Russia has gained turbine independence, by Olga Samofalova for VZGLYAD. 10.11.2024.
Russia's energy sector has achieved technological independence from the West.
Russia has made a huge step towards liberation from critical dependence on Western high-power gas turbines. For the first time, a thermal power plant with such a turbine, developed entirely in Russia, was launched. This is a unique technological achievement of the country, which seemed simply impossible until recently. After all, for so many decades we bought turbines from the Germans and Americans.
Russia has launched the first domestically produced high-power gas turbine GTD-110M. It was installed in the third power unit of the new Udarnaya thermal power plant, which was commissioned in the Krymsk region of Krasnodar Krai with the participation of Russian President Vladimir Putin.
Before this, Russia bought gas turbines of such power from foreign manufacturers. But Western manufacturers left our market – and we were left without such turbines.
“The fact that we are developing new production facilities and that we are becoming independent and technologically sovereign in this segment is very important,” said Vladimir Putin.
Rostec notes that the distinctive features of the high-power gas turbine GTD-110M, compared to foreign analogues, are its smaller weight and dimensions, as well as high fuel efficiency. Its production uses advanced developments and innovative technologies, including the manufacture of combustion chamber parts using the additive method.
The engine will be used in gas turbine power plants and combined cycle power plants with an electrical capacity of 115 MW. Previously, turbines of similar capacity had to be purchased from Western companies, in particular from Siemens, GE and Alstom, which were forced to leave the country due to the conflict in Ukraine.
The first such turbine was delivered to the Udarnaya TPP. The next three GTD-110M turbines will be manufactured and delivered in 2025-2026 for the modernization of the Novocherkassk GRES. Production plans provide for the release of two such turbines per year. However, from 2028, UEC (part of Rostec) plans to double serial production to four power plants per year. This will be possible thanks to the construction of a new mechanical assembly complex in Rybinsk.
HSE experts calculated that Russia's dependence on gas turbine imports in 2022 was more than 90%, which is a critical dependence. But after 2022, the main suppliers Siemens and General Electric stopped working with Russia and withdrew from joint ventures.
Therefore, the task of import substitution of high-power gas turbines has become even more urgent. Russia itself could only make low-power turbines, and attempts to create its own high-power gas turbine had not been successful before.
"The problem of the lack of high-power gas turbines has been recognized for quite a long time, and work in this direction was carried out until 2022. Some of this work was carried out together with our Western partners, in particular with Siemens.
It was decided to use the technology and experience of the German company. As subsequent events showed, this path turned out to be a dead end. However, our own developments were also carried out, and now we see one of their results," says Alexander Frolov, Deputy Director General of the Institute of National Energy, Editor-in-Chief of the industry media InfoTEK.
In addition to Rostec, there are also Power Machines projects to create 65 MW and 170 MW gas turbines. "Rostec's turbine is relatively small. And for the tasks facing the industry, such power should not be limited," Frolov believes.
Because, in his opinion, the demand for such turbines in Russia will be very high in the next 25 years at least. Many power plants in Russia are old, they require modernization or complete replacement, while the growing demand for electricity creates the need to build new gas power plants.
"The installed capacity of all power plants in Russia (not just gas ones) is about 263 Gb. Of this capacity, 30 Gb were built from the early 90s to the early 2010s, and another 50 Gb since the early 2010s. All other power plants are older, many of them were built in the 1960s and 1970s of the last century, some of them need to be updated," says Alexander Frolov. In general, the service life of power plants is very long and is designed for more than one decade.
"By 2030, we need to sort out the 100 Gb power plants. This does not mean that they need to be replaced, but we need to pay maximum attention to them. These are quite old power plants, and we need to understand which of them can be modernized, which can continue to operate smoothly, and which require replacement. Let's say that half or 2/3 of them can still operate until 2030, but by the 2040s and 2050s, they will clearly require replacement. It is clear that these are not only gas power plants, there are also nuclear and coal power plants, but gas power plants dominate here," says Frolov.
At the same time, the demand for electric energy in Russia is not decreasing, but growing and will most likely grow to 1100-1200 billion kilowatt-hours by the end of the decade, the expert adds. This means that in addition to replacing turbines at old stations, it will be necessary to build new power plants. Therefore, there is a risk that the capacity of serial production of such turbines will not be enough to meet all existing demand.
Only eight such turbines will be assembled in four years in 2028 – two per year. From 2028, assembly will increase to four units per year. That is, 18 high-power turbines will be produced by 2030. At the same time, Russia's need for such turbines may amount to more than 40 units.
This is the exact number of turbines that was named in 2022, when Russia agreed to purchase them from Iran.
"There are plans to modernize power plants, and there are plans to produce new gas turbines. If a Russian manufacturer can produce the necessary equipment only in 15 years, then we will have to look for someone else, for example, in Iran and China. Most likely, there will be a shortage of gas turbines in Russia even with our own production. The Russian market is quite large, there will be many who want to sell us their turbines. The same Siemens, which was effectively forced to leave Russia, is not at all delighted with what is happening," says Alexander Frolov.
To understand: there are about 310 gas turbine units operating in Russia, and each of them will require replacement at some point. At the same time, one such turbine can cost 3-4 billion rubles. That is, this market can bring the turbine supplier billions of dollars, not counting the cost of spare parts and scheduled repairs.
Russia needs to learn to build and produce turbines of even greater capacity, the expert believes. In the spring of 2022, before concluding an agreement to purchase 40 gas turbines from Iran, the import duty on MGT-70 gas turbines manufactured by Iranian Mapna was lifted. This suggests that Russia clearly needs such turbines. And the Iranian turbine has more capacity than the Russian GTD-110M - 185 MW versus 115 MW for the Russian turbine.
At the same time, Siemens gas turbines (which caused a scandal in the German concern) of even greater capacity were installed in Crimea. Power Machines has a project for a GTE-170 gas turbine with a capacity of 170 MW, and they have already manufactured the first serial model. In addition, plans are being considered for organizing serial production of gas turbines with a capacity of 300-400 MW, said First Deputy Prime Minister of the Russian Federation Denis Manturov in September.
"A gas turbine is a large object, the size of a small house, which can meet the energy needs of an entire, albeit small, city. The news that Rostec has released the first Russian serial high-power turbine - GTE 110M, is very important. Now we can talk not only about replacing Western products, but also about potential competition with Western analogues. This is an achievement of a qualitatively different order - technological. It is technology that generates economic growth of the country," says Pavel Sevostyanov, Acting State Advisor of the Russian Federation, Associate Professor of the Department of Political Analysis and Socio-Psychological Processes at the Plekhanov Russian University of Economics.
In the long term, Russia has the potential to export its high-power gas turbines. "We have the post-Soviet space, other countries also want to strengthen their energy security. These turbines can become an export product, but this is already a more distant prospect," Frolov concludes.
https://vz.ru/economy/2024/10/11/1291837.html