The SRC-II process

1981 ◽  
Vol 300 (1453) ◽  
pp. 129-139 ◽  
Keyword(s):  
Gas Turbines ◽  
Large Scale ◽  
Coal Gasification ◽  
The United States ◽  
Electric Utility ◽  
Department Of Energy ◽  
Fuel Oil ◽  
United States Department ◽  
Selling Price ◽  
Home Heating

Extensive laboratory and pilot plant experimental work on the Solvent Refined Coal process by Gulf Oil Corporation over the past 18 years, sponsored by the Fossil Fuel Division of the United States Department of Energy and its predecessor agencies, has led to the development of an improved version of the process known as SRC-II. This work has shown considerable promise in recent years and plans are now being made to demonstrate the SRC-II process with commercial size equipment in a 6000 ton/day (5440 t/day) plant to be located near Morgantown, West Virginia. On the basis of recent economic studies, the products (both liquid and gas) from a future large-scale commercial plant are expected to have an overall selling price of $4.25-4.75/GJ (first quarter 1980 basis). The major product of the primary process is distillate fuel oil of less than 0.3 % sulphur for use largely as a non-polluting fuel for generating electrical power and steam, especially in the east where utilities and industry are currently using petroleum products. In such applications, SRC-II fuel oil is expected to be competitive with petroleum-derived fuels within the next decade. During this period, SRC-II fuel oil should be economically attractive compared with coal combustion with flue gas desulphurization in electric utility and industrial boilers, particularly in the major metropolitan areas. Naphtha produced by the SRC-II process can be upgraded to a high-octane unleaded gasoline to supplement petroleum-derived supplies. Significant quantities of pipeline gas are also produced at a cost that should be competitive with s.n.g. from direct coal gasification. Light hydrocarbons (ethane, propane) from the process may be effectively converted to ethylene. In addition, certain fractions of the fuel oil might also be used in medium-speed diesel engines and automotive gas turbines. For many of these applications, the fuel oil and other products from the SRC-II process would displace high-quality petroleum fractions, which could then be used for production of diesel fuels, jet fuels, home heating oil and gasoline by conventional refinery processes.

Application of SPSLIFE to Preliminary Design Evaluation and Life Assessment of CSGT Components

1995 ◽  
Vol 117 (3) ◽  
pp. 424-431
Author(s):  
A. Saith ◽  
P. F. Norton ◽  
V. M. Parthasarathy
Keyword(s):  
Gas Turbines ◽  
Computer Code ◽  
The United States ◽  
Department Of Energy ◽  
Life Assessment ◽  
Design Evaluation ◽  
United States Department ◽  
Preliminary Design ◽  
Detail Design ◽  
Stage 1

The Ceramic Stationary Gas Turbine (CSGT) Program has utilized the SPSLIFE computer code to evaluate the preliminary design of ceramic components. The CSGT program is being performed under the sponsorship of the United States Department of Energy, Office of Industrial Technology, to improve the performance of stationary gas turbines in cogeneration through the selective replacement of hot section components with ceramic parts. Preliminary design evaluation and life assessment results are presented here for the following components: (1) Stage 1 turbine blade, (2) Stage 1 turbine nozzle, and (3) combustor inner liner. From the results of the analysis, recommendations are made for improving the life and reliability of the components. All designs were developed in Phase I (preliminary design) of the CSGT program and will be optimized in Phase II (detail design) of the program.

Application of Spslife to Preliminary Design Evaluation and Life Assessment of CSGT Components

1994 ◽  
Author(s):  
Arun Saith ◽  
Paul F. Norton ◽  
Vijay M. Parthasarathy
Keyword(s):  
Gas Turbines ◽  
Computer Code ◽  
The United States ◽  
Department Of Energy ◽  
Life Assessment ◽  
Design Evaluation ◽  
United States Department ◽  
Preliminary Design ◽  
Detail Design ◽  
Stage 1

The Ceramic Stationary Gas Turbine (CSGT) Program has utilized the SPSLIFE computer code to evaluate the preliminary design of ceramic components. The CSGT program is being performed under the sponsorship of the United States Department of Energy, Office of Industrial Technology, to improve the performance of stationary gas turbines in cogeneration through the selective replacement of hot section components with ceramic parts. Preliminary design evaluation and life assessment results are presented here for the following components: (1) Stage 1 Turbine Blade, (2) Stage 1 Turbine Nozzle, and (3) Combustor Inner Liner. From the results of the analysis, recommendations are made for improving the life and reliability of the components. All designs were developed in Phase I (preliminary design) of the CSGT program and will be optimized in Phase II (detail design) of the program.

scholarly journals Ceramic Stationary Gas Turbine Development Program — Fifth Annual Summary

1998 ◽  
Author(s):  
Jeffrey R. Price ◽  
Oscar Jimenez ◽  
Les Faulder ◽  
Bryan Edwards ◽  
Vijay Parthasarathy
Keyword(s):  
Gas Turbines ◽  
Development Program ◽  
Field Testing ◽  
The United States ◽  
Turbine Rotor ◽  
Department Of Energy ◽  
Inlet Temperature ◽  
United States Department ◽  
Performance Improvements ◽  
Ceramic Components

A program is being performed under the sponsorship of the United States Department of Energy, Office of Industrial Technologies, to improve the performance of stationary gas turbines in cogeneration through the selective replacement of metallic hot section components with ceramic parts. The program focuses on design, fabrication, and testing of ceramic components, generating a materials properties data base, and applying life prediction and nondestructive evaluation (NDE). The development program is being performed by a team led by Solar Turbines Incorporated, and which includes suppliers of ceramic components, U.S. research laboratories and an industrial cogeneration end user. The Solar Centaur 50S engine was selected for the development program. The program goals included an increase in the turbine rotor inlet temperature (TRIT) from 1010°C (1850°F) to 1121°C (2050°F), accompanied by increases in thermal efficiency and output power. The performance improvements are attributable to the increase in TRIT and the reduction in cooling air requirements for the ceramic parts. The ceramic liners are also expected to lower the emissions of NOx and CO. Under the program uncooled ceramic blades and nozzles have been inserted for currently cooled metal components in the first stage of the gas producer turbine. The louvre-cooled metal combustor liners have been replaced with uncooled continuous-fiber reinforced ceramic composite (CFCC) liners. Modifications have been made to the engine hot section to accommodate the ceramic parts. To-date all first generation designs have been completed. Ceramic components have been fabricated, and are being tested in rigs and in the Centaur 50S engine. Field testing at an industrial co-generation site was started in May, 1997. This paper will provide an update of the development work and details of engine testing of ceramic components under the program.

scholarly journals Results of Small Gas Turbine for Distributed Generation Strategies Workshop

1996 ◽  
Author(s):  
George A. Hay ◽  
Art Cohn ◽  
Paul Baustista ◽  
George Touchton ◽  
William Parks ◽  
...  
Keyword(s):  
Gas Turbine ◽  
San Francisco ◽  
Distributed Generation ◽  
Gas Turbines ◽  
Operating Experience ◽  
The United States ◽  
Electric Utility ◽  
Department Of Energy ◽  
Research Activities ◽  
Research Institute

This paper summarizes the proceedings of the 1995 workshop in San Francisco, CA on “Small Gas Turbines for Distributed Generation” and the planned winter of 1996 follow-on workshop. The working definition for distributed generation used in the workshop was modular generation (generally 1–50 MW) in various applications located on electric customers sites or near load centers in an electric grid. The workshop was sponsored by the Electric Power Research Institute (EPRI), the Gas Research Institute (GRI), the U.S. Department of Energy (DOE) and Pacific Gas and Electric (PG&E). The objectives were to: • review historical operating experience, market trends and the current state of the art of small gas turbine based options (1–50 MW size range); • characterize benefits, motivations, application requirements and issues of small gas turbines in distributed generation strategies amongst “stakeholders”; • identify what further efforts, technology or otherwise, should be pursued to enhance future opportunities for small gas turbine “stakeholders’; and • define “stakeholder” interest in future forums for coordination and discussion of improved distributed generation strategies based on small gas turbines. The workshop was attended by over 42 electric or gas utilities, 12 independent power companies and a broad cross section of equipment suppliers. Architect and Engineers (A&E’s), Research Development and Demonstration (RD&D) programs, government organizations, international utilities and other interested parties. The total workshop attendance was over 140. Small gas turbine technologies, user case histories, operating experiences, electric and gas system requirements, distributed generation economic theory, regulatory issues and general industry perspectives were reviewed. Industry input was gathered through a formal survey and four break-out sessions on future small gas turbine user needs, market requirements and potential hurdles for distributed generation. Presentations by suppliers and users highlighted the significant commercial operating experience with small gas turbines in numerous electric utility and non-electric utility “distributed” generation applications. The primary feedback received was that there is significant and growing market interest in distributed generation strategies based on small gas turbines options. General consensus was that small gas turbine systems using natural gas would be the technology of choice in the United States for much of the near-term distributed generation market. Most participants felt that improved gas turbine technology, applications and distributed generation benefit economic evaluation models could significantly enhance the economics of distributed generation. Over 30 utility or other users expressed support for the formation of a small gas turbine interest group and an equal number expressed interest in hosting or participating in demonstration projects. A strong interest was indicated in the need for a follow-on workshop that would be more applications focused and provide a forum for coordinating research activities. Current plans by EPRI, GRI and DOE will be to include the follow-on as part of a planned workshop on “Flexible Gas Turbine Strategies” in the fall of 1996.

scholarly journals Ceramic Stationary Gas Turbine Development Program: Design and Life Assessment of Ceramic Components

1995 ◽  
Author(s):  
Paul F. Norton ◽  
Gary A. Frey ◽  
Hamid Bagheri ◽  
Aaron Flerstein ◽  
Chris Twardochleb ◽  
...  
Keyword(s):  
Gas Turbine ◽  
Gas Turbines ◽  
Failure Modes ◽  
Development Program ◽  
The United States ◽  
Department Of Energy ◽  
Life Assessment ◽  
United States Department ◽  
Ceramic Component ◽  
Engine Operation

A program is being performed under the sponsorship of the United States Department of Energy, Office of Industrial Technology, to improve the performance of stationary gas turbines in cogeneration through the selective replacement of hot section components with ceramic parts. It is envisioned that the successful demonstration of ceramic gas turbine technology, and the systematic incorporation of ceramics in existing and future gas turbines will enable more efficient engine operation, resulting in significant fuel savings, increased output power, and reduced emissions. The engine selected for the program, the Centaur 50 (formerly named Centaur ‘H’) will be retrofitted with first stage ceramic blades, first stage ceramic nozzles, and a ceramic combustor liner. The engine hot section is being redesigned to adapt the ceramic parts to the existing metallic support structure. The program currently in Phase II focuses on detailed engine and component design, ceramic component fabrication, ceramic component testing, establishment of a long term materials property database, and the development and application of supporting technologies in the areas of life prediction and non-destructive evaluation. This paper outlines the design activities associated with the introduction of a ceramic first stage nozzle and two configurations of ceramic first stage turbine blade. In addition, probabilistic life assessment of the ceramic parts for major failure modes (fast fracture, slow crack growth and where relevant, creep and oxidation) will be discussed.

Ceramic Stationary Gas Turbine Development Program — Design and Test of a Ceramic Turbine Blade

1998 ◽  
Author(s):  
Oscar Jimenez ◽  
John McClain ◽  
Bryan Edwards ◽  
Vijay Parthasarathy ◽  
Hamid Bagheri ◽  
...  
Keyword(s):  
Gas Turbine ◽  
Turbine Blade ◽  
Gas Turbines ◽  
Fuel Efficiency ◽  
Development Program ◽  
Field Testing ◽  
The United States ◽  
Department Of Energy ◽  
United States Department ◽  
Engine Operation

The goal of the Ceramic Stationary Gas Turbine (CSGT) Development Program, under the sponsorship of the United States Department of Energy (DOE), Office of Industrial Technologies (OIT), is to improve the performance (fuel efficiency, output power, and exhaust emissions) of stationary gas turbines in cogeneration through the selective replacement of hot section components with ceramic parts. This program, which is headed by Solar Turbines Incorporated and supported by various suppliers, and national research institutes, includes detailed engine and component design, procurement, and field testing. A major challenge in the successful introduction of ceramic parts into a gas turbine is the design of the interface between the ceramic parts and metallic hardware. A turbine blade, which incorporated a dovetail root, was designed with such considerations. A relatively thin compliant layer between the ceramic-metallic loading surface was considered for equalizing pressure face load distributions. Five monolithic siliocn nitride ceramic materials were considered: AS800 and GN10, AlliedSignal Ceramic Components; NT164, Norton Advanced Ceramics; SN281 and SN253, Kyocera Industrial Ceramics Corporation. The probability of survival using NASA/CARES for 30,000 hours of engine operation was calculated for each material. The blade frequencies, stresses, and temperatures were predicted. The influence of the dovetail angle was also analyzed to determine the most optimum configuration. Prior to engine installation all blades underwent extensive nondestructive evaluation and spin proof testing. This paper will review the design, life prediction, and testing of the first stage ceramic turbine blade for the Solar Turbines Centaur 5OS engine.

scholarly journals Design of a High Efficiency Industrial Turbine Blade Utilizing Third Generation Single Crystal Alloy CMSX®-10

1997 ◽  
Author(s):  
Michael D. Fitzpatrick ◽  
William D. Brentnall ◽  
Andrew Meier ◽  
Gary L. Erickson ◽  
Gary DeBoer
Keyword(s):  
Single Crystal ◽  
Gas Turbines ◽  
Life Cycle Cost ◽  
High Efficiency ◽  
The United States ◽  
Department Of Energy ◽  
Advanced Materials ◽  
United States Department ◽  
Third Generation ◽  
Microstructural Stability

Future advancements in the efficiency and reliability of Industrial Gas Turbines (IGT) will be closely tied to the application of advanced materials, together with increasingly sophisticated turbine hot section designs. An example of this trend is illustrated by the recent design of a first stage blade component for an advanced IGT concept utilizing the third generation single crystal superalloy CMSX-10. It is anticipated that alloy CMSX-10 will permit the use of increased turbine firing temperatures with reduced cooling flows compared to previous recuperated turbine designs, while maintaining acceptable blade durability and life-cycle cost. This paper discusses some of the design/materials analyses and cost studies performed on the blade, which ultimately led to the consideration of alloy CMSX-10 for the IGT application. The solid modeling and finite element blade design methods which allowed the incorporation of state-of-the-art cooling technology and aerodynamics are described. Alloy CMSX-10 characteristics, particularly mechanical properties and microstructural stability considerations, are discussed. Additionally, the results of a recent casting demonstration in an IGT blade configuration are presented. Finally, future tasks supporting the application of the alloy are outlined, such as coatings development efforts and the DOE/ORNL sponsored Land Based Turbine Casting Initiative; activities sponsored through a cooperative agreement with the United States Department of Energy within the Advanced Turbine System (ATS) Program.

CSGT: Final Design and Test of a Ceramic Hot Section

2003 ◽  
Author(s):  
Oscar Jimenez ◽  
Hamid Bagheri ◽  
John McClain ◽  
Ken Ridler ◽  
Tibor Bornemisza
Keyword(s):  
Silicon Nitride ◽  
Gas Turbines ◽  
Fuel Efficiency ◽  
Development Program ◽  
The United States ◽  
Department Of Energy ◽  
United States Department ◽  
Engine Test ◽  
Metallic Component ◽  
Ceramic Components

The Ceramic Stationary Gas Turbine (CSGT) Development Program was performed under the sponsorship of the United States Department of Energy (DOE), Office of Industrial Technologies (OIT). The goal was to improve the performance (fuel efficiency, output power, and exhaust emissions) of stationary gas turbines in cogeneration through the selective replacement of hot section metallic components with ceramic components. The team was headed by Solar Turbines Incorporated and supported by ceramic component suppliers and national research institutes. The team performed a detailed engine and component design, fabrication, and field-testing of ceramic components. This program culminated in an engine test at 1121°C (2050°F) TRIT. This was a major challenge in that the engine ran with a continuous fiber reinforced ceramic composite liner (CFCC) and with silicon nitride (Si3N4) stage one ceramic blades and nozzles. The design and testing of all three components will be discussed in this paper, with emphasis on the ceramic nozzles. Another test that will be discussed in this paper is a heavily instrumented engine test that took place prior to the test mentioned above. This instrumented engine test was performed in order to better understand the temperature effects between the ceramic and metallic component interfaces. The results from this were then used to correlate the analytical model with test data. This led to additional design changes to the outer and inner shroud ceramic / metallic interfaces, as well as ceramic nozzles, fabricated from Kyocera SN 282 silicon nitride material. These nozzle changes were then engine tested successfully for a total of 100 hours at full load [1010°C (1850°F) TRIT and 100% speed]. During the engine test, the firing temperature was increased to 1121°C (2050°F) TRIT for an adequate duration to ensure meaningful performance data were gathered.

Ceramic Stationary Gas Turbine Development Program—Fifth Annual Summary

1999 ◽  
Vol 121 (4) ◽  
pp. 586-592 ◽  
Author(s):  
J. R. Price ◽  
O. Jimenez ◽  
L. Faulder ◽  
B. Edwards ◽  
V. Parthasarathy
Keyword(s):  
Gas Turbines ◽  
Development Program ◽  
Field Testing ◽  
The United States ◽  
Turbine Rotor ◽  
Department Of Energy ◽  
Inlet Temperature ◽  
United States Department ◽  
Performance Improvements ◽  
Ceramic Components

A program is being performed under the sponsorship of the United States Department of Energy, Office of Industrial Technologies, to improve the performance of stationary gas turbines in cogeneration through the selective replacement of metallic hot section components with ceramic parts. The program focuses on design, fabrication, and testing of ceramic components, generating a materials properties data base, and applying life prediction and nondestructive evaluation (NDE). The development program is being performed by a team led by Solar Turbines Incorporated, and which includes suppliers of ceramic components, U.S. research laboratories, and an industrial cogeneration end user. The Solar Centaur 50S engine was selected for the development program. The program goals included an increase in the turbine rotor inlet temperature (TRIT) from 1010°C (1850°F) to 1121°C (2050°F), accompanied by increases in thermal efficiency and output power. The performance improvements are attributable to the increase in TRIT and the reduction in cooling air requirements for the ceramic parts. The ceramic liners are also expected to lower the emissions of NOx and CO. Under the program uncooled ceramic blades and nozzles have been inserted for currently cooled metal components in the first stage of the gas producer turbine. The louvre-cooled metal combustor liners have been replaced with uncooled continuous-fiber reinforced ceramic composite (CFCC) liners. Modifications have been made to the engine hot section to accommodate the ceramic parts. To date, all first generation designs have been completed. Ceramic components have been fabricated, and are being tested in rigs and in the Centaur 50S engine. Field testing at an industrial co-generation site was started in May, 1997. This paper will provide an update of the development work and details of engine testing of ceramic components under the program.

scholarly journals Ceramic Stationary Gas Turbine Development Program: First Annual Summary

1994 ◽  
Author(s):  
Mark van Roode ◽  
William D. Brentnall ◽  
Paul F. Norton ◽  
Gary L. Boyd
Keyword(s):  
Gas Turbine ◽  
Phase Ii ◽  
Gas Turbines ◽  
Development Program ◽  
The United States ◽  
Department Of Energy ◽  
Phase Iii ◽  
United States Department ◽  
Engine Operation ◽  
Component Design

A program is being performed under the sponsorship of the United States Department of Energy, Office of Industrial Technology, to improve the performance of stationary gas turbines in cogeneration through the selective replacement of hot section components with ceramic parts. It is envisioned that the successful demonstration of ceramic gas turbine technology, and the systematic incorporation of ceramics in existing and future gas turbines will enable more efficient engine operation, resulting in significant fuel savings, increased output power, and reduced emissions. The engine selected for the program, the Centaur 50 (formerly named Centaur ‘H’) will be retrofitted with first stage ceramic blades, first stage ceramic nozzles, and a ceramic combustor liner. The engine hot section is being redesigned to adapt the ceramic parts to the existing metallic support structure. The work in Phase 1 of the program involved concept and preliminary engine and component design, ceramic materials selection, technical and economic evaluation, and concept assessment. A detailed work plan was developed for Phases II and III of the program. The work in Phase II addresses detailed engine and component design, and ceramic specimen and component procurement and testing. Ceramic blades, nozzles, and combustor liners will be tested in subscale rigs and in a gasifier rig which is a modified Centaur 50 engine. The Phase II effort also involves long term testing of ceramics, development of appropriate nondestructive technologies for part evaluation, and component life prediction. Phase III of the program focuses on a 4,000 hour engine test at a cogeneration site. This paper summarizes the progress on the program through the end of 1993.

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