The aim of the project is to produce 1 MW of electricity in a combined cycle using a gas turbine that is fired with a mixture of propane and air. The system will be set up in a ceramic company. The exhaust gases from the gas turbine will then be used in the several dryers in the plant. Due to the lack of natural gas presently in Portugal, the initial fuel will be the mixture of the propane and air. Economic feasibility of small scale turbines associated with technical aspects like very low levels of NOx, CO and unburned hydrocarbons and reasonable efficiency levels will also be areas covered within the scope of the project. The gas turbine response to changes in gas quality will be assessed and the NOx formation will be monitored.
The project will basically involve a gas turbine specially modified to burn a mixture of air and propane to generate 1 MW of electricity to be used in a ceramic plant. The total system will involve the following components :
- A propane supply reservoir,
- A gas mixer,
- An air fan,
- A compressor,
- A gas turbine,
- A compressor attached to the gas turbine,
- A generator,
- Hot gas duct, and
- A heat recovery system.
The propane supply reservoir will be a conventional system in which propane will be kept under a pressure of 2.6 bars. The gas from the reservoir will be supplied to a mixer with a capacity of 50 m3. The pressure in the mixer will be kept at about 100 mmH2O above atmospheric. An air fan will also be connected to the mixer which will supply the air for the mixture. The required back pressure will be about 120 mmH2O. The mixture leaving the mixer will then be fed to the gas turbine under pressure of about 6 bars. The turbine to be used is a single gas turbine engine designed to drive a 750 kVA electrical generator. It has two main modules and ancillary systems. The two main modules are the power module and the gearbox. The power module is the basic gas turbine engine and consists of a compressor, a combustion chamber and a turbine. The compressor comprises an intake, single stage, swept back centrifugal impeller, vaneless space, radial diffuser, bend from radial to axial flow, axial straightener vane row, and dump. The compressor has a pressure ratio of 6:1 at an isentropic efficiency of about 88%. The compressor material is martensitic stainless steel. In standard form the combustor features a single reverse flow pipe flame tube with its axis perpendicular to the engine rotor axis. Engine speed is maintained constant by a hydromechanical governor. A surface discharge igniter is provided and a main function of the fuel igniter air assistance is to create a fine spray of fuel for ignition. Combustor exit gas is distributed into the first turbinestator row by a fabricated plenum chamber. The exhaust system comprises an annular flared diffuser with truncated bullet supported by uncambered aerofoil struts. The gearbox is two stage layshaft gear which is capable, by the choice of gears on build, of reduction to four optional output speeds - 1500 rpm, 1800 rpm, 3000 rpm and 3600 rpm. The engine is started by an electric starter motor mounted on and driving through the gearbox.
The turbine operating conditions are as follows :
Output power 1000 kW
Turbine entry temperature 1100 deg. C
Compressor delivery pressure 620 KPa abs.
Compressor delivery temperature 219 deg. C
Air mass flow 5.53 Kg/s
Fuel mass flow 185 Kg/h
Exhaust gas temperature 617 deg. C
The system will work 8,400 hours that is 350 days and 24 hours per day. It is assumed that for a period of 15 days each year there will be maintenance shut-down.