Objective
To prove the technical and economical feasibility of the gas expander concept with integrated gas expander of much larger power output than constructed so far.
The goals for this project are fourfold :
1. An electrical conversion rate from the heat used, that is 80 % and more.
2. The high performance levels are achieved and maintained independently of the load (between 35 % partial load and 100 % full load).
3. An "intrinsic" safety character of the installation in handling natural gas. Also, interferences with tasks of normal gas distribution and with electrical grid will be minimized and disturbance free.
4. Low emission rates for C02, CO, NOX and noise.
1. TECHNICALLY
This first COGENT-project is a full success :
Notwithstanding the initial problems, it has been operated during a six month probational operation at a high degree of reliability (superior 90%), which will be enhanced to above 96% when industrially operated.
2. PERFORMANCES
Providing the corrections, made to adapt the installation to the altered design conditions and to improve the initial deficiency of the expander, the aims and guarantees og the COGENT-project are all met.
. Nett electrical efficiency of 78%
. Thermal efficiency in excess of 85% for all loads between 50 and 100%.
. Maximum power output of 2100 + 2140 = 4240 kW
. Disturbance free operation.
. Zero gasleakage and negligible oil losses (< 0,65 ppm).
. 100% automated and remotely supervised.
3. ECONOMICALLY
The economical feasibility of the project is proved.
This concept, based on components of modular design should make the implementation of similar installations for other gas expansion conditions very easy and economical.
The innovative character is fourfold:
1. Gas expander development :
- Uprating of the turbine from 1100 to 2100 kW
- Expander wheel materials
- Generator forced cooling, with 100 % heat loss recovery
- Inlet guide vanes control system
- Coupling of 2 x 50 % generators
- Oil free system : thrust bearing - ball bearings
- Frequency converter and controls
2. Modular installations :
- Expander noise attenuation house (outdoor 65 dBA)
- Convertor & control container
3. Heat recovery/hot water system
- Gas engine flue gas recovery
- Integral recovery of all heat losses produced by the expander (generator cooling - oil cooling - converter cooling - leading to 80% efficiency.
4. Plant control system
- Master control of the gas expander, gas engines, auxiliary boiler, heating/cooling water system, expander bypass system controlling and optimizing the efficiency of the process.
- The plant is to be designed for 100 % unmanned operation.
Programme(s)
Topic(s)
Call for proposal
Data not availableFunding Scheme
DEM - Demonstration contractsCoordinator
1930 Zaventem
Belgium