Vol 63, No 12 (2016)

The development of distributed power generation systems as a supplement to the centralized unified power grid increases the operational stability and efficiency of the entire power generation industry and improves the power supply to consumers. An all-regime cogeneration combined-cycle plant with a power of 20–25 mW (PGU-20/25T) and an electrical efficiency above 50% has been developed at the All-Russia Thermal Engineering Institute (ATEI) as a distributed power generation object. The PGU-20/25T two-circuit cogeneration plant provides a wide electrical and thermal power adjustment range and the absence of the mutual effect of electrical and thermal power output regimes at controlled frequency and power in a unified or isolated grid. The PGU-20/25T combined-cycle plant incorporates a gas-turbine unit (GTU) with a power of 16 MW, a heat recovery boiler (HRB) with two burners (before the boiler and the last heating stage), and a cogeneration steam turbine with a power of 6/9 MW. The PGU-20/25T plant has a maximum electrical power of 22 MW and an efficiency of 50.8% in the heat recovery regime and a maximum thermal power output of 16.3 MW (14 Gcal/h) in the cogeneration regime. The use of burners can increase the electrical power to 25 MW in the steam condensation regime at an efficiency of 49% and the maximum thermal power output to 29.5 MW (25.4 Gcal/h). When the steam turbine is shut down, the thermal power output can grow to 32.6 MW (28 Gcal/h). The innovative equipment, which was specially developed for PGU-20/25T, improves the reliability of this plant and simplifies its operation. Among this equipment are microflame burners in the heat recovery boiler, a vacuum system based on liquid-ring pumps, and a vacuum deaerator. To enable the application of PGU-20/25T in water-stressed regions, an air condenser preventing the heat-transfer tubes from the risk of covering with ice during operation in frost air has been developed. The vacuum system eliminates the need for an extraneous source of steam for the startup of the PGU-20/25T plant. The vacuum deaerator provides prestartup deaeration and the filling of the entire condensate feed pipeline with deaerated water and also enables the maintenance of the water temperature before the boiler at a level of no lower than 60°C and the oxygen content at a level of no higher than 10 μg/L during operation under load. The microflame burners in the heat recovery boiler enable the independent adjustment of the electrical power and the thermal power output from the PGU-20/25T plant. All the innovative equipment has been tested on experimental prototypes.

Fatigue test results of the rotating steel blades of the fourth stage of the K-25-0.6 low pressure cylinder Geo steam turbine manufactured in the Kaluga Turbine Plant (hereinafter, KTP) with the ion-plasma coating were presented. Coating formation was carried out at the National Research University (MPEI) on the Gefest vacuum pilot plant by the magnetron sputtering method. Characteristics of the obtained coating were analyzed with the use of the scientific-research equipment of the National Research University (MPEI). Fatigue tests of the rotating blades and determination of the fatigue strength of the material with the ion-plasma coating were carried out on the electrodynamic vibration machines VEDS-400A in the KTP structural laboratory. The following characteristics were obtained after tests: Ti-TiN composition, 10–11 μm thickness, 1200 HV 0.05 microhardness. Fatigue tests showed that destruction, regardless of availability or nonavailability of the coating, took place by cross-section in the root zone both on the leading and trailing edges of the blade, i.e., in the most stressed zones. It was found out that the maximum stresses during tests were revealed in the root section along the trailing edge on the blade pressure side, and the less stresses were on the leading edge. Fatigue strength of the working blades after coating formation increased by 12% minimum. Results of the fatigue tests prove the previously obtained data concerning 10–12% increase of the fatigue strength of the blade steel with the ion-plasma coating and allow claiming that the process of their formation exerts the positive influence on the fatigue characteristics of the blade materials.

An analysis of the state of equipment of 72 outdated coal HPP (heat power plants) of a total capacity 14.3 GW with steam parameters before the turbines p_before ≤ 9 MPa, t_before = 420–540°С was performed. The equipment is characterized by a considerably low efficiency factor, even if it were converted to burning the natural gas, and by increased release of harmful substances. However, on the most part of the considered HPP, the steam turbines, unlike the boilers, have thus far retained the operation applicability and satisfactory reliability of performance. The analysis has shown that it makes sense to effectively modernize the outdated coal HPP by transformation of their equipment into combined-cycle plant (CCP) with coal gasification, which has high economic and ecological indicators due to thermodynamic advantage of the combined cycle and simpler purification of the generator gas in the process under pressure. As the most rational way of this transformation, the one was recognized wherein—instead of the existing boiler (boilers) or parallel to it—a gasification and gas turbine system is installed with a boiler-utilizer (BU), from which steam is fed to the HPP main steam pipe. In doing this, the basic part of the power station equipment persists. In the world, this kind of reconstruction of steam power equipment is applied widely and successfully, but it is by use of natural gas for the most part. It is reasonable to use the technology developed at Heat Engineering Research Institute (HERI) of hearth-steam gasification of coal and high-temperature purification of the generator gas. The basic scheme and measures on implementation of this method for modernization of outdated coal HPP is creation of CCP with blast-furnace of coal on the basis of accessible and preserved HPP equipment. CCP power is 120 MW, input-output ratio (roughly) 44%, emissions of hazardous substances are 5 mg/МJ dust, 20–60 mg/МJ SO₂, and 50–100 mg/МJ NO_х. A considerable decrease of specific CCP cost is expected: down to approximately half compared to that of CCP with coal gasification created elsewhere abroad. Verification and debugging of accepted solutions can be carried out at a small-scale pilot plant.

Experimental research of conditions and characteristics of ignition of the pulverized coal (with a particle size of approximately 80 μm) of different-type brown coals (1B, 2B, and 3B) during convective heating by a heated airflow (at a temperature of 425–600°С and velocity of 1–5 m/s) is carried out. The use of low-inertia thermocouples, a high-speed video camera, and dedicated software has made it possible to determine the minimum oxidizer parameters needed for coal dust ignition, and the approximation dependences of a main characteristic of the process under study―ignition delay time―on the air temperature. Results of experimental studies provide a basis for developing an optimal scheme of the boiler startup without heavy oil, which differs from the known schemes by the relatively low energy consumption for fuel-burning initiation. By example of the BKZ 75-39FB boiler, the economic usefulness of applying the boiler startup without heavy oil is shown. This scheme can be implemented using the proposed ignition burner that functions as a part of the direct system of pulverized-fuel preparation.

Analysis of Al₂O₃/water nanofluid flow in thermally developing region of a circular tube is the subject of present numerical study. In order to consider the hydrodynamically fully developed condition in the tube, a fully developed velocity profile is defined in the inlet section of tube. Three-dimensional computations are performed for a wide variety of nanoparticle concentrations (1 ≤ γ ≤ 10%). On the other hand, for examination of nanoparticle size, effects on the thermal characteristics, two different particle sizes of d_p = 25 and 75 nm are applied. The resulting governing equations are solved numerically by means of the finite volume method. For enhanced visualization, different results are presented in thermally developing region. It is obtained that suspending the Al₂O₃ nanoparticles in pure water increases the thermal boundary layer growing rate. In addition, an increase on the heat transfer rate is observed in thermal boundary layer using the Al₂O₃ nanoparticles in which this enhancement varies as a function of nanoparticle size and nanoparticle volume concentration. However, it is found that the role of nanoparticle volume concentration on the thermal characteristics such as thermal boundary layer growing rate, temperature gradient, and heat transfer enhancement is significantly important comparing to the nanoparticle size.

The geothermal energy development problems based on using binary power plants utilizing lowpotential geothermal resources are considered. It is shown that one of the possible ways of increasing the efficiency of heat utilization of geothermal brine in a wide temperature range is the use of multistage power systems with series-connected binary power plants based on incremental primary energy conversion. Some practically significant results of design-analytical investigations of physicochemical properties of various organic substances and their influence on the main parameters of the flowsheet and the technical and operational characteristics of heat-mechanical and heat-exchange equipment for binary power plant operating on extremely-low temperature geothermal brine (70°С) are presented. The calculation results of geothermal brine specific flow rate, capacity (net), and other operation characteristics of binary power plants with the capacity of 2.5 MW at using various organic substances are a practical interest. It is shown that the working fluid selection significantly influences on the parameters of the flowsheet and the operational characteristics of the binary power plant, and the problem of selection of working fluid is in the search for compromise based on the priorities in the field of efficiency, safety, and ecology criteria of a binary power plant. It is proposed in the investigations on the working fluid selection of the binary plant to use the plotting method of multiaxis complex diagrams of relative parameters and characteristic of binary power plants. Some examples of plotting and analyzing these diagrams intended to choose the working fluid provided that the efficiency of geothermal brine is taken as main priority.

One of the methods for the improvement of reliability and efficiency of the equipment at heat power plants is the decrease in the rate of corrosion of structural materials and sedimentation in water/steam circuit. These processes can be reduced to minimum by using the water with low impurity content and coolant treatment. For many years, water and steam quality standards were developed in various countries (United States, Germany, Japan, etc.) for specific types of equipment. The International Association for the Properties of Water and Steam (IAPWS), which brings together specialists from 21 countries, developed the water and steam quality standards for various types of power equipment based on theoretical studies and long-term operating experience of power equipment. Recently, various water-chemistry conditions are applied on heatpower equipment including conventional boilers and HRSGs with combined cycle power plants (Combined Cycle Power Plants (CCPP)). In paper, the maintenance conditions of water chemistry with ammonia or volatile amine dosing are described: reducing AVT(R), oxidizing AVT(O), and oxygen OT. Each of them is provided by the water and steam quality standards and recommendations are given on their maintenance under various operation conditions. It is noted that the quality control of heat carrier must be carried out with a particular care on the HPPs with combined cycle gas turbine units, where frequent starts and halts are performed.