VOLVO Microturbines

Microturbines
2005-04-21
Rolf Gabrielsson, Volvo Aero Corporation
Section 1
Microturbines, Section 1
Gas Turbine Applications

Aero
Industry
Power
Combined Heat and Power, CHP
Mechanical drive for pumps and
compressors
Marine
Automotive
Microturbines
Microturbine lecture 2005-04-21, Rolf Gabrielsson
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Gas Turbine - Civil aircraft

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Solar Mercury 50
Click here to enlarge image
Ref.: Solar Turbines

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Marine Gas Turbine

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Small Gas Turbine development line

z1960- Sven-Olof Kronogrd works at Volvo with the S-tank and a
Volvo gas turbine project for the tank
z1990-1992 Development of HSG 40

z1994-1995 Development of VT100
z1970-Turbokonsult founded by Professor Kronogrd
z1998 Turbec was established to develop T100
z1974-United Turbine founded by Kronogrd and AB Volvo

z1972-1984 Automotive gas turbine for cars, KTT 150 MK1
z1984-1987 Development of GT110 for Volvo Cars
LPP combustor
KTT150 MK I
Car GT (1972-1984)
GT 110 with LPP
HSG 40
VT 100
Car GT (1984-1987)
Volvo / ABB / Vattenfall
for ECB/ ECT
Turbec T100
New company
Volvo / ABB
1970
1975
1980
1985
Ref.:Lars Sundin, Volvo Aero Presentation 10-11 July 2003 Brussels

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1990
1995
2000
Volvo experience in automotive Gas Turbines
KTT 150 Mk I developed 1972-1984
Automotive GT for cars.
Power 100 hp
3-shaft design with patented KTT

transmission system
z
Conventional combustor
Rotary ceramic heat exchanger
Demonstrated in cars from 1977 including

the first car ever with ceramic HP turbine
z
One car in daily use to gain experience

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KTT MK II / GT110
Developed 1985-1987
Automotive GT for cars.
Power 115 kW (155 hp)
2-shaft with ceramic HP turbine
Low emission combustor (LPP)
Rotary ceramic heat exchanger
Design with low parasitic losses

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Volvo Environmental Concept Vehicles
zVT40
for ECC (Environmental Concept Car)
zVT100
for ECT/ECB (Truck and Bus)
zSeries
Hybrid Drive lines
zCombined
Gas Turbine and High Speed
Generator
z1-shaft
Regenerative Engine

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Volvo Environmental Concept Vehicles

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The Power Module of T100 microturbine
Very few moving parts

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T100 installed in a boiler room

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Gas Turbines
Typical conditions
Pressure
TIT
Bar
C
Industrial, Combined and simple cycle 10-40 -> 1500
Recuperated
< 10
->1300
Aero
20-40
->1600
Automotive / Microturbines

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4-6
Combustor
inlet temp.
C
300 - 650
600 - 800
450-650
1000-1350
600-900
Gas Turbine Design Features Related to Output Capacity
Ref.: Advanced Microturbine Systems, US DoE, March 2000, www.eere.energy.gov

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Microturbine system

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Microturbine characteristics
Electricity power output 25 500 kW
Market:
- Distributed generation
- Standby power
- Combined Heat and Power generation (CHP)
- Direct mechanical drive for air conditioning system
Simplified design for mass production
- Radial flow compressors
- Low pressure ratios defined by single or possibly two-stage compression
- Minimal use of vane rotor cooling
- Use of materials that are amendable to low cost production
Recuperation of exhaust heat for air preheating - Electrical efficiency 2530%
Very high shaft rotational speed (>40 000 rpm)
Direct drive high-frequency alternator

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Comparison: Microturbine - Gas Engine
Microturbine
Number of mowing parts
+
Package size
+
Electric efficiency
=
Fuel utilization
=
Emissions NOx, CO, HC
+
Noise, vibrations
+
Fuel flexibility
+
Opportunity to utilize waste fuel
+

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Gas Engine
=
=
-
Microturbine Cycles

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Microturbine Cycles
Simple cycle, metallic
el (%)
< 20
Recuperated, metallic
ceramic
25-30
40
Inter-cooled Recuperated (ICR)
>40
Combined cycle with Organic

Rankine Cycle (ORC)
> 40
CHP, metallic

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tot (%)
80
Recuperated Gas Turbine

Efficiency and Specific Power
v.s. Turbine inlet temperature (TIT) and Pressure Ratio ()

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System studies
Future microturbines or automotive gas turbines
Intercooling a regenerative gas turbine
advanced cycles
zIntercooling
turbines
zBottoming
zIncreased
46,00%
RC 1000C
of recuperated gas
RC 1250C
IRC 1000C
44,00%
IRC 1250C
cycles
temperature
zCeramics
zCooling
concepts for small

components
Thermal efficiency
zMore
42,00%
IRC
40,00%
38,00%
= 5
4
6
Recuperated
7
36,00%
150
200
250
300
Specific Power (kWs/kg)

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350
Turbec Microturbine
Combined Heat and Power (CHP) System
High efficiency
Low emissions levels
1.
Generator
2.
Inlet air
3.
Combustion chamber
4.
Air to Recuperator
5.
Net electrical output:
100 kW
Net electrical efficiency:
30%
Net total efficiency:
80% (at 50 oC
WRT)
Compressor
Noise level:
70 dBA at 1 meter
6.
Turbine
Emissions, 15% O2
7.
Recuperator
8.
Exhaust gases
9.
Heat exchanger
Ref.: Turbec datasheet

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Performance at ISO-conditions
NOx:
< 15 ppmv
CO:
< 15 ppmv
UHC:
< 10 ppmv
Compressor

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Compressor
Typical characteristics:
Radial flow compressors
Low pressure ratios defined by
single or possibly two-stage
compression
Materials that are amendable to
low cost production
Very high shaft rotational speed
(>40 000 rpm)

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Compressor diagram
4,2
Pressure
Ratio,
nredV = 112.6 * 103 min-1
3,8
104.5
3,4
0.73
98.5
0.75
92.5
3,0
0.76
0.70
0.77
84.4
2,6
0.70
2,2
0.65
74.4
0.60
isV = 0.78
1,8
1,4
62.3
46.2
0.65
1,0
0,04
0,08
0,12
0,16
0,20
0,24
0,28
0,32
0,36
0,40
0,44
0,48
0,52
Air mass flow

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0,56
Component development
Compressors
z Development steps
z
Inverse design method
Parametric design
Introduction of 3D viscous CFD
Compressor
KTT 150 MK1
HSG 40 v1
HSG 40 v2
VT600
VT100/T100
T100 prot
Pressure
ratio
5.1
3.5
4.0
9.2
4.4
4.6
Efficiency
Method
Year
75%
75%
77%
77%
77%
80%
Inverse design
Inverse design
Parametric/Streamline
Parametric/3D CFD
1976
1991
1993
1992
1994
2002
Polytropic efficiency
Polytropic efficiency development

88,5%
88,0%
87,5%
87,0%
86,5%
86,0%
85,5%
85,0%
84,5%
1970
1975
1980
1985
1990
Development Year

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1995
2000
2005
Combustor

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Combustor development
Gas turbine with conventional combustor

Typical NOx emission = 150 ppm @15%O2
LowNOx Combustor
Typical NOx emission = 25 --> 9 ppm
@15%O2

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Gas Turbine combustor design
Diffusion combustor

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LowNOx combustor
Emission trends - NOx

Large Gas Turbines
California: NOx < 3 ppm
Microturbines Distributed generation

State of the art: 15 ppm
US Dept. of Energy goal:
NOx < 7 ppm
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Volvo Aero / Turbec Combustor development

zLean
Premixed Prevaporized
combustor system
Engine
Fuel
T100
T100
Natural gas
Petroleum gas,
Propane 95%
Petroleum gas,
Propane/butane 20/80
Landfill gas (HLHV19
MJ/kg)
Methanol
Ethanol (E85)
Kerosene
Diesel
T100
T100
zOriginal
development for the

automotive GT 110
zMulti
fuel capability
zUsed
in Turbec T100

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T100
VT100
T100
VT40/T100
VT4400DLE
VT4400
Low Calorific Fuel

(HLHV5 MJ/kg, no NH3)
Type of
combustor
Emissions at 100%
load and 15% O2
CO
NOx
<15 ppm <15 ppm
<10 ppm <10 ppm
LPP
LPP
<10 ppm
<10 ppm
LPP
<12 ppm
<5 ppm
LPP
<10 ppm
<20 ppm
<10 ppm
<10 ppm
<25 ppm
<9 ppm
<5 ppm
<40 ppm
<15 ppm
<15 ppm
<15 ppm
<20 ppm
LPP
LPP
LPP
LPP
LPP
Diffusion
Ingersoll-Rand 250 kWe PowerWorks Combustor
Ref.: Jim Kesseli Presentation at the IGTI Turbo Expo June 18 2003, Atlanta USA
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Honda Microturbine Combustor
Ref.: Koichi Shinmura Presentation at the IGTI Turbo Expo, June 18 2003, Atlanta, USA
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Capstone C60 Microturbine
Recuperator
Combustion Chamber
Fuel Injector
Turbine
Ref.: Capstone Product Datasheet
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Catalytic Combustor

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High Temperature Catalytic Combustor

Project AGATA, Complete reaction in the catalyst section
Diesel fuel
Catalyst outlet temperature 1350C

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Catalytica
Hybrid catalytic combustor
Catayst section + Post catalyst zone
NOx emissions as low as 2.5 ppm.

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Ref.: Kawasaki Gas Turbines, Datasheet

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Turbine

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Volvo Aero / Turbec Component development

Turbines
zAxial
turbines
zBLISK
designs
zIntroduction
zRadial
of 3D Compound Lean
turbines
zIn-house
method
developed inverse design
z3D
Stress&CFD for optimal tradeoffs Performance-Life
zT100
Performance
zExpansion
z89%
ratio 4
total-total
zDiameter
175 mm

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Ref.:Lars Sundin, Volvo Aero, Presentation 10-11 July 2003 Brussels
Microturbines - Turbine material

Today standard material
Ni-based materials
Example: MAR-M247, max temperature 1050 C
Turbine Inlet Temperature today: approx. 950 - 1000 C
Thermal Barrier Coating, TBC, will increase service life
Future ceramic materials

Si3N4
Turbine Inlet Temperature 1350C

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Heat exchanger

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Heat exchangers
Key component for microturbines
Accounts for about half heat input
Regenerator
-
Automotive application
Ref.: Bowman Power
Recuperator
Microturbine application

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Regenerator
+
High efficiency
Compact and low weight
Suitable for ceramics
Can be used for high temperatures
Difficult to seal - lifing problems

Leakage problems
5% leakage will reduce power with > 12.5%
5% leakage will reduce system efficiency by >4%-units
Leakage means reduced engine life due to increasing hot parts
temperature. Ex.: Increased combustor liner temperature

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Recuperator
+
Reliable and durable
Close to zero leakage
Reduced efficiency, approx. 90%

Can be bulky
More complex piping can mean increased weight
Increased volume and exposed area require improved insulation - or
innovative design

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Alternative recuperator development

zDevelopment
of a recuperator for
volume production in Recuperator
Svenska AB.
zStamped
zLaser
plates
welded
zModularised
zPerformance
according to specification
(Efficiency~90% at dp/p<4.5 %)
zFirst
full size prototype tested for

~4500 h
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Recuperators - Annular design
Honda Microturbine
Ref.: Koichi Shinmura Presentation at the IGTI
Turbo Expo, June 18 2003, Atlanta, USA

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Capstone Microturbine
Ref.: Capstone Product Datasheet
Recuperator materials
Metallic materials
Type 347 stainless steel - Today standard material
Max temperature (exhaust): 1200F = 650C
Inconel - Advanced material
Max temperature (exhaust): 1500F = 820C
Ceramics
>1600F = 870C

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Ceramic materials

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Ceramic components
zDevelopment
of ceramic turbine
components started 1981
zTurbine
wheel from ASEA CERAMA

tested in a car 1982
zSeveral
components including
combustor, inlet scroll and turbine
developed for the GT110 gas turbine
zGT110
demonstrated reliable at 1250
C 1987
zEuropean
AGATA project developed
zCeramic
radial turbine
zCeramic
recuperator
zCeramic
catalytic combustor

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Ceramic development in Japan and USA
Japan
- MITI (Ministry of International Trade and Industry)

- Kyocera
USA:
- DoE (Department of Energy)

- ORNL
- Honeywell

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Specification:
Combustor inlet temperature:
935C
Turbine inlet temperature, TIT: 1350C

Cycle efficiency:
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42%

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Ceramic Turbine
Ref.: Jim Kesseli et al, presentation at the IGTI Turbo Expo June 18 2003, Atlanta USA
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AGATA
Ceramic Heat Exchanger with casing and seals

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AGATA
Cordierite Ceramic Heat Exchanger Matrix

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Power Electronics

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Power Electronics
Generator
High speed alternator permanent magnet
rotor inside the stator. The generator
produce a high frequency AC (Alternating
currency)
Rectifier
Rectify to DC (Direct currency)
Converter
Converts to 50 or 60 Hz AC, 400 480 V

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Microturbines

Gas Turbine Applications

Microturbine lecture 2005-04-21, Rolf Gabrielsson

Gas Turbine - Civil aircraft

Microturbine lecture 2005-04-21, Rolf Gabrielsson

Microturbine lecture 2005-04-21, Rolf Gabrielsson

Click here to enlarge image

Ref.: Solar Turbines

Microturbine lecture 2005-04-21, Rolf Gabrielsson

Marine Gas Turbine

Microturbine lecture 2005-04-21, Rolf Gabrielsson

Small Gas Turbine development line

Volvo gas turbine project for the tank

z1990-1992 Development of HSG 40

z1970-Turbokonsult founded by Professor Kronogrd

z1998 Turbec was established to develop T100

z1974-United Turbine founded by Kronogrd and AB Volvo

GT 110 with LPP

Volvo / ABB / Vattenfall

for ECB/ ECT

Ref.:Lars Sundin, Volvo Aero Presentation 10-11 July 2003 Brussels

Volvo experience in automotive Gas Turbines

KTT 150 Mk I developed 1972-1984

Automotive GT for cars.

3-shaft design with patented KTT

Rotary ceramic heat exchanger

Demonstrated in cars from 1977 including

One car in daily use to gain experience

Ref.:Lars Sundin, Volvo Aero Presentation 10-11 July 2003 Brussels

Ref.:Lars Sundin, Volvo Aero Presentation 10-11 July 2003 Brussels

Volvo Environmental Concept Vehicles

for ECC (Environmental Concept Car)

for ECT/ECB (Truck and Bus)

Hybrid Drive lines

Gas Turbine and High Speed

Ref.:Lars Sundin, Volvo Aero Presentation 10-11 July 2003 Brussels

Volvo Environmental Concept Vehicles

Ref.:Lars Sundin, Volvo Aero Presentation 10-11 July 2003 Brussels

The Power Module of T100 microturbine

Very few moving parts

Ref.:Lars Sundin, Volvo Aero Presentation 10-11 July 2003 Brussels

T100 installed in a boiler room

Ref.:Lars Sundin, Volvo Aero Presentation 10-11 July 2003 Brussels

Microturbine lecture 2005-04-21, Rolf Gabrielsson

Gas Turbine Design Features Related to Output Capacity

Ref.: Advanced Microturbine Systems, US DoE, March 2000, www.eere.energy.gov

Microturbine lecture 2005-04-21, Rolf Gabrielsson

Microturbine lecture 2005-04-21, Rolf Gabrielsson

Comparison: Microturbine - Gas Engine

Microturbine lecture 2005-04-21, Rolf Gabrielsson

Microturbine lecture 2005-04-21, Rolf Gabrielsson

Simple cycle, metallic

Inter-cooled Recuperated (ICR)

Combined cycle with Organic

Microturbine lecture 2005-04-21, Rolf Gabrielsson

Recuperated Gas Turbine

Microturbine lecture 2005-04-21, Rolf Gabrielsson

concepts for small

Specific Power (kWs/kg)

Ref.:Lars Sundin, Volvo Aero Presentation 10-11 July 2003 Brussels

Net electrical output:

Net electrical efficiency:

Net total efficiency:

Ref.: Turbec datasheet