VOCATIONAL TRAINING REPORT

ON

UREA MANUFACTURING AND POWER GENERATION

Duration
03-Aug-15 To 02-Sep-15
VT No. :- 866
SUBMITTED TO: - SUBMITTED BY: -
Mr.D.Kalia Nitin Rathore
D.G.M. Training B.Tech 4th Year(ME)
IFFCO Aonla FET,GKV,Haridwar
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 ACKNOWLEDGEMENT

I am glad to present this vocational training report on IFFCO AONLA, BAREILLY U.P.

Other department also exposed me to a variety of people workers & officers at every step of
my training. I noted immense, which plays a vital role in an industry.

During my training, I had gathered a vast knowledge about various machines and tools and
operation held in this unit. The knowledge gained from here will help me to stand in my life.

I am thank full to all person, the manager, staff members & workers who helped me during
my training period.

Lastly, I have honoured to state that I have successfully completed the training at the IFFCO
AONLA UNIT BAREILLY.

I would like to pay my special regard & thanks to training manager Dr. Dinesh Kalia , training
officer Mr. K.K. Pandey.

(M.E. 4th YEAR)

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 CONTENTS

1. INTRODUCTION
2. LOCATION
3. PRODUCT AND RAW MATERIALS
4. DEPARTMENT AT IFFCO AONLA UNIT
5. GAS TURBINE
6. HISTORY
7. THEORY OF OPERATION
8. BRAYTON CYCLE
9. TYPES OF GAS TURBINES
10. AMATEUR GAS TURBINES
11. AUXILIARY POWER UNITS
12. INDUSTRIAL GAS TURBINES FOR POWER GENERATION
13. INDUSTRIAL GAS TURBINES FOR MECHANICAL DRIVE
14. COMPRESSED AIR ENERGY STORAGE
15. TURBOSHAFT ENGINES
16. RADIAL GAS TURBINES
17. SCALE JET ENGINES
18. MICROTURBINE
19. ADVANCES IN TECHNOLOGY
20. ADVANTAGES OF GAS TURBINE ENGINES
21. DISADVANTAGES OF GAS TURBINE ENGINES

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 INTRODUCTION

Aonla project is one of the six natural gas basrd fertilizer plants set up in the country on
H.B.J. pipe line which runs through four vstates. Aonla IFFCO is IFFCO’s fourth plant and with
the investment of Rs. 696 crores and annual capacity of 7.26 lakh tones has coramenced
production from april 1998.

Towards increasing the fertiliser production the overall national planning for utilisation of
natural gas available from Bombay high, Indian Farmers Fertiliser Cooperative Ltd. (IFFCO)
was entrusted for setting up a urea fertiliser complex with annual capacity of 8.646 lakh
tonnes of urea at Aonla, Bareilly.

The site at Aonla is about 28 KM south west of Bareilly on Bareilly-Aonla road. In the year
1996 the production capacity was doubled with the commissioning of Aonla-II having urea
production capacity of 8.646 lakh tonnes.

Aonla-I is IFFCO’s fourth giant fertiliser complex having a 1520 MT per day ammonia plant
and two urea plants with a total capacity of 2620 MT per day. Steam and power generation
units, inert gas generation plant, water treatment plant, cooling towers, product handling
plant, ammonia storage, urea silo etc. are the other auxiliary units of the fertilizer complex.

Right from the inception of the project, IFFCO-Aonla-I has achieved several milestones in
record time. Aonla-I project was completed in a record time of 36 months and started
commercial production in 42 months from the zero date. The implementation of Aonla-I
project has been taken as a model for future fertilizer projects by Government of India.

IFFCO Aonla-I has also bagged two prestigious national awards – one for best project
implementation (second prize) from Ministry of Programmed implementation, Govt. of India
and other for technical film “New Horizons – Aonla project” from Fertilizer Association of
India (FAI) in the year 1989.

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LOCATION
THE SITE OF AONLA PROJECT IS 28 KM SOUTHWEST OF BAREILLY ON BAREILLY AONLA ROAD. THE
TOTAL LAND ACQUIRED SI 1273 ACRES FOR FACTORY & TOWNSHIP.ALTHOUGH THE LAND
ALMOST FALLS IN THE GANGETIC DELTA ,THE IS GENERALLY BARREN DUE TO ALKALINE NATURE
AND HIGHER CONTENT OF CLAY IN THE SOIL.

PRODUCT AND RAW MATERIALS

PRODUCT NAME: UREA

RAW MATERIAL: NATURAL GAS, WATER

PRODUTION CAPACITY: 4400MT/DAY

TOTAL PRODUCTS: 1 LAKH PACK /DAY (50 KG PER PACK)

DEPARTMENT AT IFFCO AONLA UNIT

 IFFCO AONLA UNIT IS DIVIDED INTO FOLOWING PARTS
 AMMMONIA PLANTS
 UREA PLANT
 POWER GENERATION PLANT
 OFFSITE
 PRODUCT HANDLING PLANT
 WATER SUPPLY
 INSTRUMENT AIR COMPRESSOR
 INERT GAS PLANT
 STEAM GENERATION PLANT
 BAGGING PLANT
 POWER GENERATION PLANT

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 PLANT INTRODUCTION

Fertilisers :
Fertilizers fall into three general categories; nitrogen (N) based, phosphorus (P) based, and
combined nitrogen-phosphorus (N-P) based. The majority of nitrogen based fertilizers are
derived from ammonia.
In the 1990s, over 95% of all commercial nitrogen fertilizer was derived from synthetic
ammonia. Worldwide, the annual production of synthetic ammonia is about 120 million
tonnes, of which about 85% is used in fertilizers, including urea.

Ammonia :
Ammonia, NH3, is a comparatively stable, colourless gas at ordinary temperatures, with a
boiling point of –33C. Ammonia gas is lighter than air, with a density of approximately 0.6
times that of air at the same temperature. Ammonia can be highly toxic to a wide range of
organisms. In humans, the greatest risk is from inhalation of ammonia vapour, with effects
including irritation and corrosive damage to skin, eyes and respiratory tracts.
At very high levels, inhalation of ammonia vapour can be fatal. When dissolved in water,
elevated levels of ammonia are also toxic to a wide range of aquatic organisms. Ammonia is
highly soluble in water, although solubility decreases rapidly with increased temperature.
Ammonia reacts with water in a reversible reaction to produce ammonium (NH4+) and
hydroxide (OH) ions, as shown in equation.
Ammonia is a weak base, and at room temperature only about 1 in 200 molecules are present
in the ammonium form (NH4+). The formation of hydroxide ions in this reaction increases the
pH of the water, forming an alkaline solution. If the hydroxide or ammonium ions react
further with other compounds in the water, more ammonia with react to reestablish the
equilibrium.
While ammonia-air mixtures are flammable when the ammonia content is 16-25% by
volume, these mixtures are quite difficult.
About 85% of the ammonia produced worldwide is used for nitrogen fertilizers. The
remainder is used in various industrial products including fibers, animal feed, explosives.

Urea :

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Urea (NH2CONH2), which is also known as carbamide, carbonyl diamine, carbamimidic
acid, and iso urea, was the leading nitrogen fertilizer worldwide in the 1990s.Urea is a stable
colour less and odorless solid at room temperature that will melt at 135C.
It is highly water soluble, and will slowly hydro-lyse in the presence of water (or water
vapour), to give ammonium carba-mate which slowly decomposes to ammonia and carbon
dioxide.

AMMONIA PRODUCTION

Essentially all the processes employed for ammonia synthesis are variations of the Haber-
Bosch process, developed in Germany from 1904-1913. This process involves the reaction of
hydrogen and nitrogen under high temperatures and pressures with an iron based catalyst.
This process also requires large energy consumption.
Ammonia is generally produced at a few large plants with stream capacities of 1000
tonnes/day or greater (Marshall 1987).
The formation of ammonia from hydrogen and nitrogen is a reversible reaction. The fraction
of ammonia in the final gas mixture is dependent on the conditions employed. Unreacted
hydrogen and nitrogen gases separated from the ammonia and are usually recycled. In almost
all modern plants, the ammonia produced is recovered by condensation to give liquid
ammonia.
The source of nitrogen is always air. Hydrogen can be derived from a number of raw
materials including water, hydrocarbons from crude oil refining, coal, and most commonly
natural gas.
Hydrogen rich reformer off-gases from oil refineries have also been used as a source of
hydrogen. Steam reforming is generally employed for the production of hydrogen from these
raw materials. This process also generates carbon dioxide, which can then be used as a raw
material in the production of urea.
Trace impurities in the feed gases, such as sulphur compounds and chlorides, can have a
detrimental effect on the production of ammonia by poisoning the catalysts employed. The
feed gases, therefore, need to be purified prior to use.

UREA MANUFACTURING

Urea (NH2CONH2) is produced from ammonia (NH3) and gaseous carbon dioxide (CO2) at
high pressure and relatively high temperature. Both reactants are obtained from ammonia
synthesis, as discussed in Section 2.1. The production of urea involves the formation of
ammonium carbamate (NH2COONH4), which is dehydrated to form urea.

2 NH3 + CO2 → NH2COONH4 + Heat

NH2COONH4 + Heat → NH2CONH2 + H2O
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Both of these reactions are reversible, and therefore ammonia and carbon dioxide exit the
reactor along with ammonium carbamate and urea. The components of this mixture are then
separated, usually by stripping off gaseous ammonia followed by carbon dioxide, to yield
urea.
There are a number of process for handling ammonia in this process, including the once
through, the partial recycle and the total recycle processes.

Solidification
Urea processes produce an aqueous solution containing 70-87% urea. The two most
commonly employed methods for the production of solid urea are prilling and granulation.

Prilling
In prilling, molten urea that is almost anhydrous is forced through spray heads or spinner
buckets. The droplets of urea fall through a countercurrent stream of air in which they
solidify to form prills (pellets). This process has potentially greater pollution problems due to
the production of a large volume of air laden with very fine dust that must be processed.
Many recovery systems have been tried for this process, but all with limited success.

Granulation
Granulation is now superceding prilling as the method of choice for urea solidification. In
this process, granules are usually formed by the successively spraying and drying (layering)
of concentrated urea solution onto recycled granules, in a rotating drum.

For both the prilling and granulation processes, formaldehyde (0.2-0.5%) is often added to
the urea melt prior to solidification. This is to condition the finished product, improving the
particle crushing strength and reducing caking during storage, without lowering the nitrogen
content. The addition of formaldehyde to the pre-solidified urea has also been used to reduce
dust formation in both processes.

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 GAS TURBINE

A gas turbine, also called a combustion turbine, is a type of internal combustion engine. It has
an upstream rotating compressor coupled to a downstream turbine, and a combustion
chamber in-between.
The basic operation of the gas turbine is similar to that of the steam power plant except that
air is used instead of water. Fresh atmospheric air flows through a compressor that brings it to
higher pressure. Energy is then added by spraying fuel into the air and igniting it so the
combustion generates a high-temperature flow.
This high-temperature high-pressure gas enters a turbine, where it expands down to the
exhaust pressure, producing a shaft work output in the process.
The turbine shaft work is used to drive the compressor and other devices such as an electric
generator that may be coupled to the shaft. The energy that is not used for shaft work comes
out in the exhaust gases, so these have either a high temperature or a high velocity.
The purpose of the gas turbine determines the design so that the most desirable energy form
is maximized. Gas turbines are used to power aircraft, trains, ships, electrical generators, or
even tanks.

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 History
 50: Hero's Engine (aeolipile) — Apparently, Hero's steam engine was taken to be no
more than a toy, and thus its full potential not realized for centuries.
 1500: The "Chimney Jack" was drawn by Leonardo da Vinci: Hot air from a fire rises
through a single-stage axial turbine rotor mounted in the exhaust duct of the fireplace
and turning the roasting spit by gear/ chain connection.
 1629: Jets of steam rotated an impulse turbine that then drove a working stamping
mill by means of a bevel gear, developed by Giovanni Branca.
 1678: Ferdinand Verbiest built a model carriage relying on a steam jet for power.

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 Fig: Sketch of John Barber's gas turbine, from his patent

 1791: A patent was given to John Barber, an Englishman, for the first true gas turbine.
His invention had most of the elements present in the modern day gas turbines. The
turbine was designed to power a horseless carriage.
 1872: A gas turbine engine was designed by Franz Stolze, but the engine never ran
under its own power.
 1894: Sir Charles Parsons patented the idea of propelling a ship with a steam turbine,
and built a demonstration vessel, the Turbine, easily the fastest vessel afloat at the
time. This principle of propulsion is still of some use.
 1895: Three 4-ton 100 kW Parsons radial flow generators were installed in Cambridge
Power Station, and used to power the first electric street lighting scheme in the city.
 1899: Charles Gordon Curtis patented the first gas turbine engine in the USA
("Apparatus for generating mechanical power", Patent No. US635, 919).
 1900: Sanford Alexander Moss submitted a thesis on gas turbines. In 1903, Moss
became an engineer for General Electric's Steam Turbine Department in Lynn,
Massachusetts.
 While there, he applied some of his concepts in the development of the turbo super
charger. His design used a small turbine wheel, driven by exhaust gases, to turn a
supercharger.
 1903: A Norwegian, Agidius Elling, was able to build the first gas turbine that was
able to produce more power than needed to run its own components, which was
considered an achievement in a time when knowledge about aerodynamics was
limited. Using rotary compressors and turbines it produced 11 hp (massive for those
days).
 1906: The Armengaud-Lemale turbine engine in France with water-cooled
combustion chamber.
 1910: Holzwarth impulse turbine (pulse combustion) achieved 150 kilowatts.
 1913: Nikola Tesla patents the Tesla turbine based on the boundary layer effect.
 1920s The practical theory of gas flow through passages was developed into the more
formal (and applicable to turbines) theory of gas flow past airfoils by A. A. Griffith
resulting in the publishing in 1926 of An Aerodynamic Theory of Turbine Design.
Working tested designs of axial turbines suitable for driving a propeller were
developed by the Royal Aeronautical Establishment proving the efficiency of
aerodynamic shaping of the blades in 1929.

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  1930: Having found no interest from the RAF for his idea, Frank Whittle patented the
design for a centrifugal gas turbine for jet propulsion. The first successful use of his
engine was in April 1937
 1932: BBC Brown, Boveri & Cie of Switzerland starts selling axial compressor and
turbine turbojets as part of the turbocharged steam generating Velox boiler. Following
the gas turbine principle, the steam evaporation tubes are arranged within the gas
turbine combustion chamber; the first Velox plant was erected in Mondeville, France.
 1934: Raul Pateras de Pescara patented the free-piston engine as a gas generator for
gas turbines.
 1936: Hans von Ohain and Max Hahn in Germany were developing their own
patented engine design.
 1936 Whittle with others backed by investment forms Power Jets Ltd
 1937, the first Power Jets engine runs, and impresses Henry Tizard such that he
secures government funding for its further development.
 1939: First 4 MW utility power generation gas turbine from BBC Brown, Boveri &
Cie. for an emergency power station in Neuchâtel, Switzerland.
 1946 National Gas Turbine Establishment formed from Power Jets and the RAE
turbine division bring together Whittle and Hayne Constant's work.

THEORY OF OPERATION

In an ideal gas turbine, gases undergo three thermodynamic processes: an isentropic

compression, an isobaric (constant pressure) combustion and an isentropic expansion.
Together, these make up the Brayton cycle.

In a practical gas turbine, mechanical energy is irreversibly transformed into heat when gases
are compressed (in either a centrifugal or axial compressor), due to internal friction and
turbulence. Passage through the combustion chamber, where heat is added and the specific
volume of the gases increases, is accompanied by a slight loss in pressure. During expansion
amidst the stator and rotor blades of the turbine, irreversible energy transformation once
again occurs.

If the device has been designed to power a shaft as with an industrial generator or a
turboprop, the exit pressure will be as close to the entry pressure as possible. In practice it is
necessary that some pressure remains at the outlet in order to fully expel the exhaust gases.

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In the case of a jet engine only enough pressure and energy is extracted from the flow to drive
the compressor and other components. The remaining high pressure gases are accelerated to
provide a jet that can, for example, be used to propel an aircraft.

Brayton Cycle

As with all cyclic heat engines, higher combustion temperatures can allow for greater
efficiencies. However, temperatures are limited by ability of the steel, nickel, ceramic, or
other materials that make up the engine to withstand high temperatures and stresses. To
combat this many turbines feature complex blade cooling systems.

As a general rule, the smaller the engine, the higher the rotation rate of the shaft must be to
maintain tip speed. Blade-tip speed determines the maximum pressure ratios that can be
obtained by the turbine and the compressor. This, in turn, limits the maximum power and
efficiency that can be obtained by the engine.

In order for tip speed to remain constant, if the diameter of a rotor is reduced by half, the
rotational speed must double. For example, large jet engines operate around 10,000 rpm,
while micro turbines spin as fast as 500,000 rpm.

Mechanically, gas turbines can be considerably less complex than internal combustion piston
engines. Simple turbines might have one moving part: the

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shaft/compressor/turbine/alternative-rotor assembly (see image above), not counting the fuel
system.

However, the required precision manufacturing for components and temperature resistant
alloys necessary for high efficiency often make the construction of a simple turbine more
complicated than piston engines.

More sophisticated turbines (such as those found in modern jet engines) may have multiple
shafts (spools), hundreds of turbine blades, movable stator blades, and a vast system of
complex piping, combustors and heat exchangers.

Thrust bearings and journal bearings are a critical part of design. Traditionally, they have
been hydrodynamic oil bearings, or oil-cooled ball bearings. These bearings are being
surpassed by foil bearings, which have been successfully used in micro turbines and auxiliary
power units.

TYPES OF GAS TURBINES

Jet engines

A typical axial-flow gas turbine turbojet, the J85, sectioned for display. Flow is left to right,
multistage compressor on left, combustion chambers center, two-stage turbine on right.

Air breathing jet engines are gas turbines optimized to produce thrust from the exhaust gases,
or from ducted fans connected to the gas turbines. Jet engines that produce thrust from the
direct impulse of exhaust gases are often called turbojets, whereas those that generate thrust
with the addition of a ducted fan are often called turbofans or (rarely) fan-jets.

Gas turbines are also used in many liquid propellant rockets, the gas turbines are used to
power a turbo pump to permit the use of lightweight, low pressure tanks, which saves
considerable dry mass.

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Turboprop engines

A turboprop engine is a type of turbine engine which drives an external aircraft propeller
using a reduction gear. Turboprop engines are generally used on small subsonic aircraft, but
some large military and civil aircraft, such as the Airbus A400M, Lockheed L-188 Electra
and Tupolev Tu-95, have also used turboprop power.

Aero derivative gas turbines

Aero derivatives are also used in electrical power generation due to their ability to be shut
down, and handle load changes more quickly than industrial machines. They are also used in
the marine industry to reduce weight. The General Electric LM2500, General Electric
LM6000, Rolls-Royce RB211 and Rolls-Royce Avon are common models of this type of
machine.

Amateur gas turbines

Increasing numbers of gas turbines are being used or even constructed by amateurs.

In its most straightforward form, these are commercial turbines acquired through military
surplus or scrapyard sales, then operated for display as part of the hobby of engine collecting.
In its most extreme form, amateurs have even rebuilt engines beyond professional repair and
then used them to compete for the Land Speed Record.

The simplest form of self-constructed gas turbine employs an automotive turbocharger as the
core component. A combustion chamber is fabricated and plumbed between the compressor
and turbine sections.

More sophisticated turbojets are also built, where their thrust and light weight are sufficient
to power large model aircraft. The Schreckling design constructs the entire engine from raw
materials, including the fabrication of a centrifugal compressor wheel from plywood, epoxy
and wrapped carbon fiber strands.

Several small companies now manufacture small turbines and parts for the amateur. Most
turbojet-powered model aircraft are now using these commercial and semi-commercial micro
turbines, rather than a Schreckling-like home-build.

Auxiliary power units

APUs are small gas turbines designed to supply auxiliary power to larger, mobile, machines
such as an aircraft. They supply:

 compressed air for air conditioning and ventilation,

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  compressed air start-up power for larger jet engines,
 mechanical (shaft) power to a gearbox to drive shafted accessories or to start large jet
engines, and
 electrical, hydraulic and other power-transmission sources to consuming devices
remote from the APU.

Compressed air energy storage

One modern development seeks to improve efficiency in another way, by separating the
compressor and the turbine with a compressed air store. In a conventional turbine, up to half
the generated power is used driving the compressor.

In a compressed air energy storage configuration, power, perhaps from a wind farm or bought
on the open market at a time of low demand and low price, is used to drive the compressor,
and the compressed air released to operate the turbine when required.

Scale jet engines

Scale jet engines are scaled down versions of this early full scale engine. Also known as
miniature gas turbines or micro-jets.

With this in mind the pioneer of modern Micro-Jets, Kurt Schreckling, produced one of the
world's first Micro-Turbines, the FD3/67. This engine can produce up to 22 newton of thrust,
and can be built by most mechanically minded people with basic engineering tools, such as a
metal lathe.

Industrial gas turbines for power generation

GE H series power generation gas turbine: in combined cycle configuration, this 480-
megawatt unit has a rated thermal efficiency of 60%.

Industrial gas turbines differ from aeronautical designs in that the frames, bearings, and
blading are of heavier construction. They are also much more closely integrated with the
devices they power— often an electric generator—and the secondary-energy equipment that
is used to recover residual energy (largely heat).

They range in size from man-portable mobile plants to enormous, complex systems weighing
more than a hundred tones housed in block-sized buildings. When the turbine is used solely
for shaft power, its thermal efficiency is around the 30% mark.

This may cause a problem in which it is cheaper to buy electricity than to burn fuel.
Therefore many engines are used in CHP (Combined Heat and Power) configurations that
can be small enough to be integrated into portable container configurations.

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Gas turbines can be particularly efficient—up to at least 60%—when waste heat from the
turbine is recovered by a heat recovery steam generator to power a conventional steam
turbine in a combined cycle configuration. They can also be run in a cogeneration
configuration: the exhaust is used for space or water heating, or drives an absorption chiller
for cooling the inlet air and increase the power output, technology known as Turbine Inlet Air
Cooling.

Another significant advantage is their ability to be turned on and off within minutes,
supplying power during peak, or unscheduled, demand. Since single cycle (gas turbine only)
power plants are less efficient than combined cycle plants.

They are usually used as peaking power plants, which operate anywhere from several hours
per day to a few dozen hours per year—depending on the electricity demand and the
generating capacity of the region.

In areas with a shortage of base-load and load following power plant capacity or with low
fuel costs, a gas turbine power plant may regularly operate most hours of the day. A large
single-cycle gas turbine typically produces 100 to 400 megawatts of electric power and has
35–40% thermal efficiency.

Industrial gas turbines for mechanical drive

Industrial gas turbines that are used solely for mechanical drive or used in collaboration with
a recovery steam generator differ from power generating sets in that they are often smaller
and feature a dual shaft design as opposed to single shaft.

The power range varies from 1 megawatt up to 50 megawatts. These engines are connected
directly or via a gearbox to either a pump or compressor assembly. The majority of
installations are used within the oil and gas industries. Mechanical drive applications increase
efficiency by around 2%.

Oil and Gas platforms require these engines to drive compressors to inject gas into the wells
to force oil up via another bore, or to compress the gas for transportation. They're also often
used to provide power for the platform.

These platforms don't need to use the engine in collaboration with a CHP system due to
getting the gas at an extremely reduced cost (often free from burn off gas). The same
companies use pump sets to drive the fluids to land and across pipelines in various intervals.

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Turbo shaft engines

Turbo shaft engines are often used to drive compression trains (for example in gas pumping
stations or natural gas liquefaction plants) and are used to power almost all modern
helicopters. The primary shaft bears the compressor and the high speed turbine (often referred
to as the Gas Generator), while a second shaft bears the low-speed turbine (a power turbine or
free-wheeling turbine on helicopters.

Especially, because the gas generator turbine spins separately from the power turbine). In
effect the separation of the gas generator, by a fluid coupling (the hot energy-rich combustion
gases), from the power turbine is analogous to a transmission’s fluid. This arrangement is used
to increase power-output flexibility with associated highly-reliable control mechanisms.

Radial gas turbines

In 1963, Jan Mowill initiated the development at Kongsberg Våpenfabrikk in Norway.

Various successors have made good progress in the refinement of this mechanism. Owing to
a configuration that keeps heat away from certain bearings the durability of the machine is
improved while the radial turbine is well matched in speed requirement.

Micro turbines
Also known as:

 Turbo alternators
 Turbo generator

Micro turbines are touted to become widespread in distributed power and combined heat and
power applications. They are one of the most promising technologies for powering hybrid
electric vehicles. They range from hand held units producing less than a kilowatt, to
commercial sized systems that produce tens or hundreds of kilowatts. Basic principles of
micro turbine are based on micro combustion.

Part of their claimed success is said to be due to advances in electronics, which allows
unattended operation and interfacing with the commercial power grid. Electronic power
switching technology eliminates the need for the generator to be synchronized with the power
grid. This allows the generator to be integrated with the turbine shaft, and to double as the
starter motor.

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Micro turbine systems have many claimed advantages over reciprocating engine generators,
such as higher power-to-weight ratio, low emissions and few, or just one, moving part.
Advantages are that micro turbines may be designed with foil bearings and air-cooling
operating without lubricating oil, coolants or other hazardous materials. Nevertheless
reciprocating engines overall are still cheaper when all factors are considered.

Micro turbines also have a further advantage of having the majority of the waste heat
contained in the relatively high temperature exhaust making it simpler to capture, whereas the
waste heat of reciprocating engines is split between its exhaust and cooling system.

However, reciprocating engine generators are quicker to respond to changes in output power
requirement and are usually slightly more efficient, although the efficiency of micro turbines
is increasing. Micro turbines also lose more efficiency at low power levels than reciprocating
engines.

Advances in Technology
Gas turbine technology has steadily advanced since its inception and continues to evolve.
Development is actively producing both smaller gas turbines and more powerful and efficient
engines. Aiding in these advances are computer based design (specifically CFD and finite
element analysis) and the development of advanced materials.

\Base materials with superior high temperature strength (e.g., single-crystalsuperalloys that
exhibit yield strength anomaly) or thermal barrier coatings that protect the structural material
from ever higher temperatures. These advances allow higher compression ratios and turbine
inlet temperatures, more efficient combustion and better cooling of engine parts.

The simple-cycle efficiencies of early gas turbines were practically doubled by incorporating
inter-cooling, regeneration (or recuperation), and reheating. These improvements, of course,
come at the expense of increased initial and operation costs, and they cannot be justified
unless the decrease in fuel costs offsets the increase in other costs. The relatively low fuel
prices, the general desire in the industry to minimize installation costs, and the tremendous

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increase in the simple-cycle efficiency to about 40 percent left little desire for opting for these
modifications.

On the emissions side, the challenge is to increase turbine inlet temperatures while at the
same time reducing peak flame temperature in order to achieve lower NOx emissions and
meet the latest emission regulations. In May 2011, Mitsubishi Heavy Industries achieved a
turbine inlet temperature of 1,600 °C on a 320 megawatt gas turbine, and 460 MW in gas
turbine combined-cycle power generation applications in which gross thermal efficiency
exceeds 60%.

Compliant foil bearings were commercially introduced to gas turbines in the 1990s. These
can withstand over a hundred thousand start/stop cycles and have eliminated the need for an
oil system. The application of microelectronics and power switching technology have enabled
the development of commercially viable electricity generation by micro turbines for
distribution and vehicle propulsion.

Advantages of Gas Turbine Engines

 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.
 Greater reliability, particularly in applications where sustained high power
output is required.
 Waste heat is dissipated almost entirely in the exhaust. This results in a high
temperature exhaust stream that is very usable for boiling water in a combined
cycle, or for cogeneration.
 Low operating pressures.
 High operation speeds.
 Low lubricating oil cost and consumption.
 Can run on a wide variety of fuels.

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  Very low toxic emissions of CO and HC due to excess air, complete
combustion and no "quench" of the flame on cold surfaces.

Disadvantages of gas turbine engines

 Cost is very high.
 Less efficient than reciprocating engines at idle speed.
 Longer startup than reciprocating engines.
 Less responsive to changes in power demand compared with reciprocating
engines.
 Characteristic whine can be hard to suppress.

Conclution:
My vocational training at IFFCO, Aonla unit (U.P.) in unit “Urea Plant and
Power Generation Plant” was very interesting and full of technical
knowledge. I learn lots of things in field of power plant. It was an experience
for me to spend time in industry as trainee and it would be very helpful for my
future in technical field.

On the basis of observation during the industrial visit, we can thus conclude that
gas turbine plays a very vital role in the preceding of this plant.

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Although it also contributes in power generation and power supply for essential
instrument which has been taking into consideration for the production point of
view.

REFERENCES:

www.google.co.in\search
en.wikipedia.com
www.wikihow.com
www.iffco.com

Journals & Diary of IFFCO

Trainers & other employees of IFFCO

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