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“Ceramic Matrix Composite AdvancedTransition for 65% Combined Cycle Efficiency”DE-FE0023955
UTSR 2016 Conference
01-Nov- 2016
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Page 2 Jonathan Shipper / Siemens Energy Inc.CMC Advanced Transition
CMC Advanced Transition for η > 65% CCProgram Overview
Content of Today’s Presentation
CMC Technology Development33
22
11 Towards a 65% CC efficient power plant
Proposed CMC AT for high TIT / Low NOx
Conclusions & Next Steps44
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Towards a 65% CC system
SGT6-8000HSGT6-5000F
SGT6-2000E
SGT6-6000G
DOE targets are driving a step change in GT combustion technology
DOE FOA:R&D complete by 2020
with deployment by 2025
Silocombustor
ULNCombustor
Next GenCombustor
* 60Hz Demonstrated Commercial operation
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Towards a 65% CC system
4
65% CC efficiency targets Firing Temperature > 1700ºC
Source: Ibrahim et. al (2012)
Brayton Cycle
• Plant output and efficiencyimproved by raising the top ofthe cycle
• i.e. Higher firingtemperature and pressure.
Rankine Cycle• Plant output and efficiency
improved with betterutilization of GT Exhaustenergy.
• i.e. Higher bottoming steamtemperature and pressure.
Brayton Cycle Rankine Cycle
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Combustion Technology “jumps” are required to shift NOx curve right
Siemens Solution to Program Challenge:Combustion Development
w/diluent
65% CCtargetcurve
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Parallel Combustion approaches for NOx reduction
Siemens Solution to Program Challenge:Combustion Development
65% CCtargetcurvew/diluent
Enablers:• Increase premixing quality• Decrease residence time• Diluents
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• Focus of this program is on Cooling & Leakage Air Reduction for Low NOx• Lower required flame temperature for a given TIT⇓ Reduced NOx
Siemens Solution to Program Challenge:Combustion Development
Original65% CCtargetcurve
New65% CCtargetcurve
Enablers:• Reduced Cooling &
Leakage Air
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Enablers: Advanced Transitions (AT)
Advanced Transition (AT) ⇓Reduced Cooling air consumption
AHE + AT
• Developed during DOE-H2program (DE-FC26-05NT42644)
• Allows for reduction ofcooling air
• Low NOx at J-classconditions
• System residence time notoptimized for 65% CCoperating conditions
AdvancedTransition (AT)
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Ceramic Matrix Composite Advanced Transition for65% Combined Cycle EfficiencyIntroduction
ƒ Objective:ƒ Phase 2: Design a CMC inlet for
Siemens Advanced Transition
ƒ Benefits:ƒ Reduction in Cooling Air⇓ NOx
reduction or RIT increaseƒ CO reduction (eliminate wall quenching)ƒ Reduced aero losses
• Due to cooling air mixing• Due to cooling air ducting
ƒ Premise:ƒ Existing Siemens’ CMC materialƒ No through-wall cooling (backside only)ƒ Shape conducive to CMC manufactureƒ Durability demonstrated in 25K hr testƒ Readily tested in combustor rigs
Concept schematic
Experience base
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Ceramic Matrix Composite Advanced Transition for65% Combined Cycle EfficiencyBenefits: Cooling Air Reduction
⇓ NOx emissions reduction at High Firing Temperatures
CMCInlet
CMC Inlet& Exit
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Ceramic Matrix Composite Advanced Transition for65% Combined Cycle EfficiencySiemens’ Hybrid CMC Technology
>
Reduction in coolingvs. TBC/metal
Increased surfacetemperature limit
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Ceramic Matrix Composite Advanced Transition for65% Combined Cycle EfficiencyCMC Technology Status
Combining two high pay-off technologies individually developed & tested
Siemens’AdvancedTransitionBlade Tip
Seals enginetested
Airfoils demonstratedin rig testing
+
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Ceramic Matrix Composite Advanced Transition for65% Combined Cycle EfficiencyCMC Component Testing Summary
ƒ Bench testingƒ Mechanical, thermal, fatigue,
impact, etc.
ƒ Rig testingƒ Simulated engine conditionsƒ Durability under combined
loadingsƒ Subscale & Full Scale
components
ƒ Engine testingƒ Customer site / durabilityƒ BTF engine
Ring segments (4 types), airfoils, subelements
Combustors, Airfoils, Ring segments (4 types)
Combustor Ring Segment
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ƒ Siemens Hybrid Oxide CMCsystem (FGI thermal barrier)
ƒ Filament wound combustorouter liner (made by COIC)
ƒ Operated in Solar Centaur 50™engine.ƒ 25,404 hours / 109 cycles;ƒ Bakersfield, CAƒ Still serviceable
ƒ Surface & CMC temperaturesrepresentative of AT inlet
This test demonstrated CMC durability in a turbine engineenvironment for representative component lifetime
Ceramic Matrix Composite Advanced Transition for65% Combined Cycle EfficiencyHybrid Oxide CMC Combustor Liner
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Ceramic Matrix Composite Advanced Transition for65% Combined Cycle EfficiencyCMC Manufacturing Options
Fabric Lay-up Vs. Filament Winding
• Both manufacturing approaches are feasible for most AT inlet concepts• Concepts with out-of-plane features more conducive to fabric lay-up
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Ceramic Matrix Composite Advanced Transition for65% Combined Cycle EfficiencyCMC Ring Segment Engine Test
Features:
Reduced Cooling from metalbaseline design
Tip seal improvement features
Retrofittable design
High temperature sealing
Full engine set: Tested successfully for > 50 hours
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Siemens Project Team
Siemens has assembled a multi-disciplinary team of internal experts andexternal vendors and partners to successfully execute this program.
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Schedule & Major Milestones
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Ceramic Matrix Composite Advanced Transition for65% Combined Cycle EfficiencyTechnology Development
PHASE 2Technology Development & Testing
PHASE 1Concept Feasibility
PHASE 3Technology Demonstration
Conceptual Design
Manufacture & Combustor Rig Testing
Engine Testing
Technology Progression for Future Phases identified
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Ceramic Matrix Composite Advanced Transition for65% Combined Cycle EfficiencyCMC AT Concept Down-selection Process
49
9Milestone Sept 2015⇓ Two Concepts
Structural CMC’s Heat Shields
5
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Two Cooling Options:1. Shell air circulation⇓ feasibility shown with 1D heat transfer2. Radiation cooling⇓ used on Solar combustor liner design
Both eliminate active (chargable) cooling
Ceramic Matrix Composite Advanced Transition for65% Combined Cycle EfficiencyHeat Transfer⇓ CMC with backside cooling
Shell Air Circulation Radiation Cooling
Radiation cooling method proven effective inprevious combustion testsInsulating characteristic of Hybrid Oxide CMC
enables use of low cooling coefficients(similar to levels in engine midframe)
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Ceramic Matrix Composite Advanced Transition for65% Combined Cycle EfficiencySupporting CMC Data & Remaining Challenges
Coupon Test Data Damage Accumulation & Life Prediction Tools
Remaining Design / Materials Challenges• Sealing methods for high temperature
• Metal-to-CMC Interfaces:• Wear resistance (anti-wear coatings)• Contact stresses / inserts / compliant layers
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Ceramic Matrix Composite Advanced Transition for65% Combined Cycle EfficiencyMicromechanics Modeling (MAC/GMC)
• Model calibrated and matches test data• Works interactively with FEA
• Constitutive model (fiber & matrix properties)• Iteratively best-fit to a series of test data (different geometries)• Matches stress-strain behavior of simple (uniaxial) and complex shape (multiaxial stress)
test data
Stre
ss
Strain
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Ceramic Matrix Composite Advanced Transition for65% Combined Cycle EfficiencyCMC Structures and Numerical Modeling
Bi-Directional DesignOptimization
Hi-Fidelity DamageSimulation
• Advanced Simulation Methods Calibrated to Lab and Sub ComponentTesting to Provide Accurate and Robust Design Rules.
Solid Mesh
NXR CAD
Workbench
ANSYS ACP
Production Layup
FE BestPractices
ConstitutiveModels &
FailureCriteria
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Objective:Simulate TBC failure under pseudo enginecondition (high heat flux, backside cooling)
Application of HHFT:• Down select coating• Characterize CMC/Coating system behavior
TBC Testing
Monitor hot sidetemperature
Monitor cold sidetemperature
TBC coated sample
Heat input(Flame or laser)
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Combustor Rig Testing
Siemens Clean Energy CentreAdvanced Transition test rig
CMC Advanced Transition Inlet section will be tested in this dedicated rigfacility (full scale; full pressure; full flow; full temperature)
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Acknowledgements
• This work is performed under US Department of Energy Award Number DE-FE0023955.
• This program is based upon prior work supported by the US Department of Energy,under Award Number DE-FC26-05NT42644.
• The Siemens team wishes to thank Dr. Seth Lawson, NETL Project Manager and Mr.Rich Dennis, NETL Turbine Technology Manager for the opportunity to collaborate on thedevelopment of these novel technologies.
&
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Answers for Energy.
Thank You. Questions?
Jay MorrisonProgram Manager - Ceramic Matrix CompositeAdvanced Transition for 65% Combined CycleEfficiency
Siemens Energy Inc.4400 Alafaya TrailOrlando, FL 32826Phone: +1 (407) 736-2000
E-mail:jay.morrison@siemens.com