Gas turbines breathe new life
Camfil designs a static EPA retrofit gas turbine filtration solution for LM6000 turbines to ensure they deliver reliable power & heating to the district. The result of the upgrade was 3x more filter life, reduction in CO2 emissions by 1 100 tons per year, and fuel consumption savings of 650 000 Sm3 per year.
Applications
Customer(s)
- A co-generation plant supplying electricity and steam
Products
Country
- Italy
Key achievements
4X greater final filter lifetime
9X greater Prefilter lifetime
540,000 Sm3 fuel consumption savings
1,100 tons CO2 reduction per year
Summary
Customer profile
A co-generation plant equipped with a 44MW LM6000 gas turbine supplies electricity and steam to the adjacent paper mill, as well as the district heating network of Riva del Garda, benefiting homes, offices, and schools. It operates with a high availability requirement of 7,900 hours per year.
Original installation
The original system featured a 2-stage design with T2[1] efficiency pleated prefilters and T9[2] efficiency composite-style, non-pulsing cartridge filters. Its limitations—low filtration efficiency, restricted filter openings and media area, and low hydrophobicity—were contributing to engine degradation and the frequent pressure spikes.
Site conditions
Located in the northwestern corner of Lake Garda, the site experiences a humid sub-Mediterranean climate with no dry season. With around 151 rainy days per year and a consistently high relative humidity of 74.12%, the area is also frequently affected by fog and mist.
Camfil solution
Camfil recommended upgrading the existing filter frame to a 2-stage static filtration solution. The system features two airtight filter banks equipped with T7 efficiency Cam-Flo GT Hybrid pocket filters and T10 efficiency CamGT 3V-600 V-bank final filters. Its EPA-efficiency, hydrophobic construction, and optimized aerodynamics led to the following results.
Problem statement
Due to a combination of challenging site conditions and limitations of the original installation, the power plant experienced rapid engine degradation and high pressure drop (dP) spikes, requiring three prefilter replacements and one final filter replacement annually.
Results
The upgrade reduced the average pressure drop by 50%, resulting in a 4x greater final filter lifetime, needing replacement only once every 4 years, and a 9x greater prefilter lifetime, needing replacement only once every 3 years. Additionally, the installation was completed in the 2-day requested timeframe, presenting no obstruction to the operation.
Approach and solution
Before recommending a solution, Camfil analyzed the site, measured contaminants, inspected the filter house, and conducted a Life Cycle Cost (LCC) analysis. Camfil also supported installation and provides ongoing follow-ups to ensure optimal performance.
Camfil replaced the original composite-style filters with the new solution. The solution utilizes static filters in a two-staged static system to facilitate better airflow, lower pressure drop and lower maintenance.
Cam-Flo GT Hybrid T7 prefilters have excellent water handling properties and help extend the life of final filters. CamGT 3V-600 T10 final filters are 24” deep, ensuring minimal pressure drop over its lifetime.
Results
See the graphs below for the comparison between the competitor and Camfil filters, in terms of their resulting pressure drops and filter lifetime in gas turbine running hours.
Graph 1 first stage: Competitor filters had a high average pressure drop of 254 Pa (1.02” w.g.), needing replacement 3 times every year had they continued using these filters. In comparison, Camfil filters had a low average pressure drop of 185 Pa (0.75” w.g.), lasting over 3 years.Graph 2 second stage: Competitor filters had a high average pressure drop of 459 Pa (1.85” w.g.), needing replacement every year had they continued using these filters. In comparison, Camfil filters had a low average pressure drop of 184 Pa (0.74” w.g.), lasting over 4 years.
In conclusion, the upgraded system reduced the average pressure drop by 50%, resulted in a ninefold longer prefilter lifetime and a fourfold longer final filter lifetime. The improved engine efficiency enabled fuel consumption savings of 540,000 Sm3 and a CO2 reduction of 1, 100 tons per year.