Aug 9, 2018 | By Thomas

Global technology giant Siemens has successfully 3D-printed and engine tested a dry low emission (DLE) pre-mixer for the SGT-A05 aeroderivative gas turbine, with the impressive results showing a potential for significant reductions in CO emissions, according to a statement from Siemens.

“This is another excellent example of how additive manufacturing is revolutionizing our industry, delivering measurable benefits and real value to our customers, particularly as they look to further reduce emissions to meet environmental targets,” said Vladimir Navrotsky, Chief Technology Officer for Siemens Power Generation Services, Distributed Generation.

3D printing gives Siemens engineers the freedom to design, manufacture power generation components that works in high load and temperature and requires tight tolerances. From concept to engine test, the development the new pre-mixer took only seven months.

SGT-A05 aeroderivative gas turbine (Image: Siemens)

Power station at Mitchelstown, Ireland. (Image: Siemens)

The Siemens DLE system reduces emissions through advanced lean burn combustion technology, and offers clean combustion for gas turbines in power generation applications. The DLE pre-mixer is highly complex with over 20 parts involved in the casting and assembly using traditional manufacturing methods. However, by utilizing Siemens qualified nickel super alloys as the 3D printing material, the 3D-printed component requires only two parts and lead time is reduced by approximately 70%.

The DLE pre-mixer was 3D printed in Siemens' AM center of competence in Finspang, Sweden. "3D printing of the DLE pre-mixer allows Siemens to simplify complexity in the production process, reduce external dependencies in the supply chain, and improves the geometry of the component, thus allowing a better fuel-air mix," said Siemens.

First engine testing of the AM-manufactured DLE pre-mixer was recently completed. According to the company, it showed no start issues, all fuel transitions were accomplished successfully without any controls modifications required, there were no combustion dynamics or noise, measurable CO emissions reductions were realized and full power was achieved.

Currently, more than 120 engines are utilizing DLE technology to reduce NOx and CO emissions with 3.9 million operating hours accumulated (as of February 2018). "And now, with AM technology we have an opportunity to go even further with emissions reduction for DLE combustion," said Douglas Willham, Siemens director of Engineering for the SGT-A05.

In early 2017, Siemens achieved the first successful commercial installation and continuing safe operation of a 3D-printed part in a nuclear power plant – an impeller for a fire protection pump. Later in the year the company achieved a breakthrough by finishing its first full-load engine tests for gas turbine blades completely produced using Additive Manufacturing technology. In April 2018, the company produced first 3D printed steam turbine replacement parts, two oil sealing rings used in keeping oil separated from steam inside the steam turbine. The rings are being installed on the SST-300 industrial steam turbine operating in Salem, India. Siemens accumulated more than 30,000 hour of successful commercial operation for SGT-800 burners repaired with AM technology and for SGT-750 burner swirls manufactured by AM.



Posted in 3D Printing Application



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