Aug 2012

GAS TURBINE WASTE HEAT

RECOVERY UNITS (WHRU)
Acknowledgment
GPSA Section 15
Pictures from many sources, suppliers, internet

Gas Turbine

Prime mover to drive compressors and generators

2 Types: Aero-derivatives and industrial




Aero-derivatives are light weight; preferred offshore and are

used to 25 MW
Heavier industrial units are used for higher duties and on onshore

Inlet compression takes 2/3

energy developed in turbines.
Recycled energy!
GT fuel efficiency: 30-40% based
on Xs air and Exhaust Temp

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Ambient air (gas) is compressed in an axial air

compressor to 10 to 20 bar


similar to BFW pump in a steam system

Fuel is fired in a combustion chamber into hot

compressed air. Hot and pressurized flue gas is let
down in pressure first thru a "gas producer" turbine similar to steam turbine, to provide energy for inlet
compression

Balance energy in the hot gas is used for jet-action in
an aircraft. In industrial unit, it is recovered thru a
"power turbine" to run a compressor or generator

Air
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Exhaust

GT Single Vs Split Shaft

Industrial GTs are made of single shaft - that is air

compressor, power turbine and driven equipment

(compressor or generator) all share the same
common shaft


Single shaft is more stable, lesser bearings but requires

higher starting power. Narrow speed range to avoid
surging in inlet air compressor

Aero-derivatives have dual shafts, the air

compressor components in one shaft and power

turbine and driven unit in another shaft


Air compressor is run at its best speed and power

turbine runs at speeds to suit the driven equipment

Single shaft: Power generation with a gearbox;

Variable speed 2 shaft for compressor/ pumps

Driven unit can be near the air-end ("cold end
drive) or exhaust end ("hot end" drive)

GT exhaust heat can be used to

generate steam or heat oil in a
WHRU
GT + exhaust steam turbine
provide a combined cycle
power plant with 45% efficiency
GTs efficiency: 35%
Air

100 u
Fuel

65 u
Exhaust
35 u

Driven Compressor/
Generator

Gas Turbine Performance

Rated by Power Delivered, kW and Heat Rate, kJ/kWh energy

supplied to get a kWh at ISO conditions:

 15C; 0 m elevation, atmospheric pressure of 101.325 kPa a and 0%

Relative Humidity - dry air, without any inlet loss (due to air filter) and
outlet loss (due to silencers/WHRU)

Ambient Temp & Altitude Correction: Inlet air compressor is a

constant volume machine. Altitude and air temperature impact

air density and mass flow and power delivered

Inlet air filter and outlet WHRU/ silencer impact air flow and
head developed hence power delivered
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Suitable corrections are then applied for site

conditions of these variables to derive site
delivered power, heat rate

Gas Turbine Typical Data

Higher the compression ratio, hotter the gas,

less fuel required to reach a given combustion

zone T1 temperature
Make

Power, kW Effcy, %

Comp Xs Air, %
Ratio

Exhaust
T, C

Solar Taurus 70

8,140

35.3

15

240

510

Solar Mars 100

11,860

34.4

17.5

260

485

GE LM 2500

25,060

37.1

18

200

566

Nuovo Pignone MS5002

28,340

29.2

8.4

280

516

Rolls Royce RB 211

30,910

38.6

20.8

250

490

Gas Turbine WHRU

GTs employ 250 - 350% excess air to limit combustion

chamber metal temperature

As combustion air

Exhaust at 500C with 15% O2: Source of waste heat - either

30 u
Exhaust

as hot combustion air or in a waste heat recovery exchanger

Combustion Air: Extensive ducting and load co-ordination

GT Vs heater load. Post firing 2-3 times of GT based on Xs air

Waste Heat: Because of high Xs air, heat recovery is limited.

Usually WHRU duty GT load. As air flow remains same, GT

part load exhaust temperature is low

With WHRU
70 %

Xs air reduction: Large machines use Inlet Guide Vanes.

IGV reduce air to 80% during part load. Below 80%

inlet Axial Flow Compressor will surge
Low NOX burners operate with lean fuel: air mix. They
employ recycle loop across air compressor to limit Xs air
in combustion chamber during part load

Air

100 u
Fuel

65 u
Exhaust

35 u
Driven Compressor/
GTs efficiency: 35%
Generator

35 u

WHRU

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GT WHRU

Bypass

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WHRU

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Heat
 hot oil, hot water, crude, amine, regen gas
 generate and superheat steam

Finned tubes, similar to heater convection section

CIBAS: (concentric integral bypass and silencer). Finned helical

coils in annulus between outer casing and internal bypass

GT WHRU

Common WHRU
for 2 Turbines
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Bypass

Bypass

WHRU

Parts
 soot-blowers, by-pass stack, auxiliary firing (oil or

gas firing)

Diverter dampers control outlet temperature

GT WHRU Supplementary Firing

Lower the ambient temperature, lower is exhaust

temperature; Exhaust temperature is also low at GT part load

Additional firing in WHRU inlet duct boosts GT exhaust temp
or waste heat recovery, specially during GT part load

As exhaust has 15-18% O2, fuel (oil or gas or both ) can be
directly fired in the duct
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Duct Burners

GT WHRU Supplementary Firing

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Duct burners: Many small burners across duct

cross section

GT WHRU Ducting

A fired heater convection is usually castable

cement or ceramic fiber lined internally on

carbon steel casing. In GT WHRU gases travel at
high velocity (Heater P = 0.5 WC (o.125 kPa);
WHRU P = 6 WC (1.5 kPa)) that will erode
insulation

GT /WHRU ducts are usually made of SS sheets
with external mineral wool type of insulation

THANK YOU