Auxiliary Compressor Air Injection for Gas Turbine Turn-Down

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Solution Overview

Problem

Gas turbines face inefficiencies and high maintenance costs due to cycling up and down in response to peak and low electrical demand, limited turn-down capability, and reduced power output at elevated ambient temperatures, which affects their ability to meet demand while maintaining efficiency and compliance with emissions standards.

Innovation Solution

The TurboPHASE system, which includes an auxiliary compressor driven by a fueled engine, produces compressed air that is heated and injected into the gas turbine system to increase air flow and power output during peak demand and reduce maintenance costs by allowing greater turn-down capability during low demand periods, using a recuperator to transfer heat from the engine's exhaust to the compressed air.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Productivity

If gas turbines are cycled up and down in response to peak and low electrical demand, then the system can meet varying electrical demand, but maintenance costs increase severely

Engineering Contradiction:

Improveelectrical power outputVSAvoidmaintenance cost

Core Design Contradiction:

ProductivityVSEase of manufacture

Solution Approach 1:

The patent changes the operating parameters of the gas turbine by injecting compressed air into the combustor, allowing the turbine to maintain stable operation at lower power levels (turn-down capability) without cycling. This enables the turbine to operate continuously through load changes rather than cycling on and off, thereby reducing maintenance costs while meeting varying electrical demand

Inventive Principle:

Principle #35Parameter changes

2Productivity

If inlet guide vanes are closed to reduce air flow during low demand, then power output is reduced, but compressor safety and emissions compliance are compromised

Engineering Contradiction:

Improvepower outputVSAvoidcompressor safety

Core Design Contradiction:

ProductivityVSReliability

Solution Approach 1:

The patent introduces compressed air from an auxiliary compressor as an intermediary substance injected into the combustor. This injected air acts as a mediator that allows the main compressor to operate at higher flow rates (improving safety margin) while the injected air absorbs some of the load reduction requirement, enabling turn-down capability without compromising compressor safety

Inventive Principle:

Principle #24Intermediary (Mediator)

3Adaptability or versatility

If warm air is introduced to the inlet to improve compressor lower operating limit, then turn down capability increases, but system efficiency decreases due to lost compressor work

Engineering Contradiction:

Improveturn down capabilityVSAvoidcompressor work

Core Design Contradiction:

Adaptability or versatilityVSLoss of energy

Solution Approach 1:

The patent extracts compressed air from an auxiliary compressor driven by the gas turbine exhaust, rather than bleeding air from the main compressor. This extracted air is then injected into the combustor. The key difference is that the auxiliary compressor is driven by exhaust energy that would otherwise be wasted, so the work required to compress this air does not represent a loss of useful compressor work from the main compression system

Inventive Principle:

Principle #2Taking out (Extraction)

4Productivity

If fuel flow is reduced to decrease power output, then electrical demand is matched, but flame temperature drops and CO emissions increase

Engineering Contradiction:

Improveelectrical power outputVSAvoidCO emissions

Core Design Contradiction:

ProductivityVSObject-generated harmful factors

Solution Approach 1:

The patent changes the combustion parameters by injecting pre-compressed air into the combustor. This injected air modifies the combustion environment, allowing the flame temperature to be maintained at appropriate levels even when overall fuel flow is reduced to match lower electrical demand. By maintaining proper flame temperature, CO emissions are controlled while still achieving the desired power reduction

Inventive Principle:

Principle #35Parameter changes

Applied Scientific Principles

This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.

Function Achieved in This Case

This solution enhances the gas turbine's power output and efficiency during peak demand while reducing maintenance costs by allowing for increased turn-down capability during low demand, maintaining a relatively constant power increase across a range of ambient temperatures, and improving overall system regulation and capacity.

Implementation Method 1

operating the fueled engine to drive the auxiliary compressor to produce compressed air

Methodology Applied

Scientific EffectCompression: Compression

Implementation Method 2

using a recuperator to transfer heat from the engine's exhaust to the compressed air

Methodology Applied

Scientific EffectHeat transfer: Heat Exchanger

Implementation Method 3

injected into the gas turbine system to increase air flow and power output

Methodology Applied

Scientific EffectFluid flow:

Data Source

PatentUS10107199B2Aero boost—gas turbine energy supplementing systems and efficient inlet cooling and heating, and methods of making and using the same

Publication Date: 2018.10.23 POWERPHASE LLC

AI summary

The invention relates generally to electrical power systems, including generating capacity of a gas turbine, and more specifically to pressurized air injection that is useful for providing additional electrical power during periods of peak electrical power demand from a gas turbine system power plant, as well as to inlet heating to allow increased engine turn down during periods of reduced electrical demand.