Is Wet Compression Safe for Gas Turbines? Proven Success with MeeFog Systems

Decades ago, some operators questioned whether wet compression could cause compressor blade erosion in gas turbines. But after more than twenty years of real-world data and field-tested reliability, the results speak for themselves:

When designed and operated correctly, with careful attention to droplet size, water purity, and injection rate, wet compression has proven to be one of the safest and most effective ways to boost gas turbine output and efficiency.

With over 1,000 installations across 30+ countries, MeeFog systems have become the trusted standard for safe, high-performance wet compression. Backed by decades of research and continuous innovation in fogging system design, MeeFog delivers measurable results without compromising turbine health.

How Wet Compression Works to Improve Turbine Output

Wet compression involves the injection of atomized water droplets directly into the compressor inlet of a gas turbine. These fine droplets evaporate within the compressor, creating an internal cooling effect, typically called evaporative intercooling. This simple process lowers compressor work, increases air density, and boosts turbine output.

In practical terms, operators usually see a 5% to 10% increase in power for every 1% of water injected relative to the inlet air mass flow. Some plants inject water equal to about 2.5% of the incoming air mass, achieving substantial performance gains.

This approach is similar in concept to a fog spray cooling system, where precision atomization and rapid evaporation create measurable cooling effects. The same principle applies here: smaller droplets evaporate faster, cooling the compressor efficiently and improving overall turbine performance.

Check this article to learn more about how to increase gas turbine efficiency through wet compression and other techniques.

Blade Erosion Myths and the Truth About Droplet Size

Many plant managers still worry about blade erosion from water injection systems. This concern is not unfounded because older wet compression systems often used outdated nozzles that produced oversized droplets. These large droplets caused impact erosion, leading to microfractures and pitting on turbine blades.

However, the issue was never the concept of wet compression itself. It was a poor fogging system design. Large droplets typically did not evaporate fully and struck compressor blades at high speed, gradually wearing away the metal surface.

Modern systems, like MeeFog’s fogging system for cooling, eliminate this risk. By producing ultra-fine droplets that evaporate almost instantly, MeeFog prevents liquid impaction and maintains compressor integrity.

Why Droplet Size Matters in Wet Compression

Droplet size is the single most important factor in avoiding erosion. MeeFog systems generate droplets averaging 20 microns in diameter, which are small enough to stay suspended in the airstream long enough to evaporate completely before reaching the compressor blades.

This precision atomization is achieved through high-pressure stainless-steel nozzles designed for consistent droplet size and distribution. The result is complete evaporation and uniform intercooling, with no risk of blade impact or material loss.