VOLVO Microturbines

7/23/2019 VOLVO Microturbines

http://slidepdf.com/reader/full/volvo-microturbines 1/64

Microturbines

2005-04-21

Rolf Gabrielsson, Volvo Aero Corporation

Section 1



Microturbine lecture 2005-04-21, Rolf Gabrielsson

Microturbines, Section 1

10111 Utg. 1

Gas Turbine Applications

• Aero

• Industry•Power

•Combined Heat and Power, CHP

•Mechanical drive for pumps and

compressors

• Marine

• Automotive

• Microturbines





10111 Utg. 1


http://slidepdf.com/reader/full/volvo-microturbines 4/64Microturbine lecture 2005-04-21, Rolf Gabrielsson


10111 Utg. 1

Gas Turbine - Civil aircraft


http://slidepdf.com/reader/full/volvo-microturbines 5/64Microturbine lecture 2005-04-21, Rolf Gabrielsson


10111 Utg. 1





10111 Utg. 1

Solar Mercury 50

Click here to enlarge image

Ref.: Solar Turbines





10111 Utg. 1

Marine Gas Turbine





10111 Utg. 1

Small Gas Turbine development l ine

1960- Sven-Olof Kronogård works at Volvo with the S-tank and a

Volvo gas turbine project for the tank

1970-Turbokonsult founded by Professor Kronogård

1974-United Turbine founded by Kronogård and AB Volvo

1972-1984 Automotive gas turbine for cars, KTT 150 MK11984-1987 Development of GT110 for Volvo Cars

1990-1992 Development of HSG 40

1994-1995 Development of VT100

1998 Turbec was established to develop T100

LPP combustor

New company

Volvo / ABB

Turbec T100KTT150 MK I

Car GT (1972-1984)

GT 110 with LPP

Car GT (1984-1987)

HSG 40

Volvo / ABB / Vattenfall

VT 100

for ECB/ ECT

1970 1975 1980 1985 1991970 1975 1980 1985 1990 1995 20000 1995 2000Ref.:Lars Sundin, Volvo Aero Presentation 10-11 July 2003 Brussels





10111 Utg. 1

Volvo experience in automotive Gas Turbines

KTT 150 Mk I developed 1972-1984

Automotive GT for cars.

Power 100 hp

3-shaft design with patented KTT

transmission system Conventional combustor

Rotary ceramic heat exchanger

Demonstrated in cars from 1977 includingthe first car ever with ceramic HP turbine

One car in daily use to gain experience

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





10111 Utg. 1

KTT MK II / GT110

• Developed 1985-1987• Automotive GT for cars.

• Power 115 kW (155 hp)

• 2-shaft with ceramic HP turbine

• Low emission combustor (LPP)

• Rotary ceramic heat exchanger

• Design with low parasitic losses






10111 Utg. 1

Volvo Environmental Concept Vehicles

VT40 for ECC (Environmental Concept Car)

VT100 for ECT/ECB (Truck and Bus)

Series Hybrid Drive lines

Combined Gas Turbine and High Speed

Generator

1-shaft Regenerative Engine






10111 Utg. 1

Volvo Environmental Concept Vehicles






10111 Utg. 1

The Power Module of T100 microturbine

Very few moving parts






10111 Utg. 1

T100 installed in a boiler room






10111 Utg. 1

Gas Turbines

Typical conditions

Pressure TIT Combustor

inlet temp.

Bar C C

Industrial, Combined and simple cycle 10-40 -> 1500 300 - 650Recuperated < 10 ->1300 600 - 800

Aero 20-40 ->1600 450-650

Automotive / Microturbines 4-6 1000-1350 600-900





10111 Utg. 1

Gas Turbine Design Features Related to Output Capacity

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

Mi t bi S ti 1





10111 Utg. 1

Microturbine system

Mi t bi S ti 1





10111 Utg. 1

Microturbine characteristics

• Electricity power output 25 – 500 kW

• Market:

- Distributed generation

- Standby power- Combined Heat and Power generation (CHP)

- Direct mechanical drive for air conditioning system

• Simplified design for mass production

- Radial flow compressors

- Low pressure ratios defined by single – or possibly two-stage compression

- Minimal use of vane rotor cooling

- Use of materials that are amendable to low cost production• Recuperation of exhaust heat for air preheating - Electrical efficiency 25–30%

• Very high shaft rotational speed (>40 000 rpm)

• Direct drive high-frequency alternator

Microturbines Section 1





10111 Utg. 1

Comparison: Microturbine - Gas Engine

Microturbine Gas Engine

• Number of mowing parts + -• Package size + -

• Electric efficiency = =

• Fuel utilization = =

• Emissions NOx, CO, HC + -

• Noise, vibrations + -

• Fuel flexibility + -

• Opportunity to utilize waste fuel + -






10111 Utg. 1

Microturbine Cycles






10111 Utg. 1

Microturbine Cycles

ηel (%) ηtot (%)

• Simple cycle, metallic < 20

• Recuperated, metallic 25-30

ceramic 40

• Inter-cooled Recuperated (ICR) >40

• Combined cycle with Organic > 40

Rankine Cycle (ORC)

• CHP, metallic 80






10111 Utg. 1

Recuperated Gas TurbineEfficiency and Specific Power

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






10111 Utg. 1

System studies

Future microturbines or automotive gas turbines

Intercooling a regenerative gas turbine

36,00%

38,00%

40,00%

42,00%

44,00%

46,00%

150 200 250 300 350

Spec ific Power (kWs/kg)

T h e r m a l e f f i c i e n

c y

RC 1000C

RC 1250C

IRC 1000C

IRC 1250C

π= 5

6

7

Recuperated

IRC

More advanced cycles

Intercooling of recuperated gasturbines

Bottoming cycles

Increased temperature

Ceramics

Cooling concepts for smallcomponents






,

10111 Utg. 1

Turbec Microturbine

Combined Heat and Power (CHP) System

High efficiency

Low emissions levels

Performance at ISO-conditions

Net electrical output: 100 kWNet electrical efficiency: 30%

Net total efficiency: 80% (at 50 oCWRT)

Noise level: 70 dBA at 1 meter

Emissions, 15% O2

NOx: < 15 ppmv

CO: < 15 ppmv

UHC: < 10 ppmv

1. Generator

2. Inlet air

3. Combustion chamber

4. Air to Recuperator

5. Compressor

6. Turbine

7. Recuperator

8. Exhaust gases

9. Heat exchanger

Ref.: Turbec datasheet





,

10111 Utg. 1

Compressor





10111 Utg. 1

Compressor

Typical characteristics:

• Radial flow compressors

• Low pressure ratios defined by

single – or possibly two-stage

compression• Materials that are amendable to

low cost production

• Very high shaft rotational speed(>40 000 rpm)





10111 Utg. 1

Compressor diagram

46.2

62.3

74.4

84.4

92.5

98.5

104.5

n redV = 112.6 * 103 min -1

is V = 0.78

0.77

0.76

0.75

0.73

0.70

0.70

0.65

0.65

0.60

1,0

1,4

1,8

2,2

2,6

3,0

3,4

3,8

4,2

0,04 0,08 0,12 0,16 0,20 0,24 0,28 0,32 0,36 0,40 0,44 0,48 0,52 0,56

Pressure

Ratio, Π

Air mass flow





10111 Utg. 1

Component development

Compressors

Development steps

Inverse design method

Parametric design

Introduction of 3D viscous CFD

Compressor Pressureratio

Efficiency Method Year

KTT 150 MK1 5.1 75% Inverse design 1976

HSG 40 v1 3.5 75% Inverse design 1991

HSG 40 v2 4.0 77% Parametric/Streamline 1993VT600 9.2 77% Parametric/Streamline 1992

VT100/T100 4.4 77% Parametric/Streamline 1994

T100 prot 4.6 80% Parametric/3D CFD 2002

Polytropic efficiency development

84,5%

85,0%

85,5%

86,0%

86,5%

87,0%

87,5%

88,0%

88,5%

1970 1975 1980 1985 1990 1995 2000 2005

Development Year

P o l y t r o

p i c

e f f i c i e n c y






10111 Utg. 1

Combustor





10111 Utg. 1

Combustor development

Gas turbine with conventional combustor

•Typical NOx emission = 150 ppm @15%O2

LowNOx Combustor

•Typical NOx emission = 25 --> 9 ppm@15%O2





10111 Utg. 1





10111 Utg. 1

Gas Turbine combustor design

Diffusion combustor LowNOx combustor





10111 Utg. 1

Emission trends - NOx

Large Gas Turbines

•California: NOx < 3 ppm

Microturbines -

Distributed generation•State of the art: 15 ppm

•US Dept. of Energy goal:

NOx < 7 ppm





10111 Utg. 1

Volvo Aero / Turbec Combustor development

Emissions at 100%load and 15% O2

Engine Fuel

NOx CO

Type ofcombustor

T100 Natural gas <15 ppm <15 ppm LPP

T100 Petroleum gas,Propane 95%

<10 ppm <10 ppm LPP

T100 Petroleum gas,Propane/butane 20/80

<10 ppm <10 ppm LPP

T100 Landfill gas (HLHV≈19MJ/kg)

<12 ppm <5 ppm LPP

T100 Methanol <10 ppm <5 ppm LPP

VT100 Ethanol (E85) <20 ppm <40 ppm LPP

T100 Kerosene <10 ppm <15 ppm LPP

VT40/T100 Diesel <10 ppm <15 ppm LPP

VT4400DLE <25 ppm <15 ppm LPP

VT4400 Low Calorific Fuel

(HLHV≈5 MJ/kg, no NH3)

<9 ppm <20 ppm Diffusion

Lean Premixed Prevaporized

combustor system

Original development for the

automotive GT 110

Multi fuel capability

Used in Turbec T100





10111 Utg. 1

Ingersoll-Rand 250 kWe PowerWorks Combustor

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





10111 Utg. 1

Honda Microturbine Combustor

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





10111 Utg. 1

Capstone C60 Microturbine

Ref.: Capstone Product Datasheet

Combustion Chamber

Turbine

Fuel Injector

Recuperator





10111 Utg. 1

Catalytic Combustor





10111 Utg. 1

High Temperature Catalytic Combustor Project AGATA, Complete reaction in the catalyst section

Diesel fuel

Catalyst outlet temperature 1350°C





10111 Utg. 1

Catalytica

• Hybrid catalytic combustor

• Catayst section + Post catalyst zone

NOx emissions as low as 2.5 ppm.





10111 Utg. 1

Ref.: Kawasaki Gas Turbines, Datasheet





10111 Utg. 1

Turbine





10111 Utg. 1

Volvo Aero / Turbec Component development

Turbines Axial turbines

BLISK designs

Introduction of 3D ”Compound Lean”

Radial turbines

In-house developed inverse design

method3D Stress&CFD for optimal trade-offs Performance-Life

T100 Performance

Expansion ratio 4

89% total-total

Diameter 175 mm Ref.:Lars Sundin, Volvo Aero, Presentation 10-11 July 2003 Brussels





10111 Utg. 1

Microturbines - Turbine material

Today standard material

• Ni-based materials

• Example: MAR-M247, max temperature 1050 °C

• Turbine Inlet Temperature today: approx. 950 - 1000 °C

• Thermal Barrier Coating, TBC, will increase service life

Future ceramic materials

• Si3N4

• Turbine Inlet Temperature 1350°C





10111 Utg. 1

Heat exchanger


Heat exchangers




10111 Utg. 1

Heat exchangers

• Key component for microturbines

• Accounts for about half heat input

Regenerator - Automotive application

Recuperator - Microturbine application

Ref.: Bowman Power



R t




10111 Utg. 1

Regenerator

+

• High efficiency

• Compact and low weight

• Suitable for ceramics• Can be used for high temperatures

-

• Difficult to seal - lifing problems

• Leakage problems

• 5% leakage will reduce power with > 12.5%

• 5% leakage will reduce system efficiency by >4%-units• Leakage means reduced engine life due to increasing hot parts

temperature. Ex.: Increased combustor liner temperature


R t




10111 Utg. 1

Recuperator

+

• Reliable and durable

• Close to zero leakage

-

• Reduced efficiency, approx. 90%

• Can be bulky

• More complex piping can mean increased weight

• Increased volume and exposed area require improved insulation - or

innovative design


Alternative recuperator development




10111 Utg. 1

p p

Development of a recuperator forvolume production in Recuperator Svenska AB.

Stamped plates

Laser welded

Modularised

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

First full size prototype tested for

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


Recuperators Annular design




10111 Utg. 1

Recuperators - Annular design

Honda Microturbine

Ref.: Koichi Shinmura Presentation at the IGTI

Turbo Expo, June 18 2003, Atlanta, USA

Capstone Microturbine

Ref.: Capstone Product Datasheet


Recuperator materials




10111 Utg. 1

Recuperator materials

Metallic materials

• Type 347 stainless steel - Today standard material

Max temperature (exhaust): 1200F = 650°C

• Inconel - Advanced material

Max temperature (exhaust): 1500F = 820°C

Ceramics

• >1600F = 870°C





10111 Utg. 1

Ceramic materials


Ceramic components




10111 Utg. 1

Ceramic components

Development of ceramic turbine

components started 1981

Turbine wheel from ASEA CERAMA

tested in a car 1982

Several components including

combustor, inlet scroll and turbine

developed for the GT110 gas turbine

GT110 demonstrated reliable at 1250

ºC 1987

European AGATA project developed

Ceramic radial turbine

Ceramic recuperator

Ceramic catalytic combustor



Ceramic development in Japan and USA




10111 Utg. 1

Ceramic development in Japan and USA

Japan - MITI (Ministry of International Trade and Industry)

- Kyocera

USA: - DoE (Department of Energy)

- ORNL

- Honeywell





10111 Utg. 1

Specification:•Combustor inlet temperature: 935°C

•Turbine inlet temperature, TIT: 1350°C

•Cycle efficiency: 42%





10111 Utg. 1


Ceramic Turbine




10111 Utg. 1

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


AGATA




10111 Utg. 1

AGATA

Ceramic Heat Exchanger with casing and seals


AGATA




10111 Utg. 1

AGATA

Cordierite Ceramic Heat Exchanger Matrix





10111 Utg. 1





10111 Utg. 1

Power Electronics


Power Electronics




10111 Utg. 1

Generator

• High speed alternator permanent magnet

rotor inside the stator. The generator produce a high frequency AC (Alternating

currency)

Rectifier

• Rectify to DC (Direct currency)

Converter

• Converts to 50 or 60 Hz AC, 400 – 480 V

VOLVO Microturbines

Documents

Transcript of VOLVO Microturbines