scholarly journals Improved Silicon Nitride Materials and Component Fabrication Processes for Aerospace and Industrial Gas Turbine Applications

1995 ◽  
Author(s):  
John P. Pollinger
Keyword(s):  
Silicon Nitride ◽  
Gas Turbine ◽  
Gas Turbines ◽  
Hybrid Electric Vehicle ◽  
Ceramic Materials ◽  
Production Volume ◽  
Cycle Times ◽  
Fine Grained ◽  
Auxiliary Power Units ◽  
Industrial Gas Turbines

New and improved silicon nitride structural ceramic materials and component fabrication processes are being developed and refined for implementation and insertion into aerospace, industrial, and automotive gas turbine applications. These improved materials and forming processes offer the potential of meeting turbomachinery manufacturers’ performance, quality, cost, and production volume goals. AlliedSignal has developed a new generation of silicon nitride materials with isotropic acicular microstructures that result in a number of property improvements compared to current HIP’ed fine-grained silicon nitride materials. Concurrently, new silicon nitride component forming processes such as gelcasting and refinements of current forming processes such as presintered component machining are being developed and refined to achieve production volume fabrication capability, yields, and short cycle times at low costs. As these materials and component fabrication processes are maturating, a number of applications are being investigated and demonstrated including hot section turbomachinery components for aircraft auxiliary power units (APU’s), industrial gas turbines, and automotive hybrid electric vehicle turboalternators.

Ceramic Stationary Gas Turbine Development

1993 ◽  
Author(s):  
Mark van Roode ◽  
William D. Brentnall ◽  
Paul F. Norton ◽  
Gregory P. Pytanowski
Keyword(s):  
Silicon Carbide ◽  
Silicon Nitride ◽  
Gas Turbine ◽  
Gas Turbines ◽  
Ceramic Materials ◽  
Ceramic Composites ◽  
Department Of Energy ◽  
Engine Operation ◽  
Component Design ◽  
Combustor Liner

A program has been initiated under the sponsorship of the Department of Energy (DOE), Office of Industrial Technology, to improve the performance of stationary gas turbines in cogeneration through the selective replacement of metallic hot section parts with uncooled ceramic components. 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 program which started in September, 1992, takes an engine of the Solar Centaur family of industrial gas turbines, and modifies the design of the hot section to accept ceramic first stage blades and first stage nozzles, and a ceramic combustor liner. The ceramic materials selected for the blade are silicon nitride, for the nozzle silicon nitride and silicon carbide, and for the combustor liner silicon carbide as well as two continuous fiber reinforced ceramic composites, one with a silicon carbide matrix and another with an oxide matrix. This paper outlines the approach, conceptual component design, and materials selection for the program.

Reliability of a Conceptual Ceramic Gas Turbine Component Subjected to Static and Transient Thermomechanical Loading

1997 ◽  
Author(s):  
Paul S. DiMascio ◽  
Robert M. Orenstein ◽  
Harindra Rajiyah
Keyword(s):  
Silicon Nitride ◽  
Gas Turbine ◽  
Gas Turbines ◽  
Ceramic Materials ◽  
Combustion Products ◽  
Tensile Creep ◽  
Creep Model ◽  
Gas Combustion ◽  
Component Reliability ◽  
Reliability Models

A three year program to evaluate the feasibility of using monolithic silicon nitride ceramic components in gas turbines was conducted. The use of ceramic materials may enable design of turbine components which operate at higher gas temperatures and/or require less cooling air than their metal counterparts. The feasibility evaluation consisted of three tasks: 1) Expand the material properties database for candidate silicon nitride materials, 2) Demonstrate the ability to predict ceramic reliability and life using a conceptual component model and 3) Evaluate the effect of proof testing on conceptual component reliability. The overall feasibility goal was to determine whether established life and reliability targets could be satisfied for the conceptual ceramic component having properties of an available material. Fast and delayed fracture reliability models were developed and validated via thermal shock and tensile experiments. A creep model was developed using tensile creep data. The effect of oxidation was empirically evaluated using four-point flexure samples exposed to flowing natural gas combustion products. The reliability- and life-limiting failure mechanisms were characterized in terms of temperature, stress and probability of component failure. Conservative limits for design of silicon nitride gas turbine components were established.

Impact of Ceramic Components in Gas Turbines for Industrial Cogeneration

1992 ◽  
Author(s):  
D. Anson ◽  
W. J. Sheppard ◽  
W. P. Parks
Keyword(s):  
Gas Turbine ◽  
Gas Turbines ◽  
Ceramic Materials ◽  
Department Of Energy ◽  
Liquid Fuels ◽  
Gas Treatment ◽  
Ceramic Components ◽  
Industrial Gas Turbines ◽  
Industrial Gas Turbine ◽  
The U.S

A development thrust for the adoption of ceramic components in industrial gas turbines, now being sponsored by the U.S. Department of Energy, may have a considerable impact on the growth rate and ultimate capacity of the cogeneration sector. The economic justification for cogeneration rests on the ability to undercut the cost of purchased power after taking credit for the useful heat recovery, and it is frequently marginal after consideration of fuel, maintenance, and pollution control devices. After reviewing briefly the factors contributing to the economic viability of cogeneration systems, this paper presents arguments to show how the use of ceramics in industrial gas turbine can be instrumental in reducing installation and operating costs. Improved gas turbines based on ceramic materials technology also will provides means for meeting environmental protection requirements without the use of back end flue gas treatment, and will be able to utilize byproduct industrial gaseous and liquid fuels more effectively. These improvements can increase substantially the economic return from cogeneration systems, and are expected to result in increased cogeneration capacity and a sustained market for industrial gas turbines. Predictions are made of the size of the U.S. industrial gas turbine cogeneration market. The annual fuel savings resulting from displacement of utility generation capacity could amount to 2 × 1017 joules (2 × 1014 Btu’s) by the year 2010.

Reliability of a Conceptual Ceramic Gas Turbine Component Subjected to Static and Transient Thermomechanical Loading

1998 ◽  
Vol 120 (2) ◽  
pp. 263-270 ◽  
Author(s):  
P. S. DiMascio ◽  
R. M. Orenstein ◽  
H. Rajiyah
Keyword(s):  
Silicon Nitride ◽  
Gas Turbine ◽  
Gas Turbines ◽  
Ceramic Materials ◽  
Combustion Products ◽  
Tensile Creep ◽  
Creep Model ◽  
Gas Combustion ◽  
Component Reliability ◽  
Reliability Models

A three year program to evaluate the feasibility of using monolithic silicon nitride ceramic components in gas turbines was conducted. The use of ceramic materials may enable design of turbine components which operate at higher gas temperatures and/or require less cooling air than their metal counterparts. The feasibility evaluation consisted of the following three tasks: (1) expand the materials properties database for candidate silicon nitride materials; (2) demonstrate the ability to predict ceramic reliability and life using a conceptual component model; and (3) evaluate the effect of proof testing on conceptual component reliability. The overall feasibility goal was to determine whether established life and reliability targets could be satisfied for the conceptual ceramic component having properties of an available material. Fast and delayed fracture reliability models were developed and validated via thermal shock and tensile experiments. A creep model was developed using tensile creep data. The effect of oxidation was empirically evaluated using four-point flexure samples exposed to flowing natural gas combustion products. The reliability and life-limiting failure mechanisms were characterized in terms of temperatures, stress, and probability of component failure. Conservative limits for design of silicon nitride gas turbine components were established.

Development and Fabrication of Silicon Nitride Components for Ceramic Gas Turbine

1997 ◽  
Author(s):  
Keisuke Makino ◽  
Ken-Ichi Mizuno ◽  
Toru Shimamori
Keyword(s):  
High Temperature ◽  
Silicon Nitride ◽  
Gas Turbine ◽  
Gas Turbines ◽  
Turbine Blades ◽  
High Strength ◽  
Inlet Temperature ◽  
Turbine Inlet Temperature ◽  
Spark Plug ◽  
Power Turbine

NGK Spark Plug Co., Ltd. has been developing various silicon nitride materials, and the technology for fabricating components for ceramic gas turbines (CGT) using theses materials. We are supplying silicon nitride material components for the project to develop 300 kW class CGT for co-generation in Japan. EC-152 was developed for components that require high strength at high temperature, such as turbine blades and turbine nozzles. In order to adapt the increasing of the turbine inlet temperature (TIT) up to 1,350 °C in accordance with the project goals, we developed two silicon nitride materials with further unproved properties: ST-1 and ST-2. ST-1 has a higher strength than EC-152 and is suitable for first stage turbine blades and power turbine blades. ST-2 has higher oxidation resistance than EC-152 and is suitable for power turbine nozzles. In this paper, we report on the properties of these materials, and present the results of evaluations of these materials when they are actually used for CGT components such as first stage turbine blades and power turbine nozzles.

A Comparison Between ORC and Supercritical CO2 Bottoming Cycles For Energy Recovery From Industrial Gas Turbines Exhaust Gas

2021 ◽  
Author(s):  
M. A. Ancona ◽  
M. Bianchi ◽  
L. Branchini ◽  
A. De Pascale ◽  
F. Melino ◽  
...  
Keyword(s):  
Gas Turbine ◽  
Thermal Efficiency ◽  
Gas Turbines ◽  
Supercritical Co2 ◽  
Energy Demand ◽  
Oil And Gas ◽  
Gas Production ◽  
Medium Size ◽  
Oil And Gas Production ◽  
Industrial Gas Turbines

Abstract Gas turbines are often employed in the industrial field, especially for remote generation, typically required by oil and gas production and transport facilities. The huge amount of discharged heat could be profitably recovered in bottoming cycles, producing electric power to help satisfying the onerous on-site energy demand. The present work aims at systematically evaluating thermodynamic performance of ORC and supercritical CO2 energy systems as bottomer cycles of different small/medium size industrial gas turbine models, with different power rating. The Thermoflex software, providing the GT PRO gas turbine library, has been used to model the machines performance. ORC and CO2 systems specifics have been chosen in line with industrial products, experience and technological limits. In the case of pure electric production, the results highlight that the ORC configuration shows the highest plant net electric efficiency. The average increment in the overall net electric efficiency is promising for both the configurations (7 and 11 percentage points, respectively if considering supercritical CO2 or ORC as bottoming solution). Concerning the cogenerative performance, the CO2 system exhibits at the same time higher electric efficiency and thermal efficiency, if compared to ORC system, being equal the installed topper gas turbine model. The ORC scarce performance is due to the high condensing pressure, imposed by the temperature required by the thermal user. CO2 configuration presents instead very good cogenerative performance with thermal efficiency comprehended between 35 % and 46 % and the PES value range between 10 % and 22 %. Finally, analyzing the relationship between capital cost and components size, it is estimated that the ORC configuration could introduce an economical saving with respect to the CO2 configuration.

Development and Integration of the Dual Fuel Combustion System for the MGT Gas Turbine Family

2021 ◽  
Author(s):  
Bernhard Ćosić ◽  
Frank Reiss ◽  
Marc Blümer ◽  
Christian Frekers ◽  
Franklin Genin ◽  
...  
Keyword(s):  
Gas Turbine ◽  
Distribution System ◽  
Gas Turbines ◽  
Liquid Fuel ◽  
Fuel Injection ◽  
Liquid Fuels ◽  
Dual Fuel ◽  
Gaseous Fuels ◽  
Supply And Distribution ◽  
Industrial Gas Turbines

Abstract Industrial gas turbines like the MGT6000 are often operated as power supply or as mechanical drives. In these applications, liquid fuels like 'Diesel Fuel No.2' can be used either as main fuel or as backup fuel if natural gas is not reliably available. The MAN Gas Turbines (MGT) operate with the Advanced Can Combustion (ACC) system, which is capable of ultra-low NOx emissions for gaseous fuels. This system has been further developed to provide dry dual fuel capability. In the present paper, we describe the design and detailed experimental validation process of the liquid fuel injection, and its integration into the gas turbine package. A central lance with an integrated two-stage nozzle is employed as a liquid pilot stage, enabling ignition and start-up of the engine on liquid fuel only. The pilot stage is continuously operated, whereas the bulk of the liquid fuel is injected through the premixed combustor stage. The premixed stage comprises a set of four decentralized nozzles based on fluidic oscillator atomizers, wherein atomization of the liquid fuel is achieved through self-induced oscillations. We present results illustrating the spray, hydrodynamic, and emission performance of the injectors. Extensive testing of the burner at atmospheric and full load high-pressure conditions has been performed, before verification within full engine tests. We show the design of the fuel supply and distribution system. Finally, we discuss the integration of the dual fuel system into the standard gas turbine package of the MGT6000.

Pressure Gain Combustion Application to Marine and Industrial Gas Turbines

2012 ◽  
Author(s):  
Philip H. Snyder ◽  
M. Razi Nalim
Keyword(s):  
Gas Turbine ◽  
Gas Turbines ◽  
Technology Development ◽  
Innovative Technology ◽  
Turbine Engines ◽  
Specific Work ◽  
Compression Pressure ◽  
Pressure Gain Combustion ◽  
Industrial Gas Turbines ◽  
Incremental Improvement

Renewed interest in pressure gain combustion applied as a replacement of conventional combustors within gas turbine engines creates the potential for greatly increased capability engines in the marine power market segment. A limited analysis has been conducted to estimate the degree of improvements possible in engine thermal efficiency and specific work for a type of wave rotor device utilizing these principles. The analysis considers a realistic level of component losses. The features of this innovative technology are compared with those of more common incremental improvement types of technology for the purpose of assessing potentials for initial market entry within the marine gas turbine market. Both recuperation and non-recuperation cycles are analyzed. Specific fuel consumption improvements in excess of 35% over those of a Brayton cycle are indicated. The technology exhibits the greatest percentage potential in improving efficiency for engines utilizing relatively low or moderate mechanical compression pressure ratios. Specific work increases are indicated to be of an equally dramatic magnitude. The advantages of the pressure gain combustion approach are reviewed as well as its technology development status.

Strength Design and Reliability Evaluation of a Hybrid Ceramic Stator Vane for Industrial Gas Turbines

1995 ◽  
Vol 117 (2) ◽  
pp. 245-250 ◽  
Author(s):  
K. Nakakado ◽  
T. Machida ◽  
H. Miyata ◽  
T. Hisamatsu ◽  
N. Mori ◽  
...  
Keyword(s):  
Gas Turbine ◽  
Gas Turbines ◽  
Power Plants ◽  
Metal Structure ◽  
Reliability Evaluation ◽  
Combustion Gas ◽  
Strength Design ◽  
Stator Vane ◽  
Industrial Gas Turbines ◽  
Hybrid Ceramic

Employing ceramic materials for the critical components of industrial gas turbines is anticipated to improve the thermal efficiency of power plants. We developed a first-stage stator vane for a 1300°C class, 20-MW industrial gas turbine. This stator vane has a hybrid ceramic/metal structure, to increase the strength reliability of brittle ceramic parts, and to reduce the amount of cooling air needed for metal parts as well. The strength design results of a ceramic main part are described. Strength reliability evaluation results are also provided based on a cascade test using combustion gas under actual gas turbine running conditions.

Support Vibration Diagnostics and Limits in Gas Turbines

2016 ◽  
Author(s):  
Marcin Bielecki ◽  
Salvatore Costagliola ◽  
Piotr Gebalski
Keyword(s):  
Gas Turbine ◽  
Test Data ◽  
Gas Turbines ◽  
Failure Modes ◽  
Real Life ◽  
Reliability Function ◽  
Vibration Diagnostics ◽  
Real Life Data ◽  
Industrial Gas Turbines ◽  
Harmful Effects

The paper deliberates vibration limits for non-rotating parts in application to industrial gas turbines. As a rule such limits follow ISO 10816-4 or API616, although in field operation it is not well known relationship between these limits and failure modes. In many situations, the reliability function is not well-defined, and more comprehensive methods of determining the harmful effects of support vibrations are desirable. In the first part, the undertaken approach and the results are illustrated based on the field and theoretical experience of the authors about the failure modes related to alarm level of vibrations. Here several failure modes and diagnostics observations are illustrated with the examples of real-life data. In the second part, a statistical approach based on correlation of support vs. shaft vibrations (velocity / displacement) is demonstrated in order to assess the risk of the bearing rub. The test data for few gas turbine models produced by General Electric Oil & Gas are statistically evaluated and allow to draw an experimentally based transfer function between vibrations recorded by non-contact and seismic probes. Then the vibration limit with objectives like bearing rub is scrutinized with aid of probabilistic tools. In the third part, the attention is given to a few examples of the support vibrations — among other gas turbine with rotors supported on flexible pedestals and baseplate. Here there is determined a transfer coefficient between baseplate and bearing vibrations for specific foundation configurations. Based on the test data screening as well as analysis and case studies thereof, the conclusions about more specific vibration limits in relation to the failure modes are drawn.

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