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Chapter 1

INTRODUCTION

Micro turbine is one of the important components in a micro gas turbine engine. Micro gas
turbine engine is a promising solution to provide high-density power source for micro
systems. A micro gas turbine engine consists of a radial inflow turbine, a centrifugal
compressor and a combustor. This thesis mainly deals with the design aspects of a micro
turbine. Various journals has been published on designing of various types of micro turbines.
Exhaustive study has been done on these papers and the major points have been highlighted
here.

Micro turbines are a relatively new distributed generation technology being used for
stationary energy generation applications. They are a type of combustion turbine that
produces both heat and electricity on a relatively small scale. Micro turbines offer several
potential advantages compared to other technologies for small-scale power generation,
including: a small number of moving parts, compact size, lightweight, greater efficiency,
lower emissions, lower electricity costs, and opportunities to utilize waste fuels. Waste heat
recovery can also be used with these systems to achieve efficiencies greater than 80%.

Because of their small size, relatively low capital costs, expected low operations and
maintenance costs, and automatic electronic control, micro turbines are expected to capture a
significant share of the distributed generation market. In addition, micro turbines offer an
efficient and clean solution to direct mechanical drive markets such as compression and air-
conditioning.

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LITERATURE REVIEW

“Principles and working of microturbine” by K.C Goli, S.V Kondi, V.B Trimmanpalli ,
development and investigation of a new small gas turbine technology is being developed
which promises to bring the economic, environmental and convenience benefits,
advancements in the automotive sector, generation of electricity and mechanical power needs
of the commercial sector. The technology is of the microturbines. The microturbine is an
example of Micro Electro Mechanical Systems, which is efficiently used to develop power
ata small scale. Microturbines are small combustion turbines approximately the size of a
refrigerator with outputs of 25 kW to 500 kW. Microturbines are part of the future of onsite,
or distributed energy and powe rgeneration. They are actually single shaft machines, in which
turbine, compressor and generator are mounted on the single shaft. This unit can be used for
distributed power, stand-alone power, stand-by power and vehicle application like
turbocharger.

“Design, fabrication and characterization of an air-driven micro turbine device” by X.

C. Shan, and Qide Zhang, development and investigations of a micro turbine device driven
by compressed air, which consists of three layers of silicon wafers and two layers of acrylic
plates has been presented. The key challenges to develop a successful high-speed turbine
device are geometry design and fabrication of micro blade profiles as well as air- bearings.
The micro air bearings have been designed, and a deep reactive ion etching (DRIE) process
has been used for fabricating micro journal bearings with high aspect ratio.

Design of turboexpander for cryogenic applications‖ by Subrata Kr. Ghosh , N.

Seshaiah, R. K. Sahoo, S. K. Sarangi focuses on design and development of turbo
expander.The paper briefly discuses the design methodology and the fabrication drawings for
the whole system, which includes the turbine wheel, nozzle, diffuser, shaft, brake
compressor, two types of bearing, and appropriate housing. With this method, it is possible to
design a turbo expander for any other fluid since the fluid properties are properly taken care
of in the relevant equations of the design procedure.

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A micro turbine device with enhanced micro air bearings by ―X. C. Shan , Q. D. Zhang
, Y. F. Sun and R. Maeda design, fabrication and testing of a silicon-based micro turbine
device, which is driven by compressed air has been shown. The thrust air bearings are
utilized for supporting the rotor from both its top- and bottom- sides.

A simple method sufficient for the design of a high efficiency expansion turbine is outlined
by Kun et. al. A study was initiated in 1979 to survey operating plants and generate the cost
factors relating to turbine by Kun & Sentz. Sixsmith et. al. in collaboration with Goddard
Space Flight Centre of NASA, developed miniature turbines for Brayton Cycle cry coolers.
They have developed of a turbine, 1.5 mm in diameter rotating at a speed of approximately
one million rpm.

Yang et. al developed a two stage miniature expansion turbine made for an 1.5 L/hr helium
liquefier at the Cryogenic Engineering Laboratory of the Chinese Academy of Sciences. The
turbines rotated at more than 500,000 rpm. The design of a small, high speed turbo expander
was taken up by the National Bureau of Standards (NBS) USA. The first expander operated
at 600,000 rpm in externally pressurized gas bearings. The turbo expander developed by Kate
et. al was with variable flow capacity mechanism (an adjustable turbine), which had the
capacity of controlling the refrigerating power by using the variable nozzle vane height.

CHAPTER 2

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GAS TURBINE

2.1 Gas Turbine

A gas turbine is a rotating engine that extracts energy from a flow of combustion gases that
result from the ignition of compressed air and a fuel (either a gas or liquid, most commonly
natural gas). It has an upstream compressor module coupled to a downstream turbine module,
and a combustion chamber(s) module (with igniter[s]) in between.

Energy is added to the gas stream in the combustor, where air is mixed with fuel and ignited.
Combustion increases the temperature, velocity, and volume of the gas flow. This is directed
through a nozzle over the turbine’s blades, spinning the turbine and powering the compressor.
Energy is extracted in the form of shaft power, compressed air, and thrust, in any
combination, and used to power aircraft, trains, ships, generators, and even tanks.

2.2 Types of Gas Turbine

There are different types of gas turbines. Some of them are named below:

 Aero derivatives and jet engines

 Amateur gas turbines
 Industrial gas turbines for electrical generation
 Radial gas turbines
 Scale jet engines
 Micro turbines

2.3 Gas Turbine Cycle

The simplest gas turbine follows the Brayton cycle (Figure 1.1). In a closed cycle (i.e., the
working fluid is not released to the atmosphere), air is compressed isentropically, combustion
occurs at constant pressure, and expansion over the turbine occurs isentropically back to the
starting pressure. As with all heat engine cycles, higher combustion temperature (the common
industry reference is turbine inlet temperature) means greater efficiency. The limiting factor
is the ability of the steel, ceramic, or other materials that make up the engine to withstand
heat and pressure. Considerable design/manufacturing engineering goes into keeping the

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turbine parts cool. Most turbines also try to recover exhaust heat, which otherwise is wasted
energy. Recuperators are heat exchangers that pass exhaust heat to the compressed air, prior
to combustion. Combined-cycle designs pass waste heat to steam turbine systems, and
combined heat and power (i.e., cogeneration) uses waste heat for hot water production.
Mechanically, gas turbines can be considerably less complex than internal combustion piston
engines. Simple turbines might have one moving part: the shaft/compressor/
turbine/alternator-rotor assembly, not counting the fuel system. More sophisticated turbines
may have multiple shafts (spools), hundreds of turbine blades, movable stator blades, and a
vast system of complex piping, combustors, and heat exchangers.

Figure 1.1- Idealized Brayton Cycle

The largest gas turbines operate at 3000 (50 hertz [Hz], European and Asian power supply) or
3600 (60 Hz, U.S. power supply) RPM to match the AC power grid. They require their own
building and several more to house support and auxiliary equipment, such as cooling towers.
Smaller turbines, with fewer compressor/turbine stages, spin faster. Jet engines operate
around 10,000 RPM and micro turbines around 100,000 RPM. Thrust bearings and journal
bearings are a critical part of the design. Traditionally, they have been hydrodynamic oil
bearings or oil cooled ball bearings.

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Features:

 Gas-turbine is used in aircraft propulsion and electric power generation.

 High thermal efficiencies up to 44%.
 Suitable for combined cycles (with steam power plant)
 High power to weight ratio, high reliability, long life
 Fast start up time, about 2 min, compared to 4 hr. for steam-propulsion systems
 High back work ratio (ratio of compressor work to the turbine work), up to 50%,
Compared to few percent in steam power plants.

2.4 Advantages of Gas Turbine

 Very high power-to-weight ratio, compared to reciprocating engines.

 Smaller than most reciprocating engines of the same power rating.
 Moves in one direction only, with far less vibration than a reciprocating engine.
 Fewer moving parts than reciprocating engines.
 Low operating pressures.
 High operation speeds.
 Low lubricating oil cost and consumption.

Chapter 3
MICRO TURBINE

3.1 Micro turbine

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Micro turbines are small gas turbines used to generate electricity. Occupying a space no
larger than a telephone box, they typically have power outputs in the range of 25 to 300kW.
In comparison, large powerstations are entire buildings and have much higher power outputs
of around 600MW to 1000MW.

The small size of microturbines is a major advantage that allows them to be situated right at
the source ofelectricity demand. This eliminates energy losses that usually occur when
transmitting electricity frompower stations. Such transmission losses are quite significant and
can easily amount to 7% of the powergenerated. Micro turbines are a new class of small gas
turbines used for distributed generation ofelectricity. Microturbines are small version of gas
turbines emerged from four different technologies viz.small gas turbines, auxiliary power
units, automotive development gas turbine and turbochargers.

Microturbines are new class of gas turbines used for distributed generation of electricity.
Microturbine development is based on turbines used for aircraft auxiliary power units, which
have been used in commercial airlines for decades. One way in which Microturbine can be
distinguished from larger turbine is that Microturbines use a single shaft to drive the
compressor, turbine and generator. Whereas in large power plants, the turbines and generator
are on separate shafts and are connected by gears that slow down the high-speed rotation of
the gas turbines, simultaneously increasing the torque sufficient to turn much large electric
generators. Some microturbines even include the ability to generate electricity from heat of
exhaust gases.

They accept most commercial fuels, such as gasoline, natural gas, propane, diesel, and
kerosene as well as renewable fuels such as E85, biodiesel and biogas. Most micro turbines
are comprised of a compressor, combustor, turbine, alternator, recuperator (a device that
captures waste heat to improve the efficiency of the compressor stage), and generator.

3.2 History

In 1900 when a 2 MW steam turbine was installed at Hartford, its size was 4 times bigger
than any of the existing steam turbines. From then on economy of scale meant bigger and
bigger. By the end of the 1970sand largely driven by nuclear power plants, steam turbines
exceeded 1000 MW. The electric efficiency of steam turbine power plants eventually reached

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34%. That trend was broken in the 1980s. More efficient gas turbines combined with steam
turbines could produce electric power with efficiencies up to 55%. This new technology,
combined cycle power plants, was the technology of choice for independent power
producers. It was now possible to build competitive power plants down to the range of 100-
200 MW. Micro turbines have been experimented with since 1945, when Rover tried to
develop one for a vehicle application. Since that time, automobile, aerospace, aircraft and
military contractors have tried to develop an economical and functional Microturbine for
different industrial and commercial applications.

3.3 Need of microturbine

In today's energy economy, most electricity is produced using fossil fuel-burning generators.
These machines consist of a motor and a dense coil of copper wires that surround a shaft
containing powerful magnets. To get that power to a home or factory typically requires a
local utility to run a heavy copper cable to the residence or business site. But what if the site
requiring energy is in a remote mountain location, or it's an offshore oil rig where electricity
is scarce and hookups don't exist? Here the microturbines come into the picture. It is one of
the best options to set up a local power-generation plant, perhaps using a Microturbine -- a
small, sometimes portable, fossil fuel-burning system that can provide enough electricity to
power anywhere from 10 to 5,000 homes. Also it has an important application as a
turbocharger in vehicles when more energy is required from the engine in less amount of fuel.

Construction of micro turbine:

Micro turbines are typically single shaft machines with the compressor and turbine mounted
on the same shaft as the electrical generator. It therefore consists of only one rotating part,
eliminating the need for a gearbox and associated numerous moving parts. Microturbines are
miniature versions of the huge machines used to generate power from natural gas, and
evolved from aircraft engines and automotive turbochargers. A cutaway view of a
Microturbine is shown in Figure1. The single stage Turbine and Compressor wheels are

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inertia welded to the shaft, which supports the generator alternator rotor and provides for a
cold end drive. A block diagram showing a complete cycle of the Microturbine is shown in
Figure2. The inner bearing is a hydrodynamic bearing and the outer bearing utilizes a ceramic
ball race. A device called recuperator plays an important role in completing the cycle of
Microturbine.

Figure 1: Sectional view of a typical micro turbine

Principle and working of micro turbines:

The high velocity exhaust gases coming from the combustor rotate the turbine used in the
micro turbine. The basic principle of working of the micro turbine is that the compressor as
well as the electric generator is mounted on the same power shaft as that of the turbine.
Because of this the compressor and the generator also rotate with the turbine. The generator
rotates with the same speed as that of the turbine and generates the electricity. The electricity
is first given to the power conditioning devices and then it is supplied to the required areas.
The combustor is supplied with the fuel in the gaseous form by the gas compressor. Also

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fresh and compressed air is supplied to the combustor by the compressor through the
recuperator. Here the recuprator plays an important role of heat exchanger. It absorbs the heat
from the hot gases coming from the turbine. Then it gives this heat to the compressed air
coming from the compressor. Thus the air supplied to the combustor is hot and compressed.
This helps to increase the overall efficiency of the cycle.

3.2 Types of Micro turbine

Micro turbines are classified by the physical arrangement of the component parts: single shaft
or two-shaft, simple cycle, or recuperated, inter-cooled, and reheat. The machines generally
rotate over 40,000 revolutions per minute. The bearing selection—oil or air—is dependent on
usage. A single shaft micro turbine with high rotating speeds of 90,000 to 120,000
revolutions per minute is the more common design, as it is simpler and less expensive to
build. Conversely, the split shaft is necessary for machine drive applications, which does not
require an inverter to change the frequency of the AC power.

Microturbines are divided into two general classes:

 Unrecuperated (or simple cycle) micro turbines— In a simple cycle, or

unrecuperated, turbine, compressed air is mixed with fuel and burned under constant
pressure conditions. The resulting hot gas is allowed to expand through a turbine to
perform work. Simple cycle micro turbines have lower efficiencies at around 15%,

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but also lower capital costs, higher reliability, and more heat available for
cogeneration applications than recuperated units.

 Recuperated micro turbines—Recuperated units use a sheet-metal heat exchanger

that recovers some of the heat from an exhaust stream and transfers it to the incoming
air stream, boosting the temperature of the air stream supplied to the combustor.
Further exhaust heat recovery can be used in a cogeneration configuration. The
figures below illustrate a recuperated micro turbine system. The fuel-energy-to-
electrical-conversion efficiencies are in the range of 20 to 30%. In addition,
recuperated units can produce 30 to 40% fuel savings from preheating.

CHAPTER-4

Description of microturbines:

3.4.3 Basic Components of Microturbines

The basic components of a micro turbine are the compressor, turbine, generator, and
recuperator (Figure 1.2). The heart of the micro turbine is the compressor-turbine package,
which is most commonly mounted on a single shaft along with the electric generator. The
single shaft is supported by two (or more) high-speed bearings. Because single-shaft turbines
have only one moving shaft, they have the potential for lower maintenance and higher
reliability than turbines with two or more shafts. There are also two-shaft versions of the
micro turbine, in which the turbine on the first shaft only drives the compressor while a
second power turbine on a second shaft drives a gearbox and conventional electric generator
producing 60 or 50 Hz of power. Moderate- to large-sized gas turbines use multistage axial
flow compressors and turbines, in which the gas flows parallel to the axis of the shaft and

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then is compressed and expanded in multiple stages. Most current micro turbines are based
on single-stage radial flow compressors and either single- or double-stage turbines.

Fig: Cut section view of microturbine

1.Turbo-Compressor Package:-The basic components of a micro turbine are the

compressor, turbine generator, and recuperator .Figure shows the heart of the micro turbine
is the compressor-turbine package, which is commonly mounted on a single shaft along with
the electric generator. Two bearings support the single shaft. The single moving part of the
one-shaft design has the potential for reducing maintenance needs and enhancing overall
reliability. There are also two-shaft versions, in which the turbine on the first shaft directly
drives the compressor while a power turbine on the second shaft drives a gearbox and
conventional electrical generator producing 60 Hz power. The two shaft design features more
moving parts but does not require complicated power electronics to convert high frequency
AC power output to 60 Hz. Moderate to large-size gas turbines use multi-stage axial flow
turbines and compressors, in which the gas flows along the axis of the shaft and is
compressed and expanded in multiple stages. However, micro turbine turbo machinery is
based on single-stage radial flow compressor and turbines.

Generator: - The micro turbine produces electrical power either via a high-speed generator
turning on the single turbo-compressor shaft or with a separate power turbine driving a

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gearbox and conventional 3,600 rpm generator. The high-speed generator of the single-shaft
design employs a permanent magnet (typically Samarium-Cobalt) alternator, and requires
that the high frequency AC output (about 1,600 Hz for a 30 kW machine) be converted to 60
Hz for general use. This power conditioning involves rectifying the high frequency AC to
DC, and then inverting the DC to 60 Hz AC. Power conversion comes with an efficiency
penalty (approximately five percent).To start-up a single shaft design, the generator acts as a
motor turning the turbo-compressor shaft until sufficient rpm is reached to start the
combustor. Full start-up requires several minutes. If the system is operating independent of
the grid (black starting), a power storage unit (typically a battery UPS) is used to power the
generator for start-up.

Recuperators:- Recuperators are heat exchangers that use the hot turbine exhaust gas
(typically around 1,200ºF) to preheat the compressed air (typically around 300ºF) going into
the combustor, thereby reducing the fuel needed to heat the compressed air to turbine inlet
temperature. Depending on micro turbine operating parameters, recuperators can more than
double machine efficiency. However, since there is increased pressure drop in both the
compressed air and turbine exhaust sides of the recuperator, power output typically declines
10 to 15% from that attainable without the recuperator. Recuperators also lower the
temperature of the micro turbine exhaust, reducing the micro turbine’s effectiveness in CHP
applications.

Air bearings:-They allow the turbine to spin on a thin layer of air, so friction is low and rpm
is high. No OIL or oil pump is needed. Air bearings offer simplicity of operation without the
cost, reliability concerns, maintenance requirements, or power drain of an oil supply and
filtering system. Concern does exist for the reliability of air bearings under numerous and
repeated starts due to metal on metal friction during start up, shutdown, and load changes.
Reliability depends largely on individual manufacturers' quality control methodology more
than on design engineering, and will only be proven after significant experience with
substantial numbers of units with long numbers of operating hours and on/off cycles.

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Fig : Micro turbine based combined heat and power system

3. Characteristics of Micro turbine

Some of the primary characteristics for micro turbines include:

 Distributed generation—stand-alone, on-site applications remote from power grids

 Quality power and reliability—reduced frequency variations, voltage transients,
surges, dips, or other disruptions
 Stand-by power—used in the event of an outage, as a back-up to the electric grid
 Peak shaving—the use of micro turbines during times when electric use and demand
charges are high
 Boost power—boost localized generation capacity and on more remote grids
 Low-cost energy—the use of micro turbines as base load or primary power that is
less expensive to produce locally than it is to purchase from the electric utility
 Combined heat and power (cogeneration)—increases the efficiency of on-site
power generation by using the waste heat for existing thermal process.

Performance Efficency:
The performance of the microturbines is given in the tabular form as below

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Configuration Efficiency
Unrecuperated 15%
Recuperated 20-30%
Heat recovery Up to 85%

Table No.1 Microturbine Efficiency for 25 to 500kw [1]

Commercial micro turbines used for power generation range in size from about 25KW to
500KW. They produce both heat and electricity on a relatively small scale. The energy to
electricity conversion efficiencies are in the range of 20 to 30%. These efficiencies are
attained when using a recuperator .Cogeneration is an option in many cases as a Microturbine
is located at the point of power utilization. The combined thermal electrical efficiency is
85%. Unrecuperated microturbines have lower efficiencies at around 15%.

3.4.5 Economics of Micro turbines

Micro turbine capital costs range from $700-$1,100/kW. These costs include all hardware,
associated manuals, software, and initial training. Adding heat recovery increases the cost by
$75-$350/kW. Installation costs vary significantly by location but generally add 30-50% to
the total installed cost.

Micro turbine manufacturers are targeting a future cost below $650/kW. This appears to be
feasible if the market expands and sales volumes increase. With fewer moving parts, micro
turbine vendors hope the units can provide higher reliability than conventional reciprocating
generating technologies. Manufacturers expect that initial units will require more unexpected
visits, but as the products mature, a once-a-year maintenance schedule should suffice. Most
manufacturers are targeting maintenance intervals of 5,000-8,000 hours. Maintenance costs
for micro turbine units are still based on forecasts with minimal real-life situations. Estimates
range from $0.005-$0.016 per kWh, which would be comparable to that for small
reciprocating engine systems.

3.4.4 Advantages

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• Small number of moving parts.
• Compact size.
• Light weight.
• Good efficiency in cogeneration.
• Low emission.
• Can utilize waste fuel.
• Long maintenance intervals

Limitations:-
• Low feul to electricity efficiency.
• Loss of power output and efficiency with higher ambient temperature and elevation

4.6 Applications

While the simplest application for a micro turbine prime mover is of power generation other
application exists. Microturbine prime movers can be used for cooling, refrigeration; air
compression and pump drive application whereby the inherent high speed of the power shaft
can be used to drive high efficiency and low cost centrifugal compressors.

Micro turbines can be used for stand-by power, power quality and reliability, peak shaving,
and cogeneration applications. In addition, because micro turbines are being developed to
utilize a variety of fuels, they are being used for resource recovery and landfill gas
applications. Micro turbines are well suited for small commercial building establishments
such as: restaurants, hotels/motels, small offices, retail stores, and many others.

The development of micro turbine technology for transportation applications is also in

progress. Automotive companies are interested in micro turbines as a lightweight and
efficient fossil-fuel-based energy source for hybrid electric vehicles, especially buses.

Other ongoing developments to improve micro turbine design, lower costs, and increase
performance in order to produce a competitive distributed generation product include heat

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recovery/cogeneration, fuel flexibility, and hybrid systems (e.g., fuel cell/micro turbine,
flywheel/micro turbine).

 Peak shaving and base load power (grid parallel)

 Combined heat and power (co-generation)

 Distributed power generation

 Stand-alone power

 Backup/standby power

 Primary power with grid as backup

 Micro grid

 Resource recovery

 Transportation applications

FUTURE SCOPE:

 Extensive field test data collected from units currently in use at commercial and
industrial facilities
 will provide the manufacturers with the ability to improve the Microturbine design,
lowering the cost and
 increasing performance, in order to produce a competitive distributed generation
product. Utilities,
 government agencies, and other
 Organizations are involved in collaborative research and field-testing.
 Development is ongoing in a variety of areas:
 1. Heat recovery/coregeneration
 2. Fuel flexibility
 3. Vehicles
 4. Hybrid systems (e.g. fuel cell/Microturbine, flywheel/Microturbine

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CHAPTER -5

CONCULSION:

Micro turbine can use low grade of fuel very effectively like waste gases, sour gases
etc. Thus micro turbine gives chance of low fuel cost and less emission.The
dimensions of micro turbine comparatively small by which it can be installed at field
where power is consumed. Micro turbine is also effective in CHP operation. In India
the micro turbine is quite useful.The power shortage effect can be solved using micro
turbine, using fuels like biogas, etc. India the technology is still underdevelopment so
the present seminar is an honest attempt to introduce micro turbine technology in
India for solving the problem of power generation in future.

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REFERENCE:

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CHAPTER 3

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