Gas Turbine development line

z1960- Sven-Olof Kronogrd works at Volvo with the S-tank and a

Volvo gas turbine project for the tank

z1990-1992 Development of HSG 40

z1994-1995 Development of VT100

z1970-Turbokonsult founded by Professor Kronogrd

z1998 Turbec was established to develop T100

z1974-United Turbine founded by Kronogrd and AB Volvo

z1972-1984 Automotive gas turbine for cars, KTT 150 MK1
z1984-1987 Development of GT110 for Volvo Cars

LPP combustor

KTT150 MK I
Car GT (1972-1984)

GT 110 with LPP

HSG 40

VT 100

Car GT (1984-1987)

Volvo / ABB / Vattenfall

for ECB/ ECT

Turbec T100
New company
Volvo / ABB

1970

1975

1980

1985

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

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1990

1995

2000

Microturbines, Section 1

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
z

Conventional combustor

Rotary ceramic heat exchanger

Demonstrated in cars from 1977 including

the first car ever with ceramic HP turbine
z

One car in daily use to gain experience

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

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Microturbines, Section 1

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

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

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Microturbines, Section 1

Volvo Environmental Concept Vehicles

zVT40

for ECC (Environmental Concept Car)

zVT100

for ECT/ECB (Truck and Bus)

zSeries

Hybrid Drive lines

zCombined

Gas Turbine and High Speed

Generator
z1-shaft

Regenerative Engine

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

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Microturbines, Section 1

Volvo Environmental Concept Vehicles

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

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Microturbines, Section 1

The Power Module of T100 microturbine

Very few moving parts

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

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Microturbines, Section 1

T100 installed in a boiler room

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

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Microturbines, Section 1

Gas Turbines
Typical conditions
Pressure

TIT

Bar
C
Industrial, Combined and simple cycle 10-40 -> 1500
Recuperated
< 10
->1300
Aero
20-40
->1600
Automotive / Microturbines

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4-6

Combustor
inlet temp.
C
300 - 650
600 - 800
450-650

1000-1350

600-900

Microturbines, Section 1

Gas Turbine Design Features Related to Output Capacity

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

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Microturbines, Section 1

Microturbine system

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Microturbines, Section 1

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 2530%
Very high shaft rotational speed (>40 000 rpm)
Direct drive high-frequency alternator

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Microturbines, Section 1

Comparison: Microturbine - Gas Engine

Microturbine
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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Gas Engine
=
=
-

Microturbines, Section 1

Microturbine Cycles

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Microturbines, Section 1

Microturbine Cycles

Simple cycle, metallic

el (%)
< 20

Recuperated, metallic
ceramic

25-30
40

Inter-cooled Recuperated (ICR)

>40

Combined cycle with Organic

Rankine Cycle (ORC)

> 40

CHP, metallic

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tot (%)

80

Microturbines, Section 1

Recuperated Gas Turbine

Efficiency and Specific Power
v.s. Turbine inlet temperature (TIT) and Pressure Ratio ()

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Microturbines, Section 1

System studies
Future microturbines or automotive gas turbines
Intercooling a regenerative gas turbine

advanced cycles

zIntercooling

turbines

zBottoming

zIncreased

46,00%

RC 1000C

of recuperated gas

RC 1250C
IRC 1000C

44,00%

IRC 1250C

cycles

temperature

zCeramics
zCooling

concepts for small

components

Thermal efficiency

zMore

42,00%

IRC

40,00%

38,00%

= 5
4
6
Recuperated
7

36,00%
150

200

250

300

Specific Power (kWs/kg)

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

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350

Microturbines, Section 1

Turbec Microturbine
Combined Heat and Power (CHP) System

High efficiency
Low emissions levels
1.

Generator

2.

Inlet air

3.

Combustion chamber

4.

Air to Recuperator

5.

Net electrical output:

100 kW

Net electrical efficiency:

30%

Net total efficiency:

80% (at 50 oC
WRT)

Compressor

Noise level:

70 dBA at 1 meter

6.

Turbine

Emissions, 15% O2

7.

Recuperator

8.

Exhaust gases

9.

Heat exchanger

Ref.: Turbec datasheet

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Performance at ISO-conditions

NOx:

< 15 ppmv

CO:

< 15 ppmv

UHC:

< 10 ppmv

Microturbines, Section 1

Compressor

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Microturbines, Section 1

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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Microturbines, Section 1

Compressor diagram
4,2

Pressure
Ratio,

nredV = 112.6 * 103 min-1

3,8

104.5

3,4

0.73

98.5
0.75

92.5

3,0

0.76

0.70

0.77

84.4

2,6

0.70

2,2

0.65

74.4

0.60

isV = 0.78
1,8

1,4

62.3

46.2
0.65

1,0
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

Air mass flow

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0,56

Microturbines, Section 1

Component development
Compressors
z Development steps
z

Inverse design method

Parametric design

Introduction of 3D viscous CFD

Compressor
KTT 150 MK1
HSG 40 v1
HSG 40 v2
VT600
VT100/T100
T100 prot

Pressure
ratio
5.1
3.5
4.0
9.2
4.4
4.6

Efficiency

Method

Year

75%
75%
77%
77%
77%
80%

Inverse design
Inverse design
Parametric/Streamline
Parametric/Streamline
Parametric/Streamline
Parametric/3D CFD

1976
1991
1993
1992
1994
2002

Polytropic efficiency

Polytropic efficiency development

88,5%
88,0%
87,5%
87,0%
86,5%
86,0%
85,5%
85,0%
84,5%
1970

1975

1980

1985

1990

Development Year

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

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1995

2000

2005

Microturbines, Section 1

Combustor

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Microturbines, Section 1

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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Microturbines, Section 1

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Microturbines, Section 1

Gas Turbine combustor design

Diffusion combustor

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LowNOx combustor

Microturbines, Section 1

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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Microturbines, Section 1

Volvo Aero / Turbec Combustor development

zLean

Premixed Prevaporized
combustor system

Engine

Fuel

T100
T100

Natural gas
Petroleum gas,
Propane 95%
Petroleum gas,
Propane/butane 20/80
Landfill gas (HLHV19
MJ/kg)
Methanol
Ethanol (E85)
Kerosene
Diesel

T100
T100

zOriginal

development for the

automotive GT 110

zMulti

fuel capability

zUsed

in Turbec T100

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T100
VT100
T100
VT40/T100
VT4400DLE
VT4400

Low Calorific Fuel

(HLHV5 MJ/kg, no NH3)

Type of
combustor

Emissions at 100%
load and 15% O2
CO
NOx
<15 ppm <15 ppm
<10 ppm <10 ppm

LPP
LPP

<10 ppm

<10 ppm

LPP

<12 ppm

<5 ppm

LPP

<10 ppm
<20 ppm
<10 ppm
<10 ppm
<25 ppm
<9 ppm

<5 ppm
<40 ppm
<15 ppm
<15 ppm
<15 ppm
<20 ppm

LPP
LPP
LPP
LPP
LPP
Diffusion

Microturbines, Section 1

Ingersoll-Rand 250 kWe PowerWorks Combustor

Ref.: Jim Kesseli Presentation at the IGTI Turbo Expo June 18 2003, Atlanta USA
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Microturbines, Section 1

Honda Microturbine Combustor

Ref.: Koichi Shinmura Presentation at the IGTI Turbo Expo, June 18 2003, Atlanta, USA
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Microturbines, Section 1

Capstone C60 Microturbine

Recuperator

Combustion Chamber

Fuel Injector

Turbine
Ref.: Capstone Product Datasheet
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Microturbines, Section 1

Catalytic Combustor

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Microturbines, Section 1

High Temperature Catalytic Combustor

Project AGATA, Complete reaction in the catalyst section
Diesel fuel
Catalyst outlet temperature 1350C

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Microturbines, Section 1

Catalytica
Hybrid catalytic combustor
Catayst section + Post catalyst zone

NOx emissions as low as 2.5 ppm.

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Microturbines, Section 1

Ref.: Kawasaki Gas Turbines, Datasheet

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Microturbines, Section 1

Turbine

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Microturbines, Section 1

Volvo Aero / Turbec Component development

Turbines
zAxial

turbines

zBLISK

designs

zIntroduction

zRadial

of 3D Compound Lean

turbines

zIn-house

method

developed inverse design

z3D

Stress&CFD for optimal tradeoffs Performance-Life

zT100

Performance

zExpansion
z89%

ratio 4

total-total

zDiameter

175 mm

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

Microturbines, Section 1

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 1350C

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Microturbines, Section 1

Heat exchanger

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Microturbines, Section 1

Heat exchangers
Key component for microturbines
Accounts for about half heat input
Regenerator
-

Automotive application

Ref.: Bowman Power

Recuperator

Microturbine application

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

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Microturbines, Section 1

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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Microturbines, Section 1

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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Microturbines, Section 1

Alternative recuperator development

zDevelopment

of a recuperator for
volume production in Recuperator
Svenska AB.

zStamped

zLaser

plates

welded

zModularised

zPerformance

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

zFirst

full size prototype tested for

~4500 h
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Ref.:Lars Sundin, Volvo Aero Presentation 10-11 July 2003 Brussels

Microturbines, Section 1

Recuperators - Annular design

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

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Capstone Microturbine
Ref.: Capstone Product Datasheet

Microturbines, Section 1

Recuperator materials
Metallic materials
Type 347 stainless steel - Today standard material
Max temperature (exhaust): 1200F = 650C
Inconel - Advanced material
Max temperature (exhaust): 1500F = 820C
Ceramics
>1600F = 870C

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Microturbines, Section 1

Ceramic materials

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Microturbines, Section 1

Ceramic components
zDevelopment

of ceramic turbine
components started 1981

zTurbine

wheel from ASEA CERAMA

tested in a car 1982

zSeveral

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

zGT110

demonstrated reliable at 1250

C 1987
zEuropean

AGATA project developed

zCeramic

radial turbine

zCeramic

recuperator

zCeramic

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

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Microturbines, Section 1

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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Microturbines, Section 1

Specification:
Combustor inlet temperature:

935C

Turbine inlet temperature, TIT: 1350C

Cycle efficiency:
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42%

Microturbines, Section 1

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Microturbines, Section 1

Ceramic Turbine

Ref.: Jim Kesseli et al, presentation at the IGTI Turbo Expo June 18 2003, Atlanta USA
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Microturbines, Section 1

AGATA
Ceramic Heat Exchanger with casing and seals

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Microturbines, Section 1

AGATA
Cordierite Ceramic Heat Exchanger Matrix

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Microturbines, Section 1

Power Electronics

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Microturbines, Section 1

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

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