3 MW Power Boost for LM 6000 Gas Turbine in Mexico
With over 1,000 systems installed, the power boost from installed MeeFog inlet air fogging systems exceeds 9,000......
Gas Turbine Inlet Air Cooling Systems for Power Optimization
Boost GT Power with a Cost-Effective MeeFog System
Increase Power Output and Fuel Efficiency with Gas Turbine Inlet Air Cooling
Inlet air cooling for gas turbines is a well-established method for increasing power output and improving fuel efficiency. Whether a facility operates in a dry climate or in hot, humid tropical conditions, evaporative cooling can provide an economically significant performance boost.
Why It Works
Gas turbine output depends on the mass of air entering the compressor. Since airflow volume remains essentially constant, lowering inlet air temperature creates immediate advantages:
- Increased Air Density: Cooler air is denser, allowing more air mass to flow through the compressor and increasing power output.
- Reduced Parasitic Load: Denser inlet air can reduce the work required by the compressor, helping improve overall efficiency.
How It Works
MeeFog inlet air cooling is simple and effective:
- Demineralized water is pressurized to 2,000 psi (138 bar) using a MeeFog pump skid.
- Specialized nozzles introduce a micro-fine mist into the turbine inlet airstream.
- As the mist evaporates, it cools the incoming air and helps improve turbine performance.
Power Optimization for High Temperatures
Challenge
High ambient temperatures cause gas turbines to lose significant power output just when energy demand is at its peak.
Solution
MeeFog systems inject micro-fine water mist directly into the gas turbine air inlet to drastically cool the incoming air.
Result
Facilities achieve up to a 25% increase in power generating capacity. Wet compression overspray fogging gives an additional 10% power boost.
MeeFog GT Installation Diagram
Click the different areas of the diagram below to learn more.
Pump Skid
Pump Skid
Stainless-steel welded frame with oversized inlet water filter. Water lubricated direct drive pumps means no oil or drive belts to change. Variable frequency drives are used to reduce flow for staging.
Evaporative Cooling Fog Nozzle Manifold
Evaporative Cooling Fog Nozzle Manifold
Cools to wet bulb temperature with droplets evaporating prior to entering compressor. Fog nozzles mounted on stainless steel tubing are wired for FOD avoidance. These precision nozzles are manufactured and tested in our own facility.
Wet Compression Nozzle Manifold
Wet Compression Nozzle Manifold
Fog droplets evaporate inside the compressor, giving an intercooling effect that reduces the work of compression. Water sprayed into the compressor will reduce NOx as well, but only about half as much as water sprayed into the combustors, because much of the air bypasses the combustion process.
WATCH: MeeFog GT Inlet Air Fogging in Action
Gas Turbine Power Boost For 20° F (11°C) of cooling
| Gas Turbine Model Number | ISO Output | Output 100 ° F (38° C) | Fog Flow | Output 80 °F (27 ° C) | Power Increase | ||
|---|---|---|---|---|---|---|---|
| MW | MW | GPM | LPM | MW | MW | % | |
| ALSTOM GT 8C | 52.6 | 41.2 | 12.1 | 45.9 | 46.1 | 4.9 | 11.90% |
| GE GT11N | 83.9 | 70.4 | 21.7 | 82.2 | 75.3 | 4.9 | 7.00% |
| GE 6541B | 39.6 | 33.9 | 10.5 | 40 | 36.7 | 2.7 | 8.00% |
| GE 7111EA | 84.9 | 70 | 20.2 | 76.6 | 75.6 | 5.6 | 7.90% |
| GE 7221 FA | 161.7 | 129.7 | 29 | 109.9 | 141 .3 | 11.6 | 8.90% |
| GE 9171E | 125.6 | 103.1 | 28.2 | 106.7 | 112 | 8.9 | 8.60% |
| GE 9FA | 259.5 | 209.8 | 43.8 | 165.8 | 230.8 | 21 | 10.00% |
| GE LM2500PH | 21.6 | 15.8 | 4.3 | 16.3 | 18.3 | 2.5 | 15.60% |
| GE LM2500+PK | 27.1 | 20 | 5.4 | 20.3 | 23 | 3 | 15.20% |
| GE LM6000PA | 41 | 25.3 | 8 | 30.4 | 33.5 | 8.2 | 32.50% |
| Solar Mars | 10 | 8.1 | 2.6 | 9.9 | 9 | 0.9 | 10.90% |
| SGT6-3000E (W501 D5A) | 109.3 | 88.7 | 25 | 94.7 | 96.7 | 8 | 9.10% |
| SGT6-5000F (W501F) | 171.8 | 140.6 | 30.2 | 114.1 | 151 .9 | 11.3 | 8.10% |
| S 701F / MHI 701F | 252.6 | 206.7 | 44.7 | 169.1 | 223.8 | 17.1 | 8.30% |
| SGT5-2000E (V94.2) | 148.8 | 122 | 34.8 | 131.7 | 132 | 10 | 8.20% |
| Ansaldo GT-26 | 331.6 | 255.5 | 48.2 | 182.3 | 287.6 | 32.1 | 12.60% |
| Ansaldo AE94.3 | 340.1 | 268.6 | 51.1 | 193.6 | 305.1 | 36.6 | 13.60% |
Featured Case Study
How Rapid ROI Pays for Additional Cooling Power | MeeFog Gas Turbine Air Inlet Cooling System
Midland Cogeneration Venture needed a cost-effective way to boost output at its facility. Mee Industries installed an inlet air cooling system to augment power production on six of their ABB11NM gas turbines. One year after the initial installation, Midland Cogen’s Brian Vokal said the results went far beyond expectations. “We are going to buy six more units using the cash generated.” Which is just what they did. As of the summer of 2011, MeeFog skids were installed on all 12 of the plant’s gas turbines.
The Challenge
To design the most economical and effective system to increase the power output and improve the fuel economy for 12 ABB combustion turbines.
The Solution
MeeFog Gas Turbine Inlet Air Cooling System was custom-designed and installed to allow fine control over a wider range of temperatures and humidity conditions.
System Overview
Nozzle Comparison
At an operating pressure of 2000 psi, the resulting average droplet size is roughly one-tenth the diameter of a single strand of human hair.
Droplet size for different nozzles at 500 ft/min airflow velocity (SI units).
Droplet Comparison
Small droplets have a larger surface-to-volume ratio than large droplets. This increases evaporation speed and cooling performance, making this one of the best inlet air cooling methods for gas turbine applications.
Want Proof?
We’ll gladly supply a detailed power recovery report for your existing gas turbines, including:
- Installed MeeFog system cost.
- Predicted MW-hr gain per year.
- Fuel savings.
MeeFog Nozzle
Gas Turbine Inlet Air Cooling FAQ
Inlet air cooling makes the air denser. Since the compressor of the gas turbine moves a fixed volume of air, the mass flow increases when the air is denser. More mass flow means more power output and improved efficiency.
When you use the inlet air cooling method for a gas turbine, it increases air density, allowing greater mass flow through the compressor. Denser, cooler air requires less compression work, resulting in higher efficiency and output.
A 20°F (11°C) reduction in inlet air temperature can increase output by 10% or more.
Efficiency rises with higher pressure ratios, hotter firing temperatures, or lower compressor workloads. While combustion upgrades help, gas turbine inlet air cooling or wet compression offers a faster, more economical improvement.
Stainless steel nozzles last indefinitely with filtered, demineralized water. Annual visual inspections are recommended to replace any nozzles that show blockage or physical damage.
The MeeFog system’s lifespan is typically 30 years or more. Stainless steel nozzles remain durable indefinitely when used correctly.
Our standard warranty is one year, but we also offer extended warranties. MeeFog gas turbine inlet air cooling systems have a useful life of at least 30 years.
Yes, while the power boost is more significant in dry climates, it remains economically significant even in very humid areas.
ROI varies, but installations often pay for themselves quickly. Midland Cogeneration Venture achieved enough savings from six systems to fund six more within one year.
The gas turbine inlet air cooling system helps reduce NOx emissions by up to 30% and lowers CO2 output per kilowatt of energy produced.
MeeFog Nozzles create droplets less than 10 micrometers, about one-tenth the diameter of a human hair. The small size promotes fast evaporation and uniform cooling before the air enters the compressor.
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