Research and Development of Practical Industrial Cogeneration Technology in Japan

2000 ◽  
Author(s):  
Toshiaki Abe ◽  
Takashi Sugiura ◽  
Shuji Okunaga ◽  
Katsuhiro Nojima ◽  
Yasukata Tsutsui ◽  
...  
Keyword(s):  
Research And Development ◽  
Gas Turbine ◽  
High Temperatures ◽  
Gas Turbines ◽  
High Efficiency ◽  
Development Project ◽  
Term Operation ◽  
Resistance To Heat

This paper presents an overview of a development project involving industrial cogeneration technology using 8,000-kW class hybrid gas turbines in which both metal and ceramics are used in parts subject to high temperatures in order to achieve high efficiency and low pollution. The development of hybrid gas turbines focuses mainly on the earlier commercialization of the turbine system. Stationary parts such as combustor liners, transition ducts, and first-stage turbine nozzles (stationary blades) are expected to be fabricated from ceramics. The project aims at developing material for these ceramic parts that will have a superior resistance to heat and oxidation. The project also aims at designing and prototyping a hybrid gas turbine system to analyze the operation in order to improve the performance. Furthermore, the prototyped hybrid gas turbine system will be tested for long-term operation (4,000 hours) to verify that the system can withstand commercialization. Studies will be conducted to ensure that the system’s soundness and reliability are sufficient for industrial cogeneration applications.

Development of the Hybrid Gas Turbine: 1st Year Summary — Research and Development on Practical Industrial Cogeneration Technology in Japan

2001 ◽  
Author(s):  
Ryozo Tanaka ◽  
Testuo Tastumi ◽  
Yoshihiro Ichikawa ◽  
Koji Sanbonsugi
Keyword(s):  
Research And Development ◽  
Gas Turbine ◽  
Gas Turbines ◽  
Industrial Applications ◽  
Medium Size ◽  
Test Plant ◽  
Inlet Temperature ◽  
Term Operation ◽  
Generation Technology

Based on the successful results of the Japanese national project for 300 kW ceramic gas turbine(CGT302) development (this project was finished in March 1999), the Ministry of International Trade and Industry (MITI) started “Research and Development on Practical Industrial Co-generation Technology” project in August 1999. The objective of this project is to encourage prompt industrial applications of co-generation technology that employs hybrid gas turbines (HGT; using both metal and ceramic parts in its high-temperature section) by confirming its soundness and reliability. The development activities are performed through material evaluation tests and long-term operation tests for the HGT of the medium size (8,000-kW class). It is expected that the development can realize low pollution and reducing the emission of CO2 with highly efficient use of energy. The HGT will be developed by applying ceramic components to an existing commercial 7,000-kW class gas turbine. The development targets are thermal efficiency of 34% or higher, output of 8,000-kW class, inlet temperature of 1250deg-C, and 4,000hrs of operation period for confirmation of reliability. The HGT for long-term evaluation tests and the test plant are under development. This paper gives the summary of last year’s developments in the HGT project.

Summary of CGT302 Ceramic Gas Turbine Research and Development Program

2000 ◽  
Author(s):  
Isashi Takehara ◽  
Tetsuo Tatsumi ◽  
Yoshihiro Ichikawa
Keyword(s):  
Research And Development ◽  
Gas Turbine ◽  
Thermal Efficiency ◽  
High Efficiency ◽  
Development Program ◽  
Pollutant Emissions ◽  
Inlet Temperature ◽  
Term Operation ◽  
Ceramic Components

The Japanese Ceramic Gas Turbine (CGT) research and development program (FY1988–1998) as a part of the New Sunshine Project funded by the Ministry of International Trade and Industry (MITI) was completed in March 1999. Kawasaki Heavy Industries, Ltd. (KM) participated in this research program from the beginning and developed a twin-shaft CGT with a recuperator, designated as the “CGT302”. The purposes of this program were: 1) to achieve both a high efficiency and low pollutant emissions level using ceramic components, 2) to prove a multi-fuel capability to be used in co-generation systems, and 3) to demonstrate long-term operation. The targets of this program were: i) to achieve a thermal efficiency of over 42% at a turbine inlet temperature (TIT) of 1350°C, ii) to keep its emissions within the regulated value by the law, and iii) to demonstrate continuous operation for more than a thousand hours at 1200°C TIT. The CGT302 has successfully attained its targets. In March 1999 the CGT302 recorded 42.1% thermal efficiency, and 31.7 ppm NOx emissions (O2 = 16%) at 1350°C TIT. At this time it had also accumulated over two thousand hours operation at 1200°C. In this paper, we summarize the development of the CGT302.

Summary of CGT302 Ceramic Gas Turbine Research and Development Program

2002 ◽  
Vol 124 (3) ◽  
pp. 627-635 ◽  
Author(s):  
I. Takehara ◽  
T. Tatsumi ◽  
Y. Ichikawa
Keyword(s):  
Research And Development ◽  
Gas Turbine ◽  
Thermal Efficiency ◽  
High Efficiency ◽  
Development Program ◽  
Pollutant Emissions ◽  
Inlet Temperature ◽  
Term Operation ◽  
Ceramic Components

The Japanese ceramic gas turbine (CGT) research and development program (FY1988-1998) as a part of the New Sunshine Project funded by the Ministry of International Trade and Industry (MITI) was completed in March 1999. Kawasaki Heavy Industries, Ltd. (KHI) participated in this research program from the beginning and developed a twin-shaft CGT with a recuperator, designated as the “CGT302.” The purposes of this program were (1) to achieve both a high efficiency and low pollutant emissions level using ceramic components, (2) to prove a multifuel capability to be used in cogeneration systems, and (3) to demonstrate long-term operation. The targets of this program were (i) to achieve a thermal efficiency of over 42 percent at a turbine inlet temperature (TIT) of 1350°C, (ii) to keep its emissions within the regulated value by the law, and (iii) to demonstrate continuous operation for more than a thousand hours at 1200°C TIT. The CGT302 has successfully attained its targets. In March 1999 the CGT302 recorded 42.1 percent thermal efficiency, and 31.7 ppm NOx emissions (O2=16 percent) at 1350°C TIT. At this time it had also accumulated over 2000 hours operation at 1200°C. In this paper, we summarize the development of the CGT302.

Fatigue Strength and Metal Condition in the Context of Gas Turbine Buckets Life Extension

2012 ◽  
Author(s):  
Sergey A. Ivanov ◽  
Alexander I. Rybnikov
Keyword(s):  
Fatigue Strength ◽  
Service Life ◽  
Gas Turbine ◽  
Fatigue Resistance ◽  
Gas Turbines ◽  
Life Extension ◽  
Term Operation ◽  
Life Estimation ◽  
Metal Properties

Criteria for remaining life estimation and methods for enhancing fatigue resistance of heavy-duty gas turbine bucket metal are based on the analysis of changes in the structure and properties of metal after long-term operation. High-cycle fatigue (HCF) resistance is shown to be a decisive characteristic in the residual life estimation of turbine buckets after operation over 100,000 hours. The tests of the buckets from cast and wrought nickel-based alloys after long-term operation demonstrated decreasing of fatigue strength by up to 25%. The metal structure in operation undergoes notable deterioration mainly in phase redistribution. The size and configuration of metal phases are changing also. It caused the changes in metal properties. The decrease of the bucket fatigue strength correlates with the decrease of metal ductility. The reconditioning heat treatment resulted in restoring mechanical properties of metal. The fatigue resistance also increased nearly to the initial level. The influence of operational factors on bucket fatigue strength deterioration has been established. The mechanical damages on bucket airfoil may decrease the fatigue resistance. We found the correlation of endurance limit and damages depth. The procedures for metal properties recovering and buckets service life substantial extension have been developed. It has resulted in the extension of the buckets service life by up to 50% over the assigned life in gas turbines operated by Gazprom.

Development of a Low NOx Combustor for 300kW-Class Ceramic Gas Turbine (CGT302)

1998 ◽  
Author(s):  
A. Okuto ◽  
T. Kimura ◽  
I. Takehara ◽  
T. Nakashima ◽  
Y. Ichikawa ◽  
...  
Keyword(s):  
Research And Development ◽  
Gas Turbine ◽  
Flow Rate ◽  
Gas Turbines ◽  
Combustion Efficiency ◽  
Development Project ◽  
Pollutant Emissions ◽  
Inlet Temperature ◽  
Outlet Temperature ◽  
Nox Emissions

Research and development project of ceramic gas turbines (CGT) was started in 1988 promoted by the Ministry of International Trade and Industry (MITI) in Japan. The target of the CGT project is development of a 300kW-class ceramic gas turbine with a 42 % thermal efficiency and a turbine inlet temperature (TIT) of 1350°C. Three types of CGT engines are developed in this project. One of the CGT engines, which is called CGT302, is a recuperated two-shaft gas turbine for co-generation use. In this paper, we describe the research and development of a combustor for the CGT302. The project requires a combustor to exhaust lower pollutant emissions than the Japanese regulation level. In order to reduce NOx emissions and achieve high combustion efficiency, lean premixed combustion technology is adopted. Combustion rig tests were carried out using this combustor. In these tests we measured the combustor performance such as pollutant emissions, combustion efficiency, combustor inlet/outlet temperature, combustor inlet pressure and pressure loss through combustor. Of course air flow rate and fuel flow rate are controlled and measured, respectively. The targets for the combustor such as NOx emissions and combustion efficiency were accomplished with sufficient margin in these combustion rig tests. In addition, we report the results of the tests which were carried out to examine effects of inlet air pressure on NOx emissions here.

scholarly journals Development of a High Pressure Ratio Centrifugal Compressor for 300kW-Class Ceramic Gas Turbine

1997 ◽  
Author(s):  
T. Sakai ◽  
Y. Tohbe ◽  
T. Fujii ◽  
T. Tatsumi
Keyword(s):  
Research And Development ◽  
Gas Turbine ◽  
Gas Turbines ◽  
High Efficiency ◽  
Pressure Ratio ◽  
Flow Distribution ◽  
Leading Edge ◽  
Inlet Temperature ◽  
Angle Distribution ◽  
Gas Generator

Research and development of ceramic gas turbines (CGT), which is promoted by the Japanese Ministry of International Trade and Industry (MITI), was started in 1988. The target of the CGT project is development of a 300kW-class ceramic gas turbine with a 42 % thermal efficiency and a turbine inlet temperature (TIT) of 1350°C. Two types of CGT engines are developed in this project. One of the CGT engines, which is called CGT302, is a recuperated two-shaft gas turbine with a compressor, a gas-generator turbine, and a power turbine for cogeneration. In this paper, we describe the research and development of a compressor for the CGT302. Specification of this compressor is 0.89 kg/sec air flow rate and 8:1 pressure ratio. The intermediary target efficiency is 78% and the final target efficiency is 82%, which is the highest level in email centrifugal compressors like this one. We measured impeller inlet and exit flow distribution using three-hole yaw probes which were traversed from the shroud to the hub. Based on the measurement of the impeller exit flow, diffusers with a leading edge angle distribution adjusted to the inflow angle were designed and manufactured. Using this diffuser, we were able to attain a high efficiency (8:1 pressure ratio and 78% adiabatic efficiency).

Analysis of Long-Term Gas Turbine Operation With a Model-Based Data Reconciliation Technique

2015 ◽  
Author(s):  
Christian Rudolf ◽  
Manfred Wirsum ◽  
Martin Gassner ◽  
Stefano Bernero
Keyword(s):  
Power Plant ◽  
Gas Turbine ◽  
Gas Turbines ◽  
Engine Performance ◽  
Combined Cycle ◽  
Data Reconciliation ◽  
Data Set ◽  
Operating Data ◽  
Term Operation

The continuous monitoring of gas turbines in commercial power plant operation provides long-term engine data of field units. Evaluation of the engine performance is challenging as, apart from variations of operating points and environmental conditions, the state of the engine is subject to changes due to the ageing of engine components. The measurement devices applied to the unit influence the analysis by means of their accuracy, which may itself alter with time. Furthermore, the available measurements do usually not cover all necessary information for the evaluation of the engine performance. To overcome these issues, this paper describes a method to systematically evaluate long term operation data without the incorporation of engine design models since the latter do not cover performance changes when components are ageing. Key focus of the methodology thereby is to assess long-term emission performance in the most reliable manner. The analysis applies a data reconciliation method to long-term operating data in order to model the engine performance including non-measured variables and to account for measurement inaccuracies. This procedure relies on redundancies in the data set due to available measurements and the identification of suitable additional constituting equations that are independent of component ageing. The resulting over-determined set of equations allows for performing a data set optimization with respect to a minimal cumulated deviation to the measurement values, which represents the most probable, real state of the engine. The paper illustrates the development and application of the method to analyse the gas path of a commercial gas turbine in a combined cycle power plant with long-term operating data.

Modelling of Gas Turbine NOx Emissions Based on Long-Term Operation Data

2016 ◽  
Author(s):  
Christian Rudolf ◽  
Manfred Wirsum ◽  
Martin Gassner ◽  
Benjamin Timo Zoller ◽  
Stefano Bernero
Keyword(s):  
Power Plant ◽  
Gas Turbine ◽  
Gas Turbines ◽  
Engine Performance ◽  
Combined Cycle ◽  
Data Set ◽  
Operating Data ◽  
Emission Performance ◽  
Term Operation

The continuous monitoring of gas turbines in commercial power plant operation provides long-term engine data of field units. Evaluation of the engine performance from such data is challenging since, apart from variations of operating points and ambient conditions, the state of the engine is subject to change due to ageing of engine components. The installed measurement devices influence the analysis due to their accuracy, which may itself alter with time. Furthermore, the available measurements usually do not cover all necessary information for assessment of the engine performance. To overcome these issues, this paper describes a method to systematically evaluate long term operation data without the incorporation of engine design models that depict the design state of the engine, but do not cover performance changes when components are ageing. Key focus of the methodology is thereby to assess long-term emission performance in the most reliable manner. The analysis applies a data reconciliation method to long-term operating data in order to model the engine performance including non-measured variables and to account for measurement inaccuracies. This procedure relies on redundancies in the data set due to available measurements and the identification of suitable additional constituting equations that are independent of component ageing. The resulting over-determined set of equations allows for performing a data set optimization with respect to a minimal cumulated deviation to the measurement values, which represents the most probable, real state of the engine. The paper illustrates the development and application of the method for analysing emission performance with long-term operating data of a commercial gas turbine combined cycle power plant.

Advanced Ceramic Technology Developed for Industrial 300kW CGT (Ceramic Gas Turbine) Research and Development Project in Japan

1993 ◽  
Author(s):  
Kazuaki Shimada ◽  
Hiroyasu Ushijima ◽  
Akira Yabe ◽  
Hisao Ogiyama ◽  
Yasukata Tsutsui
Keyword(s):  
Research And Development ◽  
Gas Turbine ◽  
Gas Turbines ◽  
Development Project ◽  
Ceramic Technology ◽  
Inlet Temperature ◽  
Turbine Inlet Temperature ◽  
All Ceramic ◽  
Evaluation Test ◽  
Ceramic Components

The characteristics and the points of innovation for the ceramic technology established in the Japanese national energy conservation project supported by Agency of Industrial Science and Technology (AIST) MITI, entitled “The 300kW Industrial Ceramic Gas Turbine Research and Development Project” have been cleared and reviewed. Especially, from the viewpoint of the role and the characteristics of the ceramic components, the progress of the three types of the ceramic gas turbines, which are: (a) “Regenerative Single–shaft Ceramic Gas Turbine for Cogeneration” (CGT–301); (b) “Regenerative Two–shaft Ceramic Gas Turbine for Cogeneration” (CGT–302) and (c) “Regenerative Two–shaft Ceramic Gas Turbine for Mobile Power Generation” (CGT–303), has been explained in parallel. All ceramic components have already been manufactured for the turbine inlet temperature of 1200 deg C and tested as the components, which will be assembled and evaluated as the interim evaluation test in 1993. Especially, the characteristics of the ceramic components have been reviewed in several points such as the fabrication process for clearing the contrast among three types of ceramic gas turbine.

An Improved Nickel Based MIMS Thermocouple for High Temperature Gas Turbine Applications

2012 ◽  
Author(s):  
Michele Scervini ◽  
Catherine Rae
Keyword(s):  
High Temperature ◽  
Gas Turbine ◽  
High Temperatures ◽  
Gas Turbines ◽  
Material Science ◽  
University Of Cambridge ◽  
Type K ◽  
Metallurgical Analysis ◽  
The University ◽  
High Temperature Gas

A new Nickel based thermocouple for high temperature applications in gas turbines has been devised at the Department of Material Science and Metallurgy of the University of Cambridge. This paper describes the new features of the thermocouple, the drift tests on the first prototype and compares the behaviour of the new sensor with conventional mineral insulated metal sheathed Type K thermocouples: the new thermocouple has a significant improvement in terms of drift and temperature capabilities. Metallurgical analysis has been undertaken on selected sections of the thermocouples exposed at high temperatures which rationalises the reduced drift of the new sensor. A second prototype will be tested in follow-on research, from which further improvements in drift and temperature capabilities are expected.

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