Gas Turbine Inlet Air Cooling System

The 3rd Annual Australian Gas Turbine Conference

6th – 7th December 2001

Melbourne
Australia

Presented by

Bob Omidvar
Manager, Power Engineering
PB Power Australia

PB Power
Heavy Duty GT - Effects of Ambient Temp

110%

105%

100%

95%

90%

85%

80%

75%
0 5 10 15 20 25 30 35 40 45
GT Inlet Temp (deg C)

Heat rate kJ/kWh Power output MW Exhaust flow t/h Exhaust temperature °C

PB Power
 Aero-Derivative GT - Effects of Ambient Temp

120%

110%

100%

90%

80%

70%

60%
0 5 10 15 20 25 30 35 40 45

GT Inlet Temp (deg C)

Exhaust temperature C Heat rate kJ/kWh Power output MW Exhaust flow t/h

PB Power
Gas Turbine Performance Design Basis
What Does ISO Condition Mean?

! Dry bulb 15°C

! Relative humidity 60%

! Wet bulb temperature 7.2°C

! Atmospheric pressure 1 bar (sea level)

Most of the gas turbine installations are not in ISO

standard locations, they are in the real world

PB Power
Ambient Air and Gas Turbine Performance
1. Air density is inversely related to the dry bulb temperature
2. Gas turbine output depends on mass flow and not the
volume of air
3. Ambient temperature affects the following points drastically
" Air flow
" Output
" Heat rate
" Exhaust temperature

PB Power
 Gas Turbine Inlet Air Cooling
Available Technologies
1. Evaporative cooler
2. Fogging system
3. Mechanical refrigeration system (direct type)
4. Mechanical refrigeration system (indirect type)
5. Mechanical refrigeration with ice storage
6. Mechanical refrigeration system with chilled water storage
7. Single stage Lithium Bromide Absorption chiller
8. Two stage Lithium Bromide Absorption chiller

PB Power
 Gas Turbine Inlet Air Cooling
Available Technologies
1. Evaporative cooler
2. Fogging system
3. Mechanical refrigeration system (direct type)
4. Mechanical refrigeration system (indirect type)
5. Mechanical refrigeration with ice storage
6. Mechanical refrigeration system with chilled water storage
7. Single stage Lithium Bromide Absorption chiller
8. Two stage Lithium Bromide Absorption chiller

PB Power
 Schematic of Evaporative Air Cooling
shown with Optional Water Treatment

Combustion
Air
Water Tank

Air Wetted
Filter Media

Water
Treatment

Make
Up Blow down
Exhaust Gas Fuel

Combustion Turbine

PB Power
 Evaporative Cooler
Applications: Areas where RH and wet bulb temperature is rather low

Advantage Disadvantage
# Lowest capital cost # Limitation on capacity
improvement
# Lowest O&M cost
# Highly influenced by the
# Can operate on raw water site wet bulb
# Quick delivery and
installation time
# Operates as an air washer
and cleans the inlet air

PB Power
 Gas Turbine Inlet Air Cooling
Available Technologies
1. Evaporative cooler
2. Fogging system
3. Mechanical refrigeration system (direct type)
4. Mechanical refrigeration system (indirect type)
5. Mechanical refrigeration with ice storage
6. Mechanical refrigeration system with chilled water storage
7. Single stage Lithium Bromide Absorption chiller
8. Two stage Lithium Bromide Absorption chiller

PB Power
 Schematic of Fog Inlet Air Cooling System
Utilizing Demineralised Water
Raw
Water

Demineralised
Demineralised
Water Treatment
Water Tank
Plant

Combustion
Air

Fog
Air
Spray
Filter
System

Exhaust Gas Fuel

Combustion Turbine

PB Power
 Fog Systems

PB Power
Demineralised Water Quality For Fog
System Inlet Air Cooling

Total dissolved solids 5 PPM maximum

pH 6-8
Na + K 0.1 PPM maximum
Silica (SiO2) 0.1 PPM maximum
Chlorides 0.5 PPM maximum
Sulphate 0.5 PPM maximum

PB Power
 Fogging System Demin. Water Consumption
Inlet air 36°C DB, 25°C WB
Chilled air temp 25.5°C DB 25°C WB, 96%RH

10
9
8
7
6
t/h

5
4
3
2
1
0
0 25 50 75 100 125 150 175 200 225 250

Gas Turbine Output MW

PB Power
 Fogging System
Applications: Areas where RH and wet bulb temperature is rather low

Advantage Disadvantage
# Low capital cost # Limitation on capacity
improvement
# Low O&M cost
# Highly influenced by the
# Can increase gas turbine site wet bulb
performance better than
evaporative cooling
# Quick delivery and
installation time

PB Power
 Gas Turbine Inlet Air Cooling
Available Technologies
1. Evaporative cooler
2. Fogging system
3. Mechanical refrigeration system (direct type)
4. Mechanical refrigeration system (indirect type)
5. Mechanical refrigeration with ice storage
6. Mechanical refrigeration system with chilled water storage
7. Single stage Lithium Bromide Absorption chiller
8. Two stage Lithium Bromide Absorption chiller

PB Power
 Schematic of a Direct System
Using an Ammonia Refrigeration Machine
Ammonia
Suction Line

Combustion
Mechanical Air
Refrigeration
Machine Air
Filter

Condensate
Drip Pan

Ammonia
Fuel Liquid Line
Exhaust Gas

Combustion Turbine

PB Power
Mechanical Refrigeration System (Direct Type)
Applications: Areas where relative humidity is rather high

Advantage
# Can increase gas turbine
performance better than
evaporative cooling, and
fog system
Disadvantage
# High initial capital cost
# High O&M cost
# Longer delivery and
installation time
# Expertise is needed to
operate and maintain the
plant

PB Power
 Gas Turbine Inlet Air Cooling
Available Technologies
1. Evaporative cooler
2. Fogging system
3. Mechanical refrigeration system (direct type)
4. Mechanical refrigeration system (indirect type)
5. Mechanical refrigeration with ice storage
6. Mechanical refrigeration system with chilled water storage
7. Single stage Lithium Bromide Absorption chiller
8. Two stage Lithium Bromide Absorption chiller

PB Power
 Schematic of an Indirect System
Using a Mechanical Chiller

Combustion
Air
Mechanical Chiller Air Cooling
Air Coil
Filter
Condensate
Drip Pan

Exhaust Gas Fuel Chilled Water

Pump

Combustion Turbine

PB Power
Mechanical Refrigeration System (Indirect Type)
Applications: Areas where relative humidity is rather high
Advantage Disadvantage
# Can increase gas turbine # High initial capital cost
performance better than # High O&M cost
evaporative cooling, and fog # Long delivery and installation
system time
# Not very sensitive to ambient # Expertise is needed to
air wet bulb temperature operate and maintain the
plant
# Requires extra chilled water
cooling circuit
# Higher parasitic load than
direct type
# Higher energy input
PB Power compared to direct type chiller
 Gas Turbine Inlet Air Cooling
Available Technologies
1. Evaporative cooler
2. Fogging system
3. Mechanical refrigeration system (direct type)
4. Mechanical refrigeration system (indirect type)
5. Mechanical refrigeration with ice storage
6. Mechanical refrigeration system with chilled
water storage
7. Single stage Lithium Bromide Absorption chiller
8. Two stage Lithium Bromide Absorption chiller

PB Power
 Inlet Air Cooling With Ice Storage,
Chilled Water Storage System Schematic

Combustion
Air
Air Cooling
Mechanical Chiller/ Air Coil
Ice Maker Filter

Ice Storage Tank Condensate

Drip Pan

Exhaust Gas Fuel Chilled Water

Pump

Combustion Turbine

PB Power
Inlet Air Cooling With Chilled Water Storage
System Schematic

Chilled Combustion
Mech. Water Air
Chiller Storage Air Cooling
Tank Air Coil
Filter
Condensate
Drip Pan

Fuel Chilled Water

Exhaust Gas
Pump

Combustion Turbine

PB Power
 Mechanical Refrigeration System
With Ice Storage
Applications: Areas where RH is rather high,plus a wide variation in
electricity tariff between peak and non peak hours
Advantage Disadvantage
# Can increase gas turbine # High initial capital cost
performance better than # High O&M cost
evaporative cooling, and fog
system # Longer delivery and
installation time
# Not very sensitive to ambient
air wet bulb temperature # Higher expertise is needed
to operate and maintain the
# Can utilise low night time plant
tariff to produce and store ice
for peak hours operation

PB Power
 Chiller Electrical Load MW
36°C DB, 25°C WB, 10°C Chilled Air Temp

6
Chiller Electrical Load MW

0
0 25 50 75 100 125 150 175 200 225 250 275 300
Gas Turbine Output MW

PB Power
 Gas Turbine Inlet Air Cooling
Available Technologies
1. Evaporative cooler
2. Fogging system
3. Mechanical refrigeration system (direct type)
4. Mechanical refrigeration system (indirect type)
5. Mechanical refrigeration with ice storage
6. Mechanical refrigeration system with chilled water storage
7. Single stage Lithium Bromide Absorption chiller
8. Two stage Lithium Bromide Absorption chiller

PB Power
 Absorption Chiller Inlet Air Cooling
System Schematic

Combustion
Air
Absorption Chiller
Air Cooling
Air Coil
Filter

Return Condensate
Condensate
Drip Pan

LP Steam

Exhaust Gas Chilled Water Fuel

Pump

Heat Recovery
Steam Generator
Combustion Turbine

PB Power
 Flow Diagram
Pressure
approx.
60 Torr
60 mm Hg tc 45°C
Condenser 37°C Tower Water Out
80 mbar
8 kPa

Generator
Steam or Hot
Heat Medium In
Water

°C
70
Heat Medium Out
°C
95

to 4°C
Pressure
6°C
approx.
6,2 Torr Chilled
6,2 mm Hg Water
Evaporator 12°C
8,2 mbar
0,83 kPa

Absorber
32,5°C

27°C Tower Water In

ta 35°C
Chilled Water
Tower Water
70°C Concentrated Solution (LiBr)
Diluted Solution (LiBr)
Steam or Hot Water
Refrigerant (Water)

50°C

PB Power Picture courtesy of York International

 Absorption Chiller Steam Consumption
36°C DB, 25°C WB, 10°C Chilled Air Temp
80

70
Steam Consumption t/h

60

50

40

30

20

10

0
0 25 50 75 100 125 150 175 200 225 250 275 300

Gas Turbine Output MW Single Stage

Two Stage

PB Power
Single Stage Lithium Bromide Absorption Chiller
Applications: Areas where relative humidity is rather high, and the plant
is going to operate in a combined cycle or cogeneration mode and has
access to low pressure steam
Advantage Disadvantage
# Can increase gas turbine # High initial capital cost
performance better than # High O&M cost
evaporative cooling, and fog
system # Longer delivery and
installation time
# Not very sensitive to ambient
air wet bulb temperature # High expertise is needed to
operate and maintain the
# Low electrical parasitic load plant
# In case of a steam operated
chiller, cannot be applied in
an open cycle gas turbine
plant
PB Power
 Two Stage Lithium Bromide Absorption Chiller
Applications: Areas where relative humidity is rather high, and the plant
is going to operate in a combined cycle or cogeneration mode and has
access to low pressure steam
Advantage Disadvantage
# Can increase gas turbine # High initial capital cost
performance better than # High O&M cost
evaporative cooling, and fog
system # Longer delivery and
installation time
# Not very sensitive to ambient
air wet bulb temperature # High expertise is needed to
operate and maintain the
# Low electrical parasitic load plant
# Requires less steam per unit # In case of a steam operated
of refrigeration than single chiller, cannot be applied in
stage chiller an open cycle gas turbine
plant
PB Power
 Condensate Formation on the Chilled Water Coil t/h
Based on 36°C DB, 25°C WB, 10°C Chilled Inlet Air
Temperature

20
Condensate Formation t/h

15

10

0
25 35 45 55 65 75 85 95 105 115 125 135 145 155 165 175 185 195 205 215 225 235 245 255 265

Gas Turbine Output MW

PB Power
 Performance Evaluation
Of Different Inlet Air Cooling Systems
Base Condition
! 35°C Dry bulb
! 25°C Dry bulb Real world condition
! 44.7% Relative humidity
Increase in power output
Percent Change

Gas turbine output before inlet air 108.23 MW

0%
cooling (net)
Gas turbine output with mechanical 124.8 MW (net
refrigeration system and inlet air including chiller 15.3%
temperature of 10°C electrical load)
Gas turbine with evaporative cooler
114.8 MW (net) 6%
running at 85% RH
Gas turbine with fog system 116.65 MW
7.69%
running at 100% RH (net)
PB Power
 Capital Cost Comparisons of
Inlet Cooling Systems
Options Relative Costs

Evaporative cooler 1
Fog system (excluding
water treatment plant)
2
Single stage LiBr
absorption chiller
8
Two stage LiBr
absorption chiller
10
Ammonia mechanical
refrigeration system
9.5

PB Power
Major Contributors To The O&M Costs
Options O&M Costs
# Make up water
Evaporative cooler
# Water treatment (if applicable)
# Make up water
Fog system (excluding
# Demineralised water treatment
water treatment plant) # Injection pump power consumption
# Steam
Single stage LiBr # Cooling tower chemical treatment
absorption chiller # Chiller maintenance
# Electric power consumption
# Steam
# Cooling tower chemical treatment and
Two stage LiBr
make up water
absorption chiller # Chiller maintenance
# Electric power consumption
# Electric power consumption
Ammonia mechanical # Cooling tower chemical treatment and
refrigeration system make up water
# Chiller maintenance
PB Power
Heavy Duty Gas Turbine NOx Emission kg/MWh
GT with Dry Low NOx burner

0.470
NOx Emission kg/MWh

0.460

0.450

0.440

0.430

0.420

0.410
0 5 10 15 20 25 30 35 40 45

Ambient Temperature deg C

PB Power
Heavy Duty Gas Turbine CO2 Emission kg/MWh

590
CO2 Emission kg/MWh

580
570
560
550
540
530
520
0 5 10 15 20 25 30 35 40 45
Ambient Temperature deg C

PB Power
Aero-Derivative Gas Turbine NOx Emission kg/MWh
GT with Dry Low NOx burner

0.43
NOx Emission kg/MWh

0.42

0.41

0.4

0.39

0.38

0.37
0 5 10 15 20 25 30 35 40 45
Ambient Temperature deg C

PB Power
Aero-Derivative Gas Turbine CO2 Emission kg/MWh

550
540
CO2 Emission kg/MWh

530
520
510
500

490
480
470
0 5 10 15 20 25 30 35 40 45

Ambient Temperature deg C

PB Power
 In Selecting Inlet Air Cooling As A
Retrofit To An Existing Plant
Points to watch:
! Check the generator capacity in order not to overload the
generator
! Quality of raw water for the evaporative cooler
! When using an existing demineralised water treatment
plant, be careful about the capacity and quality of
available demineralised water
! With an existing heat recovery steam generator, inlet air
cooling will change the behaviour of the existing HRSG,
leading to a drop in steam production at high pressure
and increase in intermediate and low pressure steam

PB Power