scholarly journals Facilities for Automotive Gas Turbine Ceramic Components

1997 ◽  
Author(s):  
Patrick Avran ◽  
Alain Leclair ◽  
Gérard Payen
Keyword(s):  
Steady State ◽  
Heat Exchanger ◽  
Combustion Chamber ◽  
Gas Turbine ◽  
Test Bench ◽  
Test Facility ◽  
Transient Conditions ◽  
Rotating Speed ◽  
Ceramic Components ◽  
Catalytic Combustor

The first part of this paper describes the test facility to characterize the catalytic combustor. The combustion chamber is a LPP combustor (Lean Premixed Prevaporised), made of preheater, premix duct, catalytic part and after burner. Each component will be validated separately for the required conditions (steady state and transient conditions). All the measurements and data acquisition are described. The second part deals with the test facility for the hot spin test of the ceramic wheel. The base of the test bench is a modified turbocharger (maximum rotating speed: 125000 r.p.m.). With this configuration it will be possible to test the ceramic radial wheel within the AGATA specifications; in this case the compressor is used like a brake. The last part is devoted to two ceramic heat exchanger test rigs: the first rig is to evaluate the themomechanical stresses on the samples; the second rig to assess the performance compared to the AGATA specifications and to duplicate the transient and thermal shock conditions. In this program the heat exchanger is fixed.

scholarly journals Status of the European Gas Turbine Program — AGATA

1998 ◽  
Author(s):  
Rolf Gabrielsson ◽  
Robert Lundberg ◽  
Patrick Avran
Keyword(s):  
Steady State ◽  
Heat Exchanger ◽  
Gas Turbine ◽  
Hybrid Electric Vehicle ◽  
High Efficiency ◽  
Full Scale ◽  
Inlet Temperature ◽  
Turbine Wheel ◽  
Ceramic Components ◽  
Catalytic Combustor

The European Gas Turbine Program “AGATA” which started in 1993 now has reached its verification phase. The objective of the program is to develop three critical ceramic components aimed at a 60 kW turbogenerator in a hybrid electric vehicle — a catalytic combustor, a radial turbine wheel and a static heat exchanger. The AGATA partners represent car manufacturers as well as companies and research institutes in the turbine, catalyst and ceramic material fields in both France and Sweden. Each of the three ceramic components is validated separately during steady state and transient conditions in separate test rigs at ONERA, France, where the high pressure/temperature conditions can be achieved. A separate test rig for laser measurements downstream of the catalytic combustor is set up at Volvo Aero Turbines, Sweden. The catalytic combustor design which includes preheater, premix duct and catalytic section operates at temperatures up to 1623 K. Due to this high temperature, the catalyst initially has undergone pilot tests including ageing, activity and strength tests. The premix duct flow field also has been evaluated by LDV measurements. The full scale combustion tests are ongoing. The turbine wheel design is completed and the first wheels have been manufactured. FEM calculations have indicated that stress levels are below 300 MPa. The material used is a silicon nitride manufactured by AC Cerama (Grade CSN 101). Cold spin tests with complete wheels have started. Hot spin tests at TTT 1623 K will be performed in a modified turbo charger rig and are expected to start in February 1998. The heat exchanger is of a high efficiency plate recuperator design using Cordierite material. Hot side inlet temperature is 1286 K. Therefore initial tests with test samples have been run to evaluate the thermomechanical properties at high temperatures. Tests are now proceeding with a 1/4 scale recuperator prototype to evaluate performance at steady state conditions. Manufacturing of the full scale heat exchanger is now in progress.

scholarly journals Progress on the AGATA Project: A European Ceramic Gas Turbine for Hybrid Vehicles

1995 ◽  
Author(s):  
Robert Lundberg ◽  
Rolf Gabrielsson
Keyword(s):  
Heat Exchanger ◽  
Gas Turbine ◽  
Hybrid Electric Vehicle ◽  
Full Scale ◽  
Turbine Wheel ◽  
Ceramic Components ◽  
Final Design ◽  
Ceramic Recuperator ◽  
Catalytic Combustor ◽  
Ceramic Honeycomb

The European EUREKA project EU 209 or AGATA - Advanced Gas Turbine for Automobiles is a program dedicated to the development of three critical ceramic components; i. catalytic combustor, ii. radial turbine wheel, iii. static heat exchanger, designed for a 60 kW turbogenerator hybrid electric vehicle. The objective is to develop and test the three components as a full scale feasibility study with an industrial perspective. The AGATA partners represent car manufacturers as well as companies and research institutes in the turbine, catalyst and ceramic material fields in France and Sweden. The program has been running since early 1993 with good progress in all three sub-projects. The turbine wheel design is now completed. FEM calculations indicate that the maximum stress occur during cold start and is below 300 MPa. Extensive mechanical testing of the Si3N4 materials from AC Cerama and C&C has been performed. The catalytic combustor operates uncooled at 1350°C. This means a severe environment for both the active catalyst and the ceramic honeycomb substrates. Catalysts with high activity even after aging at 1350°C have been developed. Ceramic honeycomb substrates that survive this temperature have also been defined. The catalytic combustor final design is ready and the configurations which will be full scale tested have been selected. The heat exchanger will be a ceramic recuperator with 90 % efficiency. Both a tube concept and a plate concept have been studied. The plate concept has been chosen for further work. Sub-scale plate recuperators made of either cordierite or SiC have been manufactured by C&C and tested.

scholarly journals AGATA: A European Ceramic Gas Turbine for Hybrid Vehicles

1994 ◽  
Author(s):  
Robert Lundberg
Keyword(s):  
Heat Exchanger ◽  
Ceramic Material ◽  
Gas Turbine ◽  
Hybrid Electric Vehicle ◽  
Hybrid Vehicles ◽  
Turbine Wheel ◽  
Research Institutes ◽  
Radial Turbine ◽  
Ceramic Components ◽  
Catalytic Combustor

The European EUREKA project EU 209 or AGATA - Advanced Gas Turbine for Automobiles is a program dedicated to the development of three critical ceramic components; i. catalytic combustor, ii. radial turbine wheel, iii. static heat exchanger, designed for a 60 kW turbogenerator for a hybrid electric vehicle. The objective is to develop and test the three components as a full scale feasibility study with an industrial perspective. The AGATA partners represent car manufacturers as well as companies and research institutes in the turbine, catalyst and ceramic material fields in France and Sweden.

scholarly journals Gas turbine power calculation method of turboshaft based on simulation and performance model

2018 ◽  
Vol 189 ◽  
pp. 02003 ◽  
Author(s):  
Heng Wu ◽  
Shufan Zhao ◽  
Jijun Zhang ◽  
Bo Sun ◽  
Hanqiang Song
Keyword(s):  
Steady State ◽  
Combustion Chamber ◽  
Gas Turbine ◽  
Calculation Method ◽  
Performance Model ◽  
Power Calculation ◽  
Outlet Temperature ◽  
Acceptance Test ◽  
Test Drive ◽  
Turboshaft Engine

Gas turbine power of turboshaft engine cannot be measured, a total of five typical steady state point test data from the ground slow state to the maximum state were selected according to the factory acceptance test drive of a certain type of carrier-based helicopter turboshaft engine. Combustion chamber three-dimensional simulation model was established to carry on simulation analysis of different typical steady state combustion process. The simulated combustion chamber exit section parameters are input into the established gas turbine isentropic adiabatic aerodynamic calculation model to obtain the gas turbine power and outlet temperature. Select five typical steady state points of five sets of turboshaft engines on the same type to repeat the above calculation process, and compare the calculated value of gas turbine outlet temperature with the acceptance test values, it is found that the error values are all within 5%, and the effectiveness and accuracy of the gas turbine power calculation method are verified.

scholarly journals Design and Experimental Validation of a Supersonic Concentric Micro Gas Turbine

2015 ◽  
Vol 138 (2) ◽  
Author(s):  
Gabriel Vézina ◽  
Hugo Fortier-Topping ◽  
François Bolduc-Teasdale ◽  
David Rancourt ◽  
Mathieu Picard ◽  
...  
Keyword(s):  
Steady State ◽  
Combustion Chamber ◽  
Gas Turbine ◽  
Structural Model ◽  
Structural Integrity ◽  
Turbine Blades ◽  
External Diameter ◽  
Impulse Turbine ◽  
Micro Gas Turbine ◽  
Steady State Operation

This paper presents the design and experimental results of a new micro gas turbine architecture exploiting counterflow within a single supersonic rotor. This new architecture, called the supersonic rim-rotor gas turbine (SRGT), uses a single rotating assembly incorporating a central hub, a supersonic turbine rotor, a supersonic compressor rotor, and a rim-rotor. This SRGT architecture can potentially increase engine power density while significantly reducing manufacturing costs. The paper presents the preliminary design of a 5 kW SRGT prototype having an external diameter of 72.5 mm and rotational speed of 125,000 rpm. The proposed aerodynamic design comprises a single stage supersonic axial compressor, with a normal shock in the stator, and a supersonic impulse turbine. A pressure ratio of 2.75 with a mass flow rate of 130 g/s is predicted using a 1D aerodynamic model in steady state. The proposed combustion chamber uses an annular reverse-flow configuration, using hydrogen as fuel. The analytical design of the combustion chamber is based on a 0D model with three zones (primary, secondary, and dilution), and computational fluid dynamics (CFD) simulations are used to validate the analytical model. The proposed structural design incorporates a unidirectional carbon-fiber-reinforced polymer rim-rotor, and titanium alloy is used for the other rotating components. An analytical structural model and numerical validation predict structural integrity of the engine at steady-state operation up to 1000 K for the turbine blades. Experimentation has resulted in the overall engine performance evaluation. Experimentation also demonstrated a stable hydrogen flame in the combustion chamber and structural integrity of the engine for at least 30 s of steady-state operation at 1000 K.

Field Demonstration of a 1.5 MW Industrial Gas Turbine With a Low Emissions Catalytic Combustion System

2000 ◽  
Vol 123 (3) ◽  
pp. 550-556 ◽  
Author(s):  
D. Y. Yee ◽  
K. Lundberg ◽  
C. K. Weakley
Keyword(s):  
Gas Turbine ◽  
Engine Performance ◽  
Silicon Valley ◽  
Electric Utility ◽  
Catalyst Design ◽  
Test Facility ◽  
Load Range ◽  
Coated Metal ◽  
Utility Grid ◽  
Catalytic Combustor

An electric utility grid connected test facility has been established at Silicon Valley Power (SVP) in Santa Clara, California to validate the reliability, availability, maintainability, and durability (RAMD) of a commercial-ready catalytic combustor system (XONON). Installed in the Silicon Valley Test Facility (SVTF) is a 1.5MW Kawasaki MIA-13A gas turbine fitted with a catalytic combustor. The gas turbine package is controlled by a Woodward MicroNet control system. The combustor utilizes a two stage lean premix preburner system to obtain the required catalyst inlet temperatures and low NOx over the operating load range. The fuel-air mixer incorporates counter rotating swirlers to mix the catalyst fuel and air to achieve the desired uniformity. The patented catalyst design is composed of specially coated metal foils. Overall engine performance was measured and the emissions were continuously monitored. As of Dec. 1999, emissions of NOx<2.5 ppmv and CO and UHC<6 ppmv have been maintained at 100 percent load for over 3700 hours of operation on the utility grid. The turbine continues to operated 24 hours a day, 7 days per week with commercial levels of unit availability.

Experimental and Theoretical Investigation of Twin-Entry Radial Inflow Gas Turbine With Unsymmetrical Volute Under Full and Partial Admission Conditions

2007 ◽  
Author(s):  
Habib Aghaali ◽  
Ali Hajilouy-Benisi
Keyword(s):  
Experimental Investigation ◽  
Steady State ◽  
Gas Turbine ◽  
Performance Prediction ◽  
Test Facility ◽  
Maximum Efficiency ◽  
Special Test ◽  
One Dimensional ◽  
Wide Range ◽  
Partial Admission

In this paper the performance characteristics of turbocharger twin-entry radial inflow gas turbine with unsymmetrical volute and rotor tip diameter of 73.6 mm in steady state and under full and partial admission conditions are investigated. The employed method is based on one dimensional performance prediction which is developed for partial admission conditions. Furthermore this method is developed for unsymmetrical volute of the turbine considering flow specifications. Experimental investigation of the research carried out on special test facility under full and partial admission conditions for a wide range of speed. The comparison of experimental and modeling results shows good agreements. Interestingly, the turbine maximum efficiency occurs when the shroud side inlet mass flow is higher than that of hub side.

scholarly journals A Unique Small Gas Turbine Test Facility for Low-Cost Investigations of Ceramic Rotor Materials and Thermal Barrier Coatings

1998 ◽  
Author(s):  
Björn Schenk ◽  
Torsten Eggert ◽  
Helmut Pucher
Keyword(s):  
Combustion Chamber ◽  
Gas Turbine ◽  
Gas Turbines ◽  
Low Cost ◽  
Temperature Gradients ◽  
Test Facility ◽  
Small Scale ◽  
Transient Temperature ◽  
Turbine Inlet ◽  
Turbine Rotors

The paper describes a test facility for small-scale gas turbines, which basically has been designed and assembled at the Institute of Combustion Engines of the Technical University Berlin. The facility exposes ceramic rotor components to the most significant loads that occur during real gas turbine operation in a clearly predefined manner (high circumferential velocities and highest turbine inlet temperatures). The test facility allows the investigation of bladed radial inflow turbine rotors, as well as — in a preceding step — geometrically simplified ceramic or coated metallic rotors. A newly designed, ceramically lined, variable geometry combustion chamber allows turbine inlet temperatures up to 1450°C (2640 F). A fast thermal shock unit (switching time of about 1s), which is integrated into the test facility between the combustion chamber and the turbine scroll, can be used to create, for example, severe transient temperature gradients within the rotor components to simulate gas turbine trip conditions. In order to generate steady state temperature gradients, especially during disk testing, the rotor components can be subjected to an impingement cooling of the rotor back face (uncoated in case of TBC-testing). The test facility is additionally equipped with a non-contact transient temperature measurement system (turbine radiation pyrometry) to determine the test rotor surface temperature distribution during operation. Apart from the possibilities of basic rotor material investigations, the test facility can also be used to automatically generate compressor and turbine performance characteristics maps. The latter might be used to assess the aerodynamic performance of bladed ceramic radial inflow or mixed flow turbine rotors with respect to manufacturing tolerances due to near-net-shape forming processes (e.g., gelcasting or injection molding).

HIPed Silicon Nitride Components for AGATA — A European Gas Turbine for Hybrid Vehicles

1997 ◽  
Author(s):  
Robert Lundberg
Keyword(s):  
Silicon Nitride ◽  
Gas Turbine ◽  
Hybrid Electric Vehicle ◽  
High Efficiency ◽  
Turbine Wheel ◽  
Joint Project ◽  
Radial Turbine ◽  
Nitride Ceramics ◽  
Ceramic Components ◽  
Catalytic Combustor

The European EUREKA project, EU 209, otherwise known as AGATA (Advanced Gas Turbine for Automobiles), is a programme dedicated to the development of three critical ceramic components — a catalytic combustor, a radial turbine wheel and a static heat exchanger — for a 60 kW turbogenerator in an hybrid electric vehicle. These three components, which are of critical importance to the achievement of low emissions and high efficiency, have been designed and developed and will be manufactured and tested as part of a full scale feasibility study. AGATA is a joint project conducted by eight commercial companies and four research institutes in France and Sweden. Silicon nitride ceramics play an important role both in the development of the catalytic combustor and for the radial turbine wheel. This paper outlines the main results of the AGATA project with special emphasis to the development of HIPed Si3N4 combustor and turbine wheel. AC Cerama has developed a HIPed Si3N4 material designated CSN 101. This material has been selected for the catalytic combustor afterburner as well as for the radial turbine wheel. Mechanical properties of the CSN 101 Si3N4 have been found to be at the level of the best available high temperature Si3N4 materials. A new glass encapsulation technique using an interlayer between the glass and the silicon nitride has been shown to give material with excellent strength and creep resistance with as-HIPed surface finish.

Fuel Cell Gas Turbine Hybrid Simulation Facility Design

2002 ◽  
Author(s):  
David Tucker ◽  
Eric Liese ◽  
John VanOsdol ◽  
Larry Lawson ◽  
Randall S. Gemmen
Keyword(s):  
Power Generation ◽  
Steady State ◽  
Fuel Cell ◽  
Gas Turbine ◽  
Test Facility ◽  
System Response ◽  
Facility Design ◽  
Transient Event ◽  
Load Following ◽  
Transient Events

Fuel cell hybrid power systems have potential for the highest electrical power generation efficiency. Fuel cell gas turbine hybrid systems are currently under development as the first step in commercializing this technology. The dynamic interdependencies resulting from the integration of these two power generation technologies is not well understood. Unexpected complications can arise in the operation of an integrated system, especially during startup and transient events. Fuel cell gas turbine systems designed to operate under steady state conditions have limitations in studying the dynamics of a transient event without risk to the more fragile components of the system. A 250kW experimental fuel cell gas turbine system test facility has been designed at the National Energy Technology Laboratory (NETL), U.S. Department of Energy to examine the effects of transient events on the dynamics of these systems. The test facility will be used to evaluate control strategies for improving system response to transient events and load following. A fuel cell simulator, consisting of a natural gas burner controlled by a real time fuel cell model, will be integrated into the system in place of a real solid oxide fuel cell. The use of a fuel cell simulator in the initial phases allows for the exploration of transient events without risk of destroying an actual fuel cell. Fuel cell models and hybrid system models developed at NETL have played an important role in guiding the design of facility equipment and experimental research planning. Results of certain case studies using these models are discussed. Test scenarios were analyzed for potential thermal and mechanical impact on fuel cell, heat exchanger and gas turbine components. Temperature and pressure drop calculations were performed to determine the maximum impact on system components and design. Required turbine modifications were designed and tested for functionality. The resulting facility design will allow for examination of startup, shut down, loss of load to the fuel cell during steady state operations, loss of load to the turbine during steady state operations and load following.

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