volvo microturbines
TRANSCRIPT
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Microturbines
2005-04-21
Rolf Gabrielsson, Volvo Aero Corporation
Section 1
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Microturbine lecture 2005-04-21, Rolf Gabrielsson
Microturbines, Section 1
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Gas Turbine Applications
• Aero
• Industry•Power
•Combined Heat and Power, CHP
•Mechanical drive for pumps and
compressors
• Marine
• Automotive
• Microturbines
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Microturbine lecture 2005-04-21, Rolf Gabrielsson
Microturbines, Section 1
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Microturbines, Section 1
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Gas Turbine - Civil aircraft
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Microturbines, Section 1
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Microturbine lecture 2005-04-21, Rolf Gabrielsson
Microturbines, Section 1
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Solar Mercury 50
Click here to enlarge image
Ref.: Solar Turbines
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Microturbine lecture 2005-04-21, Rolf Gabrielsson
Microturbines, Section 1
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Marine Gas Turbine
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Microturbine lecture 2005-04-21, Rolf Gabrielsson
Microturbines, Section 1
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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
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Microturbine lecture 2005-04-21, Rolf Gabrielsson
Microturbines, Section 1
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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
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Microturbine lecture 2005-04-21, Rolf Gabrielsson
Microturbines, Section 1
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KTT MK II / GT110
• Developed 1985-1987• Automotive GT for cars.
• Power 115 kW (155 hp)
• 2-shaft with ceramic HP turbine
• Low emission combustor (LPP)
• Rotary ceramic heat exchanger
• Design with low parasitic losses
Ref.:Lars Sundin, Volvo Aero Presentation 10-11 July 2003 Brussels
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Microturbine lecture 2005-04-21, Rolf Gabrielsson
Microturbines, Section 1
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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
Ref.:Lars Sundin, Volvo Aero Presentation 10-11 July 2003 Brussels
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Microturbine lecture 2005-04-21, Rolf Gabrielsson
Microturbines, Section 1
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Volvo Environmental Concept Vehicles
Ref.:Lars Sundin, Volvo Aero Presentation 10-11 July 2003 Brussels
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Microturbine lecture 2005-04-21, Rolf Gabrielsson
Microturbines, Section 1
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The Power Module of T100 microturbine
Very few moving parts
Ref.:Lars Sundin, Volvo Aero Presentation 10-11 July 2003 Brussels
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Microturbine lecture 2005-04-21, Rolf Gabrielsson
Microturbines, Section 1
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T100 installed in a boiler room
Ref.:Lars Sundin, Volvo Aero Presentation 10-11 July 2003 Brussels
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Microturbine lecture 2005-04-21, Rolf Gabrielsson
Microturbines, Section 1
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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
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Microturbine lecture 2005-04-21, Rolf Gabrielsson
Microturbines, Section 1
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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
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Microturbine lecture 2005-04-21, Rolf Gabrielsson
Microturbines, Section 1
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Microturbine system
Mi t bi S ti 1
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Microturbine lecture 2005-04-21, Rolf Gabrielsson
Microturbines, Section 1
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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
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Microturbine lecture 2005-04-21, Rolf Gabrielsson
Microturbines, Section 1
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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 + -
Microturbines Section 1
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Microturbine lecture 2005-04-21, Rolf Gabrielsson
Microturbines, Section 1
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Microturbine Cycles
Microturbines Section 1
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Microturbine lecture 2005-04-21, Rolf Gabrielsson
Microturbines, Section 1
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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
Microturbines Section 1
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Microturbine lecture 2005-04-21, Rolf Gabrielsson
Microturbines, Section 1
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Recuperated Gas TurbineEfficiency and Specific Power
v.s. Turbine inlet temperature (TIT) and Pressure Ratio ( )
Microturbines, Section 1
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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
Ref.:Lars Sundin, Volvo Aero Presentation 10-11 July 2003 Brussels
Microturbines, Section 1
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Microturbine lecture 2005-04-21, Rolf Gabrielsson
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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
Microturbines, Section 1
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Microturbine lecture 2005-04-21, Rolf Gabrielsson
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Compressor
Microturbines, Section 1
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Microturbine lecture 2005-04-21, Rolf Gabrielsson
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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)
Microturbines, Section 1
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Microturbine lecture 2005-04-21, Rolf Gabrielsson
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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
Microturbines, Section 1
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Microturbine lecture 2005-04-21, Rolf Gabrielsson
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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
Ref.:Lars Sundin, Volvo Aero Presentation 10-11 July 2003 Brussels
Microturbines, Section 1
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Microturbine lecture 2005-04-21, Rolf Gabrielsson
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Combustor
Microturbines, Section 1
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Microturbine lecture 2005-04-21, Rolf Gabrielsson
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Combustor development
Gas turbine with conventional combustor
•Typical NOx emission = 150 ppm @15%O2
LowNOx Combustor
•Typical NOx emission = 25 --> 9 ppm@15%O2
Microturbines, Section 1
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Microturbines, Section 1
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Gas Turbine combustor design
Diffusion combustor LowNOx combustor
Microturbines, Section 1
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Microturbine lecture 2005-04-21, Rolf Gabrielsson
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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
Microturbines, Section 1
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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
Microturbines, Section 1
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Microturbine lecture 2005-04-21, Rolf Gabrielsson
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Ingersoll-Rand 250 kWe PowerWorks Combustor
Ref.: Jim Kesseli Presentation at the IGTI Turbo Expo June 18 2003, Atlanta USA
Microturbines, Section 1
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Microturbine lecture 2005-04-21, Rolf Gabrielsson
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Honda Microturbine Combustor
Ref.: Koichi Shinmura Presentation at the IGTI Turbo Expo, June 18 2003, Atlanta, USA
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Capstone C60 Microturbine
Ref.: Capstone Product Datasheet
Combustion Chamber
Turbine
Fuel Injector
Recuperator
Microturbines, Section 1
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Catalytic Combustor
Microturbines, Section 1
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High Temperature Catalytic Combustor Project AGATA, Complete reaction in the catalyst section
Diesel fuel
Catalyst outlet temperature 1350°C
Microturbines, Section 1
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Catalytica
• Hybrid catalytic combustor
• Catayst section + Post catalyst zone
NOx emissions as low as 2.5 ppm.
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Ref.: Kawasaki Gas Turbines, Datasheet
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Microturbine lecture 2005-04-21, Rolf Gabrielsson
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Turbine
Microturbines, Section 1
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Microturbine lecture 2005-04-21, Rolf Gabrielsson
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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
Microturbines, Section 1
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Microturbine lecture 2005-04-21, Rolf Gabrielsson
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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
Microturbines, Section 1
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Microturbine lecture 2005-04-21, Rolf Gabrielsson
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Heat exchanger
Microturbines, Section 1
Heat exchangers
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Microturbine lecture 2005-04-21, Rolf Gabrielsson
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Heat exchangers
• Key component for microturbines
• Accounts for about half heat input
Regenerator - Automotive application
Recuperator - Microturbine application
Ref.: Bowman Power
Ref.:Lars Sundin, Volvo Aero Presentation 10-11 July 2003 Brussels
Microturbines, Section 1
R t
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Microturbine lecture 2005-04-21, Rolf Gabrielsson
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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
Microturbines, Section 1
R t
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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
Microturbines, Section 1
Alternative recuperator development
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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
Microturbines, Section 1
Recuperators Annular design
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Microturbine lecture 2005-04-21, Rolf Gabrielsson
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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
Microturbines, Section 1
Recuperator materials
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Microturbine lecture 2005-04-21, Rolf Gabrielsson
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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
Microturbines, Section 1
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Ceramic materials
Microturbines, Section 1
Ceramic components
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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
Ref.:Lars Sundin, Volvo Aero Presentation 10-11 July 2003 Brussels
Microturbines, Section 1
Ceramic development in Japan and USA
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Ceramic development in Japan and USA
Japan - MITI (Ministry of International Trade and Industry)
- Kyocera
USA: - DoE (Department of Energy)
- ORNL
- Honeywell
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Specification:•Combustor inlet temperature: 935°C
•Turbine inlet temperature, TIT: 1350°C
•Cycle efficiency: 42%
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Microturbines, Section 1
Ceramic Turbine
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Ref.: Jim Kesseli et al, presentation at the IGTI Turbo Expo June 18 2003, Atlanta USA
Microturbines, Section 1
AGATA
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AGATA
Ceramic Heat Exchanger with casing and seals
Microturbines, Section 1
AGATA
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AGATA
Cordierite Ceramic Heat Exchanger Matrix
Microturbines, Section 1
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Microturbine lecture 2005-04-21, Rolf Gabrielsson
10111 Utg. 1
Microturbines, Section 1
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Microturbine lecture 2005-04-21, Rolf Gabrielsson
10111 Utg. 1
Microturbines, Section 1
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Microturbine lecture 2005-04-21, Rolf Gabrielsson
10111 Utg. 1
Microturbines, Section 1
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Microturbine lecture 2005-04-21, Rolf Gabrielsson
10111 Utg. 1
Power Electronics
Microturbines, Section 1
Power Electronics
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Microturbine lecture 2005-04-21, Rolf Gabrielsson
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