The document describes a new design for a gas flare steam turbine plant for power generation. It would convert waste heat from gas flares into steam using a steam plant, which would power a steam turbine and generate electricity. The steam plant uses thermal barrier coating and insulation on its walls to efficiently transfer heat to water and produce high pressure steam. This steam would drive a steam turbine, which could power a generator and produce electricity on a large scale in a cost effective manner, while reducing pollution from gas flaring.

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2013
AJUMOGOBIA
IGONIKON TARIAH.
INSTITUTE OF MANAGEMENT
AND TECHNOLOGY, ENUGU.
12/15/2013
NEW DESIGNED GAS FLARE STEAM
TURBINE PLANT FOR POWER
GENERATION.
[Type text] [Type text] [Type text]
2013
AJUMOGOBIA
IGONIKON TARIAH.
INSTITUTE OF MANAGEMENT
AND TECHNOLOGY, ENUGU.
12/15/2013
NEW DESIGNED GAS FLARE STEAM
TURBINE PLANT FOR POWER
GENERATION.
[Type text] [Type text] [Type text]
2013
AJUMOGOBIA
IGONIKON TARIAH.
INSTITUTE OF MANAGEMENT
AND TECHNOLOGY, ENUGU.
12/15/2013
NEW DESIGNED GAS FLARE STEAM
TURBINE PLANT FOR POWER
GENERATION.

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DEDICATION
I ardently dedicate this project to the Almighty God for His absolute
wisdom and knowledge in putting up an imagination into reality.

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TABLE OF CONTENTS
Title
Dedication
Table of Contents
1. Introduction ------------------------------------------------------------ page 1
2. Project Statement ----------------------------------------------------- page 3
2.1 Steam Plant --------------------------------------------------------------page 3
2.2 Combustion Chamber ------------------------------------------------ page 7
2.3 Walls of the Steam Plant ---------------------------------------------page 12
2.4 Steam Turbine-----------------------------------------------------------page 15
3. Project Objectives------------------------------------------------------ page 19
4. Project Implementation---------------------------------------------- page 20
5. Project Monitoring---------------------------------------------------- page 21
6. Project Budget----------------------------------------------------------page 22
7. Conclusion---------------------------------------------------------------page 23
INTRODUCTION

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This project is all about bringing sanity to our environment, by reducing
the negative effect of pollution to the Ozone Layer, and also creating a
conducive environment for mankind by increasing the economical
growth/value of the nation.
The total process of achieving this project is of a low cost to be
compared with the effect/disadvantages it causes to mankind and his
environment.
Gas Flare Stack at one of the dispatch station in USA.
It is rightly stated that health is life and wealth, so the aim of this
project is to actualize the safety of our ozone layer which is health,

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creating better living for mankind which is life, and increasing the
economic standard of living in our society which is wealth.
The idea of this project is to convert the Oil and Gas flare
NNPC Flare stack in Port Harcourt
which stands as a pollution and negative output causing an
uncompromised flux to our climate condition, mankind and its
environment into electricity.

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Project Statement
In operation, we are converting the Oil and Gas Flare which has heat
energy, gaining 92% of the energy into steam to propel a steam turbine
which power ranges from 1horsepower up to 1.5GW(Approximately
2,000,000Hp).
The possibility of achieving steam energy is by conserving the loss heat
energy from the gas flare into an enclosed chamber having less heat
loss of 8%. A boiler plant is set to run a steam turbine as in other cases,
but in this process, we are designing a new brand system to generate
the steam energy called Steam Plant to run the turbine.
Steam Plant
Steam plant generates high pressure steam by transferring the heat of
Combustion from the heat transfer sections. This part of the article
series briefly describes the flow and arrangement of the heat transfer
section in the steam plant. In line diagrams help make the concept
clear.

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waterinlet
steamoutlet
gas burner/cooker
water tank
An in line diagram of a Steam Plant.
1
2
3
4b
Gas inlet
Ignition
Transparent
Tempered Gas
Walls
Steam Plant showing both the gas inlet and the ignition.
(Diagram 1)

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steam outlet
1
2
3
4b
Steam Plant showing the steam outlet. (Diagram 2)
Assembly part of the Steam Plant (Diagram 1a)

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2
Assembly part of the Steam Plant (Diagram 1b)
3
Assembly part of the Steam Plant (Diagram 1c)

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Combustion Chamber
It can also be called the interference chamber, the chamber were the
heat energy from the burner at a higher temperature relate with water
(H20) to form steam.
tempered glassgas inlet
ignition
Side view of the combustion chamber showing both the
gas inlet and the ignition. (Diagram i)

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steam outlet
Side view of the combustion chamber showing the Steam
Outlet. (Diagram ii)
The chamber is in cooperated with the following:
 Gas Burner/cooker
 Ignition
 Water tanks/panels.

Gas Burner/Cooker
This section can also be called the burning section or the burner. The
burner serves as the outlet of the gas that produces flame. Is from the
burner that the heat for converting water into steam is been generated.
The burner comprises of both the gas and the ignition.

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Gas Burner/Cooker
Ignition
Is a device or apparatus used for starting up the fire at the cooker, it
diffuse with the expel gas to produce fire which gives heat or produces
heat energy.
Water tanks/Panels.
Volume of one unit mass of steam is thousand times that of water,
when water is converted to steam in a closed vessel the pressure will
increase. Boiler uses this principle to produce high pressure steam.
Conversion of Water to Steam evolves in three stages.
o Heating the water from cold condition to boiling point or
saturation temperature – sensible heat addition.
o Water boils at saturation temperature to produce steam - Latent
heat. Addition.
o Heating steam from saturation temperature to higher
temperature called Superheating to increase the power plant
output and
o Efficiency.

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2water inlet
steam outlet
Single Phase Water Tank.
The tanks are medium is sizes and cylindrical in shapes that functions as
the storage and feeding point for water and the collection point for
water and steam mixture. This is the most important pressure part in
the steam plant that gives rises to the pressurized steam after heated.
Each of the tanks has two (2) major orifice (inlet and outlet). The inlet
allows the flow of water from an external feed tank outside the plant
into the chamber (internal tank), while the outlet gives way for the
highly pressurized steam to flow into the turbine for the rotation of the
turbine blade, transmitting its rotational motion to the alternator for
the generating of electricity.

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gas inlet
ignition
Water tanks/panels placed in parallel on the gas burner.
Feed Water Pump
The first step is to get a constant supply of water at high pressure into
the steam plant. Since the plant is always at a high pressure. ‘Steam
plant feed water pump’ pumps the water at controlled pressure into
the water tank/panels’. The pump is akin to the heart in the human
body.

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Walls of the Steam Plant
The wall of the entire system is incorporated with both Thermal Barrier
Coating (TBC) and Super Wool Fibre Mastics (SFM).
.
Thermal Barrier Coating (TBC) are highly advanced material systems
usually applied to metallic surfaces, such as gas turbine or aero-engine
parts, operating at elevated temperatures, as a form of exhaust heat
management. These coatings serve to insulate components from large
and prolonged heat loads by utilizing thermally insulating materials
which can sustain an appreciable temperature difference between the
load-bearing alloys and the coating surface.[1]
In doing so, these
coatings can allow for higher operating temperatures while limiting the
thermal exposure of structural components, extending part life by
reducing oxidation and thermal fatigue. In conjunction with active film

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cooling, TBCs permit working fluid temperatures higher than the
melting point of the metal airfoil in some turbine applications. In
conjunction with active film cooling, TBCs permit working fluid
temperatures higher than the melting point of the metal airfoil in some
turbine applications.
Structure
Thermal barrier coatings typically consist of four layers: the metal
substrate, metallic bond coat, thermally grown oxide, and ceramic
topcoat. The ceramic topcoat is typically composed of yttria-stabilized
zirconia (YSZ) which is desirable for having very low conductivity while
remaining stable at nominal operating temperatures typically seen in
applications. Recent advancements in finding an alternative for YSZ
ceramic topcoat identified many novel ceramics (rare earth zirconates)
having superior performance at temperatures above 1200 °C, however
with inferior fracture toughness compared to that of YSZ. This ceramic
layer creates the largest thermal gradient of the TBC and keeps the
lower layers at a lower temperature than the surface.
TBCs fail through various degradation modes that include mechanical
rumpling of bond coat during thermal cyclic exposure, especially,
coatings in aircraft engines; accelerated oxidation, hot corrosion,
molten deposit degradation. There are issues with oxidation (areas of
the TBC getting stripped off) of the TBC also, which reduces the life of
the metal drastically, which leads to thermal fatigue.
The TBC can also be locally modified at the interface between the
bondcoat and the thermally grown oxide so that it acts as a
thermographic phosphor, which allows for remote temperature
measurement.

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Mastic
Morgan thermal Ceramics’ mastic products are used in high
temperature applications where patching and filling of voids is
required. These products are available as pumpables (with pumps),
moldables, air-setting cements, and coatings.
Superwool® Fibre mastic is a mouldable form of fibre which can be
trowelled, hand moulded, or injected from a hand held pressure gun.
Drying converts the Mastic into a strong, hard - yet light weight -
insulating material which has great thermal stability up to its typical
continuous use temperature. Although air drying is possible, it is
recommended that assisted drying be carried out below 100°C (212°F).
This product features excellent resistance to cracking and spalling and
the dried material has strong adhesive properties.
Our Superwool® Fibre mastic is a ready to use, highly insulating
material with a homogenous structure.

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The Steam Turbine
Working Principle of Steam Turbine
The working principle of steam turbine is very important to be known
in the power plant system. Steam turbine is the engine, where the
energy of working fluid is used directly to rotate the turbine blades. In
the turbine, the working fluid undergoing a process of expansion,
namely the pressure drop and flow continuously. The working fluid of
steam turbine is steam. Steam turbine classification can be categorized
based on steam flow direction, working principle, exit steam and steam
pressure.
In general, the steam turbine system consists of several components,
such as: pumps, steam plant, combustion chamber, condenser and
turbine. Turbine is much in use for power generation, aircraft, in the
industry, and others.
Steam turbine is one of machine types that use a method of external
combustion engine. The heating of working fluid (steam) is done
outside the system. In brief the working principle of steam turbine as
follows:
 Steam enters into the turbine through a nozzle. In the nozzle, heat
energy from steam is converted into kinetic energy and the steam
is expanding. Steam pressure at the exit of nozzle is smaller when
compared with at the time of enter into nozzle, but otherwise the
velocity of steam out from nozzle is greater than at the time of
enter into the nozzle.
 The steam gushing out of the nozzle is directed to the turbine
blades with arches shaped and fitted around the wheel turbines.
Steam flowing through gaps between the turbine blades is
deflected towards following the curve of the turbine blades. The

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changes in steam velocity raise the force that encourages and
then rotate the turbine wheel and shaft.
 If the steam still has velocity when it leaves the turbine blades
means that only some of the kinetic energy of steam is taken by
the turbine blades which are running. More than one line of blade
motion is installed to utilize the remaining kinetic energy when
steam leaves the turbine blades.
 Before entering the second line of blade motion, so between the
first row and second row blades motion is mounted one line fixed
blade (blade guide) that allows you to change the direction of the
steam velocity, so steam can enter the second line of blade
motion in the right direction.
 The velocity of steam when it leaves the last blade motion should
be made as small as possible, so that the available kinetic energy
can be utilized as much as possible. Thus the steam turbine
efficiency is higher because of energy loss is relatively small.
Steam turbine plants generally have a history of achieving up to 95%
availability and can operate for more than a year between shutdowns
for maintenance and inspection. Their unplanned or forced outage
rates are typically less than 2% or less than one week per year.

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Elliott steam turbine generator set with Elliott turbines, Model BYRH-
UG, Serial Number B!002145-C 2, single stage back pressure style units.
Engine, gearbox and generator are mounted in a common skid. t
He Elliott gearbox reduces the turbine speed of 5750RPM to a final
speed of 1800RPM to drive a conventional 4-pole, 2-bearing alternator
rated 1000KW/1607KVA with 0.85PF,163AMPS and wound for
2400/4160V/3/60HZ service.

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PROJECT OBJECTIVES
The project is carried out with the following objectives:
1. To protect the Ozone Layer, environment and the living of
mankind.
2. To enhance the economic growth of the nation and as well the
better living of human.
3. To enhance our transportation system.
4. To enhance productivity of our industries.
5. To enhance preservation.

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Conclusion
The mean aim of this project is to actualize the safety of our Ozone
Layer, preserving our climate condition for better living for mankind
and its environment. This project if achieve will increase the economic
standard, employment and growth of the nation, and will also beautify
each home with electricity.
This project (steam plant) is low in cost construction, easy to maintain
and can be manufactured locally here in Nigeria.