Oxy-Fuel Turbomachinery Development for Energy Intensive Industrial Applications

Abstract

Future fossil-fueled power generation systems will require emission control technologies such as carbon capture and sequestration (CCS) to comply with government greenhouse gas regulations. The three prime candidate technologies which permit carbon dioxide (CO2) to be captured and safely stored include pre-combustion, post-combustion capture and oxy-fuel (O-F) combustion. For more than a decade Clean Energy Systems, Inc. (CES) has been designing and demonstrating enabling technologies for oxy-fuel power generation; specifically steam generators, hot gas expanders and reheat combustors. Recently CES has partnered with Florida Turbine Technologies, Inc. (FTT) and Siemens Energy, Inc. to develop and demonstrate turbomachinery systems compatible with the unique characteristics of oxy-fuel working fluids. The team has adopted an aggressive, but economically viable development approach to advance turbine technology towards early product realization. Goals include short-term, incremental advances in power plant efficiency and output while minimizing capital costs and cost of electricity. Phase 2 of this development work has been greatly enhanced by a cooperative agreement with the U.S. Department of Energy (DOE). Under this program the team will design, manufacture and test a commercial-scale intermediate-pressure turbine (IPT) to be used in industrial O-F power plants. These plants will use diverse fuels and be capable of capturing 99% of the produced CO2 at competitive cycle efficiencies and cost of electricity. Initial plants will burn natural gas and generate more than 200MWe with near-zero emissions. To reduce development cost and schedule an existing gas turbine engine will be adapted for use as a high-temperature O-F IPT. The necessary modifications include the replacement of the engine’s air compressor with a thrust balance system and altering the engine’s air-breathing combustion system into a steam reheating system using direct fuel and oxygen injection. Excellent progress has been made to date. FTT has completed the detailed design and issued manufacturing drawings to convert a Siemens SGT-900 to an oxy-fuel turbine (OFT). Siemens has received, disassembled and inspected an SGT-900 B12 and ordered all necessary new components for engine changeover. Meanwhile CES has been working to upgrade an existing test facility to support demonstration of a “simple” oxy-fuel power cycle. Low-power demonstration testing of the newly assembled OFT-900 is expected to commence in late 2012.

Compact High Efficiency and Zero-Emission Gas-Fired Power Plant with Oxy-Combustion and Carbon Capture

“…Works on the above-mentioned solution are underway in the United States, where, for over 15 years, clean energy systems (CES) have been introducing technologies used in rocket engines for conventional power engineering, thereby building zero-emission power units with power of up to 200:MW [13]. CES cycles have undergone numerous modifications, but the crucial idea is presented in the paper by Hustad et al [14].…”

“…In CES, the water is injected through a sequential cooling system with appropriately positioned holes. Papers describing the development of the aforementioned solution, both the combustion chamber and the CES cycle itself include [13][14][15][16][17]. Such a concept is fundamentally different from the one described in this article because, water is to be supplied here in the process of thermal transpiration and velocity slip over the entire surface of the combustion chamber [18].…”

“…In Figure 5, the following thermodynamic processes can be distinguished: 14-15acceleration of the working medium in the primary nozzle; 14-15 s -ideal process of accelerating the working medium; 2 bap -3 bap -suction of the medium into the suction chamber; 15-16 and 3 bap -4 bap -exchange of mass, momentum, and energy in the mixing chamber; and 16-5 (or 4 bap -5)-compression of the working medium in the diffuser. Additionally, processes occurring in pumps can be identified, i.e., in P 1 (7)(8)(9)(10)(11)(12)(13)(14) and P 2 (7)(8)(9), in the regeneration exchanger (points 9-10), and separation in S+CHE (thermodynamic processes 5-6 and 5-7).…”

Automatic Construction of REDIM Reduced Chemistry with a Detailed Transport and Its Application to CH4 Counterflow Flames

“…So far, the performance of the REDIM has been validated for steady flames, namely, counterflow diffusion flames with constant strain rates. In most practical industrial combustion facilities such as gas turbine or industrial furnace where oxy-fuel combustion technology has been put into use, − most reacting flows are operated under unsteady situations and the strain rate is characterized with an intermittent turbulent nature. ,− In our previous work, ,, REDIMs which are generated using the conventional algorithm are tested for unsteady processes. In this section, the performance for unsteady processes using 2D and 3D REDIM reduced chemistries using the newly developed automatic generation method is tested; a time-dependent strain rate has been modeled as a pulse function periodically given to the counterflow flames.…”

Analysis of thermally coupled chemical looping combustion-based power plants with carbon capture

“…CO 2 turbines operating around 1200C are under development. A number of industry collaborative efforts are ongoing to adapt existing turbines so that they accommodate high temperature oxy-fuel exhaust working fluids [45][46][47]. Future work will incorporate the performance characteristics and limitations of state of the art CO 2 turbines in order to determine the currently feasible performance of the rotary CLC power plant.…”