Wondering How To Go Green in the Turbomachinery Industry?

January 31, 2024 | Reading time: 3 min

As governments worldwide step up their efforts to tackle climate change and reduce industrial emissions, companies like Doosan Enerbility face mounting pressure to innovate. The energy sector, in particular, is feeling the heat to develop cleaner, more efficient technologies. Doosan, a South Korea-based leader in energy systems, is proving that embracing cutting-edge solutions like additive manufacturing (AM) can help meet tough environmental standards while boosting operational efficiency.

The Global Push for Cleaner Air and Lower Emissions

Over the last few years, both regulators and public opinion have pushed sustainability into the spotlight. In South Korea, where Doosan is headquartered, strict air pollution controls have been the norm for some time. For example, recent regulations lowered the permitted daily average for PM 2.5 fine dust has been lowered from 50µg/m³ to 35. Similarly, governments worldwide are rolling out aggressive new guidelines that leave industries with little choice but to adapt.

Governments worldwide are introducing stricter environmental regulations, driving industries to innovate in order to meet ambitious emissions reduction goals. In the U.S., new standards by the Environmental Protection Agency (EPA) target significant greenhouse gas and nitrogen oxide reductions, while the European Union focuses on methane and industrial emissions. These measures reflect a global push for sustainability, encouraging companies to adopt advanced technologies to meet compliance and environmental goals.

Why Conventional Manufacturing Doesn’t Cut It Anymore

For enterprises like Doosan, meeting these ambitious regulations calls for more than just a few tweaks to traditional manufacturing. Gas turbines, which play a central role in power generation, require incredibly complex internal designs to ensure cleaner combustion and lower emissions. Conventional methods like casting, molding, and CNC machining often fall short in delivering the required level of detail.

These older methods also come with extra baggage — multiple components that need assembly, which drives up costs, lead times, and inefficiencies. On top of that, additional post-treatment equipment is usually needed to meet compliance, making it even tougher to keep costs down. For industries on tight budgets and timelines, this approach just doesn’t fly.

Additive Manufacturing: The Game-Changer

Enter EOS’ M 400-4 machine, a breakthrough in AM technology that has redefined what is possible in turbine component manufacturing. Doosan leveraged the EOS M 400-4 to produce a critical gas turbine nozzle — a component integral to achieving precise air-fuel mixing for cleaner combustion.

The four-laser system, coupled with double re-coating capabilities, allowed Doosan’s engineers to create highly intricate internal channel designs that were impossible to achieve with conventional methods.

By using STS 321 stainless steel, a material renowned for its durability at high temperatures, Doosan ensured that its components could withstand the demanding conditions of power generation while preventing intergranular corrosion. The results? Unmixed fuel was reduced by 68%, bringing NOx emissions down to just 15 ppm and CO emissions to 10 ppm.

A Global Blueprint for Industrial Innovation

Doosan’s success isn’t just a win for them; it’s a playbook for how companies everywhere can adapt to new regulations while staying ahead of the curve. AM’s advantages — design flexibility, less material waste, and localized production — make it a cornerstone technology for industries facing sustainability challenges.

But it’s not just about compliance. AM can also give businesses a serious edge. By cutting production lead times and streamlining operations, companies can focus more on research and development, speeding up innovation. For example, Doosan slashed production lead time by 50%, showing how AM can deliver efficiency alongside regulatory compliance.

"The high productivity and utilization of the EOS M 400-4 have led to remarkable customer satisfaction, thanks to its quality, reliability, the use of optical tomography, and excellent technical support provided, such as field service and technology downloads."
Doosan Enerbility AM Business Team