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I. Overview

The major trend of system for the thermal power generation in recent years is the combined cycle comprising of the steam turbine and gas turbine(s) both in Japan and abroad. This method features the highest thermal efficiency of various types of

power generation system. Furthermore, it uses clean fuels such as LNG, providing

excellent operability and environmental compatibility. It also features comparatively

lower power generation cost.

However, further improvement of the thermal efficiency is required due to the gradual decline of the fossil clean fuel resource, global warming caused by exhaust gas (carbon dioxide gas, nitrogen oxides, etc.) and the problem of ozone layer depletion.

To meet growth of power demands under these circumstances year by year, it is expected to realize a new power generation system of higher efficiency.

As an example, attention is drawn to the inter-cooled, two-fluid cycle plant (ISTIG) which has the same level of efficiency and economy as those of the combined cycle plant with “H” technology and the HAT (Humid Air Turbine) cycle plant.

Since there has been a rapid improvement in the capacity and performances of the super-fan engine for aircraft, we have studied the effect of applying the super-fan engine to the ISTIG cycle plant, as a middle capacity power generation and decentralized power generation plant.

1. Current and subsequent trend of highly efficient gas turbine power generation system technology and its use.

A combined cycle plant or steam injection cycle plant is available as a highly efficient gas turbine power generation plant currently under operation or construction.

The combined cycle plant with temperature of 1,300°C (1,350 to 1,400°C) has

already started.

What has permitted such a high temperature is the improvement of cooling

technology for turbine blade.

The efficiency of the 1,300°C class power generation plant has increased to 50

through 53 (based on LHV), by the improvement of the bottoming cycle. The

NOx in exhaust gas is kept down to 5 ppm by means of premixed combustion

technology and denitrization.

Furthermore, there is a re-heating type gas turbine where the efficiency is

improved by re-heating the combustion gas after the first stage of the turbine.

As a steam injection cycle plant, on the hand other, there is a 50- MW plant of

Meidensha Corporation (Numazu Plant): it has been operating effectively since

July, 1991.

The steam injection cycle gas turbine coupled with the LM5000 gas turbine is

made up of the GE turbo fan engine for aircraft CF6-50 modified for industrial

use.

Water cost including the treatment cost is comparatively low; 200 yen per ton.

So water is not recovered from exhaust gas. Steam is injected into the high

pressure compressor outlet and low pressure turbine inlet.

2. Trend of highly efficient gas turbine technology development and prospects for

commercialization

Efficiency of the gas turbine has been improved by increasing the turbine inlet

temperature so far. Adoption of higher temperature has been supported by

advances in heat resistant material and air cooling technology.

The temperature of the gas turbine currently adopted for commercial use is 1,350

through 1,400°C both for industrial and aeroderivative type. This is realized by

uni-directional coagulation, crystalline controlled alloy such as monocrystalline

material, and partially blowout film cooling technology. The efficiency of the

combined cycle plant with these technologies reaches 50 to 53%. This is the

highest one in all the power generation system currently put into commercial

operation.

In future, temperature at the turbine inlet will become high, and the gas turbine

with 1,500°C is expected to be developed before the year 2000 through the

adoption of steam cooling technology. The thermal efficiency of the combined

cycle power generation system in this case is anticipated to reach 60%.

On the other hand, the latest high performance fan engine featuring high

compression and high bypass ratio can be used for power generation system of

high performances and middle capacity. In this case, the high and low pressure,

two-axis type is utilized; this makes it easier to install the inter cooler between

them and to ensure enhanced cycle and improved thermal efficiency. This is

exemplified by ICAD, ISTIG and HAT

The thermal efficiency of these cycles is comparable to that of the combined cycle

power generation plant of a large capacity for industrial use. Their operability is

also excellent; therefore, they are expected to be used as middle capacity and

decentralized power generation plant.

3. Highly efficient inter-cooled regeneration type two-fluid cycle plant (ISTIG cycle).

3.1 Application of the following breakthrough technologies is essential to get a high

efficiency of 60% in the ISTIG cycle plant:

■ Pre-heating of fuel gas

Pre-heating of fuel by combustion gas is one of the ways of reducing excelgy

loss and improving efficiency. The pre-mixed combustion technology,

however, is adopted for the reduction of NOx emission in the combined cycle

plant. So preheating of fuel is difficult because of back fire in pre-mixed

gas.

On the other hand, the diffusion flame combustion technology is used and

much moisture is contained in combustion air, in the STIG plant. This makes

it possible to pre-heat fuel gas without fear of causing back fire.

Partial steam cooling

In the cycle adopting the inter-cooled system, temperature at the high pressure

compressor inlet is lowered. This will result in reduced drive power, and

discharge temperature is decreased accordingly. This makes it possible to

use low temperature air to cool the high temperature parts. Thus, high

temperature combustion can be possible.

Conversely, work of the high pressure turbine is decreased by reduced high

pressure compressor drive power, high temperature combustion gas is shifted

downstream. This requires some considerations to be given to cooling

method of low pressure turbine and power turbine.

This will require steam cooling to ensure a minimize volume of cooling air.

Re-heat cycle

After-burning technology is employed in the aircraft engine, and

re-heat technology is used in the aero derivative gas turbine

cogeneration plant. Application of these technologies will become

necessary.

3.2 Water consumption is about the same as that of combined cycle plant

with wet type cooling tower.

When it is difficult to obtain the required amount of water, it is

sufficient to provide water recovery system to recover water from

moisture contained in combustion gas, using sea water for the seaside

area and air for the inland area.

3.3 Plant construction cost

The bottoming cycle (steam turbine plant) of the combined cycle plant is not required. This makes it possible to reduce the unit construc­tion cost per kW about 20 percent.

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t as mw

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^2%'C&6o S 2.2-3 IH x S 2.2-4 Elti^il^nx %&##0$x L/£€>©!!$> £o

Plant turndown capabilities comparedLoad following capability for CHAT designs said to be superior to simple or combined cycle plants. Down at 40% of rated power, CHAT efficiency level drops only about 10%—compared with 28% drop for combined cycle and nearly 35% for simple cycle gas turbine.

-180%

- 160%

-140%

- 120%

100%

0%

Simple Cycle W501F

Combined Cycle 1 x 1 W501F

20%

Load (Percentage of Design)

40% 60% 80% 100% 120%

m 2.

1-37

CHAT ratings ‘flat’ over wide temperature rangeCompared with simple and combined cycle plants, CHAT cycle is flat-rated across a very wide range of ambient temperature conditions, with less than 1% power reduction at 90°F, compared to an 10% power reduction for com­bined cycle and 11 % for simple cycle gas turbine.

Simple Cycle Power CHAT Cycle

Heat Rate— 1.15

Simple CycleHeat RateCHAT Cycle

Power \- 1.05

- 0.95 Combined Cycle Heat Rate

- 0.85Combined Cycle

Power

-- 0.75Compressor Inlet Temperature

0°F 20°F 40°F 60°F 80°F 100°F 120°FI I I I I I I

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NOx©SWISS&

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(%,LHV) 54.7 51.3

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£ififrir>Zo X, CHAT ©##%#, SEI6 1,600° F*5> 1,800° F~2,000° F^±(f6Ch(:ZD, DOE © ATS 7 D

A©gS*lffe5 60% ©SWF £ MTS C tftX'gZt LTVi^o S 2.2-5 0 a 501F CHAT ©Mt- X, m 2.2-6 0(1 CHAT fgSSx

esmww

300 MW 'CHAT’ PlantCycle heat and mass balance based on Westinghouse 501 F gas turbine at ISO base load conditions firing natural gas fuel. Plant net output is 316.8 MW, net heat rate is 6235 Btu/kWh (LHV) for 54.7% thermal efficiency.

FUEL (METHANE)GAS COMPRESSOR

MOTORT 60P 400

LP TURBINE COOUNC AIRM 25.5

HP EXPANDERHP COMPRESSORIP COMPRESSOR

BALANCI

T 249

T 1600

FROM/TOCOOLINGTOWER

P 1141

~ JJ

POWER GENERATION SHAFT

STACKLP TURBINELP COMPRESSOR

HEAT RECOVERY

MAKEUPWATER

P 14.7

RECUPERATOR

15.92% H20 MASS FRACTION

LEGEND:T-TEMPERATURE,F P-PRESSURE, PSIA M - MASS FLOW, L8S7SEC

SATURATOR

3 0 0 MW CHATt^7il't-hA7>XiH

300 MW Plant LayoutArrangement of utility-scale CHAT plant based on 501 F and Dresser-Rand compression components (in scale). Plant design is similar to gas turbine power station, with rotating equipment delivered in skid-mounted modules, similar BOP systems, fuel storage and treatment, with the addition of a number of heat exchangers and a saturator.

300 mw chatV'T ?

f. am#C/C —

CHAT (10MW-C- 46%) #cHATd.

T&fi£j£U L/^L/x 0.8~ 1.0kg/kWh CDtKS

2.3

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cc-ekL Ebk&^cw^jito^ft't^ax

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^ ^ - k: > a ^ a &&-j:a##amwo

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Turbine) ?)IX, XP^ AC#fl[]l/"tU1999 ^1C7d bf

ft® L'CV'i^ocagt

###, m *B Pacific Gas andElectric ft, SS(i EPRI C<£ ^ LT, CCD7°P

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Lfcf^T, iWf^bt^E*ttAMi5ti£^E*i:t

X#l"An Assessment of the Thermodynamic Performance of Mixed Gas-Steam Cycles : Part A-Intercooled and Steam Injected Cycles, Transaction of the ASME(1995-7), Vol. 117, 489Pj "Ckt, ^mzMt

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44%@j^^#%. btl-So IrK 3^|#\rICAD offers 60 per cent efficient turbine cycles,

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ICR Design for Advanced Turbine SystemsFlow diagram of the intercooled-recuperated (ICR) gas turbine design in Solar Turbines small-engine ATS program has system efficiency goal of 50% overall. Also evaluating a reheat combustor option between LP turbine and power tur­bine; possible use of auto thermal reforming in the low emissions combustor.

Water

Intercooler ▲ Recuperator

# 2.3-3EI

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2.3.mm(o^mzm^a ^^tbnrz tRiTmur, ^E*kL 41 h^spe*tt£ n-t ^ a <,

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Z Mtf&ALLtlUoTrit £ 1,250°C^ 6 l,500°CC±{f a ME^Jtti; 36 fr b 45 <

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54

52

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45

IST1Gsurface 1C 3-60

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45 «— 400 500 600 700 600 900

Specific work, kJ/kg

m 2.3-4H

m 2.3-5 *USME fiktt zm L

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JF3 2.3-1M ft 5E 54 # §1 © i® ( 1992*F3F9UE)

tb ti ismem(MW) (h) (IB)

Pacfic Gas & Electric Company GE F3R 10 76,998 682Delevan, CADelevan, CA

GE F3R 10 50.206 508

Texas Eastern Transmission Corp.Athens, OH GE F3R 10 79,608 434Athens, OH GE F3R 10 77,988 336Athens, OH GE F3R 10 54,743 472Athens, OH GE F3R 10 53,743 443

Transwestem PipelineCorona, NM GE F3R 10 29,129 393

Dow Chemical PlantLouisiana WEC-352R 25 91, 950 240Louisiana WEC-352R 25 93,272 280

Tennessee Gas PipelineLeeville, LA GE P3R 10 81,225 292Port Sulphur, LA GE F3R 10 33, 802 139Alexandria, LA GE F3R 10 9, 921 80Co 11 inwood, TN GE F3R 10 30, 000 180Bay St. Louis, MS GE F3R 10 60,885 371Port Sulphur, LA GE F3R 10 36,602 158Hamilton, AL GE F3R 10 18,481 158Morehead, KY GE F3R 10 14, 000 140Columbus, MS GE F3R 10 20, 000 220Savanna!, TN GE F3R 10 13, 300 135

Texas Gas Transmission CO.Columbia, LA GE F3R 10 47.499 109Greenville, MS GE F3R 10 1,952 94Slaughters, KY GE F3R 10 41.999 140Lake Cormorant, LA GE F3R 10 47,592 107Jeffersontown, KY GE F3R 10 31,011 261Clarksdale, MS GE F3R 10 39, 504 173Kenton, TN GE F3R 10 37, 704 230Hardingsburg, KY GE F3R 10 22. 421 168

ANR Pipeline CompanyDelhi, LA GE F3R 10 35,358 526

Philadelphia ElecricPhiladelphia, PA GE F7R 60 17, 799 *Philadelphia, PA GE F7R 60 17,799 *Philadelphia, PA GE F7R 60 16.143 *Philadelphia, PA GE F7R 60 16,143 *Philadelphia, PA GE F7R 60 16,014 3468Philadelphia, PA GE F7R 60 16, 014 3468

6^B©m#(3468IB) 6|5]Umg6#%$^%o

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05-H

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(ML) <7K —63d,3Jr (®9)

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L) ^ 551

FT4000 HAT Gas Turbine

Recuperator Humid Air From Saturator/RecuperatorAir Inlet

FuelFromCoal

Gasifier

FromIntercoolerTo

Aftercooler/Saturator/

4)

hat in w®#

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15°C/l.033ata15°C/l.033ata/6 0 %WS6 15°C15°C/ lOata

m%%#m 13,050kcal/kg ll,740kcal/kg 12,200kcal/kg (JISZ9204 PSbSOfcffi

1t'f y ;w±AE(^%^-b»A;^-b>APSl

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■A0

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1,100°C

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EP 15°C

AP 15°C

EP 30°C

SM^-b>8^X56

iWEfSE

722mmHg (0.00517ata)

22°C (7 °C)

60ata4ata

E -52

b.

HATtH^lV

(MW) 351.8

G/T 252.9

S/T 68.9

324.6

Em#m± (Mw) 147.2 133.4

% # # % m ^ ^ 55.8 58.9(HHV%)

me (°o

fSEEMEP — 156.1iftEEMEP 273.6 158.0iiSSAP — 84.0#m#mo — 107.6m^xp 273.5 502.6^-kT>AP 1,100 1,100^ —h*>EP 622.6 532.6m ^ e p 99.0 84.0{gE^fStsEP 142.9 —#E#m@m#EP 602.6 —

^tm(t/h)

m # 41.53 36.22& 7-K — 180

# ^ ^ 2,042 2,216@E#m 66.7 —SEII 237.4 —

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m x m m (a^)rn. M 0.00# # 609.63MtK 1.83

# m 7.70£B ± 302.57^Sl7k 7.07a & (mmm 173.86

17.073.12

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D. HATK^^(## : MMkcaI¥h)

m A m m (a^)# M 0.00# n 444.44

1.83

# U 17.56iU jl 278.57a ^ 1.16

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8.841.39

•n- ti 444.44 -n- ti 444.50

;v (Siti) $

38.07 33.3534.11 29.50

40.61 37.30

d. *§ S

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MW (I6%m) y7>hA#T©^%^%##!!&#5%%U:K:&:5o

rKalina cycle provides 25% more power and 3% better net efficiency, Gas

Turbine World(1995-7/8), 38PjC£*X«x7 z:7 c 6: c «k cTx 9

m^#^io%@mmiRia*^^x #@#miamc2c<:&ao mi:xGE7FA izTs9-\L>fcx* V-99-4' y;vmSr L,^##:©#A&#mf'9Xx

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Chemically Recuperated Combustion Turbine (CRCT)

Exhaust heat from the power turbine is used to make steam and to help con­vert natural gas to a hydrogen-rich fuel.

Fuel Water

£Intercooler

Com­pressor

Hydrogen-Rich Fuel and Steam

Hydrogen-Rich Fuel and Steam t

Combustor GasTurbine

Stack

HRSGReformer

ReheatCombustor

Exhaust

PowerTurbine

itElectric

Generator

2.3-10 Ei

#2.3-2^

m s ft m m m m mat a 915 kVV 905 kW

% ft ® m (3S«JS, HHV) 31.0%(11.4 3%-f > h)

28.0%(9.7 > F)

& m & b e so b#=r - ;v K 3 #18fry F (DS S) l#^40^ lWM30e

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Fig. 1: Efficiency Trends

Table #1: CAGT Phase I Sponsors

U.S. Organizations European and Canadian Organizations

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1.

(1) An Evaluation of Advanced Gas Turbine Cycles. 1 - 1

2.

(1) BOMWSmWStfx 9 -1" t Kig&m#

(2) LM 5000 Steam-Injected Gas Turbine System

(3) Steam-Injected Gas Turbine Enhance Cogeneration Plant Performance

(4) im 5000 fix?-1:

(5) 50 mw mmmw.ax

(6) An Assessment of the Thermodynamic Performance of Mixed Gas

Steam Cycles : Part A - Intercooled and Steam Injected Cycles

(7) An Assessment of the Thermodynamic Performance of Mixed Gas

Steam Cycles : Part B - Water Injected and HAT Cycles

2 - 1

2 - 2

2 - 3

2-4

2-5

2-6

2-7

(1) A Simplified Immiscible Liquid Dual Pressure Cycle for Gas turbine

Waste Heat Recovery

(2) Gas turbine Bottoming Cycle : Triple-Pressure Steam Versus

Kalina.

3-2

4. ICAD1M?;H:KN-a&©

(1) ICAD Offers 60 Percent Efficient Turbine Cycle

(2) Inter cooled Aero Derivative (ICAD) Gas Turbine Initiative

4 - 1

4-2

5. CHAT-tM?;W:imi-at)©

(1) CHAT Technology at 54.7 % Efficiency, $ 350/kW Ready for Commercial 5 - 1

Demo.

(2) Achieving a competitive Edge with CHAT 5-2

(3) CHAT rivals 52% Comb Cycle Plant Efficiency at 20% less 5-3

Capital Cost.

6.

(1) Europe has its Own Technology Base to Complete with ATS Programin US 6—1

(2) Small Engine “ATS” Design Project Stresses Inter Cooling, Recuperation 6-2

7. (HAT&^tr)

(1) An Assessment of the Thermodynamic Performance of Mixed Gas-Steam 7 — 1

Cycle : Part A Intercooled and Steam Injected Cycles.

(2) Ditto, Part B Water Injected HAT Cycle. 7-2

(3) Next Generation “Superfans” could Plug Electric Utility 7 — 3

Capacity Gaps.

(4) Advanced Turbine System Study, System, Scoping and Feasibility 7 — 4

Study.

(5) nysU's 7-5

(6) “H” Gas Turbine Combined Cycles Power Generation System 7 — 6

for the Futere.

(7) A New Generation of Advanced Gas Turbine. 7-7

(8) Steam-Cooled 501G Rated 230MW with 2,600° F Rotor Inlet Temperature. 7-8

(9) Predict $600/kW for HAT Cycle Compressed Air Storage 7-9

Plants.

8. ii >) —j-V-J 2MzW&Z) £><D

(1) T >tz.7»s -1(2) Kalina Cycle Provides 25% More Power and 3% Better

Net Efficiency.

W-2

8-2

9.

(1) 9-1

%

10.

(1) 10-1

(2) A Methane-Steam Reformer for a Basic Chemically Recuparated 10- 2

Gas Turbine.

(3) 10-3

11. bo

(1) Ceramic Stationary Cas Turbine 11— 1

(2) 11-2

(3) ^^-t'>Sx-/N"-7oT®yntx • 11- 3

(4) ^ >mm<DWjfa n-4

12. f<Df&

(1) 12-1

(2) 12-2

(3) GT 12- 3

(4) The Design of an Advanced Cooled First Stage for a Full Scale 12-4

Utility Combustion Turbine.

(5) An Advanced Gas Turbine Combined Cycle Power Generation Plant 12— 5

IV-3