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Advanced Turbine Systems Program conceptual design and product development. Quarterly report, November 1994--January 1995

Description: Objective of Phase II of the ATS Program is to provide the conceptual design and product development plan for anultra high efficiency, environmentally superior and cost competitive industrial gas turbine system to be commercialized by the year 2000. Technical progress covered in this report is confined to Task 4 (conversion to coal) and the nine subtasks under Task 8 (design and test of critical components). These nine subtasks address six ATS technologies: catalytic combustion, recuperator, autothermal fuel reformer, high temperature turbine disc, advanced control system, and ceramic materials.
Date: February 1, 1995
Partner: UNT Libraries Government Documents Department

Subpilot-scale testing of acoustically enhanced cyclone collectors. Final report, September 1988--September 1994

Description: Gas turbines are used to recover energy from high temperature exhaust gases in coal-fired pressurized-fluidized bed, combined-cycle power generation systems. However, prior to entering the turbine hot-section, the majority of the fly ash must be removed in order to protect the turbine components from erosion, corrosion, and deposition of the ash. The U.S. Department of Energy under the direction of the Morgantown Energy Technology Center (METC) sponsored the development of an acoustically enhanced cyclone collector which offers the potential of achieving environmental control standards under Pressurized Fluid Bed Combustors (PFBC) conditions without the need for post-turbine particulate control. Pulse combustors developed by Manufacturing and Technology Conversation International, Inc. (MTCI) produced the acoustic power necessary to agglomerate ash particles into sizes large enough to be collected in a conventional cyclone system. A hot gas cleanup system that meets both turbine protection and emissions requirements without post-turbine particulate controls would also have improved overall system economics.
Date: August 1, 1994
Creator: Galica, M.A.; Campbell, A.H. & Rawlins, D.C.
Partner: UNT Libraries Government Documents Department

Ceramic stationary gas turbine development. Final report, Phase 1

Description: This report summarizes work performed by Solar Turbines Inc. and its subcontractors during the period September 25, 1992 through April 30, 1993. The objective of the work is to improve the performance of stationary gas turbines in cogeneration through implementation of selected ceramic components.
Date: September 1, 1994
Partner: UNT Libraries Government Documents Department

Ceramic Stationary Gas Turbine Development. Technical progress report, April 1, 1993--October 31, 1994

Description: This report summarizes work performed by Solar Technologies Inc. and its subcontractors, during the period April 1, 1993 through October 31, 1994 under Phase II of the DOE Ceramic Stationary Gas Turbine Development program. The objective of the program is to improve the performance of stationary gas turbines in cogeneration through the implementation of selected ceramic components.
Date: December 1, 1994
Partner: UNT Libraries Government Documents Department

Ceramic stationary gas turbine

Description: The performance of current industrial gas turbines is limited by the temperature and strength capabilities of the metallic structural materials in the engine hot section. Because of their superior high-temperature strength and durability, ceramics can be used as structural materials for hot section components (blades, nozzles, combustor liners) in innovative designs at increased turbine firing temperatures. The benefits include the ability to increase the turbine inlet temperature (TIT) to about 1200{degrees}C ({approx}2200{degrees}F) or more with uncooled ceramics. It has been projected that fully optimized stationary gas turbines would have a {approx}20 percent gain in thermal efficiency and {approx}40 percent gain in output power in simple cycle compared to all metal-engines with air-cooled components. Annual fuel savings in cogeneration in the U.S. would be on the order of 0.2 Quad by 2010. Emissions reductions to under 10 ppmv NO{sub x} are also forecast. This paper describes the progress on a three-phase, 6-year program sponsored by the U.S. Department of Energy, Office of Industrial Technologies, to achieve significant performance improvements and emissions reductions in stationary gas turbines by replacing metallic hot section components with ceramic parts. Progress is being reported for the period September 1, 1994, through September 30, 1995.
Date: December 31, 1995
Creator: Roode, M. van
Partner: UNT Libraries Government Documents Department

Task 8.4 - High Temperature Turbine Disk Development

Description: The goal of this task is to demonstrate a bonding technique to produce a dual-alloy turbine disk concept which will satisfy the diverse property requirements of the rim and hub areas of the disk. The program examines methods of attaching a cast superalloy rim with sufficient rupture strength to a fine grain hub materials with the required LCF properties. The goals of the program were established in the context of a preliminary turbine design by Solar Turbines, Inc. designated ATS 5. The initial target for the ATS 5 application was to allow rim operating temperatures in the 1350-1400 {degrees} F range. The life goal of the Dual-Alloy Disk was envisioned to maintain Solar`s standard turbine disk philosophy of 1000,000 hours.
Date: February 27, 1997
Partner: UNT Libraries Government Documents Department

Task 8.6 -- Advanced man machine interface (MMI)

Description: The Solar/DOE ATS engine program seeks to improve the utilization of turbomachinery resources through the development of an Advanced Man Machine Interface (MMI). The program goals include timely and succinct feedback to the operations personnel to enhance their decision making process. As part of the Solar ATS Phase 2 technology development program, enabling technologies, including graphics environments, communications technology, and operating systems were explored to determine their viability to support the overall MMI requirements. This report discusses the research and prototyping effort, as well as the conclusions reached.
Date: December 31, 1997
Partner: UNT Libraries Government Documents Department

Task 8.8 -- Low cost ceramic materials

Description: This subtask was originally titled ``Reheat Combustor Materials`` and was proposed in anticipation of the addition of a reheat combustor to the ICR gas turbine cycle. When the emphasis of ATS became the optimized recuperated cycle, the goal of the subtask was changed to the evaluation of low cost materials for gas turbine combustor liners. It now supplements similar work being conducted by Solar under DOE Contract No.DE-ACO2-92-CE40960, titled ``Ceramic Stationary Gas Turbine (CSGT) Development.`` The use of a ceramic combustor liner in gas turbines contributes to emissions reductions by freeing cooling air for use as primary combustion air and by allowing higher wall temperatures, which contribute to more complete combustion of hydrocarbons. Information from a literature survey, manufacturer`s data, and Solar`s experience was used to select three materials for testing. In addition to material properties requirements for selection, subscale combustor liner cost was required to be at least half of the high modulus continuous fiber reinforced composite part cost. The three materials initially selected for evaluation are listed in Table 1. Four hour subscale rig tests were planned for eight inch diameter liners made from each material. Upon successful completion of each four hour test, a fifty hour test was planned.
Date: June 30, 1997
Partner: UNT Libraries Government Documents Department

Task 8.9 - Advanced ceramic materials

Description: Advanced ceramic materials such as Continuous Fiber Reinforced Ceramic Matrix Composites (CFCCs) have had promising results on the companion program entitled ``Ceramic Stationary Gas Turbine`` (CSGT). In particular, CFCCs have outperformed monolithic tiles in structural integrity as a combustor liner. Also, CFCCs have provided the higher temperature operation and improved emissions performance that is required for the ATS combustor. The demonstrated advantages on CSGT justified work to explore the use of advanced ceramic composite materials in other gas turbine components. Sub-tasks include development of a practical, cost effective component fabrication process, development of finite element stress analysis to assure 30,000 hours of component life, and fabrication of a demonstration article.
Date: June 30, 1997
Partner: UNT Libraries Government Documents Department

Task 8.2 - subscale catalytic combustor development

Description: The Solar/DOE ATS engine program seeks to reduce engine pollutant emissions to single digit levels and low pattern factor. Program goals include the attainment of emissions (NOx, CO and UHC corrected to 15% O{sub 2}) below 10 ppmvd over the 50 to 100% load range, pattern factor less than 0.2, and long term combustor component durability. Recent improvements in Solar`s dry low NOx combustion technology guarantee less than 25 ppmvd NOx and 50 ppmvd CO (@ 15% O{sub 2}) in field units. It is expected that with the incorporation of advanced combustion technology (e.g. variable geometry, use of ceramics in combustion liners, improved CO sensor based control systems, improved fuel-air premixing, advanced liner cooling, etc.) into present combustion systems, substantial reductions in emissions over currently guaranteed levels will be possible. However, the next generation of low emissions gas turbines may be required to incorporate catalytic combustion to guarantee the lowest possible levels of pollutant emissions with available technology, As part of the Solar ATS Phase II program, catalytic combustion was selected as the primary combustion approach capable of attaining the emissions goals of the ATS program for medium sized industrial gas turbines. Catalytic combustion technology development in Phase II consisted of two main tasks: Task 2.8.2 involving the evaluation and demonstration of catalytic combustion technology at simulated engine conditions in a subscale rig environment, and Task 2.8.5 involving the design and evaluation of a single can full scale catalytic combustion system based on subscale results. Successful full scale rig operation will be followed by sector rig testing, and the procurement of a full set of engine hardware for an engine demonstration as part of Solar ATS Phase III program, If successful in the ATS program, catalytic combustion will be introduced in Solar`s production turbines depending on market requirements and cost.
Date: August 15, 1996
Partner: UNT Libraries Government Documents Department

Solar turbines perspective on advanced fuel cell/gas turbine systems

Description: Solar Turbines Inc. has a vested interest in integrating gas turbines and high-temperature fuel cells(eg, solid oxide fuel cells (SOFCs)). Approach is to develop more efficient recuperated engines, which would be followed by more efficient intercooled and recuperated engines and finally by a humid air turbine cycle system. This engine system would be capable of providing efficiencies on the order of 60% with potentially low exhaust emissions. Because of possible fossil fuel shortages and severe CO{sub 2} emissions regulations, Solar adopted an alternative approach in the development of high efficiency machines; it involves combining SOFCs with recuperated gas turbines. Preliminary results show that the performance of TCPS (Tandem Cycle Unified Power System) is much better than expected, especially the efficiency. Costs are acceptable for the introductory models, and with full production, cost reductions will make the system competitive with all future energy conversion systems of the same power output. Despite the problems that must be overcome in creating a viable control system, it is believed that they are solvable. The efficiency of TCPS would be synergetic, ie, higher than either fuel cell or gas turbine alone.
Date: December 31, 1996
Creator: White, D.J.
Partner: UNT Libraries Government Documents Department

Task 4 -- Conversion to a coal-fueled advanced turbine system (CFATS)

Description: Solar is developing the technologies for a highly efficient, recuperated, Advanced Turbine System (ATS) that is aimed at the dispersed power generation market. With ultra-low-emissions in mind the primary fuel selected for this engine system is natural gas. Although this gas fired ATS (GFATS) will primarily employ natural gas the use of other fuels particular those derived from coal and renewable resources cannot be overlooked. The enabling technologies necessary to direct fire coal in gas turbines were developed during the 1980`s. This Solar development co-sponsored by the US Department of Energy (DOE) resulted in the testing of a full size coal-water-slurry fired combustion system. In parallel with this program the DOE funded the development of integrated gasification combined cycle systems (IGCC). This report describes the limitations of the Solar ATs (recuperated engine) and how these lead to a recommended series of modifications that will allow the use of these alternate fuels. Three approaches have been considered: direct-fired combustion using either a slagging combustor, or a pressurized fluidized bed (PFBC), externally or indirectly fired approaches using pulverized fuel, and external gasification of the fuel with subsequent direct combustion of the secondary fuel. Each of these approaches requires substantial hardware and system modifications for efficient fuel utilization. The integration issues are discussed in the sections below and a recommended approach for gasification is presented.
Date: April 15, 1996
Partner: UNT Libraries Government Documents Department

Advanced turbine systems program conceptual design and product development task 5 -- market study of the gas fired ATS. Topical report

Description: Solar Turbines Incorporated (Solar), in partnership with the Department of Energy, will develop a family of advanced gas turbine-based power systems (ATS) for widespread commercialization within the domestic and international industrial marketplace, and to the rapidly changing electric power generation industry. The objective of the jointly-funded Program is to introduce an ATS with high efficiency, and markedly reduced emissions levels, in high numbers as rapidly as possible following introduction. This Topical Report is submitted in response to the requirements outlined in Task 5 of the Department of Energy METC Contract on Advanced Combustion Systems, Contract No, DE AC21-93MC30246 (Contract), for a Market Study of the Gas Fired Advanced Turbine System. It presents a market study for the ATS proposed by Solar, and will examine both the economic and siting constraints of the ATS compared with competing systems in the various candidate markets. Also contained within this report is an examination and analysis of Solar`s ATS and its ability to compete in future utility and industrial markets, as well as factors affecting the marketability of the ATS.
Date: May 1, 1995
Partner: UNT Libraries Government Documents Department

Advanced turbine systems program conceptual design and product development: Task 8.1, Low-pressure drop recuperator

Description: Purpose of the ATS program is to develop a new baseline for industrial gas turbine systems for the 21st century. A recuperated gas turbine cycle was selected; the eventual engine that result will utilize Solar`s Primary Surface Recuperator (PSR) technology. Besides higher thermal efficiency, other goals included lower emission, cost of power, and improved RAMD (reliability, availability, maintainability). Performance data have been obtained for the candidate heat transfer surface, and on a scaled rig. Pretest predictions of air-side and gas-side pressure drop were in very good agreement with tests results; predicted effectiveness also agreed well with experiment. A flattened tube test to determine changes of the PSR heat transfer surface profile after exposure is underway.
Date: September 1, 1995
Partner: UNT Libraries Government Documents Department

Advanced Turbine Systems Program industrial system concept development

Description: Solar approached Phase II of ATS program with the goal of 50% thermal efficiency. An intercolled and recuperated gas turbine was identified as the ultimate system to meet this goal in a commercial gas turbine environment. With commercial input from detailed market studies and DOE`s ATS program, Solar redefined the company`s proposed ATS to fit both market and sponsor (DOE) requirements. Resulting optimized recuperated gas turbine will be developed in two sizes, 5 and 15 MWe. It will show a thermal efficiency of about 43%, a 23% improvement over current industrial gas turbines. Other ATS goals--emissions, RAMD (reliability, availability, maintainability, durability), cost of power--will be met or exceeded. During FY95, advanced development of key materials, combustion and component technologies proceeded to the point of acceptance for inclusion in ATS Phase III.
Date: December 31, 1995
Creator: Gates, S.
Partner: UNT Libraries Government Documents Department

Advanced turbine systems program conceptual design and product development. Annual report, August 1993--July 1994

Description: This Yearly Technical Progress Report covers the period August 3, 1993 through July 31, 1994 for Phase 2 of the Advanced Turbine Systems (ATS) Program by Solar Turbines Incorporated under DOE Contract No. DE-AC421-93MC30246. As allowed by the Contract (Part 3, Section J, Attachment B) this report is also intended to fulfill the requirements for a fourth quarterly report. The objective of Phase 2 of the ATS Program is to provide the conceptual design and product development plan for an ultra-high efficiency, environmentally superior and cost-competitive industrial gas turbine system to be commercialized in the year 2000. During the period covered by this report, Solar has completed three of eight program tasks and has submitted topical reports. These three tasks included a Project Plan submission of information required by NEPA, and the selection of a Gas-Fueled Advanced Turbine System (GFATS). In the latest of the three tasks, Solar`s Engineering team identified an intercooled and recuperated (ICR) gas turbine as the eventual outcome of DOE`s ATS program coupled with Solar`s internal New Product Introduction (NPI) program. This machine, designated ``ATS50`` will operate at a thermal efficiency (turbine shaft power/fuel LHV) of 50 percent, will emit less than 10 parts per million of NOx and will reduce the cost of electricity by 10 percent. It will also demonstrate levels of reliability, availability, maintainability, and durability (RAMD) equal to or better than those of today`s gas turbine systems. Current activity is concentrated in three of the remaining five tasks a Market Study, GFATS System Definition and Analysis, and the Design and Test of Critical Components.
Date: November 1, 1994
Partner: UNT Libraries Government Documents Department

Advanced turbine systems program conceptual design and product development. Annual report, August 1994--July 1995

Description: This report summarizes the tasks completed under this project during the period from August 1, 1994 through July 31, 1994. The objective of the study is to provide the conceptual design and product development plan for an ultra high efficiency, environmentally superior and cost-competitive industrial gas turbine system to be commercialized by the year 2000. The tasks completed include a market study for the advanced turbine system; definition of an optimized recuperated gas turbine as the prime mover meeting the requirements of the market study and whose characteristics were, in turn, used for forecasting the total advanced turbine system (ATS) future demand; development of a program plan for bringing the ATS to a state of readiness for field test; and demonstration of the primary surface recuperator ability to provide the high thermal effectiveness and low pressure loss required to support the proposed ATS cycle.
Date: November 1, 1995
Partner: UNT Libraries Government Documents Department

Advanced turbine systems program conceptual design and product development. Quarterly report, August--October, 1994

Description: The objective of Phase 2 of the Advanced Turbine Systems (ATS) Program is to provide the conceptual design and product development plan for an ultra-high efficiency, environmentally superior and cost competitive industrial gas turbine system to be commercialized by the year 2000. A secondary objective is to begin early development of technologies critical to the success of ATS. During this report period, the following tasks were completed: Market study; System definition and analysis; and Integrated program plans. Progress on Task 8, Design and Test of Critical Components, is also discussed. This particular task includes expanded materials and component research covering recuperators, combustion, autothermal fuel reformation, ceramics application and advanced gas turbine system controls.
Date: January 1, 1995
Partner: UNT Libraries Government Documents Department

Advanced turbine systems program conceptual design and product development. Quarterly report, February 1995--April 1995

Description: This Quarterly Technical Progress Report covers the period February 1, 1995, through April 30, 1995, for Phase II of the Advanced Turbine Systems (ATS) Program by Solar Turbines Incorporated under DOE contract No. DE-AC21-93MC30246. The objective of Phase II of the ATS Program is to provide the conceptual design and product development plan for an ultra high efficiency, environmentally superior and cost competitive industrial gas turbine system to be commercialized by the year 2000. A secondary objective is to begin early development of technologies critical to the success of ATS. Tasks 1, 2, 3, 5, 6 and 7 of Phase II have been completed in prior quarters. Their results have been discussed in the applicable quarterly reports and in their respective topical reports. With the exception of Task 7, final editions of these topical reports have been submitted to the DOE. This quarterly report, then, addresses only Task 4 and the nine subtasks included in Task 8, {open_quotes}Design and Test of Critical Components.{close_quotes} These nine subtasks address six ATS technologies as follows: (1) Catalytic Combustion - Subtasks 8.2 and 8.5, (2) Recuperator - Subtasks 8.1 and 8.7, (3) Autothermal Fuel Reformer - Subtask 8.3, (4) High Temperature Turbine Disc - Subtask 8.4, (5) Advanced Control System (MMI) - Subtask 8.6, and (6) Ceramic Materials - Subtasks 8.8 and 8.9. Major technological achievements from Task 8 efforts during the quarter are as follows: (1) The subscale catalytic combustion rig in Subtask 8.2 is operating consistently at 3 ppmv of NO{sub x} over a range of ATS operating conditions. (2) The spray cast process used to produce the rim section of the high temperature turbine disc of Subtask 8.4 offers additional and unplanned spin-off opportunities for low cost manufacture of certain gas turbine parts.
Date: July 1, 1995
Creator: Karstensen, K.W.
Partner: UNT Libraries Government Documents Department

Industrial Advanced Turbine Systems: Development and Demonstration. Annual report, September 14, 1995--September 30, 1996

Description: The U.S. Department of Energy (DOE) has initiated a program for advanced turbine systems (ATS) that will serve industrial power generation markets. The objective of the cooperative agreements granted under the program is to join the DOE with industry in research and development that will lead to commercial offerings in the private sector. The ATS will provide ultra-high efficiency, environmental superiority, and cost competitiveness. The ATS will foster (1) early market penetration that enhances the global competitiveness of U.S. industry, (2) public health benefits resulting from reduced exhaust gas emissions of target pollutants, (3) reduced cost of power used in the energy-intensive industrial marketplace and (4) the retention and expansion of the skilled U.S. technology base required for the design, development and maintenance of state-of-the-art advanced turbine products. The Industrial ATS Development and Demonstration program is a multi-phased effort. Solar Turbines Incorporated (Solar) has participated in Phases 1 and 2 of the program. On September 14, 1995 Solar was awarded a Cooperative Agreement for Phases 3 and 4 of the program (DE-FC21-95MC31173) by the DOE`s Office of Energy Efficiency and Renewable Energy (EE). Technical administration of the Cooperative Agreement will be provided from EE`s Chicago Operations Office. Contract administration of the Cooperative Agreement will be provided from DOE`s Office of Fossil Energy, Morgantown Energy Technology Center (METC).
Date: December 31, 1998
Partner: UNT Libraries Government Documents Department

Industrial advanced turbine systems: Development and demonstration. Quarterly report, January 1--March 31, 1998

Description: The US Department of Energy (DOE) has initiated a program for advanced turbine systems (ATS) that will serve industrial power generation markets. The objective of the cooperative agreements granted under the program is to join the DOE with industry in research and development that will lead to commercial offerings in the private sector. The ATS will provide ultra-high efficiency, environmental superiority, and cost competitiveness. The ATS will foster (1) early market penetration that enhances the global competitiveness of US industry, (2) public health benefits resulting from reduced exhaust gas emissions of target pollutants, (3) reduced cost of power used in the energy-intensive industrial marketplace, and (4) the retention and expansion of the skilled US technology base required for the design, development and maintenance of state-of-the-art advanced turbine products. The Industrial ATS Development and Demonstration program is a multi-phased effort. Solar Turbines Incorporated (Solar) has participated in Phases 1 and 2 of the program. On September 14, 1995 Solar was awarded a Cooperative Agreement for Phases 3 and 4 of the program. Phase 3 of the work is separated into two subphases: Phase 3A entails Component Design and Development; Phase 3B will involve Integrated Subsystem Testing. Phase 4 will cover Host Site Testing. As of the end of the reporting period work on the program is 29.1% complete (24.7% last quarter). Work on the Mercury 50 development and ATS technology development portions of the program (WBS 10000 et seq) is 48.9% complete (41.6% last quarter). Estimates of percent complete are based upon milestones completed. In order to maintain objectivity in assessing schedule progress, Solar uses a 0/100 percent complete assumption for milestones rather than subjectively estimating progress toward completion of milestones. Cost and schedule variance information is provided in Section 4.0 Program Management.
Date: August 1, 1998
Partner: UNT Libraries Government Documents Department

Advanced Turbine Systems Program -- Conceptual design and product development. Quarterly report, August 1--October 31, 1995

Description: The objective of Phase 2 of the Advanced Turbine Systems (ATS) Program is to provide the conceptual design and product development plan for an ultra high efficiency, environmentally superior and cost competitive industrial gas turbine system to be commercialized by the year 2000. A secondary objective is to begin early development of technologies critical to the success of ATS. This quarterly report, addresses only Task 4, conversion of a gas turbine to a coal-fired gas turbine, which was completed during the quarter and the nine subtasks included in Task 8, design and test of critical components. These nine subtasks address six ATS technologies as follows: catalytic combustion; recuperator; autothermal fuel reformer; high temperature turbine disc; advanced control system (MMI); and ceramic materials.
Date: December 31, 1995
Partner: UNT Libraries Government Documents Department

Fuel cell and advanced turbine power cycle

Description: Solar has a vested interest in integration of gas turbines and high temperature fuels (particularly solid oxide fuel cells[SOFC]); this would be a backup for achieving efficiencies on the order of 60% with low exhaust emissions. Preferred cycle is with the fuel cell as a topping system to the gas turbine; bottoming arrangements (fuel cells using the gas turbine exhaust as air supply) would likely be both larger and less efficient unless complex steam bottoming systems are added. The combined SOFC and gas turbine will have an advantage because it will have lower NOx emissions than any heat engine system. Market niche for initial product entry will be the dispersed or distributed power market in nonattainment areas. First entry will be of 1-2 MW units between the years 2000 and 2004. Development requirements are outlined for both the fuel cell and the gas turbine.
Date: December 31, 1996
Creator: White, D.J.
Partner: UNT Libraries Government Documents Department

Industrial Advanced Turbine Systems Program overview

Description: DOE`s ATS Program will lead to the development of an optimized, energy efficient, and environmentally friendly gas turbine power systems in the 3 to 20 MW class. Market studies were conducted for application of ATS to the dispersed/distributed electric power generation market. The technology studies have led to the design of a gas-fired, recuperated, industrial size gas turbine. The Ceramic Stationary Gas Turbine program continues. In the High Performance Steam Systems program, a 100 hour development test to prove the advanced 1500 F, 1500 psig system has been successfully completed. A market transformation will take place: the customer will be offered a choice of energy conversion technologies to meet heat and power generation needs into the next century.
Date: December 31, 1995
Creator: Esbeck, D.W.
Partner: UNT Libraries Government Documents Department