Turbo-Expander Augments Compressor Airflow for Power Output
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Solution Overview
Problem
Existing power generation systems face challenges in increasing power output on demand, especially on hot days, due to decreased compressor flow and the high costs associated with upgrading older gas turbine systems to accommodate higher capacity compressors, which require simultaneous upgrades of other expensive system components.
Innovation Solution
A power generation system that includes a gas turbine system with an integral compressor having a higher flow capacity than the turbine component and combustor, utilizing a turbo-expander and eductor to manage excess air flow, allowing for the augmentation of air flow without the need for extensive system upgrades, by directing the excess air flow to the turbo-expander and then back to the compressor inlet.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If a higher capacity compressor is installed to increase air flow, then power output is improved, but the cost of upgrading other system components increases
Solution Approach 1:
The system segments the compressor output into two separate pathways: one pathway supplies air to the combustor and turbine (maintaining existing component compatibility), while the other pathway directs excess air to a turbo-expander. This segmentation allows the high-capacity compressor to operate without requiring upgrades to other system components, as the excess air is utilized independently through the turbo-expander system.
Solution Approach 2:
The turbo-expander acts as an intermediary component that receives excess air from the compressor and converts it into useful work to drive the generator. This intermediary mechanism enables the system to utilize the additional air flow capacity without directly upgrading the combustor or turbine, thereby reducing overall system upgrade costs.
2Productivity
If a storage vessel is added to increase air flow to the combustor, then power output is improved, but the need for a separate power source increases system complexity
Solution Approach 1:
The system employs self-service principles by using the excess air flow generated by the high-capacity compressor itself as the driving force for the turbo-expander. The excess air, which would otherwise be wasted, is converted into useful work to drive the generator, eliminating the need for a separate power source or additional storage vessels.
Solution Approach 2:
Instead of discarding the excess air flow as waste, the system recovers it by directing it to the turbo-expander. The excess air is converted into useful mechanical work to drive the generator, thereby recovering the value of what would otherwise be wasted air flow and eliminating the need for additional power sources.
3Quantity of substance
If compressor flow capacity is increased, then air flow to combustor is improved, but compressor efficiency decreases due to mismatch with combustor intake capacity
Solution Approach 1:
The system segments the compressor output into two separate pathways: one pathway supplies air to the combustor (maintaining efficient operation within combustor capacity limits), while the other pathway directs excess air to a turbo-expander. This segmentation allows the high-capacity compressor to operate efficiently by utilizing its full flow capacity without forcing all air through the combustor, thereby maintaining compressor efficiency while increasing total air flow capability.
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 power generation efficiency and output on hot days while reducing the costs associated with upgrading the entire system, as it efficiently utilizes the excess air flow to improve compressor performance without requiring extensive upgrades to other components.
Implementation Method 1
an eductor positioned in the excess air flow path for using the excess air flow as a motive force to augment the excess air flow with additional air
Implementation Method 2
a turbo-expander for powering the generator
Implementation Method 3
a multi-stage axial flow compressor having a rotating shaft. Air enters the inlet of the compressor and is compressed by the compressor blade stages
Data Source
AI summary
A power generation system may include a generator, and a gas turbine system for powering the generator, the gas turbine system including a turbine component, an integral compressor and a combustor to which air from the integral compressor and fuel are supplied, the combustor arranged to supply hot combustion gases to the turbine component, and the integral compressor having a flow capacity greater than an intake capacity of at least one of the combustor and the turbine component, creating an excess air flow. A turbo-expander may also power the generator. A first control valve control flow of the excess air flow along an excess air flow path to an inlet of the turbo-expander. An educator may be positioned in the excess air flow path for using the excess air flow as a motive force to augment the excess air flow with additional air. A discharge of the turbo-expander is supplied to an inlet of the integral compressor.