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, “ Business Russia”, President of the Association of Small-Scale Energy 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 Committee on Energy, 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. 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 standard 9001.
Kawasaki Heavy Industries
Japanese company Kawasaki Heavy Industries, Ltd. (KHI) is a diversified engineering company. important place in her production program 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 for the production, storage and transportation of liquefied gases, Kawasaki is actively researching and developing in the field of using 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 are 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 M1A-17D, M7A-03D gas turbines, 25 ppm for M7A-02D turbine and 15 ppm for L20A and L30A turbines.
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 free system online monitoring (TechnoNet) with the provision of reports and forecasts, technical support by highly qualified personnel, as well as the replacement of a gas turbine engine through a trade-in during a major overhaul (a downtime of a gas turbine is reduced to 2-3 weeks), etc.
In September 2011, Kawasaki introduced latest system combustion chamber, which has reduced NOx emissions to less than 10 ppm for the M7A-03 gas turbine engine, which is 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 GTU GPB70D (M7A-02D) were delivered for 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 the power supply of the scientific and educational complex "Primorsky Oceanarium" located on the island. Two GPB70D gas turbines have been 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, developed and production facilities MPP Energotechnika assembled five EGTEPS KORVET-1.7K. 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 terms of reference PJSC Gazprom within the framework of the Science and Technology Cooperation Program between 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 expertise 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 is made with a horizontal axial split, which ensures ease of 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-scale generation facilities in Russia is the operation as part of a cogeneration unit for the own needs of the JSC Ammonii 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 pipeline transmission 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 (e.g. industrial plants) and 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 multi-kilometer 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 the combined production of thermal and electrical energy(TPP). 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. incinerators. 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 units with high reliability and efficiency with the MES gasification / pyrolysis system, which allows for efficient conversion various kinds waste (including MSW, oil sludge, contaminated land, biological and medical waste, wood waste, 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 fuel fractions, 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.
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. For the first time, gas turbines appeared in late XIX v. 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 stationary 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 fed into the interblade channels of the nozzle apparatus with 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 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 generating 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.
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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 area of industrial use gas turbine and combined cycle 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 combined-cycle 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. WITH | 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. WITH | 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. WITH | 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 |
In autonomous generation - small power generation in Lately considerable attention is given gas turbines different power. Power plants at the base gas turbines are used as the main or backup source of electricity and heat for industrial or domestic facilities. gas turbines as part of power plants are designed for operation in any climatic conditions of Russia. Areas of use gas turbines practically unlimited: oil and gas industry, industrial enterprises, structures housing and communal services.
Positive use factor gas turbines in the field of housing and communal services is that the content of harmful emissions in the exhaust gases of NO x and CO is at the level of 25 and 150 ppm, respectively (for piston plants, these values are much higher), which allows you to install a power plant near residential areas. Usage gas turbines as power units of power plants avoids the construction of high chimneys.
Depending on the needs gas turbines equipped with steam or hot water waste heat boilers, which allows you to receive from the power plant either steam (low, medium, high pressure) for process needs, or hot water (DHW) with standard temperature values. You can get steam and hot water at the same time. The power of thermal energy produced by a power plant based on gas turbines, as a rule, is twice that of electricity.
At the power plant gas turbines in this configuration, the fuel efficiency increases to 90%. High usage efficiency gas turbines as power units is provided during long-term operation with maximum electrical load. With enough power gas turbines there is the possibility of combined use of steam turbines. This measure allows to significantly increase the efficiency of using the power plant, increasing the electrical efficiency up to 53%.
How much does a gas turbine power plant cost? What is its full price? What is included in the turnkey price?
Autonomous thermal power plant based on gas turbines has a lot of additional expensive, but often, just necessary equipment(a real-life example is a completed project). With the use of first-class equipment, the cost of a power plant of this level, on a turnkey basis, does not exceed 45,000 - 55,000 rubles per 1 kW of installed electric capacity. The final price of a power plant based on gas turbines depends on the specific tasks and needs of the consumer. The cost includes design, construction and commissioning. Gas turbines themselves, as power units, without additional equipment, depending on the manufacturer and power, cost from 400 to 800 dollars per 1 kW.
To obtain information on the cost of building a power plant or thermal power plant in your particular case, you must send a completed questionnaire to our company. After that, after 2-3 days, the customer-client receives a preliminary technical and commercial proposal - TCH (short example). Based on the TCH, the customer makes the final decision on the construction of a power plant based on gas turbines. As a rule, before making a decision, the client visits an existing facility in order to see a modern power plant with his own eyes and “touch everything with his hands”. Directly at the facility, the customer receives answers to existing questions.
The concept of block-modular construction is often taken as the basis for the construction of power plants based on gas turbines. Block-modular design provides a high level of factory readiness of gas turbine power plants and reduces the construction time for energy facilities.
Gas turbines - some arithmetic on the cost of energy produced
To produce 1 kW of electricity, gas turbines consume only 0.29–0.37 m³/h of gas fuel. When burning one cubic meter of gas, gas turbines generate 3 kW of electricity and 4–6 kW of thermal energy. With the price (averaged) for natural gas in 2011, 3 rubles. per 1 m³, the cost of 1 kW of electricity received from a gas turbine is approximately 1 ruble. In addition to this, the consumer receives 1.5–2 kW of free thermal energy!
With autonomous power supply from a power plant based on gas turbines, the cost of electricity and heat produced is 3–4 times lower than the tariffs in force in the country, and this does not take into account the high cost of connecting to state power grids (60,000 rubles per 1 kW in the Moscow region, 2011).
Construction of autonomous power plants based on gas turbines allows for significant savings Money By eliminating the costs of construction and operation of expensive power lines (TL), power plants based on gas turbines can significantly increase the reliability of electrical and heat supply for both individual enterprises or organizations, and regions as a whole.
The degree of automation of the power plant based on gas turbines makes it possible to abandon a large number of maintenance personnel. During the operation of a gas power plant, only three people ensure its operation: an operator, an electrician on duty, and a mechanic on duty. When emergencies Reliable protection systems are provided to ensure the safety of personnel, the safety of systems and units of the gas turbine.
Atmospheric air is fed through an air intake equipped with a filter system (not shown in the diagram) to the inlet of a multistage axial compressor. The compressor compresses atmospheric air and delivers it at high pressure to the combustion chamber. At the same time, a certain amount of gas fuel is supplied to the combustion chamber of the turbine through the nozzles. Fuel and air mix and ignite. The air-fuel mixture burns, releasing a large amount of energy. The energy of the gaseous products of combustion is converted into mechanical work due to the rotation of the turbine blades by jets of hot gas. Part of the energy received is used to compress the air in the turbine compressor. The rest of the work is transferred to the electric generator through the drive axle. This work is the useful work of the gas turbine. Combustion products, which have a temperature of about 500-550 °C, are removed through the exhaust tract and turbine diffuser, and can be further used, for example, in a heat exchanger, to generate thermal energy.
Gas turbines, as engines, have the highest specific power among internal combustion engines, up to 6 kW/kg.
As a gas turbine fuel, kerosene, diesel fuel, gas can be used.
One of the advantages of modern gas turbines is the long life cycle- engine life (full up to 200,000 hours, before overhaul 25,000–60,000 hours).
Modern gas turbines are highly reliable. There is evidence of continuous operation of some units for several years.
Many gas turbine suppliers produce overhaul equipment on site, replacing individual components without transporting them to the manufacturing plant, which significantly reduces time costs.
The possibility of long-term operation in any power range from 0 to 100%, the absence of water cooling, operation on two types of fuel - all this makes gas turbines popular power units for modern autonomous power plants.
The use of gas turbines is most effective at medium power plants, and at capacities above 30 MW, the choice is obvious.
A gas turbine is commonly referred to as a continuously operating engine. Next, we will talk about how a gas turbine is arranged, what is the principle of operation of the unit. A feature of such an engine is that inside it, energy is produced by compressed or heated gas, the result of which is mechanical work on the shaft.
History of the gas turbine
Interestingly, turbine mechanisms have been developed by engineers for a very long time. The first primitive steam turbine was created in the 1st century BC. e.! Of course, its essential
This mechanism has reached its heyday only now. Turbines began to be actively developed at the end of the 19th century, simultaneously with the development and improvement of thermodynamics, mechanical engineering and metallurgy.
The principles of mechanisms, materials, alloys have changed, everything has been improved, and now, today, mankind knows the most perfect of all previously existing forms gas turbine, which is divided into different types. There is an aviation gas turbine, and there is an industrial one.
It is customary to call a gas turbine a kind of heat engine, its working parts are predetermined with only one task - to rotate due to the action of a gas jet.
It is arranged in such a way that main part The turbine is represented by a wheel on which sets of blades are attached. , acting on the blades of a gas turbine, makes them move and rotate the wheel. The wheel, in turn, is rigidly fastened to the shaft. This tandem has a special name - the turbine rotor. Due to this movement occurring inside the gas turbine engine, obtaining mechanical energy, which is transmitted to the electric generator, to the propeller of the ship, to air propeller aircraft and other operating mechanisms of a similar principle of operation.
Active and jet turbines
The impact of the gas jet on the turbine blades can be twofold. Therefore, turbines are divided into classes: the class of active and reactive turbines. Reactive and active gas turbines differ in the principle of the device.
Impulse turbine
An active turbine is characterized by the fact that there is a high rate of gas flow to the rotor blades. With the help of a curved blade, the gas jet deviates from its trajectory. As a result of the deflection, a large centrifugal force develops. With the help of this force, the blades are set in motion. During the entire described path of the gas, a part of its energy is lost. Such energy is directed to the movement of the impeller and shaft.
jet turbine
In a jet turbine, things are somewhat different. Here, the flow of gas to the rotor blades is carried out at low speed and under the influence of a high level of pressure. The shape of the blades is also excellent, due to which the gas velocity is significantly increased. Thus, the jet of gas creates a kind of reactive force.
From the mechanism described above, it follows that the device of a gas turbine is rather complicated. In order for such a unit to work smoothly and bring profit and benefit to its owner, you should entrust its maintenance to professionals. Service profile companies provide service maintenance installations using gas turbines, supplies of components, all kinds of parts and parts. DMEnergy is one such company () that provides its customer with peace of mind and confidence that he will not be left alone with the problems that arise during the operation of a gas turbine.
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