The principle of operation of GTU. How the efficiency of gas turbines and CCGTs differ for domestic and foreign power plants How do the power of power units of power plants and ambient temperature correlate
Gritsyna V.P.
In connection with the multiple growth of electricity tariffs in Russia, many enterprises are considering the construction of their own low-capacity power plants. In a number of regions, programs are being developed for the construction of small or mini thermal power plants, in particular, as a replacement for obsolete boiler houses. At a new small CHP plant with a fuel utilization rate of up to 90% with full use of the body in production and for heating, the cost of electricity received can be significantly lower than the cost of electricity received from the power grid.
When considering projects for the construction of small thermal power plants, power engineers and specialists of enterprises are guided by the indicators achieved in the large power industry. Continuous improvement of gas turbines (GTUs) for use in large-scale power generation has made it possible to increase their efficiency to 36% or more, and the use of a combined steam-gas cycle (CCGT) has increased the electrical efficiency of TPPs to 54% -57%.
However, in the small-scale power industry it is inappropriate to consider the possibility of using complex schemes of combined cycles of CCGT for the production of electricity. In addition, gas turbines, in comparison with gas engines, as drives for electric generators, lose significantly in terms of efficiency and performance, especially at low powers (less than 10 MW). Since in our country neither gas turbines nor gas piston engines have yet been widely used in small-scale stationary power generation, the choice of a specific technical solution is a significant problem.
This problem is also relevant for large-scale energy, i.e. for power systems. In modern economic conditions, in the absence of funds for the construction of large power plants on obsolete projects, which can already be attributed to the domestic project of a 325 MW CCGT, designed 5 years ago. Energy systems and RAO UES of Russia should pay special attention to the development of small-scale power generation, at whose facilities new technologies can be tested, which will make it possible to begin the revival of domestic turbine-building and machine-building plants and subsequently switch to large capacities.
In the last decade, large diesel or gas engine thermal power plants with a capacity of 100-200 MW have been built abroad. The electrical efficiency of diesel or gas engine power plants (DTPP) reaches 47%, which exceeds the performance of gas turbines (36%-37%), but is inferior to the performance of CCGTs (51%-57%). CCGT power plants include a large range of equipment: a gas turbine, a waste heat steam boiler, a steam turbine, a condenser, a water treatment system (plus a booster compressor if natural gas of low or medium pressure is burned. Diesel generators can run on heavy fuel, which is 2 times cheaper than gas turbine fuel and can operate on low-pressure gas without the use of booster compressors.According to S.E.M.T. PIELSTICK, the total cost over 15 years for the operation of a diesel power unit with a capacity of 20 MW is 2 times less than for a gas turbine thermal power plant of the same capacity when using liquid fuel by both power plants.
A promising Russian manufacturer of diesel power units up to 22 MW is the Bryansk Machine-Building Plant, which offers customers power units with an increased efficiency of up to 50% for operation both on heavy fuel with a viscosity of up to 700 cSt at 50 C and a sulfur content of up to 5%, and for operation on gaseous fuel.
The option of a large diesel thermal power plant may be preferable to a gas turbine power plant.
In small-scale power generation, with unit capacities of less than 10 MW, the advantages of modern diesel generators are even more pronounced.
Let us consider three variants of thermal power plants with gas turbine plants and gas piston engines.
The fuel utilization factor for the first two options of power plants (with different electrical efficiency) due to heat supply can reach 80% -94%, both in the case of gas turbines and for motor drives.
The profitability of all variants of power plants depends on the reliability and efficiency, first of all, of the "first stage" - the drive of the electric generator.
Enthusiasts for the use of small gas turbines are campaigning for their widespread use, noting the higher power density. For example, in [1] it is reported that Elliot Energy Systems (in 1998-1999) is building a distribution network of 240 distributors in North America providing engineering and service support for the sale of "micro" gas turbines. The power grid ordered a 45 kW turbine to be ready for delivery in August 1998. It also stated that the electrical efficiency of the turbine was as high as 17%, and noted that gas turbines were more reliable than diesel generators.
This statement is exactly the opposite!
If you look at Table. 1. then we will see that in such a wide range from hundreds of kW to tens of MW, the efficiency of the motor drive is 13% -17% higher. The indicated resource of the motor drive of the company "Vyartsilya" means a guaranteed resource until a complete overhaul. The resource of new gas turbines is a calculated resource, confirmed by tests, but not by statistics of work in real operation. According to numerous sources, the resource of gas turbines is 30-60 thousand hours with a decrease with a decrease in power. The resource of diesel engines of foreign production is 40-100 thousand hours or more.
Table 1
Main technical parameters of electric generator drives
G-gas-turbine power plant, D-gas-piston generating plant of Vyartsilya.
D - diesel from the Gazprom catalog
* The minimum value of the required pressure of the fuel gas = 48 ATA!!
Performance characteristics
Electrical efficiency (and power) According to Värtsilä data, when the load is reduced from 100% to 50%, the efficiency of an electric generator driven by a gas engine changes little.
The efficiency of a gas engine practically does not change up to 25 °C.
The power of the gas turbine drops evenly from -30°C to +30°C.
At temperatures above 40 °C, the reduction in gas turbine power (from nominal) is 20%.
Start time gas engine from 0 to 100% load is less than a minute and emergency in 20 seconds. It takes about 9 minutes to start a gas turbine.
Gas supply pressure for a gas turbine it should be 16-20 bar.
The gas pressure in the network for a gas engine can be 4 bar (abs) and even 1.15 bar for a 175 SG engine.
Capital expenditures at a thermal power plant with a capacity of about 1 MW, according to Vartsila specialists, they amount to $1,400/kW for a gas turbine plant and $900/kW for a gas piston power plant.
Combined cycle application at small CHPPs, by installing an additional steam turbine is impractical, since it doubles the number of thermal and mechanical equipment, the area of the turbine hall and the number of maintenance personnel with an increase in power only 1.5 times.
With a decrease in the power of the CCGT from 325 MW to 22 MW, according to the NPP "Mashproekt" plant (Ukraine, Nikolaev), the front efficiency of the power plant decreases from 51.5% to 43.6%.
The efficiency of a diesel power unit (using gas fuel) with a capacity of 20-10 MW is 43.3%. It should be noted that in the summer, at a CHPP with a diesel unit, hot water supply can be provided from the engine cooling system.
Calculations on the competitiveness of power plants based on gas engines showed that the cost of electricity at small (1-1.5 MW) power plants is approximately 4.5 cents / kWh), and at large 32-40 MW gas-powered plants 3, 8 US cents/kWh
According to a similar calculation method, electricity from a condensing nuclear power plant costs approximately 5.5 US cents/kWh. , and coal IES about 5.9 cents. US/kWh Compared to a coal-fired CPP, a plant with gas engines generates electricity 30% cheaper.
The cost of electricity produced by microturbines, according to other sources, is estimated at between $0.06 and $0.10/kWh
The expected price for a complete 75 kW gas turbine generator (US) is $40,000, which corresponds to the unit cost for larger (more than 1000 kW) power plants. The big advantage of power units with gas turbines is their smaller dimensions, 3 or more times less weight.
It should be noted that the unit cost of Russian-made electric generator sets based on automobile engines with a capacity of 50-150 kW may be several times less than the mentioned turbo blocks (USA), given the serial production of engines and the lower cost of materials.
Here is the opinion of Danish experts who evaluate their experience in the implementation of small power plants.
"Investment in a completed turnkey natural gas CHP plant with a capacity of 0.5-40 MW is 6.5-4.5 million Danish krone per MW (1 krone was approximately equal to 1 ruble in the summer of 1998) Combined cycle CHP plants below 50 MW will achieve an electrical efficiency of 40-44%.
Operating costs for lubricating oils, maintenance and personnel at the CHP plant reach 0.02 kr per 1 kWh produced by gas turbines. At CHP plants with gas engines, operating costs are about 0.06 dat. kroons per 1 kWh. At current electricity prices in Denmark, the high performance of gas engines more than offsets their higher operating costs.
Danish specialists believe that most CHP plants below 10 MW will be equipped with gas engines in the coming years."
conclusions
The above estimates, it would seem, unambiguously show the advantages of a motor drive at low power of power plants.
However, at present, the power of the proposed Russian-made motor drive on natural gas does not exceed the power of 800 kW-1500 kW (RUMO plant, N-Novgorod and Kolomna Machine Plant), and several plants can offer turbo drives of higher power.
Two factories in Russia: plant im. Klimov (St. Petersburg) and Perm Motors are ready to supply complete power units of mini-CHP with waste heat boilers.
In the case of organizing a regional service center, issues of maintenance and repair of small turbines of turbines can be resolved by replacing the turbine with a backup one in 2-4 hours and its further repair in the factory conditions of the technical center.
The efficiency of gas turbines can currently be increased by 20-30% by applying power injection of steam into a gas turbine (STIG cycle or steam-gas cycle in one turbine). In previous years, this technical solution was tested in full-scale full-scale field tests of the Vodoley power plant in Nikolaev (Ukraine) by Mashproekt Research and Production Enterprise and Zarya Production Association, which made it possible to increase the power of the turbine unit from 16 to 25 MW and the efficiency was increased from 32 .8% to 41.8%.
Nothing prevents us from transferring this experience to smaller capacities and thus implementing a CCGT in serial delivery. In this case, the electrical efficiency is comparable to that of diesel engines, and the specific power increases so much that capital costs can be 50% lower than in a gas engine-driven CHP plant, which is very attractive.
This review was carried out in order to show: that when considering options for the construction of power plants in Russia, and even more so the directions for creating a program for the construction of power plants, it is necessary to consider not individual options that design organizations can offer, but a wide range of issues taking into account the capabilities and interests of domestic and regional manufacturers equipment.
Literature
1. Power Value, Vol.2, No.4, July/August 1998, USA, Ventura, CA.
The Small Turbine Marketplace
Stan Price, Northwest Energy Efficiency Council, Seattle, Washington and Portland, Oregon
2. New directions of energy production in Finland
ASKO VUORINEN, Assoc. tech. Sciences, Vartsila NSD Corporation JSC, "ENERGETIK" -11.1997. page 22
3. District heating. Research and development of technology in Denmark. Ministry of Energy. Energy Administration, 1993
4. DIESEL POWER PLANTS. S.E.M.T. PIELSTICK. POWERTEK 2000 Exhibition Prospectus, March 14-17, 2000
5. Power plants and electrical units recommended for use at the facilities of OAO GAZPROM. CATALOG. Moscow 1999
6. Diesel power station. Prospect of OAO "Bryansk Machine-Building Plant". 1999 Exhibition brochure POWERTEK 2000/
7. NK-900E Block-modular thermal power plant. OJSC Samara Scientific and Technical Complex named after V.I. N.D. Kuznetsova. Exhibition brochure POWERTEK 2000
Thermal turbine of constant action, in which the thermal energy of compressed and heated gas (usually fuel combustion products) is converted into mechanical rotational work on a shaft; is a structural element of a gas turbine engine.
Heating of compressed gas, as a rule, occurs in the combustion chamber. It is also possible to carry out heating in a nuclear reactor, etc. Gas turbines first appeared at the end of the 19th century. as a gas turbine engine and in terms of design, they approached a steam turbine. Structurally, a gas turbine is a series of orderly arranged fixed blade rims of the nozzle apparatus and rotating rims of the impeller, which as a result form a flow part. The turbine stage is a nozzle apparatus combined with an impeller. The stage consists of a stator, which includes stationary parts (housing, nozzle blades, shroud rings), and a rotor, which is a set of rotating parts (such as rotor blades, disks, shaft).
The classification of a gas turbine is carried out according to many design features: in the direction of the gas flow, the number of stages, the method of using the heat difference and the method of supplying gas to the impeller. In the direction of the gas flow, gas turbines can be distinguished axial (the most common) and radial, as well as diagonal and tangential. In axial gas turbines, the flow in the meridional section is transported mainly along the entire axis of the turbine; in radial turbines, on the contrary, it is perpendicular to the axis. Radial turbines are divided into centripetal and centrifugal. In a diagonal turbine, the gas flows at some angle to the axis of rotation of the turbine. The impeller of a tangential turbine has no blades; such turbines are used at very low gas flow rates, usually in measuring instruments. Gas turbines are single, double and multi-stage.
The number of stages is determined by many factors: the purpose of the turbine, its design scheme, the total power and developed by one stage, as well as the actuated pressure drop. According to the method of using the available heat difference, turbines with speed stages are distinguished, in which only the flow turns in the impeller, without pressure change (active turbines), and turbines with pressure stages, in which the pressure decreases both in the nozzle apparatus and on the rotor blades (jet turbines). In partial gas turbines, gas is supplied to the impeller along a part of the circumference of the nozzle apparatus or along its full circumference.
In a multistage turbine, the energy conversion process consists of a number of successive processes in individual stages. Compressed and heated gas is supplied to the interblade channels of the nozzle apparatus at an initial speed, where, in the process of expansion, a part of the available heat drop is converted into the kinetic energy of the outflow jet. Further expansion of the gas and the conversion of the heat drop into useful work occur in the interblade channels of the impeller. The gas flow, acting on the rotor blades, creates a torque on the main shaft of the turbine. In this case, the absolute velocity of the gas decreases. The lower this speed, the greater part of the gas energy is converted into mechanical work on the turbine shaft.
Efficiency characterizes the efficiency of gas turbines, which is the ratio of the work removed from the shaft to the available gas energy in front of the turbine. The effective efficiency of modern multistage turbines is quite high and reaches 92-94%.
The principle of operation of a gas turbine is as follows: gas is injected into the combustion chamber by a compressor, mixed with air, forms a fuel mixture and is ignited. The resulting combustion products with high temperature (900-1200 °C) pass through several rows of blades mounted on the turbine shaft and cause the turbine to rotate. The resulting mechanical energy of the shaft is transmitted through a gearbox to a generator that generates electricity.
Thermal energy gases leaving the turbine enter the heat exchanger. Also, instead of producing electricity, the mechanical energy of the turbine can be used to operate various pumps, compressors, etc. The most commonly used fuel for gas turbines is natural gas, although this cannot exclude the possibility of using other types of gaseous fuels. But at the same time, gas turbines are very capricious and place high demands on the quality of its preparation (certain mechanical inclusions, humidity are necessary).
The temperature of gases leaving the turbine is 450-550 °С. The quantitative ratio of thermal energy to electrical energy in gas turbines ranges from 1.5: 1 to 2.5: 1, which makes it possible to build cogeneration systems that differ in the type of coolant:
1) direct (direct) use of exhaust hot gases;
2) production of low or medium pressure steam (8-18 kg/cm2) in an external boiler;
3) production of hot water (better when the required temperature exceeds 140 °C);
4) production of high pressure steam.
A great contribution to the development of gas turbines was made by Soviet scientists B. S. Stechkin, G. S. Zhiritsky, N. R. Briling, V. V. Uvarov, K. V. Kholshchevikov, I. I. Kirillov and others. the creation of gas turbines for stationary and mobile gas turbine plants was achieved by foreign companies (the Swiss Brown-Boveri, in which the famous Slovak scientist A. Stodola worked, and Sulzer, the American General Electric, etc.).
In the future, the development of gas turbines depends on the possibility of increasing the gas temperature in front of the turbine. This is due to the creation of new heat-resistant materials and reliable cooling systems for rotor blades with a significant improvement in the flow path, etc.
Thanks to the widespread transition in the 1990s. natural gas as the main fuel for power generation, gas turbines have occupied a significant segment of the market. Despite the fact that the maximum efficiency of the equipment is achieved at capacities from 5 MW and higher (up to 300 MW), some manufacturers produce models in the 1-5 MW range.
Gas turbines are used in aviation and power plants.
- Previous: GAS ANALYZER
- Following: GAS ENGINE
The article describes how the efficiency of the simplest gas turbine is calculated, tables of different gas turbines and combined cycle plants are given to compare their efficiency and other characteristics.
In the field of industrial use of gas turbine and steam-gas technologies, Russia has lagged far behind the advanced countries of the world.
World leaders in the production of high-capacity gas and combined-cycle power plants: GE, Siemens Wistinghouse, ABB - achieved values of unit power of gas turbine plants of 280-320 MW and an efficiency of over 40%, with a utilizing steam-power superstructure in a steam-gas cycle (also called binary) - capacities of 430- 480 MW with efficiency up to 60%. If you have questions about the reliability of CCGT - then read the article.
These impressive figures serve as benchmarks in determining the development paths for the power engineering industry in Russia.
How is the efficiency of a gas turbine determined?
Here are a couple of simple formulas to show what the efficiency of a gas turbine plant is:
Turbine internal power:
- Nt = Gex * Lt, where Lt is the operation of the turbine, Gex is the flow rate of exhaust gases;
GTU internal power:
- Ni gtu \u003d Nt - Nk, where Nk is the internal power of the air compressor;
GTU effective power:
- Nef \u003d Ni gtu * Efficiency mech, efficiency mech - efficiency associated with mechanical losses in bearings, can be taken 0.99
Electric power:
- Nel \u003d Ne * efficiency eg, where efficiency eg is the efficiency associated with losses in the electric generator, we can take 0.985
Available heat of fuel:
- Qsp = Gtop * Qrn, where Gref - fuel consumption, Qrn - the lowest working calorific value of the fuel
Absolute electrical efficiency of a gas turbine plant:
- Efficiency \u003d Nel / Q dist
CCGT efficiency is higher than GTU efficiency since the combined-cycle plant uses the heat of the exhaust gases of the gas turbine. A waste heat boiler is installed behind the gas turbine, in which the heat from the exhaust gases of the gas turbine is transferred to the working fluid (feed water), the generated steam is sent to the steam turbine to generate electricity and heat.
Read also: How to choose a gas turbine plant for a CCGT plant
CCGT efficiency is usually represented by the ratio:
- PGU efficiency \u003d GTU efficiency * B + (1-GTU efficiency * B) * PSU efficiency
B is the degree of binarity of the cycle
Efficiency PSU - Efficiency of a steam power plant
- B = Qks/(Qks+Qku)
Qks is the heat of fuel burned in the combustion chamber of a gas turbine
Qku - heat of additional fuel burned in the waste heat boiler
At the same time, it is noted that if Qku = 0, then B = 1, i.e., the installation is completely binary.
Influence of the degree of binarity on the CCGT efficiency
| B | GTU efficiency | PSU efficiency | CCGT efficiency |
| 1 | 0,32 | 0,3 | 0,524 |
| 1 | 0,36 | 0,32 | 0,565 |
| 1 | 0,36 | 0,36 | 0,590 |
| 1 | 0,38 | 0,38 | 0,612 |
| 0,3 | 0,32 | 0,41 | 0,47 |
| 0,4 | 0,32 | 0,41 | 0,486 |
| 0,3 | 0,36 | 0,41 | 0,474 |
| 0,4 | 0,36 | 0,41 | 0,495 |
| 0,3 | 0,36 | 0,45 | 0,51 |
| 0,4 | 0,36 | 0,45 | 0,529 |
Let's sequentially present the tables with the characteristics of the efficiency of gas turbines and after them the indicators of the CCGT with these gas engines, and compare the efficiency of a separate gas turbine and the efficiency of the CCGT.
Characteristics of modern powerful gas turbines
ABB gas turbines
| Characteristic | GTU model | |
| GT26GTU with reheat | GT24GTU with reheat | |
| ISO power MW | 265 | 183 |
| efficiency % | 38,5 | 38,3 |
| 30 | 30 | |
| 562 | 391 | |
| 1260 | 1260 | |
| 610 | 610 | |
| 50 | 50 | |
Combined-cycle plants with ABB gas turbines
GE gas turbines
| Characteristic | GTU model | |||
| MS7001FA | MS9001FA | MS7001G | MS9001G | |
| ISO power MW | 159 | 226,5 | 240 | 282 |
| efficiency % | 35,9 | 35,7 | 39,5 | 39,5 |
| Compressor pressure ratio | 14,7 | 14,7 | 23,2 | 23,2 |
| Consumption of the working fluid at the GTU exhaust kg/s | 418 | 602 | 558 | 685 |
| Initial temperature, in front of the working blades 1 tbsp. FROM | 1288 | 1288 | 1427 | 1427 |
| The temperature of the working fluid at the exhaust C | 589 | 589 | 572 | 583 |
| Generator speed 1/s | 60 | 50 | 60 | 50 |
Read also: Why build Combined Cycle Thermal Power Plants? What are the advantages of combined cycle plants.
Combined-cycle plants with GE gas turbines
| Characteristic | GTU model | |||
| MS7001FA | MS9001FA | MS7001G | MS9001G | |
| The composition of the gas turbine part of the CCGT | 1хMS7001FA | 1хMS9001FA | 1хMS9001G | 1xMS9001H |
| CCGT model | S107FA | S109FA | S109G | S109H |
| CCGT power MW | 259.7 | 376.2 | 420.0 | 480.0 |
| CCGT efficiency % | 55.9 | 56.3 | 58.0 | 60.0 |
Siemens gas turbines
| Characteristic | GTU model | |||
| V64.3A | V84.3A | V94.3A | ||
| ISO power MW | 70 | 170 | 240 | |
| efficiency % | 36,8 | 38 | 38 | |
| Compressor pressure ratio | 16,6 | 16,6 | 16,6 | |
| Consumption of the working fluid at the GTU exhaust kg/s | 194 | 454 | 640 | |
| Initial temperature, in front of the working blades 1 tbsp. FROM | 1325 | 1325 | 1325 | |
| The temperature of the working fluid at the exhaust C | 565 | 562 | 562 | |
| Generator speed 1/s | 50/60 | 60 | 50 | |
Combined-cycle plants with Siemens gas turbines
Westinghouse-Mitsubishi-Fiat gas turbines
| Characteristic | GTU model | ||||
| 501F | 501G | 701F | 701G1 | 701G2 | |
| ISO power MW | 167 | 235,2 | 251,1 | 271 | 308 |
| efficiency % | 36,1 | 39 | 37 | 38,7 | 39 |
| Compressor pressure ratio | 14 | 19,2 | 16,2 | 19 | 21 |
| Consumption of the working fluid at the GTU exhaust kg/s | 449,4 | 553,4 | 658,9 | 645 | 741 |
| Initial temperature, in front of the working blades 1 tbsp. FROM | 1260 | 1427 | 1260 | 1427 | 1427 |
| The temperature of the working fluid at the exhaust C | 596 | 590 | 569 | 588 | 574 |
| Generator speed 1/s | 60 | 60 | 50 | 50 | 50 |
Like a diesel or gasoline engine, a gas turbine is an internal combustion engine with an intake-compression-combustion (expansion)-exhaust duty cycle. But, the basic movement is significantly different. The working body of a gas turbine rotates, and in a piston engine it moves reciprocating.
The working principle of a gas turbine is shown in the figure below. First, the air is compressed by the compressor, then the compressed air is fed into the combustion chamber. Here, the fuel, continuously burning, produces gases with high temperature and pressure. From the combustion chamber, the gas, expanding in the turbine, presses on the blades and rotates the turbine rotor (a shaft with impellers in the form of discs carrying rotor blades), which in turn again rotates the compressor shaft. The remaining energy is removed through the working shaft.
Features of gas turbines
Types of gas turbines by design and purpose
The most basic type of gas turbine is the jet thruster, which is also the simplest in design.
This engine is suitable for aircraft flying at high speed and is used in supersonic aircraft and jet fighters.
This type has a separate turbine behind the turbojet that spins a large fan in front. This fan increases airflow and draft.
This type is quiet and economical at subsonic speeds, which is why gas turbines of this type are used for passenger aircraft engines.
This gas turbine delivers power as torque, with the turbine and compressor sharing a common shaft. Part of the useful power of the turbine goes to the rotation of the compressor shaft, and the rest of the energy is transferred to the working shaft.
This type is used when a constant rotation speed is needed, for example, as a generator drive.
In this type, the second turbine is placed after the gas generator turbine and the rotational force is transferred to it by the jet. This rear turbine is called the power turbine. Since the shafts of the power turbine and compressor are not mechanically connected, the speed of rotation of the working shaft is freely adjustable. Suitable as a mechanical drive with a wide range of rotational speeds.
This type is widely used in propeller-driven aircraft and helicopters, as well as applications such as pump/compressor drives, marine main engines, generator drives, etc.
What is GREEN series gas turbine?
The principle that Kawasaki has followed in the gas turbine business since the development of our first gas turbine in 1972 has allowed us to offer customers ever more advanced equipment, i.e. more energy efficient and environmentally friendly. The ideas embodied in our products have been highly appreciated by the global market and have allowed us to accumulate references for more than 10,000 turbines (at the end of March 2014) as part of standby generators and cogeneration systems.
Kawasaki gas turbines have always been a great success, and we have given them the new name "GREEN Gas Turbines" to show our even greater commitment to this principle.
The development of new types of gas turbines, the growing demand for gas compared to other types of fuel, large-scale plans of industrial consumers to create their own capacities cause a growing interest in gas turbine construction.
R The small generation market has great development prospects. Experts predict an increase in demand for distributed energy from 8% (currently) to 20% (by 2020). This trend is explained by the relatively low tariff for electricity (2-3 times lower than the tariff for electricity from the centralized network). In addition, according to Maxim Zagornov, a member of the general council of Delovaya Rossiya, president of the Association of small-scale power generation of the Urals, director of the MKS group of companies, small generation is more reliable than the network: in the event of an accident on the external network, the supply of electricity does not stop. An additional advantage of decentralized energy is the speed of commissioning: 8-10 months, as opposed to 2-3 years for the creation and connection of network lines.
Denis Cherepanov, co-chairman of the Delovaya Rossiya committee on energy, claims that the future belongs to its own generation. According to Sergei Yesyakov, First Deputy Chairman of the State Duma Energy Committee, in the case of distributed energy in the energy-consumer chain, it is the consumer, not the energy sector, that is the decisive link. With its own generation of electricity, the consumer declares the necessary capacities, configurations and even the type of fuel, saving, at the same time, on the price of a kilowatt of energy received. Among other things, experts believe that additional savings can be obtained if the power plant operates in cogeneration mode: the utilized thermal energy will be used for heating. Then the payback period of the generating power plant will be significantly reduced.
The most actively developing area of distributed energy is the construction of low-capacity gas turbine power plants. Gas turbine power plants are designed for operation in any climatic conditions as the main or backup source of electricity and heat for industrial and domestic facilities. The use of such power plants in remote areas allows you to get significant savings by eliminating the costs of building and operating long power lines, and in central areas - to increase the reliability of electrical and heat supply to both individual enterprises and organizations, and territories as a whole. Consider some gas turbines and gas turbine units that are offered by well-known manufacturers for the construction of gas turbine power plants in the Russian market.
General Electric
GE's wind turbine solutions are highly reliable and suitable for applications in a wide range of industries, from oil and gas to utilities. In particular, GE gas turbine units of the LM2500 family with a capacity of 21 to 33 MW and an efficiency of up to 39% are actively used in small generation. The LM2500 is used as a mechanical drive and a power generator drive, they work in power plants in simple, combined cycle, cogeneration mode, offshore platforms and pipelines.
For the past 40 years, GE turbines of this series have been the best-selling turbines in their class. In total, more than 2,000 turbines of this model have been installed in the world with a total operating time of more than 75 million hours.
Key features of the LM2500 turbines: lightweight and compact design for quick installation and easy maintenance; reaching full power from the moment of launch in 10 minutes; high efficiency (in a simple cycle), reliability and availability in its class; the possibility of using dual-fuel combustion chambers for distillate and natural gas; the possibility of using kerosene, propane, coke oven gas, ethanol and LNG as fuel; low NOx emissions using DLE or SAC combustion chambers; reliability factor - more than 99%; readiness factor - more than 98%; NOx emissions - 15 ppm (DLE modification).
To provide customers with reliable support throughout the life cycle of generating equipment, GE opened a specialized Energy Technology Center in Kaluga. It offers customers state-of-the-art solutions for the maintenance, inspection and repair of gas turbines. The company has implemented a quality management system in accordance with ISO 9001.
Kawasaki Heavy Industries
Japanese company Kawasaki Heavy Industries, Ltd. (KHI) is a diversified engineering company. An important place in its production program is occupied by gas turbines.
In 1943, Kawasaki created the first gas turbine engine in Japan and is now one of the world's recognized leaders in the production of gas turbines of small and medium power, having accumulated references for more than 11,000 installations.
With environmental friendliness and efficiency as a priority, the company has achieved great success in the development of gas turbine technologies and is actively pursuing promising developments, including in the field of new energy sources as an alternative to fossil fuels.
Having good experience in cryogenic technologies, technologies of production, storage and transportation of liquefied gases, Kawasaki conducts active research and development work in the field of hydrogen as a fuel.
In particular, the company already has prototypes of turbines that use hydrogen as an additive to methane fuel. In the future, turbines are expected, for which, much more energy-efficient and absolutely environmentally friendly, hydrogen will replace hydrocarbons.
GTU Kawasaki GPB series designed for baseload operation, including both parallel and isolated network interaction schemes, while the power range is based on machines from 1.7 to 30 MW.
In the model range there are turbines that use steam injection to suppress harmful emissions and use DLE technology modified by the company's engineers.
Electrical efficiency, depending on the generation cycle and power, respectively, from 26.9% for GPB17 and GPB17D (M1A-17 and M1A-17D turbines) to 40.1% for GPB300D (L30A turbine). Electric power - from 1700 to 30 120 kW; thermal power - from 13,400 to 8970 kJ / kWh; exhaust gas temperature - from 521 to 470°C; exhaust gas consumption - from 29.1 to 319.4 thousand m3/h; NOx (at 15% O2) - 9/15 ppm for gas turbines M1A-17D, M7A-03D, 25 ppm for turbine M7A-02D and 15 ppm for turbines L20A and L30A.
In terms of efficiency, Kawasaki gas turbines, each in its class, are either the world leader or one of the leaders. The overall thermal efficiency of power units in cogeneration configurations reaches 86-87%. The company produces a number of GTUs in dual-fuel (natural gas and liquid fuel) versions with automatic switching. At the moment, three models of gas turbines are most in demand among Russian consumers - GPB17D, GPB80D and GPB180D.
Kawasaki gas turbines are distinguished by: high reliability and long service life; compact design, which is especially attractive when replacing equipment of existing generating facilities; ease of maintenance due to the split design of the body, removable burners, optimally located inspection holes, etc., which simplifies inspection and maintenance, including by the user's personnel;
Environmental friendliness and economy. The combustion chambers of Kawasaki turbines are designed using the most advanced techniques to optimize the combustion process and achieve the best turbine efficiency, as well as reduce NOx and other harmful substances in the exhaust. Environmental performance is also improved through the use of advanced dry emission suppression technology (DLE);
Ability to use a wide range of fuels. Natural gas, kerosene, diesel fuel, type A light fuel oils, as well as associated petroleum gas can be used;
Reliable after-sales service. High level of service, including a free online monitoring system (TechnoNet) with reports and forecasts, technical support by highly qualified personnel, as well as trade-in replacement of a gas turbine engine during a major overhaul (GTU downtime is reduced to 2-3 weeks), etc. .d.
In September 2011, Kawasaki introduced a state-of-the-art combustion chamber system that lowered NOx emissions to less than 10 ppm for the M7A-03 gas turbine engine, even lower than current regulations require. One of the company's design approaches is to create new equipment that meets not only modern, but also future, more stringent environmental performance requirements.
The highly efficient 5 MW GPB50D gas turbine with a Kawasaki M5A-01D turbine uses the latest proven technologies. The plant's high efficiency makes it optimal for electricity and cogeneration. Also, the compact design of the GPB50D is particularly advantageous when upgrading existing plants. The rated electrical efficiency of 31.9% is the best in the world among 5 MW plants.
The M1A-17D turbine, through the use of an original combustion chamber design with dry emission suppression (DLE), has excellent environmental performance (NOx< 15 ppm) и эффективности.
The ultra-low weight of the turbine (1470 kg), the lowest in the class, is due to the widespread use of composite materials and ceramics, from which, for example, the impeller blades are made. Ceramics are more resistant to operation at elevated temperatures, less prone to contamination than metals. The gas turbine has an electrical efficiency close to 27%.
In Russia, by now, Kawasaki Heavy Industries, Ltd. implemented a number of successful projects in cooperation with Russian companies:
Mini-TPP "Central" in Vladivostok
By order of JSC Far Eastern Energy Management Company (JSC DVEUK), 5 GTUs GPB70D (M7A-02D) were delivered to TPP Tsentralnaya. The station provides electricity and heat to consumers in the central part of the development of Russky Island and the campus of the Far Eastern Federal University. TPP Tsentralnaya is the first power facility in Russia with Kawasaki turbines.
Mini-CHP "Oceanarium" in Vladivostok
This project was also carried out by JSC "DVEUK" for power supply of the scientific and educational complex "Primorsky Oceanarium" located on the island. Two GPB70D gas turbines were delivered.
GTU manufactured by Kawasaki in Gazprom PJSC
Kawasaki’s Russian partner, MPP Energotekhnika LLC, based on the M1A-17D gas turbine, produces the Korvette 1.7K container power plant for installation in open areas with an ambient temperature range of -60 to + 40 °С.
Within the framework of the cooperation agreement, five EGTEPS KORVET-1.7K were developed and assembled at the production facilities of MPP Energotechnika. The areas of responsibility of the companies in this project were distributed as follows: Kawasaki supplies the M1A-17D gas turbine engine and turbine control systems, Siemens AG supplies the high-voltage generator. MPP Energotekhnika LLC manufactures a block container, an exhaust and air intake device, a power unit control system (including the SHUVGm excitation system), electrical equipment - main and auxiliary, completes all systems, assembles and supplies a complete power plant, and also sells APCS.
EGTES Korvet-1.7K has passed interdepartmental tests and is recommended for use at the facilities of Gazprom PJSC. The gas turbine power unit was developed by MPP Energotechnika LLC according to the terms of reference of PJSC Gazprom within the framework of the Scientific and Technical Cooperation Program of PJSC Gazprom and the Japan Natural Resources and Energy Agency.
Turbine for CCGT 10 MW at NRU MPEI
Kawasaki Heavy Industries Ltd., has manufactured and delivered a complete gas turbine plant GPB80D with a nominal power of 7.8 MW for the National Research University "MPEI" located in Moscow. CHP MPEI is a practical training and, generating electricity and heat on an industrial scale, provides them with the Moscow Power Engineering Institute itself and supplies them to the utility networks of Moscow.
Expansion of the geography of projects
Kawasaki, drawing attention to the advantages of developing local energy in the direction of distributed generation, proposed to start implementing projects using gas turbines of minimum capacity.
Mitsubishi Hitachi Power Systems
The model range of H-25 turbines is presented in the power range of 28-41 MW. The complete package of turbine production, including R&D and remote monitoring center, is carried out at the plant in Hitachi, Japan by MHPS (Mitsubishi Hitachi Power Systems Ltd.). Its formation falls on February 2014 due to the merger of the generating sectors of the recognized leaders in mechanical engineering Mitsubishi Heavy Industries Ltd. and Hitachi Ltd.
H-25 models are widely used around the world for both simple cycle operation due to high efficiency (34-37%), and combined cycle in 1x1 and 2x1 configuration with 51-53% efficiency. Having high temperature indicators of exhaust gases, the GTU has also successfully proven itself to operate in cogeneration mode with a total plant efficiency of more than 80%.
Many years of experience in the production of gas turbines for a wide range of capacities and a well-thought-out design of a single-shaft industrial turbine distinguish the N-25 with high reliability with an equipment availability factor of more than 99%. The total operating time of the model exceeded 6.3 million hours in the second half of 2016. The modern gas turbine unit is made with a horizontal axial split, which ensures the convenience of its maintenance, as well as the possibility of replacing parts of the hot path at the place of operation.
The countercurrent tubular-annular combustion chamber provides stable combustion on various types of fuel, such as natural gas, diesel fuel, liquefied petroleum gas, flue gases, coke oven gas, etc. pre-mixing of the gas-air mixture (DLN). The H-25 gas turbine engine is a 17-stage axial compressor coupled to a three-stage active turbine.
An example of reliable operation of the N-25 GTU at small generation facilities in Russia is the operation as part of a cogeneration unit for the own needs of the Ammoniy JSC plant in Mendeleevsk, the Republic of Tatarstan. The cogeneration unit provides the production site with 24 MW of electricity and 50 t/h of steam (390°C / 43 kg/cm3). In November 2017, the first inspection of the turbine combustion system was successfully carried out at the site, which confirmed the reliable operation of the machine components and assemblies at high temperatures.
In the oil and gas sector, N-25 GTUs were used to operate the Sakhalin II Onshore Processing Facility (OPF) site of the Sakhalin Energy Investment Company, Ltd. The OPF is located 600 km north of Yuzhno-Sakhalinsk in the landfall area of the offshore gas pipeline and is one of the company's most important facilities responsible for preparing gas and condensate for subsequent transmission via pipeline to the oil export terminal and LNG plant. The technological complex includes four N-25 gas turbines, which have been in commercial operation since 2008. The cogeneration unit based on the N-25 GTU is maximally integrated into the OPF integrated power system, in particular, the heat from the exhaust gases of the turbine is used to heat crude oil for the needs of oil refining .
Siemens Industrial Gas Turbine Generator Sets (hereinafter referred to as GTU) will help to cope with the difficulties of the dynamically developing market of distributed generation. Gas turbines with a unit rated power from 4 to 66 MW fully meet the high requirements in the field of industrial combined energy production, in terms of plant efficiency (up to 90%), operational reliability, service flexibility and environmental safety, ensuring low life cycle costs and high return on investment. Siemens has more than 100 years of experience in the construction of industrial gas turbines and thermal power plants based on them.
Siemens GTUs ranging from 4 to 66 MW are used by small utilities, independent power producers (eg industrial plants) and the oil and gas industry. The use of technologies for distributed generation of electricity with combined generation of thermal energy makes it possible to refuse from investing in many kilometers of power lines, minimizing the distance between the energy source and the facility that consumes it, and achieve serious cost savings by covering the heating of industrial enterprises and infrastructure facilities through heat recovery. A standard Mini-TPP based on a Siemens GTU can be built anywhere where there is access to a fuel source or its prompt supply.
SGT-300 is an industrial gas turbine with a rated electric power of 7.9 MW (see Table 1), which combines a simple, reliable design with the latest technology.
Table 1. Specifications of SGT-300 for Mechanical Drive and Power Generation
|
Energy production |
mechanical drive |
||
|---|---|---|---|
|
7.9 MW |
8 MW |
9 MW |
|
|
Power in ISO |
|||
|
Natural gas / liquid fuel / dual fuel and other fuels on request; Automatic fuel change from main to reserve, at any load |
|||
|
Oud. heat consumption |
11.773 kJ/kWh |
10.265 kJ/kWh |
10.104 kJ/kWh |
|
Power turbine speed |
5.750 - 12.075 rpm |
5.750 - 12.075 rpm |
|
|
Compression ratio |
|||
|
Exhaust gas consumption |
|||
|
Exhaust gas temperature |
542°C (1.008°F) |
491°C (916°F) |
512°C (954°F) |
|
NOX emissions Gas fuel with DLE system |
|||
1) Electrical 2) Shaft mounted
Rice. 1. Structure of the SGT-300 gas generator
For industrial power generation, a single-shaft version of the SGT-300 gas turbine is used (see Fig. 1). It is ideal for combined heat and power (CHP) production. The SGT-300 gas turbine is an industrial gas turbine, originally designed for generation and has the following operational advantages for operating organizations:
Electric efficiency - 31%, which is on average 2-3% higher than the efficiency of gas turbines of lower power, due to the higher efficiency value, an economic effect on saving fuel gas is achieved;
The gas generator is equipped with a low-emission dry combustion chamber using DLE technology, which makes it possible to achieve levels of NOx and CO emissions that are more than 2.5 times lower than those established by regulatory documents;
The GTP has good dynamic characteristics due to its single-shaft design and ensures stable operation of the generator in case of fluctuations in the load of the external connected network;
The industrial design of the gas turbine provides a long overhaul life and is optimal in terms of organizing service work that is carried out at the site of operation;
A significant reduction in the building footprint, as well as investment costs, including the purchase of plant-wide mechanical and electrical equipment, its installation and commissioning, when using a solution based on SGT-300 (Fig. 2).
Rice. 2. Weight and size characteristics of the SGT-300 block
The total operating time of the installed fleet of SGT-300 is more than 6 million hours, with the operating time of the leading GTU 151 thousand hours. Availability/availability ratio - 97.3%, reliability ratio - 98.2%.
OPRA (Netherlands) is a leading supplier of energy systems based on gas turbines. OPRA develops, manufactures and markets state-of-the-art gas turbine engines around 2 MW. The key activity of the company is the production of electricity for the oil and gas industry.
The reliable OPRA OP16 engine delivers higher performance at lower cost and longer life than any other turbine in its class. The engine runs on several types of liquid and gaseous fuels. There is a modification of the combustion chamber with a reduced content of pollutants in the exhaust. The OPRA OP16 1.5-2.0 MW power plant will be a reliable assistant in harsh operating conditions.
OPRA gas turbines are the perfect equipment for power generation in off-grid electric and small-scale cogeneration systems. The design of the turbine has been under development for more than ten years. The result is a simple, reliable and efficient gas turbine engine, including a low emission model.
A distinctive feature of the technology for converting chemical energy into electrical energy in OP16 is the COFAR patented fuel mixture preparation and supply control system, which provides combustion modes with minimal formation of nitrogen and carbon oxides, as well as a minimum of unburned fuel residues. The patented geometry of the radial turbine and the generally cantilever design of the replaceable cartridge, including the shaft, bearings, centrifugal compressor and turbine, are also original.
The specialists of OPRA and MES Engineering developed the concept of creating a unique unified technical complex for waste processing. Of the 55-60 million tons of all MSW generated in Russia per year, a fifth - 11.7 million tons - falls on the capital region (3.8 million tons - the Moscow region, 7.9 million tons - Moscow). At the same time, 6.6 million tons of household waste are removed from Moscow outside the Moscow Ring Road. Thus, more than 10 million tons of garbage settle in the Moscow region. Since 2013, out of 39 landfills in the Moscow Region, 22 have been closed. They should be replaced by 13 waste sorting complexes, which will be commissioned in 2018-2019, as well as four waste incineration plants. The same situation occurs in most other regions. However, the construction of large waste processing plants is not always profitable, so the problem of waste processing is very relevant.
The developed concept of a single technical complex combines fully radial OPRA plants with high reliability and efficiency with the MES gasification / pyrolysis system, which allows for the efficient conversion of various types of waste (including MSW, oil sludge, contaminated land, biological and medical waste, waste woodworking, sleepers, etc.) into an excellent fuel for generating heat and electricity. As a result of long-term cooperation, a standardized waste processing complex with a capacity of 48 tons / day has been designed and is under implementation. (Fig. 3).
Rice. 3. General layout of a standard waste processing complex with a capacity of 48 tons/day.
The complex includes a MES gasification unit with a waste storage site, two OPRA gas turbines with a total electrical power of 3.7 MW and a thermal power of 9 MW, as well as various auxiliary and protective systems.
The implementation of such a complex makes it possible on an area of 2 hectares to obtain an opportunity for autonomous energy and heat supply to various industrial and communal facilities, while solving the issue of recycling various types of household waste.
The differences between the developed complex and existing technologies stem from the unique combination of the proposed technologies. Small (2 t/h) volumes of consumed waste, along with a small required area of the site, allow placing this complex directly near small settlements, industrial enterprises, etc., significantly saving money on the constant transportation of waste to their disposal sites. Complete autonomy of the complex allows you to deploy it almost anywhere. The use of the developed standard project, modular structures and the maximum degree of factory readiness of the equipment makes it possible to minimize the construction time to 1-1.5 years. The use of new technologies ensures the highest environmental friendliness of the complex. The MES gasification unit simultaneously produces gas and liquid fractions of fuel, and due to the dual-fuel nature of the OPRA GTU, they are used simultaneously, which increases fuel flexibility and reliability of power supply. The low demands of the OPRA GTU on fuel quality increase the reliability of the entire system. The MES unit allows the use of waste with a moisture content of up to 85%, therefore, waste drying is not required, which increases the efficiency of the entire complex. The high temperature of the exhaust gases of the OPRA GTU makes it possible to provide reliable heat supply with hot water or steam (up to 11 tons of steam per hour at 12 bar). The project is standard and scalable, which allows for the disposal of any amount of waste.
The calculations show that the cost of electricity generation will be from 0.01 to 0.03 euros per 1 kWh, which shows the high economic efficiency of the project. Thus, the OPRA company once again confirmed its focus on expanding the range of fuels used and increasing fuel flexibility, as well as focusing on the maximum use of "green" technologies in its development.
