Gas Turbine Combustion Systems

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About me

2007-Present Solar Turbines Inc., Caterpillar Company

2002-2007 Ph.D. Combustion Science, MAE, UCSD

2000-2002 General Electric Global Research Center

1998-2000 M.S., Aerospace Engineering, Indian Institute of

Technology & University of Stuttgart

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 Motivation to study about Industrial Gas Turbines

What does combustor do?

Types of combustors

Design requirements

Introduction to combustion chemistry

Alternative fuels, pollutants, oscillations

Challenges related with variable load conditions

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Energy Outlook Report
US DOE

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Trend of worlds energy consumption (Data from US Department of Energy)

1 Quadrillion = 1015, 1 BTU = 1.055x103 J

1 Quadrillion BTU = 45M Tons Coal or 1T ft3 Natural Gas or 170M Barrels of crude oil
1 Barrel crude oil = 42 gallon = 6.1 GJ of energy

Worlds energy requirement can largely be classified into Electric power, transportation energy

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Trend of worlds electricity consumption (Data from US Department of Energy)

*Organization of economic cooperation and development

Major sources of electricity production

Fossil fuels: Coal, gasoline, diesel, natural gas and other petroleum products
Alternative sources of energy: Wind turbines, solar panels, hydroelectric, nuclear,
geothermal, tidal, and list goes on
Alternative fuels: Ethanol, bio-diesel, biomass, coke oven gas, syngas, municipal waste,
landfill gases, anything rotting

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 There is a very well established energy infrastructure based
on fossil fuels in US and across the globe.

The worlds proven fossil fuel reserves and lifetimes

Lifetime (y) Lifetime (y)

Fuel Reserves (Q) No Growth w/ Growth
Coal 24,000 258 140
Oil 9280 60 50
Gas 6966 90 50

The advantage of alternative fuels is that the existing infrastructure can

be used.

Gas turbines industry is going to stay in business for a long time

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About Solars Gas Turbines

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 How does this story relate with Gas Turbines Combustion systems?

Strictly speaking, energy is not consumed, but rather is converted into different forms.

Various types of engines are used to achieve this objective.

Types of engines
- Power generation: Gas Turbines, Steam Turbines, Nuclear, Hydro
-Transportation : diesel, gasoline, aircraft engines (based on gas turbine
cycles)

Steam turbines are similar to gas turbines but they have different principles of
operation. Nuclear power plants use nuclear energy to make steam which rotates
the steam turbines.

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Gas Turbines find their applications in

- electricpower generation, mechanical drive systems, supply

of process heat and compressed air, pump drives for gas or
liquid pipelines

- jet propulsion, land and sea transport (infancy state)

Industrial turbines or prime movers

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 Solar Turbines Incorporated, a subsidiary of Caterpillar
Company is a world leading producer of mid-range (1 MW
25 MW) industrial gas turbines for use in power generation,
natural gas compression, and pumping systems.

There are 12,500+ engines installed in 102 countries

Solar ranks as one of the 50 largest exporters in the United

States

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Our units are used for power generation, gas compression,
and mechanical drive applications

-Power generation is the production of electrical energy

whether for stand-by or base load power applications.

- Gas compression applications include gathering (at the

well head), transmission (pipeline), re-injection (storage),
and pressure boost (compression).

- Mechanical drive applications are units sold as prime-

movers for non-Solar packaged driven equipment, whether
generators, compressors, or pumps

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Harbor Drive Facility
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Gas Turbines OEMs

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 Output 7.7 MW
Output 1.2 MW Output 4.6 MW Thermal Eff. 34.8%
Thermal Eff. 24.5% Thermal Eff. 29.9%

Output 15.3 MW Output 4.6 MW

Thermal Eff. 35.7% Thermal Eff. 39.5%
Output 11.2 MW
Thermal Eff. 33.9%

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Latest addition

Output 22.3 MW
Thermal Eff. 40%

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Power Generation

Single Shaft
Output
Turbine Engine Shaft Power

3)Expansion
(Turbine)

2) Combustion

1) Compression

Two Shaft
Output Turbine Engine
Shaft Power
Mechanical Drive
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 Simplistic Gas Turbines working principles

1-2 Isentropic compression (in a compressor)

2-3 Constant pressure heat addition (in a combustor)
3-4 Isentropic expansion (in a turbine)
4-1 Constant pressure heat rejection

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 Power generation for gas fields in Siberia

Petrobras, offshore Brazil, Power

generation and crude oil production

Natural gas transmission,

Desert environment

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Solars presence in San Diego
- two, soon to be three, Titan 130's at UCSD
- two Taurus 60's at SDSU
- some recuperated Saturns at landfills in
San Marcos and Santee
- a Saturn genset at the Hotel Del
- a Mercury 50 at the VA hospital
- two Mercurys at Qualcomm
- two Centaur 40s at the Balboa Naval
Hospital
- a Taurus 60 at the Children's Hospital

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List of companies and their products

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Difference between Heavy Duty and Aeroderivative Turbines

Industrial Aero-derivatives
Overhaul Life 48,000 hours 30,000 hours
Hot section inspection 8000 hours 6000 hours
Overhaul Life On-site Gas generator removal
Engine weight Heavy Duty Light
Fast start capability No Yes
Tolerance to poor fuel Fair Poor
Ease of automation Good Good
Suitable for off-shore Fair Good
Power Up to 325 MW Up to 55 MW
Thermal Efficiency 25-39% 25-42%

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Evolution of products : Uprates

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Performance of Gas Turbines is limited by
1. Component efficiencies
2. Turbine working temperature

Current state of the art

Pr = 35/1
components = 85-90%
TIT = 1650 K

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What makes Gas Turbines attractive for Industrial prime movers?
Advantages
Very high power-to-weight ratio, compared to reciprocating engines
Smaller than most reciprocating engines of the same power rating
Fewer moving parts than reciprocating engines
Low operating pressures
High operation speeds
Low lubricating oil cost and consumption
High reliability
Goes for 30-50K hours before first overhaul. Usually runs for 100K-300K hours (10+
years) life cycle

Disadvantages
Cost is much greater than for a similar-sized reciprocating engine since the material
must be stronger and more heat resistant. Machining operations are more complex
Usually less efficient than reciprocating engines, especially at idle
Delayed response to changes in power settings
These make GT less suitable for road transport and helicopters

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Some Basics

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Gas Turbine components
Inlet system Collects and directs air into the gas turbine. Often, an air
cleaner and silencer are part of the inlet system. It is designated for a
minimum pressure drop while maximizing clean airflow into the gas turbine.

Compressor Provides compression, and, thus, increases the air density for
the combustion process. The higher the compression ratio, the higher the
total gas turbine efficiency . Low compressor efficiencies result in high
compressor discharge temperatures, therefore, lower gas turbine output
power.

Combustor Adds heat energy to the airflow. The output power of the gas
turbine is directly proportional to the combustor firing temperature; i.e., the
combustor is designed to increase the air temperature up to the material
limits of the gas turbine while maintaining a reasonable pressure drop.

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Gas Producer Turbine Expands the air and absorbs just enough energy from
the flow to drive the compressor. The higher the gas producer discharge
temperature and pressure, the more energy is available to drive the power
turbine, therefore, creating shaft work.

Power Turbine Converts the remaining flow energy from the gas producer
into useful shaft output work. The higher the temperature difference across the
power turbine, the more shaft output power is available.

Exhaust System Directs exhaust flow away from the gas turbine inlet. Often a
silencer is part of the exhaust system. Similar to the inlet system, the exhaust
system is designed for minimum pressure losses.

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What drives Research and Development work in Gas Turbines?

In 1950s component efficiencies

In 1990s emissions
In 21st century it is emissions and alternative fuels
Nature of application and location are always the factors

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 Simplistic Gas Turbines working principles

1-2 Isentropic compression (in a compressor); h2-h1 = mCp(T2-T1)

2-3 Constant pressure heat addition (in a combustor); h3-h2 = mCp(T3-T2)
3-4 Isentropic expansion (in a turbine); h3-h4 = mCp(T3-T4)
4-1 Constant pressure heat rejection

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 mFqRcomb

minCpTin Gas Turbine (min+mF)CpTout

Shaft power

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 Consider Centaur and Mercury

Known
P ratio = 10
TIT = 1350 K
Compressor Eff. = 0.86
Turbine Eff. = 0.89
Heat exchanger effectiveness = 0.8
Ambient temperature and pressure, 300 K, 1 bar
Specific heat Cp = 1.005 kJ/Kg-K
Specific heat ratio = 1.4

Calculate (a) Compressor outlet temperature (b) Turbine out temperature (c)
Compressor work (d) Turbine work (e) back work ratio (f) Efficiency for ideal, actual,
and recuperator engine

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 First Law: Q h2 h1
1 2
2

V2 V12 W
V2
Stagnation enthalpy h0 h
2
Compressor work h2 h1 c p (T2 T1 )

h3 h4 c p (T3 T4 )
Turbine work

Heat input h3 h2 c p (T3 T2 )

1
1
T2 P2

T3
r

For isentropic process
T1 P1 T4

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 net work output cp (T3 T4 ) cp (T2 T1 )
Thermal Efficiency
energy input cp (T3 T2 )

1

1
1
r

Net work out Wnet c p T3 T4 c p (T2 T1 )

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Equipment efficiencies
3

T02' T01
C T
T02 T01
4
2 4
2

1

T01 P02
1

T02 T01 1
C P01
S
Process 1-2 and 3-4 ideal
Process 1-2 and 3-4 actual
T03 T04
T
T03 T04'

1

1
T03 T04 T T03 1
03 04
P / P

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Recuperator
3

T
Heat exchanger effectiveness 5
4
2 4
2

T05 T02 6

T04 T02 1

net work output cp (T3 T4 ) cp (T2 T1 )

energy input cp (T3 T5 )

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Variation of Cp with temperature

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