This document discusses the design of a vapor turbine for a Kalina cycle power plant. It begins with an introduction to the Kalina cycle and how it differs from a traditional Rankine cycle by using an ammonia-water working fluid rather than pure water. It then discusses the design of a 5.27MW turbine in India, the first of its kind, highlighting the challenges of sealing and material selection for the ammonia mixture. The document provides an overview of the turbine design process, codes and standards, modeling tools used, and highlights key areas like seal design, CFD analysis, and the varying thermodynamic properties of the ammonia-water working fluid that impact the turbine design.

1. DESIGN OF
VAPOR (STEAM &
AMMONIA) TURBINE
FOR KALINA CYCLEFOR KALINA CYCLE
WORKSHOP ON ADVANCED ENERGY EFFICIENT TECHNOLOGIES
JUNE 2012, NEW DELHI & CHENNAI

2. ContentContent
Intent For Design of the Kalina Cycle TurbineIntent For Design of the Kalina Cycle Turbine
IntroductionIntroduction
Rankine Cycle Steam TurbineRankine Cycle Steam Turbine
Kalina Cycle Vapor TurbineKalina Cycle Vapor Turbine
Design of Ammonia Mixture TurbineDesign of Ammonia Mixture TurbineDesign of Ammonia Mixture TurbineDesign of Ammonia Mixture Turbine
Design Process involved in TurbineDesign Process involved in Turbine
Challenges in Turbine Design for Kalina CycleChallenges in Turbine Design for Kalina Cycle
Product Development CycleProduct Development Cycle
Properties of the Water & Ammonia MixtureProperties of the Water & Ammonia Mixture

3. ContentContent
1.1. Intent For Design of the Kalina Cycle TurbineIntent For Design of the Kalina Cycle Turbine
2.2. IntroductionIntroduction
3.3. Rankine Cycle Steam TurbineRankine Cycle Steam Turbine
4.4. Kalina Cycle Vapor TurbineKalina Cycle Vapor Turbine
5.5. Design of Ammonia Mixture TurbineDesign of Ammonia Mixture Turbine
6.6. Design Process involved in TurbineDesign Process involved in Turbine
7.7. Challenges in Turbine Design for Kalina CycleChallenges in Turbine Design for Kalina Cycle
8.8. Product Development CycleProduct Development Cycle
9.9. Properties of the Water & Ammonia MixtureProperties of the Water & Ammonia Mixture

4. Intent For Design of the Kalina Cycle TurbineIntent For Design of the Kalina Cycle Turbine
Arani power system achieved an historic milestone in the Indian turbine manufacturing
industry by bagging a 5.27MW Kalina cycle vapor turbine order from FLSmidth, Chennai.
It is a waste heat recovery from Cement plant. This type of turbine is the first of this
kind being designed and manufactured in India.
This turbine is ranked third in the world in power generation capacity.
With 3 decades expertise in design, development, manufacturing and commissioning of
steam turbines by the Arani power system technical team, it could able to over come the
challenges in the design of turbine sealing, control systems and selection of the special
materials.

5. INTRODUCTIONINTRODUCTION
Compared to the conventional century-old Rankine cycle, a Kalina cycle power plant
may offer efficiency gains of up to 50percent for low heat energy sources such as
geothermal brine at 150°C to 210°C
. Gains of up to 20 percent may be realized for higher temperature heat sources such as
direct fired boilers and exhaust gases from a gas turbine. i.e. bottoming cycle of a
combined cycle plant.
It is likely that Kalina cycle plants will even cost less to build than Rankine cycle plants
of equal output.
Up to 30 percent savings for low heat applications and up to 10 percent savings for
direct fired or bottoming cycle plants have been approximated.

6. The Kalina cycle is principally a “modified” Rankine cycle. The transformation starts
with an important process change to the Rankine cycle - changing the working fluid in the
cycle from a “pure” component (typically water) to a “mixture” of ammonia and water.
INTRODUCTION Cont…INTRODUCTION Cont…

7. Rankine Cycle Steam TurbineRankine Cycle Steam Turbine

8. Kalina Cycle Vapor TurbineKalina Cycle Vapor Turbine

9. Kalina Cycle Vapor TurbineKalina Cycle Vapor Turbine

10. Comparison of Rankine & Kalina Cycle Vapor TurbineComparison of Rankine & Kalina Cycle Vapor Turbine
In Scope
Basic Diagram of Thermodynamic Advantages

11. Design of Ammonia Mixture TurbineDesign of Ammonia Mixture Turbine
Conventional axial flow steam turbines can be used in Kalina cycle plants.
This is possible because the molecular weight of ammonia and water are
similar - 17 for ammonia and 18 for water.
Turbines for Kalina cycle plants will also be smaller and therefore less
expense than turbines in Rankine cycle plants.
This is because Kalina cycle plants can utilize back pressure turbines as
condensing turbines. Turbines in Rankine cycle plants exhaust to a condenser
under vacuum, whereas Kalina cycle plants exhaust to a condenser under
pressure. This creates a big difference in specific volumes and therefore a big
difference in the size of the flow area in the exhausting turbine.

12. Design Process involved in TurbineDesign Process involved in Turbine
Vapor Flow Path Design
Material Selection
Journal and Thrust Bearing Selection
Mechanical Seal Design
Control systems for seal and TurbineControl systems for seal and Turbine
Rotor dynamics
3D Modeling
Manufacturing drawings

13. Challenges in Turbine Design for Kalina CycleChallenges in Turbine Design for Kalina Cycle
The Materials used in Kalina cycle should be free from Copper. If copper
is present in the Material the ammonia will react with Copper and leads
to corrosion.
The Ammonia and Steam are not allowed to leak to the atmosphere. So,
complete leak proof sealing system is required for the Turbine. Special
seals to be used in addition to the labyrinth seal and Specialseals to be used in addition to the labyrinth seal and Special
constructional features are to be provided in Throttle Valve, ESV etc.

14. Seal DesignSeal Design
HP leak to exhaust pipe
N2 Injection
Mixture (Steam+NH3) +N2
Leakage to blow down tank
(1bar (A))
Inlet
Turbine
N2 Injection
Mixture (Steam+NH3)+N2
Leakage to blow down tank
(1bar (A))
Exit
Atmosphere
Turbine
(NH3+Steam)
Atmosphere
Leak Off steam
Circumferential Seal Design

15. Product Development CycleProduct Development Cycle

16. DESIGN CODES & STANDARDSDESIGN CODES & STANDARDS
ARANI Steam Turbines are designed as per following
Turbine Design IEC 45, API 612, NEMA
SP23
Balancing API 612, ISO 1940
Rotor Dynamics API 612
Vibration Monitoring System API 670
Performance Test IEC 953

17. Technology & ToolsTechnology & Tools
THERMAL DESIGN
Meanline code(2D) for Preliminary design
SLEQ (Quasi 3D) for Optimum Design
In-house code for preparation for HMBD
MODELLING & DESIGN
Pro/E for 3D Modeling & Manufacturing Drawings
AutoCAD for Conceptual Design

18. SECTIONAL VIEWSECTIONAL VIEW -- TURBINE ASSEMBLYTURBINE ASSEMBLY

19. 3D Models3D Models
HP CASINGStraight Blade

20. Technology & ToolsTechnology & Tools
CFD ANALYSIS
Bladegen for Modelling of Blades
Turbogrid for Flow domain & Meshing
CFX for Analysis and Simulation
STRUCTURAL ANALYSIS
ANSYS for Analysis
ROTORDYNAMIC ANALYSISROTORDYNAMIC ANALYSIS
In-House code based on Transfer Matrix Method
XL ROTOR based on FEM method
TORSIONAL & SHORT CIRCUIT ANALYSIS
TORVIB based on Transfer Matrix Method

21. HP Blade Flow SimulationHP Blade Flow Simulation

22. HP Casing Structural AnalysisHP Casing Structural Analysis

23. Rotor dynamic Lateral AnalysisRotor dynamic Lateral Analysis

24. Torsional & Short Circuit AnalysisTorsional & Short Circuit Analysis
• Evaluate dynamic behavior of TG train
• Determine Torsional natural
frequencies
• Evaluate resonance occurrence with
Campbell diagram & select couplings
Generator Gear Box
Turbine
Couplings

25. Properties of the Water & Ammonia MixtureProperties of the Water & Ammonia Mixture
Ammonia-water mixtures have many basic features unlike that of either pure water
or pure ammonia. A mixture of the two fluids behaves like a totally new fluid
altogether.
There are four primary differences.
1. An ammonia-water mixture has a varying boiling and condensing temperature.
Conversely, both pure water and pure ammonia have constant boiling and
condensing temperatures.
2. The thermo-physical properties of an ammonia-water mixture can be altered by2. The thermo-physical properties of an ammonia-water mixture can be altered by
changing the ammonia concentration. The thermo-physical properties of water
and ammonia are fixed.
3. Ammonia-water has thermo-physical properties that causes mixed fluid
temperatures to increase or decrease without a change in the heat content. The
temperature of water or ammonia do not change without a change in energy.
4. The final difference is not really a change in a basic feature, but rather an
important change in a fluid property. This is the freeze temperature. Water
freezes at a relatively high temperature of 0°C, while pure ammonia freezes at
-78°C.Solutions of ammonia-water have very low freezing temperatures.

26. Phase DiagramPhase Diagram
The essence of the Kalina cycle takes advantage of the first feature change - the
ability of an ammonia-water mixture, at any given pressure. to boil or condense at
a “variable”temperature.
Ammonia-Water Phase Diagram

27. Varying Boiling TemperatureVarying Boiling Temperature
The temperature of the heat source drops as it gives up its energy to the working
fluid. Because of the variable boiling temperature, the temperature rise of an
ammonia-water mixture, in a counter-flow heat exchanger, more closely follows
the straight line temperature drop of a sensible heat source
Heat Exchange Process - Heat Source
to 3450 kPa
Ammonia-Water Solution
Heat Exchange Process - Heat Source to
3450 kPa Water

28. Comparison at different PressuresComparison at different Pressures
Heat Exchange Process - Heat
Source to 690 kPa Water
Heat Source Process - Heat
Source to 55 kPa Water

29. Varying Condensing TemperatureVarying Condensing Temperature
Both “steam” in a Rankine cycle and ammonia-water vapor in a Kalina cycle will
exhaust from a condensing turbine at or near their respective vapor saturation
points. However, given equal condenser cooling water temperatures, the
ammonia water will have a significantly higher pressure and temperature
than the steam.
The higher pressure is a result of ammonia being more volatile than water. TheThe higher pressure is a result of ammonia being more volatile than water. The
higher temperature is a result of the variable condensing temperature feature of
an ammonia-water mixture.

30. RecuperationRecuperation--CondensationCondensation
Heat Exchange Process – Recuperation-Condensation
There is also a secondary benefit of this Kalina cycle design. Since the temperature
rise of the cooling water for the ammonia- water can be higher than that for
condensing steam, the cooling water flow rate for the ammonia-water can be less
than that required for the steam. This means smaller cooling towers, pumps and
piping, along with lower auxiliary power requirement for pumping and cooling
Lower fans. This can result in significant capital cost savings for the cooling
system and further increases in the “net” power plant output for the Kalina cycle.

31. Specific Composition ChangeSpecific Composition Change
The Kalina cycle has a design option that can effectively reduce the pressure and
temperature of the vapor at the turbine exhaust. Taking a page out of an
ammonia absorption refrigeration design book, the Kalina cycle has the ability to
readily change the thermo-physical properties of the working fluid in different
parts of the cycle by changing the ratio of the ammonia-water mixture.
Phase Diagram – Absorption-Condensation
Another feature of the Kalina cycle is that the composition of the ammonia-water
mixture, and therefore the thermo-physical properties of the working fluid can be
readjusted throughout the entire system if operating parameters change.

32. Operation Below Freezing TemperaturesOperation Below Freezing Temperatures
Kalina cycle plants, however, can take advantage of this opportunity. Ammonia
has a very low freezing temperature. Just a small amount of ammonia in water
greatly reduces the freezing temperature. For example, even a lean 25/75
ammonia-water solution has a very low freezing temperature of -51°C. As a result,
condensation temperatures of ammonia-water fluids can go down to arctic
temperatures.

33. Arani Power Systems is a STEAM TURBINE manufacturer and supplier of
Turbo-Generator (TG) packages based in Hyderabad, India. Arani power
Operations cover from CONCEPT to COMMISSIONING of TG Packages of
capacities 4 to 48MW and other services up to 150MW. Arani Power designs and
manufactures high quality, customized and most efficient steam turbines to meet
unique needs of different industries like Independent, captive and cogeneration
About ARANI POWER SYSTEMS LIMITEDAbout ARANI POWER SYSTEMS LIMITED
unique needs of different industries like Independent, captive and cogeneration
power plants.
Eminent experts in specialized disciplines form the bedrock on which ARANI
is founded. The in-depth experience of our team members that spans over more
than three decades with well known Steam turbine manufacturing companies
across the country and overseas, is to fulfill the needs of the Power industry
across the globe.

34. Evolving to meet ever increasing demand, ARANI uses the latest and superior
technology in developing steam turbines according to the global standards.
ARANI designs and delivers cost effective customized products to international
standards.
About ARANI POWER SYSTEMS LIMITED Cont..About ARANI POWER SYSTEMS LIMITED Cont..
Arani Power Systems has an excellent infrastructure of operates of well
established R&D, and Engineering departments, state of the art manufacturing
facility inclusive of mechanical run test facility, good supply chain management
systems in place, sound Trouble shooting capability. Further it has a good Erection
& commissioning, after sales and Renovation & Modernization departments to
meet and exceed customer’s requirements.