«WE'LL HAVE GREAT FUTURE TOGETHER WITH AVIADVIGATEL»
GURGEN OLKHOVSKY
General Director
of All-Russian Heat Engineering Institute OJSC.
The history of the Perm design bureau has many glorious pages. Nowadays the Russian civil aircraft use mostly Perm engines. Perm engineers began to work at on-ground application of their engines rather recently: about 15 years ago. They arranged this very thoroughly: they examined what consumers needed, what they demanded from gas turbines designed for gas compressor plants and power gensets; created effective organizational structures which provided design, manufacturing and maintenance of industrial gas turbines; developed a wide range of engines rated at 2.5 ... 25 MW, organized competent marketing, deliveries and service, and, as a result, have obtained a prosperous market on which they have gained stable position.
The All-Russian Heat Engineering Institute is working together with Aviadvigatel in different areas. We carried out the certification of their power gas turbines, developed the power performance of GTU-6P gas turbines used at Ivanovo cogeneration heat and power plant TEC-1, helped to design powerful 180 MW gas turbines for gensets.
At the moment we have two interesting projects: high-efficiency combined cycle plant (CCP) and experimental-industrial CCP with coal gasification. Both projects imply application of 16 MW gas turbines developed by Aviadvigatel.
The CCP general parameters at ambient air temperature of 0 ºÑ are stated in the Table 1, and the CCP design is presented in Fig. 1.
In addition to GTE-16PA the CCP includes a drum-type recovery boiler with two steam circuits of high and low pressure. The condensate is heated before deaeration in a gas heater, and the deaeration itself is carried out in the low pressure drum. The condensate temperature at the heater inlet is maintained at the rate of 60 ºÑ by means of recirculation.
| Table 1. FEATURES AND PARAMETERS OF THE HIGH-EFFICIENCY CCP |
| Features | CCP configuration and operational conditions | |||
| Heat-recovery | Fuel fired before the boiler | |||
| GAS TURBINE | ||||
| - Gas turbine power, MW | 15.5 | 15.5 | ||
| - Gas temperature at boiler inlet, ºÑ | 450.1 | 600 | ||
| - Gas flow, kg/sec | 57 | 57 | ||
| - Gas turbine efficiency, % | 35.2 | 35.2 | ||
| BOILER | ||||
| - High pressure (HP) steam flow, t/hour | 19.57 | 31.68 | ||
| - HP steam pressure, MPa | 4.0 | 9.0 | ||
| - HP steam temperature, ºÑ | 435 | 540 | ||
| - Low pressure (LP) steam flow, t/hour | 5.195 | |||
| - LP steam pressure, MPa | 0.45 | 0.8 | ||
| - LP steam temperature, ºÑ | 200 | 210 | ||
| - Fuel consumption before the boiler, kg/sec | - | 0.203 | ||
| - Outgoing gas temperature, ºÑ | 127.7 | 110.9 | ||
| STEAM TURBINE | ||||
| - HP steam temperature, ºÑ | 430 | 535 | ||
| - LP steam pressure, MPa | 0.43 | 0.76 | ||
| - Condenser | Condens. | Heat-extr. | Condens. | Heat-extr. |
| - Steam flow, t/hour | 23.0 | 2.3 | 34.0 | 3.9 |
| - Temperature, ºÑ | 24.1 | 23 | 25.5 | 23.2 |
| - Pressure, kPa | 3.04 | 2.75 | 3.24 | 2.84 |
| - Electric power, MW | 5.26 | 3.05 | 9.66 | 5.91 |
| - Heat generation, Gcal/hour | - | 10.7 | - | 15.8 |
| COMBINED CYCLE PLANT | ||||
| - CCP power, MW | 20.76 | 18.55 | 25.16 | 21.41 |
| - Standard fuel rate for electricity g/kW-hour | 260.7 | 205.2 | 263.9 | 199.4 |
| - CCP electrical efficiency, % | 47.1 | 42 | 46.6 | 39.6 |
| - Fuel heat utilization factor, % | 47.1 | 70.4 | 46.6 | 73.6 |
| - Electricity / heat ratio | - | 1.494 | - | 1.165 |
Two stages of additional fuel burning are provided in the recovery boiler. The first stage is at the boiler inlet to increase, if necessary, the steam capacity, steam parameters and the steam turbine power (columns 2 and 4 of the Table 1). The second is at the condensate gas heater inlet to increase heat load during cold seasons.
The electric efficiency of the combined cycle plant will be very high: 46.5...47 % without heat generation and 40...42 % at full heat load and fuel utilization rate of 70...74 %.
Such combined cycle plants are attractive for power and heat supply to small and average towns and large urban areas. They will find a wide application in gas-supplied areas of the country.
In the areas where natural gas application is impossible or expensive it is possible to integrate a similar CCP combined with coal gasification system, as shown in Fig. 2.
The coal for gasification is treated in the system of fuel preparation, after which the coal lump part is delivered to gas generator through a lock and the dust is delivered by blast.
The coal gasification is carried out under pressure by the air blast with slag-tap removal in hearth gas generator. The coal lumps are gasified in a layer where the hot air with the coal dust is blown through tuyers, and that provides the high-temperature combustion source and the steam necessary for the process temperature regulation in the bottom part of the gas generator. The gas generated in the combustion source passes through a layer of fuel in which CO2 is reduced to CO, and the gas is enriched by the coal-volatile matter.
After the gas generator the unstripped gas is cooled in a special heat exchanger approximately from 800 up to 500 ºÑ by the steam, purged in a whirler from coarse particles, which come back in the gas generator by blasting, and in recyclable gauze filter - from fine dust.
Then the gas is delivered to the desulfurization system, consisting of two reactors alternately connected to the generator gas circuit, where the hydrogen sulphide adsorption is carried out in the layer of natural ferrimanganese compounds.
The purged gas with temperature of about 500 ºÑ is delivered to GTU-16 PER gas turbine reconstructed especially for operation on the low-calorific generator gas. Its electric power in the experimental-industrial plant will make 16.5 MW.
The major part of air necessary for gasification is collected at the gas turbine compressor outlet, in addition the air from atmosphere is delivered by a special compressor in which the air is compressed approximately up to 2.0 MPa with intercooling after the 1st and 2nd compression stages. After mixing with the air collected at gas turbine compressor outlet, the total flow of blast air is compressed up to 2.7 MPa and is delivered to the gas generator (Fig. 2).
After the reconstruction for integration with the coal gasification system GTU-16PER gas turbine is still able to operate normally on natural gas with the same economic and operational performance as a standard gas turbine of such a type. Their general parameters values are also stated in the Table 2.
| Table 2. PARAMETERS OF THE COMBINED CYCLE PLANT, RUNNING ON VARIOUS KINDS OF FUEL |
| Features | Fuel | |
| Coal | Natural gas | |
| - Gas turbine electrical power, MW | 16.5 | 16.0 |
| - Gas turbine efficiency, % | 33.1 | 33.9 |
| - Gas temperature at turbine outlet, ºÑ | 482 | 485 |
| - Gas temperature at turbine inlet, ºÑ | 1 166 | 1 143 |
| - Gas flow at turbine outlet, kg/sec | 59.6 | 56.7 |
| - Pressure ratio | 20.2 | 19.6 |
| CONDENSATION MODE | ||
| - Fuel consumption in the combustion chamber, kg/sec | 8.06 | 1.0 |
| - Raw coal consumption, kg/sec | 2.6 | - |
| - Heat delivered with coal, MW | 61.6 | - |
| - Steam turbine power, MW | 6.7 | 5.0 |
| - CCP power, MW | 23.2 | 21.0 |
| - CCP efficiency, % | 37.6 | 44.5 |
| HEAT-EXTRACTION MODE | ||
| - Heat load, Gcal/hour | 12 | 9 |
| - Steam turbine power, MW | 4.7 | 3.5 |
| - CCP power, MW | 21.2 | 19.5 |
| - Electrical efficiency, % | 34.4 | 41.3 |
| - Fuel utilization factor, % | 57.0 | 63.5 |
Now the Russian Academy of Sciences has initiated the designing of a powerful gas turbines power generating set competitive in the global market by 2020. Keeping in mind the similar initiative of Aviadvigatel OJSC concerning the works on creation of GTU-180P, the highly important experience of interaction with the companies of power industry and power machines engineering and personal contacts arisen at that time, I hope that this gas turbine development will be headed by the United Engine Corporation OJSC and the leading role will be given to Aviadvigatel. I am sure that the work will be executed on the common scientific and technological basis of advance aviation engines which will be created in the nearest years.
