AIR CLEANING DEVICES FOR GAS TURBINES. ANALYSIS AND OPTIMIZATION WAYS.

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AIR CLEANING DEVICES FOR GAS

TURBINES. ANALYSIS AND OPTIMIZATION
WAYS.

Provolovich O.V.
Technical Director of NPP FOLTER LLC, Ph.D.

Over the past twenty years, there has been a rapid growth in the use of gas turbine units (GTU) in the energy

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AIR CLEANING DEVICES FOR GAS TURBINES. ANALYSIS AND OPTIMIZATION WAYS.

sector in Russia, where they help to solve the issue of increasing the capacity of electricity supply in a relatively
short time.

Large industrial enterprises are following a similar path, thus meeting the need for energy capacity and
simultaneously reducing their risks from rising tariffs for electricity purchased on the market.

A traditional and long-standing consumer of GTU is PAO Gazprom, which provides transportation of natural
gas throughout the country, as well as large-scale gas supplies to foreign consumers.

It should be noted that in recent years the construction of gas pipelines to Europe, China, and Turkey has
intensified.

The basis of the Unified Gas Pipeline System of PJSC Gazprom are gas pumping stations, where gas is
transported using gas turbine units of various capacities. Moreover, along with domestic gas turbine units, gas
turbine units from foreign manufacturers such as Siemens and GE Energy are also used in the projects.

GTUs are consumers of a large amount of atmospheric air, which is necessary for the gas combustion
process in the GTU. Since the operation of a GTU with a capacity of 25 MW requires about 260 thousand m?/h of
air, and for the most powerful GTUs (about 400 MW) the air requirement is 2.5 million m?/h.

Atmospheric air always contains some amount of dust particles of natural origin, associated with soil erosion,
generation of various dusts, plants (poplar fluff, dandelion, pollen, etc.). Additional air pollution is caused by man-
made factors associated with human activity (exhaust from motor vehicles, ventilation emissions from industrial
enterprises, etc.). This leads to the fact that air containing dust particles gets to the moving and rotating elements
of gas turbine and compressor units. Abrasive wear is especially characteristic of gas turbine blades, which leads
to a decrease in the efficiency of the entire gas turbine unit.

Contamination of gas turbine components results in additional costs associated with disassembling and
cleaning these components.

For the above reasons, there is a need for highly efficient cleaning of cycle air in gas turbines.

To solve this problem, special air cleaning devices (ACD) are used. ACDs are, as a rule, a separate structure
connected by an air duct to a gas turbine unit. Air intake into the ACD is carried out at a height of, as a rule, no
less than 8-10 meters. In the inlet part of the ACD, there are elements that protect it from the impact of direct
atmospheric precipitation (rain and snow) using special canopies, louvered drip collectors, etc.

As noted above, the task of the VOU is the highly efficient purification of large volumes of air using various
filter elements, the productivity of which ranges from 2 to 5 thousand m3/h.

In this regard, the VOU are large-sized metal structures weighing from several tens to several hundred tons.

Therefore, the developers of the VOU are faced with the task of creating filtering systems, which are the basis
of the VOU, allowing to reduce the dimensions and weight of the VOU.

Currently, several hundred gas turbine units of foreign manufacture from all well-known energy companies GE
Energy, Siemens, Alstom, Ansaldo, Mitsubishi and others have been installed in Russia with a unit capacity of 30
to 400 MW, as well as domestically produced gas turbine units with a capacity of 6 to 110 MW.

The proposed analysis will consider gas turbines with a capacity of more than 30 MW, for air purification of
which VOC weighing more than 25-30 tons is used.

Filtration systems in WWTPs are divided into two types.

- 1st: a multi-stage system with storage filters;
- 2nd: with self-cleaning pulse filters, which in most cases operate as storage filters, and their total share is 3-5%
of all WWTPs in Russia.

Taking this into account, all further analysis will be devoted to VOUs with static storage filters.

The system with accumulative filters is a two-, three- or four-stage filtration system, in which, as a rule,

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AIR CLEANING DEVICES FOR GAS TURBINES. ANALYSIS AND OPTIMIZATION WAYS.

moisture-trapping filters are installed at the entrance to the VOU, and after them, air purification is provided by 2
or 3 stages of filters with final cleaning of classes F8 or F9. It should be noted here that in recent years, more
efficient filters of classes E10-E12 have begun to be used as final filters.

Filters installed before the finishing filters provide protection for the finishing stage from coarse dust,
increasing its service life.

All filters: moisture traps, coarse (FGO), fine (FTO) and final cleaning are installed in metal panels of a
honeycomb structure, which are placed step by step in the design of the VOU. The total number of filters of each
stage in the VOU of different productivity ranges from 100 to 600 pieces, which requires significant volumes for
their placement and leads to the creation of a VOU of large mass.

A single filter element of the VOU, as a rule, has overall dimensions of the inlet section of 592x592 mm and a
capacity of 3000 to 5000 m3/h.

The above shows that in order to reduce the dimensions and weight of the WOU, it is necessary to use high-
performance and compact filtration systems.

To reduce the dimensions of the VOU, a combination of two or three stages on one panel for installing filters
is used.

Fig. 1. The first version of the combined filtration system in the VOU:
a – FGO, class G4, filtration area 2–2.5 sq. m, service life of six months;
b – FTO, class F8–F9, service life of about a year.

Fig. 2. The second version of the combined filtration system in the VOU:
a – pocket-type FGO, class G4, filtration area of ​2.5 sq. m, service life of six months;
b – FGO block housing;
c – FTO, class F8–F9, service life of about one year;
d – filtration system in working position.

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AIR CLEANING DEVICES FOR GAS TURBINES. ANALYSIS AND OPTIMIZATION WAYS.

Fig. 3. The third version of the combined filtration system in the VOU:
a – FGO reversible pocket type, class G4, filtration area 2.5–3.5 sq. m, service life of six months;
b – FTO, class F8–F9, service life 1.5–2 years

Fig. 4. The fourth variant of the combined filtration system in the VOU:
a – reversible FGO, class G4, filtration area 5–14 sq. m, service life 1–3 years;
b – FTO, class F8–F9, filtration area 20–45 sq. m, service life 1–3 years;
c – filtration system in working position

Fig. 5. The fifth variant of the combined filtration system in the WOU:
a – moisture trap (MT), class G2, regenerated with water flushing;
b – reversible FGO, class G4, filtration area 5–14 sq. m, service life 1–3 years;
c – FTO, class F8–F9, filtration area 20–45 sq. m, service life 1–3 years;
d – filtration system in working position

Fig. 1 – Fig. 5 show five variants of combined filtration systems in WOUs currently in use.

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4 and 5 options, developed by NPP Folter, are distinguished from those listed above by a higher service life
and reduced resistance due to the use of coarse filters with a large filtration surface, which allows for an increase
in the service life of filters and a reduction in operating costs during gas turbine operation.

Analyzing all VOUs operated with foreign gas turbines and storage filters, they can be divided into two groups

The first type of VOU, in which the filtration system is located perpendicular to the direction of the air flow (Fig.
6). Such VOUs are used in their gas turbines by Siemens, Ansaldo, Alstom, Mitsubishi and others.

Fig. 6. Frontal installation of filters

Fig. 7. VOU with one- (a) and three-way (b) air inlet

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VOUs of this design are produced with one-sided or three-sided air inlet (Fig. 7).

In the second type of VOU, the filtration system is installed in the form of a W-shaped system, where the air
filters are installed at an angle to the direction of the air flow (Fig. 8).

This design of the VOU was developed by the AAF company (USA) and is used by the GE Energy company
to equip its gas turbines.

The VOU of the described design (Fig. 8) are operated at the Vologda Thermal Power Plant, Syzran Thermal
Power Plant, Novomoskovsk State District Power Plant, etc., and as a filtration system they use a combined
arrangement of coarse and fine filters, corresponding to option 1 (Fig. 1).

Fig. 8. VOU with a W-shaped filtration system and the first

option for placing the FTO and FGO (Fig. 1).

Fig. 9. VOU with a W-shaped filtration system and the

third option for placing the FTO and FGO (Fig. 3).

In the last few years, GE Energy has begun to use combined coarse and fine filters in a W-shaped system
according to option 3 (Fig. 3) (Kazan CHPP-2 and CHPP-3 (Fig. 9)).

To compare different design solutions of the VOU with each other, the author proposes to introduce the
indicator of Specific metal consumption, that is, the ratio of the mass of the VOU without the air duct from the
VOU to the gas turbine to the nominal volume of purified air.

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Mu is the specific metal consumption;

M is the mass of the purified air (g);
Q is the nominal volume of purified air (m3/h).

Table 1 shows the specific metal consumption indicators of the three main design types of VOU and the
relative reduction in metal consumption compared to the worst according to Mu.

Item Mu, Reduction of metal consumption

Type VOU
No. g/m?/h relative to VOU according to item 1, %

1. Three-way air inlet (GTU-160 MVT). 79 -

2. One-way air inlet (GTU 160 MW). 70 eleven

Single-sided air inlet with W-shaped 55-

3. 25-30
AAF system (GTU 77-400 MW). 65

When comparing the data provided, it is clear that with a “frontal” installation of the filtration system, the VOU
with a one-sided air inlet is 11% lighter than the VOU with a three-sided inlet, and the VOU with a W-shaped
system is 25-30% lighter.

As is known, reducing the metal content of a gas turbine unit almost linearly reduces its cost, which allows for
a significant reduction in capital costs during the construction of a gas turbine unit.

The analysis also showed that the speed in the VOU with a “frontal” installation of filtration systems is about 2
m/s, and with a W-shaped system about 4 m/s, which allows us to conclude that it is necessary to develop a VOU
with the maximum possible air speed in the live cross-section of the VOU while fulfilling all the main technical
requirements (aerodynamic resistance, cleaning efficiency) for filtration systems.

Based on the above analysis of the designs of the VOU, theoretical studies were conducted of various
possible design solutions for the VOU with the aim of developing new types of VOU that would reduce their metal
consumption and, accordingly, cost.

During the proposed research, 3D modeling of various design solutions for the VOU and mathematical
modeling of aerodynamic air flows were performed in the ANSYS computational fluid dynamics software package,
which made it possible to visualize and implement flow lines, air velocity fields, total and static pressures.

The calculations were based on a more efficient combined filtration system according to variant 4 (Fig. 4), for
which there were data on three standard sizes obtained during previously conducted tests on certified
aerodynamic stands. Figs. 10, 11 and 12 show diagrams of three standard sizes of the combined filtration system
according to variant 4 (Fig. 4).

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Fig. 10. Standard Folter filtration system for the fourth variant of FGO and FTO placement:
a – FGO (G4) + FTO (F8–F9);
b – filtration system in working position, throughput capacity 3400–4250 m3/h

Fig. 11. High-performance filtration system Folter for the fourth variant of placement of FGO and FTO:
a – FGO (G4) + FTO (F8–F9);
b – filtration system in working position.
Capacity of 4250–4500 m3/h increased by 20%, service life – by 1.5 times

Fig. 12. Super-productive Folter filtration system according to the fourth variant of FGO and FTO placement:
a – FGO (G4) + FTO (F8–F9);
b – filtration system in working position.
Capacity of 5000–5200 m3/h increased by 30%, service life – by 2–3 times

As the first variant of the research, the proposed parallel air filtration system in the VOU for the 110MV GTU
was considered. The basic diagram of such a VOU is shown in Fig. 13.

In this design solution, the moisture filters are arranged in a W-shaped system to increase the velocity in the
live cross-section of the VOU (Fig. 13).

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As coarse filters (CFF) class G4 and filters (FTO) class F9, their combined installation was adopted according
to option 4 (Fig. 4) with overall dimensions of CFF+FTO=400+400 mm (Fig. 11).

The FGO and FTO filters were located in two parallel rows along the air flow. The first row of filters along the
air flow had channels in the VOU at the edges for the passage of part of the cycle air to the second row of FGO
and FTO filters, and the second row had a channel in the middle for the outlet of air purified in the first row (Fig.
13).

Fig. 13. Scheme of the VOU with a parallel filtration system

For mathematical modeling, a filtration system of coarse and fine filters 400+400 mm (Fig. 11) with a capacity
of 4170 m3/h (240 sets) was considered.

The simulation was carried out at different air velocities in the live cross-section of the VOU. Fig. 14 shows the
static pressure field for a parallel filtration system at a velocity in the VOU of 4 m/s, which corresponded to the
nominal air flow rate for a 110 MW GTU (1020 thousand m3/h).

The studies also showed that a further increase in air velocity in the VOU leads to a sharp increase in the
resistance of the entire structure.

In order to compare the parallel and W-shaped systems, similar mathematical modeling was performed using
the example of the VOU of Kazan TPP-2.

The results of modeling the two specified systems are shown in Fig. 14.

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Fig. 14:
a – pressure field for a W-shaped filtration system at an air speed of 4.3 m/s;
b – pressure field for a parallel filtration system at an air speed of 4.1 m/s

Calculations showed that the aerodynamic resistance of both two-stage systems at an air velocity in the live
cross-section of about 4 m/s was 420 Pa.

The analysis also showed that the W-shaped and parallel systems are also comparable in terms of overall
dimensions, which allows us to conclude that it is possible to use a parallel filtration system as an alternative to
the W-shaped system. The parallel filtration system, due to its high velocity in the live section (4 m/s), has a low
metal consumption, like the W-shaped system. At the same time, it is simpler to manufacture.

Further analysis of numerous VOU projects in Russia at operating gas turbines revealed a feature, which was
that, as a rule, VOUs are always located at some distance from the gas turbine and an additional, in some cases
extended, air duct is required to connect the outlet confuser (plenum) of the VOU with the inlet flange of the gas
turbine compressor.

Rice. 15. Schemes of some VOU with air ducts for a number of operating gas turbines:
a – Ivanovskaya GRES, GTE-110 MW;
b – Kirov TPP-3, GTU-180 MW;
in – Izhevsk CHPP-1, GTE-160 MW;
g – Moscow TPP-21, GTE-160 MW

Fig. 15 shows diagrams of some VOUs with air ducts for a number of operating gas turbines (Ivanovskaya
GRES, 110 MW GTU; Kirovskaya CHPP-3, 180 MW GTU; Izhevskaya CHPP-1, 160 MW GTU; Moscow CHPP-
21, 160 MW GTU).

From the given diagrams it is clear that the length of the overhead lines from the VOU to the GTU is 25 m for
the Ivanovskaya GRES, 19 m for the Izhevskaya TPP-1, 30 m for the Moscow TPP-21 and the Kirov TPP.

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In all the projects presented, these air ducts have a large open cross-section to allow the placement of a noise
suppressor closer to the gas turbine unit.

The air speed in these air ducts is 7-8 m/s.

In most cases, the mass of these air ducts is comparable to the mass of the VOU.

This type of arrangement of the VOU with long air ducts occurs in cases where reconstruction of existing
energy facilities occurs, where the GTU or CCGT (combined steam and gas turbine unit) is installed in an existing
building, and the VOU is placed on the roof of this building or on columns attached to the building. In this case,
sufficiently long air ducts are required to transport air purified in the VOU to the GTU.

Based on the above analysis, the possibility of placing the VOU elements in the air duct was proposed for
consideration.

The initial analysis was carried out using the example of the current project of the GTU-SGT5-2000E with a
capacity of 180 MW turbine from Siemens (Kirov CHPP-3).

The design of the VOU with a wedge-shaped arrangement of the filtration system, called a “channel VOU”,
was adopted as the calculation model; the diagram of this design is shown in Fig. 16.

Rice. 16. Scheme of channel-type VOU for 180 MW GTU

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As can be seen from Fig. 16, the ducted VOU includes: weather canopies, an anti-icing system, moisture
filters, and coarse (G4) and fine (F9) filters, located according to the fourth option (Fig. 4 and Fig. 12), with overall
dimensions of 600+600 mm. A noise muffler is located at the air outlet from the filtration system.

The total number of coarse and fine filters (G4+F9) was 368 sets, placed in 2 floors, 4 tiers per floor.

The nominal productivity of a single FGO+FTO set was 4300 m3/h.

Due to the features of the considered coarse and fine filtration system, namely the large filtering surface of the
FGO G4 (15 m?) and FTO F9 (45 m?), the service life of this system will be at least 2-2.5 years.

The overall dimensions of the channel VOU in terms of the live cross-section were taken to be close to the
dimensions of the channel of the existing project (5.5 x 11 m).

The length of the channel-type VOU without canopies was about 20 m, which fits into the length of the air
ducts of the above-mentioned projects.

For the channel KVOU circuit shown in Fig. 16, mathematical modeling was performed, the results of which
are shown in Fig. 17.

The total air consumption was taken as 1587 thousand m3/h, corresponding to the air consumption for a 180
MW gas turbine.

Fig. 17. Mathematical modeling of the aerodynamics of the filtration system in the ducted VOU GTU-180 MW:
a – field of total pressures, Pa;
b – field of air flow velocities, m/s

The aerodynamic resistance of the two-stage filtration system was 380 Pa, and the total resistance of the
VOU, including the silencer and air duct, before entering the GTU was 750-800 Pa, which meets the requirements
for a 180 MW GTU.

If it is necessary to solve the problem of reducing the resistance of a channel amplifier, it can be achieved by
increasing the number of filters with a slight increase in the length of the amplifier.

To estimate the mass of the considered channel-type VOU for the 180 MW GTU, 3D modeling was performed
(Fig. 18), which shows that the mass of the channel-type VOU is 40% less than the existing VOU together with
the air duct.

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Similar calculations and modeling were performed for the GTE-110 MW based on a real project (Ivanovskaya
GRES) and the technical specifications for the VOU GTU-32 MW.

Fig. 18. Comparison of two variants of the KVOU for the GTU-180 MW:
a – weight of the KVOU and air duct without filters and muffler for the GTU-180 MW (Kirov TPP-3) – 190 t;
b – weight of the channel KVOU for the GTU-180 MW without filters and muffler – 115 t.

Fig. 19 shows the diagram of the channel VOU for GTE-110 MW with a wedge filtration system FGO+FTO
(400+400 mm) according to the 5th option (Fig. 5), i.e. a three-stage system. In this case, the productivity of a
single module was 4050 m3/h. A total of 252 sets, 2 floors, 4 and 3 tiers on the first and second floors,
respectively. The total length of the channel VOU was about 15 m.

Mathematical modeling of the channel-type VOU showed that with a nominal capacity of 1020 thousand m3/h,
the aerodynamic resistance of the three-stage system will be about 500 Pa, and the total resistance will be no
more than 850 Pa.

It should be noted here that in this calculation the channel size was chosen based on the specifics of the
Ivanovo GRES project, where the air channel passes between two columns with a limitation of this size. In the
event of removing these restrictions and reconfiguring the filtration system, the aerodynamic resistance of the
filtration system can be reduced.

3D modeling of the channel-type VOU for the GTE-110 MW is shown in Fig. 20 in comparison with the
existing design, and it is clear from it that the mass of the channel-type VOU is more than two times lighter than
the existing VOU and can be placed along the length of the existing air duct.

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Rice. 19. Scheme of channel VOU for GTE-110 MW

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Fig. 20. Comparison of two designs of the VOU for the GTE-110 MW (Ivanovskaya GRES):
a) – weight of the KVOU with an air tract without a muffler and filters – 80 t;
b) – weight without a muffler and filters – 34 t.

Further studies of the applicability of the channel-type VOU for the GTU-32 MW were carried out on the basis
of the technical specifications, for which sketch drawings of the standard VOU according to the technical
specifications and the channel-type VOU were made.

The diagram of the standard VOU according to the technical specifications is shown in Fig. 21 and it is
evident from the diagram that the purified air from the upper part of the VOU is directed to combustion in the gas
turbine unit, and from the lower part to the ventilation of the gas turbine unit. According to the technical
specifications for air purification in the gas turbine unit, a three-stage diagram of the filtration system according to
option 5 (Fig. 5) with overall dimensions of FGO+FTO (292+292 mm) in the amount of 96 sets (3200 m3/h/set)
was accepted for consideration. And for ventilation, a two-stage diagram with a G2 moisture trap and a FGO G4
reversible filter (292 mm) - 32 sets (2700 m3/h/set).

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Rice. 21. Scheme of standard VOU for GTU-32 MW

Fig. 22 shows a diagram of a channel VOU with similar filters in the same quantity. The overall dimensions of

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the channel VOU for the GTU combustion process were 2.7 x 4.4 m in the live cross-section, and the length
without canopies was 9.5 m, which allows it to be placed within the boundaries of the designed building.

Mathematical modeling showed that the aerodynamic resistance of the three-stage combined filtration system
of the channel-type air-cooled wastewater treatment plant for the combustion process of the gas turbine was 360
Pa at a nominal gas turbine flow rate of 307,200 m3/h, and the total resistance of the air-cooled wastewater
treatment plant was about 600 Pa, which meets the requirements of the technical specifications.

Rice. 22. Diagram of the channel VOU for GTU-32 MW

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To compare the two options, 3D modeling of the VOU according to the technical specifications and the
channel VOU was performed, the results of which are shown in Fig. 23. The comparison shows that the channel
VOU is 48% lighter than the standard VOU.

Fig. 23. Comparison of two designs of the KVOU for the GTU-32 MW:
a – the mass of the KVOU according to the technical specifications without filters is 35,000 kg;
b – the mass of the channel KVOU without filters is 18,500 kg.

The conducted analysis and theoretical studies have shown that in cases where the VOU is located at some
distance from the entrance to the gas turbine, it is advisable to use a channel VOU, which allows reducing the
metal consumption and, accordingly, the cost of the VOU, which can be up to 40-50%.

In a number of cases, the reduction in the metal content of the VOU also leads to a reduction in the cost of
construction and installation work associated with the manufacture of foundations for VOU located outdoors.

The conducted analysis of the design features of the VOU of the gas turbine units operating in Russia allows
us to draw the following conclusions.

1. VOU GTUs are designed to purify large volumes of air, and therefore their design consists of large-sized
and metal-intensive products.

2. The use of standard fine filters in one block with reverse (reversible) coarse filters with an increased
filtration area allows for a reduction in resistance and an increase in the service life of both stages in existing GTU
VOUs, as well as the development of new VOU designs with reduced metal consumption.

3. An analysis of all operating VOUs in Russia showed that VOUs with a W-shaped arrangement of the FGO
and FTO filtration system have the lowest specific metal consumption.

4. A new parallel filtration system in the VOU is proposed, which is not inferior to the W-shaped filtration
system in terms of metal consumption, and theoretical calculations and mathematical modeling have shown its
practical applicability.

https://www.folter.ru/stati/vozduhoochistnye-ustrojstva-dlya-gazovyh-turbin.-analiz-i-puti-optimizacii/[2024-07-05 0:11:46]
AIR CLEANING DEVICES FOR GAS TURBINES. ANALYSIS AND OPTIMIZATION WAYS.

5. Analysis of the existing VOU GTU showed that in many cases the VOU is located at some distance from
the GTU and requires the use of an additional air duct to connect the outlet confuser (plenum) of the VOU with the
inlet of the GTU compressor. This leads to an increase in the cost of the VOU and the cost of its construction.

6. A new design of a channel-type VOU has been proposed, which allows for a reduction in metal
consumption and, accordingly, cost by 40-50% compared to existing VOU designs.

7. Reducing the metal content of the channel-type VOU can also lead to a reduction in the construction and
installation work of the gas turbine unit.

8. Theoretical calculations and mathematical modeling have shown the applicability of the channel-type VOU
for existing VOU GTU projects of 32, 110 and 180 MW.

9. Mathematical modeling of various options for a channel-type VOU showed that by varying the dimensions
of the channel cross-section (width, height), as well as using various combined filtration systems FGO and FTO
from 292+292 mm to 600+600 mm, it is possible to achieve a given aerodynamic resistance of the entire VOU as
a whole.

10. It is advisable to continue research into new design solutions for VOU at gas turbines of other capacities
of specific projects.

REPRESENTATIVE OFFICES:

NPP Folter-SPb St. Petersburg: +7 (999) 231-32-33

e-mail: [email protected]

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e-mail: [email protected]

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Representative in Uzbekistan: +998 90 9249604 (Telegram, WhatsApp);

e-mail: [email protected]

CONTACT INFORMATION

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Office hours: 9:30am to 6:00pm, Friday 9:30am to 5:00pm

Phone: +7 499 519-13-99, +7 495 287-17-99

Fax: +7 499 519-13-99 ext. 110

E-mail: [email protected]

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INDUSTRIAL FILTERS
- air purification filters
- pocket filters

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AIR CLEANING DEVICES FOR GAS TURBINES. ANALYSIS AND OPTIMIZATION WAYS.

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- cartridge filters
- carbon filters
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