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Wrap-Up of Industrial Power Generation, Turbines I GEOS 24705/ ENST 24705

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Wrap-Up of Industrial Power Generation, Turbines I GEOS 24705/ ENST 24705 Wrap-up of industrial power generation, Turbines I GEOS 24705/ ENST 24705 Copyright E. Moyer 2011 Tesla’s AC is “three-phase” 3-phase generation animation http://www.launc.tased.edu.au/online/sciences/physics/ 3phase/threeph.htm Generators are virtually unchanged in 100 yrs Stator, 3-phase generator, Wellluck Co., Stator, 3-phase generator, Brakpan, South China, 12.5 MW, 2010 Africa, 1897. Photo: Siemens Industrial generation design specs • Generator should be large for heat dissipaon • Voltage much higher than 110 V to minimize resis3ve heang • Many loops to increase voltage and power output • No sliding mechanisms that carry big current: current carried in stator • Magnet in stator, use electromagnet for bigger B-field • Mul3ple poles if needed for higher frequencies Rotor carries electromagnet Old mill rotor (source unknown) Small Hydro Generator rotor - Rotor Assembly Area - Alstom Hydro Manufacturing site in Galindo (Spain) copyright © 2010 M. Monteaux for Alstom Turbo-generator power grew very quickly (though seems to be leveling of) * Requires growth not just in generators but in prime movers that power them * exponential growth in several stages * topping-out of steam P and T ca. 1960 From Vaclav Smil, “Energy at the Crossroads” First major hydropower station, Niagara Falls, 1895 Adams power station, 10 5MW AC generators. Photo: Tesla Society Hoover Dam hydropower station, upgraded 1961 17 generators, average 120 MW. Photo: source unknown The prime movers driving the world’s electricity supply Invented by Parsons, 1884. 80% of world’s electricity today (all external combus3on). Power growth rapid: first turbine 75 kW (1890), by 1912 turbo-generator system installed in Chicago (at Fisk!) was 25 MW, -> 50 MW in Parson’s life3me, > 1 GW now Efficiency gain rapid: More efficient than reciprocang engines, also simpler – fewer moving parts. By 1916 best demonstrated ε ~ 37%. Modern turbines average ~ 33%. 1. STEAM TURBINE Mari:me use: demonstraon of turbine- propelled ship, the Turbinia, 1897 Chief drawback: high rotaon rates The prime movers driving the world’s electricity supply Conceived of in 1791. But no means of prac3cal building l 1903 (Elling). Power growth slow: no commercializaon l 1918, no roune use l 1930s. Lowest-cost new fossil generaon choice today. 2. GAS TURBINE Turbine diversity: all kine3c -> kine3c, and yet look different. Why? all designed to use flowing fluid to rotate something – yet diversity of designs. Features that may matter to turbine design • Fluid velocity • Fluid density • Pressure drops - whether turbine works by changing fluid pressure (“reac3on turbine”) or just allowing molecules to push on blades (“impulse turbine”), or something in between (“impulse-reac3on”) Features that may matter to turbine design Wind: Water wheel or run-of-river hydro: Dam hydro: Gas or steam turbine: Features that may matter to turbine design Wind: low velocity, low density, no pressure drop Water wheel, run-of-river hydro: low velocity, high density, no pressure drop Dam hydro: low velocity, high density, large p drop Gas or steam turbine: high velocity, low density, large pressure drop Steam and gas turbine similarities & differences Steam and gas turbine similarities & differences Both • Work by leng high-pressure gas expand • Blades of turbine are turned by the “wind” of steam • Combinaon impulse-reac3on turbines • To make high-pressure gas, heat the gas • Both are heat engines Steam and gas turbine similarities & differences Steam – Rankine cycle • external combus3on • condensible species (so can’t raise temperature adiaba4cally – must put heat in for latent heat) • Tmax lower than combus3on temperature (limited by what boiler can withstand) • slow to dispatch (hours - must heat water to make steam) • expensive to build & install (needs firebox, boiler) Gas – Brayton cycle • internal combus3on • non-condensible species • Tmax is gas is combus3on temperature – more efficient • fast to dispatch (ca. 10 minutes) • cheap to build & install (compact, single unit) What’s not to like about gas? …only that coal is cheaper! Gas turbine – internal combustion Why are blades so different on the sides of the turbine? Brayton cycle patented 1791 (john Barber), first use in piston engine 1872 (George Brayton) First successful turbine build: 1903 (Aegidius Elling) … by 1918 General Electric has a gas turbine division. Now generator of choice for fast installaon. Image: from LidyaSavitri.wordpress.com; Copyright unknown. Gas turbine – internal combustion Image: from dieselduck.net Copyright: Martin Leduc? Where does air/gas enter? What is compression ratio? Gas turbine – internal combustion Image: from dieselduck.net Copyright: Martin Leduc? Air-fuel mixture enters from left into compressor, which compresses air 5-20x. Air/fuel ignites in combustor, and expands to right, turning rotor. The rotor powers both a generator and drives the compressor itself (which can take up ½ the power output of the turbine). Combustion temperatures typically > 1000 C (1300 K) as opposed to ~600 C (900K) for steam. Note that the walls of the turbines must be kept cooler than the gases inside else their metal would degrade, and even so, special steel is required to withstand the high Ts. Gas turbine thermodynamic cycle: Brayton cycle Two adiabats and two isobars (constant pressure) Diagram: Wikimedia Commons Compression and expansion are still nearly adiabatic, as in Carnot cycle. But gas combustion means that heat is input at constant pressure instead of constant temperature, and cooling also takes place at constant pressure. Intrinsically less efficient than the Carnot cycle since heat isn’t added at hottest temperature and removed at coolest. But temperatures are hot! (> 1300 K). Efficiency depends on compressor P too. Carnot efficiency would be ~75%. Ideal Brayton cycle ~ 60%. Commercial units actually ~ 40-50%. Steam turbine – external combustion Image: from LidyaSavitri.wordpress.com; Copyright unknown. Steam turbine thermodynamic cycle: Rankine cycle Trying to be adiabats and isotherms, but limited by Clausius-Clapeyron The Clausius-Clapeyron relationship of liquid and vapor prevents raising T at constant entropy, so cannot make the same rectangular T-S diagram as the Carnot cycle. Stages: In stage 1-2 the liquid is compressed by a pump. 2-3 has two segments: heating of liquid, then evaporation to make steam. If you then try to expand adiabatically, water would condense. Superheating the steam (3-3’) both prevents condensation on expansion and also produces more work. Superheat also makes the cycle more Carnot-like and more efficient: think of making the cycle on a T-S plot more rectangular. After expansion the steam is brought into contact with cooling water and condensed (4-1 Diagram: Wikimedia Commons or 4’-1) at constant temperature. Steam turbine thermodynamic cycle: Rankine cycle Adding more reheat cycles improves efficiency Most modern steam systems use two separate expansion stages (3-4) and (5-6), with the steam re-heated in between. The steam is never allowed to condense. In the second reheat stage some cooling is needed to drop temperature so that steam can condense (the segment by the “6”). Ideal Rankine-with-reheat efficiency for 1000 F (550 C or 800 K) is ~40%. Carnot would be ~60%. actual turbines get a bit over 30% Rankine not worse than Brayton – ε would be about the same if a steam turbine could be run Diagram: Wikimedia Commons as hot as a gas turbine. Steam turbine efficiency is achieved with multiple stages Original idea: Parsons, 1910s Diagram: Govt. of Australia Steam enters at left. Blades increase in size as P drops. Steam is removed and reheated (and superheated) before being reintroduced at the low-pressure stage. Steam turbines no longer increasing in efficiency • As seen before.. steam P and T topped out ca. 1960 • Efciency stalled as well • A bit below ideal Rankine limit • Note that average is below best possible – best is closer to ideal Rankine unnecessary waste heat in condensation stage? turbine design? From Vaclav Smil, “Energy at the Crossroads” Steam turbines are virtually unchanged in 100 yrs Low-pressure turbine rotor, for installation in a nuclear power plant (Siemens SST5 9000) Photo: Siemens Power Generation Low-pressure turbine rotor, 50 MW turbine, ca. 1929 Photo: “The Steam Turbine and Other Inventions of Sir Charles Parsons, O.M.” R.H. Parsons, 1942. Copyright, The British Council Where is steam injected? How do you know? Turbo-generators are virtually unchanged in 100 yrs Turbine hall with steam turbine & generators, ca 20 MW each,1929 Photo: “The Steam Turbine and Other Inventions of Sir Charles Parsons, O.M.” R.H. Parsons, 1942. Copyright, The British Council Turbo-generators are virtually unchanged in 100 yrs The turbine hall of Bruce Power's Bruce A nuclear power plant in Ontario, Canada. Photo: Bruce Powell Steam and gas turbine similarities & differences Steam – Rankine cycle • external combus3on • condensible species (so can’t raise temperature adiaba4cally – must put heat in for latent heat) • Tmax lower than combus3on temperature (limited by what boiler can withstand) • slow to dispatch (hours - must heat water to make steam) • expensive to build & install (needs firebox, boiler) Gas – Brayton cycle • internal combus3on • non-condensible species • Tmax is gas is combus3on temperature – more efficient • fast to dispatch (ca. 10 minutes) • cheap to build & install (compact, single unit) What’s not to like about gas? …only that coal is cheaper! Selected power plant options Coal-fired power (steam turbine) cheap fuel, lowest efficiency (30-35%) Natural gas power plant (gas turbine) expensive fuel, beer efficiency (40-50%) Combined-cycle power (gas + steam) expensive fuel, high efficiency (55-60%) IGCC (coal-fired gas + steam) cheap fuel, high efficiency (55-60% - cost of making syngas) Cogeneraon (generally gas, re-use waste heat) expensive fuel, can be highest “efficiency” (> 80%) since waste heat is no longer wasted Coal-fired power always involves steam Diagram: Tennessee Valley Authority Fuel burns to make heat; heat boils water to make steam; steam drives steam turbine; turbine spins generator; generator make electricity.
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