The PGT2, a New 2-MW Class Efficient Gas Turbine: Applications and Operating Experience in Cogeneration

1996 ◽  
Author(s):  
Erio Benvenuti ◽  
Marco Sargenti
Keyword(s):  
Gas Turbine ◽  
Pressure Ratio ◽  
Operating Experience ◽  
Paper Mill ◽  
Medium Size ◽  
Economic Evaluations ◽  
Cogeneration Plant ◽  
Two Stage ◽  
Paper Mills ◽  
Operational Data

The PGT2 is a single-shaft gas turbine with a 2 MW ISO electric output that, after an extensive factory development program has been launched into industrial service with a number of cogeneration applications in small-medium size industries. The two-stage high pressure ratio compressor combined with the single-can combustor and the two-stage air-cooled transonic turbine provides a compact and rugged architecture. The turbine inlet temperature in the 1050–1100 °C class and the 12.5:1 pressure ratio provide a 25% electrical efficiency and a high exhaust temperature that make this machine attractive for a variety of both civil and industrial applications like hospitals and pulp and paper mills, textile, tiles, cement, glass and food production. The exhaust heat recovery boiler can be either a commercial unit or compact once-through type of proprietary design that is housed in a vertical exhaust duct to substantially reduce powerplant footprint area when space is limited. The first application that has provided the most extensive operating experience so far is cogeneration in a paper mill in central Italy. Detailed studies on the potential energy saving and on the return of investment cycle were made in collaboration with the client, and provided a valuable basis for further studies that led to additional orders for paper mills, textile and tile industries. The first installed unit is a package comprising a once-through-flow boiler that was full-load tested at the factory before shipping. Commissioning of the cogeneration plant was started in 30 days after shipment and the plant was taken over by the client in less than three months. A dedicated telephone line allows the power plant to be monitored directly from Florence, thus making it possible to gather operational data in real time and to provide this first customer with prompt assistance during the 4-year service and maintenance contract period. This paper describes the PGT2 design and performance features, the technical and economic evaluations made for the first application, the cogeneration plant layout and a summary of the most significant operational data collected in the initial months or regular service in the paper mill.

Operating Experience With a 42.5 MW Gas Turbine Used in a Cogeneration Plant at a Paper Mill in the U.S.

1989 ◽  
Author(s):  
S. T. O’Neill
Keyword(s):  
Gas Turbine ◽  
Operating Experience ◽  
Paper Mill ◽  
Cogeneration Plant ◽  
History Of ◽  
Operating History ◽  
Base Load ◽  
The U.S ◽  
Reliability And Availability

The CW251B10 Gas Turbine has been in service at the Procter & Gamble Paper Mill located at Mehoopany, Pennsylvania since July 1985, and has exhibited outstanding reliability and availability since that time. It operates continuously at base load supplying both electricity and process air for the plant. This paper reviews the operating history of the gas turbine, and describes some of the problems experienced, together with their solutions.

scholarly journals A Cogeneration Plant Based on a Steam Injection Gas Turbine With Recovery of the Water Injected: Design Criteria and Initial Operating Experience

1994 ◽  
Author(s):  
Ennio Macchi ◽  
Aurelio Poggio
Keyword(s):  
Gas Turbine ◽  
Nox Reduction ◽  
Operating Experience ◽  
Industrial Process ◽  
Steam Injection ◽  
Hot Water ◽  
Medium Size ◽  
Operational Experience ◽  
Cogeneration Plant ◽  
Efficiency Increase

The idea of re-injecting into a gas turbine cycle the steam generated by the heat recovery steam generator (HRSG) is a well-established practice, especially in small-medium size cogeneration plants operating under variable heat demand. Power augmentation, electrical efficiency increase, NOx reduction and operating flexibility are the most obvious advantages brought about by steam injection. On the other hand, the discharge to the ambient of the injected steam has two major drawbacks: (i) a relevant water consumption and (ii) the large thermal loss related to the latent heat of steam. The addition of a recuperator downstream of the HRSG, whereby steam condensation takes place, can solve both problems, by achieving very high first-law efficiencies (over 100%, if reference is made to the lower heating value) and the integral recovery of water. The present paper describes the design philosophy and the operational experience of a cogeneration plant where such a condensation is accomplished. To the Authors’s knowledge, it is the first time in the world that this is achieved with gas turbine exhausts. The plant is located inside the “CARROZZERIA BERTONE”, a car manufacturing factory near Turin, Italy. It was designed to fulfill all the energy needs of the factory: it supplies all the electricity, steam and hot water required by the industrial process and during peaking hours, sells excess electricity to the national grid, at special increased tariffs offered to energy-saving plants in Italy. The plant erection (including the recuperator/condenser) was completed in December 1992; commercial operation began in February 1993.

Evolution of Gas Turbine Intake Air Filtration in a 420 MW Cogeneration Plant

2014 ◽  
Author(s):  
Steve Ingistov ◽  
Michael Milos ◽  
Rakesh K. Bhargava
Keyword(s):  
Gas Turbine ◽  
Gas Turbines ◽  
Economic Benefits ◽  
Cogeneration Plant ◽  
Air Filtration ◽  
Air Filter ◽  
Filter System ◽  
Turbine Performance ◽  
Filtration System ◽  
Operational Data

A suitable inlet air filter system is required for a gas turbine, depending on installation site and its environmental conditions, to minimize contaminants entering the compressor section in order to maintain gas turbine performance. This paper describes evolution of inlet air filter systems utilized at the 420 MW Watson Cogeneration Plant consisting of four GE 7EA gas turbines since commissioning of the plant in November 1987. Changes to the inlet air filtration system became necessary due to system limitations, a desire to reduce operational and maintenance costs, and enhance overall plant performance. Based on approximately 2 years of operational data with the latest filtration system combined with other operational experiences of more than 25 years, it is shown that implementation of the high efficiency particulate air filter system provides reduced number of crank washes, gas turbine performance improvement and significant economic benefits compared to the traditional synthetic media type filters. Reasons for improved gas turbine performance and associated economic benefits, observed via actual operational data, with use of the latest filter system are discussed in this paper.

ADVANCED TREATMENT OF PAPER MILL EFFLUENTS BY A TWO-STAGE ACTIVATED SLUDGE PROCESS

1994 ◽  
Vol 30 (3) ◽  
pp. 173-181 ◽  
Author(s):  
L. Knudsen ◽  
J. A. Pedersen ◽  
J. Munck
Keyword(s):  
Activated Sludge ◽  
Treatment Plant ◽  
Paper Mill ◽  
Pilot Scale ◽  
Activated Sludge Process ◽  
Two Stage ◽  
Paper Mills ◽  
Paper Mill Effluents ◽  
Scale Test ◽  
Oxygen Requirements

The work presented in this paper concerns the application of a two-stage aerobic activated sludge process for treatment of effluents from paper mills in Denmark. The paper describes both pilot-scale test results and fullscale experience with the process. The treatment process is characterised by a bigh-load first stage (2-4 kg COD/kg MLSSxd) followed by a low-load second stage to secure full nitrification and denitrification of remaining nitrogen compounds. The results of continuous pilot-scale tests show that it is possible to obtain a reduction of more than 85% of the incoming COD,01 and a 99% reduction of the incoming BOD5, resulting in an effluent quality of 230 mg CODsol/l and less than 10 mg BOD5/l. As indicated, practically all the biodegradable organic substances are removed by the process. The remaining fraction of soluble organics measured as COD is considered to be non-biodegradable by conventional biological treatment systems. The results produced in the pilot-scale tests are confirmed by the effluent qualities obtained in a full-scale treatment plant at another paper mill, involving an identical process concept. During the pilot-scale tests, special attention bas been paid to the removal of organic compounds, organic nitrogen as well as nutrients and nitrification. In addition, the sludge characteristics and the oxygen requirements have been considered.

A Small Gas Turbine Plant for Cogeneration of Electricity, Thermal and Cooling Thermal Energy With an Absorption Unit

1997 ◽  
Author(s):  
Maurizio De Lucia ◽  
Carlo Lanfranchi ◽  
Antonio Matucci
Keyword(s):  
Gas Turbine ◽  
Thermal Energy ◽  
Operating Conditions ◽  
Hot Water ◽  
Plant Performance ◽  
Cooling Power ◽  
Operating Parameters ◽  
The European Union ◽  
Cogeneration Plant ◽  
Two Stage

A cogeneration plant with a small gas turbine was installed in a pharmaceutical factory and instrumented for acquiring all the values necessary to appraise both its energetic and cost advantages. The plant was designed and built as a demonstrative project under a program for energy use improvement in industry, partially financed by the European Union. The system comprises as its main components: 1) a gas turbine cogeneration plant for production of power and thermal energy under the form of hot water, superheated water, and steam; 2) a two-stage absorption unit, fueled by the steam produced in the cogeneration plant, for production of cooling thermal energy. The plant was provided with an automatized control system for the acquisition of plant operating parameters. The large amount of data thus provided made it possible to compare the new plant, under actual operating conditions, with the previously existing cooling power station with compression units, and with a traditional power plant. This comparative analysis was based on measurements of the plant operating parameters over nine months, and made it possible to compare actual plant performance with that expected and ISO values. The analysis results reveal that gas turbine performance is greatly affected by part-load as well as ambient temperature conditions. Two-stage absorber performance, moreover, turned out to decrease sharply and more than expected in off-design operating conditions.

Strategy for a Cost Optimized Operation of a Flexible Cogeneration Gas Turbine Plant

2000 ◽  
Author(s):  
D. Hein ◽  
K. Kwanka ◽  
M. Nixdorf
Keyword(s):  
Gas Turbine ◽  
Control Strategy ◽  
Operating Experience ◽  
Economic Potential ◽  
Cogeneration Plant ◽  
Turbine Plant ◽  
Mode Of Operation ◽  
Gas Turbine Plant ◽  
Technical Framework

A new gas turbine cogeneration plant based on the Cheng cycle was installed to supply electricity and heat for the Technische Universität München’s campus site at Garching. To utilize fully the Cheng cycle flexibility, an optimizing system was developed which controls the mode of operation continuously and adapts the point of operation without manual interface. Only with such a system it is possible to exploit the full economic potential of the system. The paper presents the technical framework and some aspects of the control strategy used to minimize the costs based on three years of operating experience.

Study of Humid Air Gas Turbine System by Experiment and Analysis

2011 ◽  
Author(s):  
Toru Takahashi ◽  
Yutaka Watanabe ◽  
Hidefumi Araki ◽  
Takashi Eta
Keyword(s):  
Gas Turbine ◽  
Thermal Efficiency ◽  
Pilot Plant ◽  
Gas Turbines ◽  
Combined Cycle ◽  
Cycle Performance ◽  
Medium Size ◽  
Water Recovery ◽  
Two Stage ◽  
Humid Air

Humid air gas turbine systems that are regenerative cycle using humidified air can achieve higher thermal efficiency than gas turbine combined cycle power plant (GTCC) even though they do not require a steam turbine, a high combustion temperature, or a high pressure ratio. In particular, the advanced humid air gas turbine (AHAT) system appears to be highly suitable for practical use because its composition is simpler than that of other systems. Moreover, the difference in thermal efficiency between AHAT and GTCC is greater for small and medium-size gas turbines. To verify the system concept and the cycle performance of the AHAT system, a 3MW-class pilot plant was constructed that consists of a gas turbine with a two-stage centrifugal compressor, a two-stage axial turbine, a reverse-flow-type single-can combustor, a recuperator, a humidification tower, a water recovery tower, and other components. As a result of an operation test, the planned power output of 3.6MW was achieved, so that it has been confirmed the feasibility of the AHAT as a power-generating system. In this study, running tests on the AHAT pilot plant is carried out over one year, and various characteristics such as the effect of changes in ambient temperature, part-load characteristics, and start-up characteristics were clarified by analyzing the data obtained from the running tests.

Development of Elemental Technologies for Advanced Humid Air Turbine System

2008 ◽  
Vol 130 (3) ◽  
Author(s):  
Hidetoshi Kuroki ◽  
Shigeo Hatamiya ◽  
Takanori Shibata ◽  
Tomomi Koganezawa ◽  
Nobuaki Kizuka ◽  
...  
Keyword(s):  
Gas Turbine ◽  
Thermal Efficiency ◽  
Pilot Plant ◽  
Pressure Ratio ◽  
High Humidity ◽  
Nox Emissions ◽  
Two Stage ◽  
Humid Air ◽  
Air Turbine ◽  
Recovery System

The advanced humid air turbine (AHAT) system improves the thermal efficiency of gas turbine power generation by using a humidifier, a water atomization cooling (WAC) system, and a heat recovery system, thus eliminating the need for an extremely high firing temperature and pressure ratio. The following elemental technologies have been developed to realize the AHAT system: (1) a broad working range and high-efficiency compressor that utilizes the WAC system to reduce compression work, (2) turbine blade cooling techniques that can withstand high heat flux due to high-humidity working gas, and (3) a combustor that achieves both low NOx emissions and a stable flame condition with high-humidity air. A gas turbine equipped with a two-stage radial compressor (with a pressure ratio of 8), two-stage axial turbine, and a reverse-flow type of single-can combustor has been developed based on the elemental technologies described above. A pilot plant that consists of a gas turbine generator, recuperator, humidification tower, water recovery system, WAC system, economizer, and other components is planned to be constructed, with testing slated to begin in October 2006 to validate the performance and reliability of the AHAT system. The expected performance is as follows: thermal efficiency of 43% (LHV), output of 3.6MW, and NOx emissions of less than 10ppm at 15% O2. This paper introduces the elemental technologies and the pilot plant to be built for the AHAT system.

scholarly journals Analysis and Improvement of a Two-Stage Centrifugal Compressor Used in an MW-Level Gas Turbine

2018 ◽  
Vol 8 (8) ◽  
pp. 1347 ◽  
Author(s):  
Wei Zhu ◽  
Xiao-Dong Ren ◽  
Xue-Song Li ◽  
Chun-Wei Gu
Keyword(s):  
High Pressure ◽  
Gas Turbine ◽  
Centrifugal Compressor ◽  
Pressure Ratio ◽  
Low Pressure ◽  
Two Stage ◽  
Vaned Diffuser ◽  
Pressure Stage ◽  
Optimization System ◽  
High Pressure Stage

The performance of a low/high-pressure-stage centrifugal compressor in a land-use MW-level gas turbine with a pressure ratio of approximately 11 is analyzed and optimized with a 1D aerodynamic design and modeling optimization system. 1D optimization results indicate that the diameter ratio of the low-pressure-stage centrifugal compressor with a vane-less diffuser, and the divergent angle of the high-pressure-stage centrifugal compressor with a vaned diffuser, are extremely large and result in low efficiency. Through modeling design and optimization system analysis, a tandem vaned diffuser is used in the low-pressure stage, and a tandem vaned diffuser with splitter vanes is adopted in the high-pressure stage. Computational fluid dynamics (CFD) results show that the pressure ratio and efficiency of the optimized low/high-pressure-stage centrifugal compressor are significantly improved. Coupling calculations of the low/high-pressure stage of the original and optimized designs are conducted based on the results of MW-level gas turbine cycles. CFD results show that the pressure ratio and efficiency of the optimized two-stage centrifugal compressor increase by approximately 8% and 4%, respectively, under three typical load conditions of 100%, 90%, and 60%.

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