Design of a Catalytic Combustor for Heavy-Duty Gas Turbines

1983 ◽  
Vol 105 (4) ◽  
pp. 797-805 ◽  
Author(s):  
G. L. Touchton ◽  
L. C. Szema ◽  
M. B. Cutrone ◽  
R. Cellamare ◽  
W. Vonkleinsmid
Keyword(s):  
Gas Turbine ◽  
Gas Turbines ◽  
Nox Formation ◽  
Load Range ◽  
Pressure Drops ◽  
System Pressure ◽  
Thermal Growth ◽  
Fuel Staging ◽  
Full Speed ◽  
Catalytic Combustor

Laboratory tests of catalytic combustors with distillate fuel have achieved ultralow NOx formation at catalytic reactor exit temperatures and combustion efficiencies consistent with state-of-the-art gas turbine requirements. Concomitant with these features, however, are design limitations such as narrow turn-down range and unique reactor mounting requirements. This paper presents fully analyzed conceptual design solutions to these problems within the constraints of fixed geometry, full catalytic combustion over 80 percent of the turbine load range, and retrofit to an existing gas turbine. The combustor design incorporates (a) a gutter stabilized pilot burner downstream of the reactor for operation from ignition to full-speed no-load, (b) a segmented fuel-air preparation system for fuel staging of the reactor, (c) a reactor mounting system which accommodates thermal growth and start-up and shutdown transients, and (d) a graded cell reactor. These features were achieved while maintaining low reactor face velocities and system pressure drops.

scholarly journals Design of a Catalytic Combustor for Heavy Duty Gas Turbines

1982 ◽  
Author(s):  
G. L. Touchton ◽  
L. C. Szema ◽  
M. B. Cutrone ◽  
R. Cellamare ◽  
W. Vonkleinsmid
Keyword(s):  
Gas Turbine ◽  
Gas Turbines ◽  
Nox Formation ◽  
Load Range ◽  
Pressure Drops ◽  
System Pressure ◽  
Thermal Growth ◽  
Fuel Staging ◽  
Full Speed ◽  
Catalytic Combustor

Laboratory tests of catalytic combustors with distillate fuel have achieved ultra low NOx formation at catalytic reactor exit temperatures and combustion efficiencies consistent with state-of-the-art gas turbine requirements. Concomitant with these features, however, are design limitations such as narrow turn down range and unique reactor mounting requirements. This paper presents fully analyzed conceptual design solutions to these problems within the constraints of fixed geometry, full catalytic combustion over 80% of the turbine load range, and retrofit to an existing gas turbine. The combustor design incorporates (a) a gutter stabilized pilot burner downstream of the reactor for operation from ignition to full speed no load, (b) a segmented fuel-air preparation system for fuel staging of the reactor, (c) a reactor mounting system which accommodates thermal growth and start-up and shutdown transients, and (d) a graded cell reactor. These features were achieved while maintaining low reactor face velocities and system pressure drops.

Catalytic Combustor Development for Ultra-Low Emissions Industrial Gas Turbines

1997 ◽  
Author(s):  
P. Dutta ◽  
D. K. Yee ◽  
R. A. Dalla Betta
Keyword(s):  
Gas Turbine ◽  
Gas Turbines ◽  
Catalytic Combustion ◽  
System Development ◽  
Technical Information ◽  
Development Program ◽  
Catalyst Design ◽  
Load Range ◽  
Catalytic Combustor ◽  
Substrate Temperatures

The goal of the Advanced Turbine Systems (ATS) program is to develop a high thermal efficiency industrial gas turbine with ultra-low emissions (<10 ppmv NOx, CO and UHC @ 15% O2) over the 50 to 100% load range. Catalytic combustion was chosen as an approach likely to meet ATS emissions goals. A subscale catalytic combustor development program was designed to develop a technical knowledge base for catalyst design (catalyst construction, length), performance (ignition, activity and emissions) and operating limitations (fuel-air turndown and sensitivity to combustor operating variables). A novel catalyst design with preferential catalyst coating to limit substrate temperatures was used in the tests. The catalytic combustor consists of a fuel-air premixer, catalytic reactor and a post-catalyst zone for completion of homogeneous gas phase reactions. In situ measurements of mean fuel concentrations at the exit of the premixer were completed to characterize fuel-air premixing levels. Performance of the catalyst was monitored through global emissions measurements at the exit of the post-catalyst combustor under simulated engine conditions, and measurement of catalyst substrate temperatures. Ultra-low emissions were achieved for relatively uniform fuel-air premixing (<10% peak to peak variation in fuel concentration) with higher inhomogeneities (>10% peak to peak variation) leading to either locally high or low substrate temperatures. Regions with low substrate temperatures led to high CO and UHC emissions. Modeling of post-catalyst homogeneous reactions using a standard stationary, one-dimensional, laminar premixed flame formulation showed good agreement with measurements. In short term tests, the catalysts showed the desired chemical activity and ability for multiple light-off. The subscale combustor development work provided the necessary technical information for full scale catalytic combustion system development for the ATS gas turbine.

Development of a Catalytic Combustor for a Biomass Fueled Gas Turbine

2000 ◽  
Author(s):  
Etienne Lebas ◽  
Gérard Henri Martin
Keyword(s):  
Gas Turbine ◽  
Gas Turbines ◽  
Catalytic Combustion ◽  
Pilot Scale ◽  
Operating Conditions ◽  
Liquid Fuels ◽  
Nox Formation ◽  
Economical Analysis ◽  
Reduce Emissions ◽  
Catalytic Combustor

Combustion of biomass derived fuels often results in high emissions levels of pollutants such as NOx, CO and unburned hydrocarbons. In gas turbines, catalytic combustion of biofuels has the potential to reduce emissions of these undesired species. The ULECAT project (Ultra Low Emissions CATalytic combustor), European project led by IFP, initiated the development of an ultra-low emission gas turbine in the range of 1 to 5 MWe, able to run with both biomass derived gases and liquid fuels. The first part of the project has been devoted to the definition of the system and the development of catalysts capable of burning both biomass derived fuels and Diesel fuel. It was mainly focused on high temperature catalyst durability and the reduction of NOx formation. This last point is of primary importance in biofuels combustion and certain catalysts have shown an important potential in reducing ammonia conversion into NOx in some operating conditions. The pilot scale tests have proven the dual fuel operability. Numerical tools were developed and have been validated by pilot tests. They provided useful help in designing the catalytic section of the combustor. An economical analysis of the system have shown the great potential of catalytic combustion in reducing the operating costs and investment compared to SCR or ammonia scrubbing.

Development of a Dual Fuel Catalytic Combustor for a 2.3 MWe Gas Turbine

1998 ◽  
Author(s):  
Jean-Hervé Le Gal ◽  
Gérard Martin ◽  
Daniel Durand
Keyword(s):  
Gas Turbine ◽  
Gas Turbines ◽  
Life Time ◽  
Pilot Scale ◽  
Operating Conditions ◽  
Liquid Fuels ◽  
Dual Fuel ◽  
Nox Formation ◽  
Waste Products ◽  
Catalytic Combustor

Biomass derived fuels are an essential alternative for heat and energy production, in order to minimise environmental impact, since they make no net contribution to the increase of CO2 emissions into the atmosphere. In certain countries, biofuels are also interesting since they are available as waste products from the agricultural or forestry industry. Unfortunately, combustion of biofuels often results in high emissions levels of pollutants such as NOx, CO and unburned hydrocarbons. In gas turbines, catalytic combustion of biofuels has the potential to reduce emissions of these undesired species. The ULECAT project (Ultra Low Emissions CATalytic combustor) described in this paper is the first step of a program aiming at the development of an ultra-low emission gas turbine in the range of 1 to 5 MWe, able to run with both biomass-derived gases and liquid fuels. The objective of the project is to assess the feasibility of a dual fuel catalytic combustor. Combustor design issues are investigated at full and part load conditions. For the comparison of combustor configuration, modelling provides a useful help for catalytic section design, in particular for the estimation of catalytic activity and wall temperature which strongly influence catalyst life time. Catalyst development is one of the main topics of this project. It is mainly focused on high temperature catalyst durability and the reduction of NOx formation. This last point is of primary importance in biofuels combustion and certain catalysts have shown an important potential in reducing ammonia conversion into NOx in some operating conditions. Catalyst performances are evaluated at lab scale and also pilot scale in representative gas turbine combustor conditions with both Diesel fuel and biomass derived fuels.

High Firing Temperature GT36 H-Class Low NOx Combustor Engine Validation and Performance

2020 ◽  
Author(s):  
V. Granet ◽  
P. Sierra Sanchez ◽  
A. Cuquel ◽  
P. Günster ◽  
A. Wickström ◽  
...  
Keyword(s):  
Gas Turbine ◽  
Firing Temperature ◽  
Gas Turbines ◽  
Thermal State ◽  
Inlet Temperature ◽  
Load Range ◽  
High Firing Temperature ◽  
Wide Range ◽  
Full Speed ◽  
High Firing

Abstract In order to minimize the footprint of human activities on the environment, technologies to reduce greenhouse gases while meeting constantly growing electricity demands are critical. Amongst the various sources of energy production, Gas Turbines (GT) are an efficient way to stabilize the grid with regards to renewable sources like wind and solar energies. The demand for higher efficiency, higher power output while reducing emission levels (especially NO and NO2) at high loads, and for higher flexibility within the H-class Gas Turbine market is thereby a natural consequence. The development and validation of a two-stage sequential combustor, so-called Constant Pressure Sequential Combustion (CPSC) system, to achieve these goals has been accomplished by Ansaldo Energia. The CPSC consists of a premix burner system (First Stage) and of a sequential burner (SB) in series within a can combustor. At the 2017 and 2019 ASME conferences, high pressure test rig validation results of the CPSC were introduced. The advantages with regards to fuel flexibility, hydrogen combustion and low emissions at high firing temperature were presented [1,2,3,4,5]. This article focuses on the validation of the combustor performance in Ansaldo Energia’s Validation Power Plant located in Birr, Switzerland, which includes detailed validation from ignition to full speed no load, part load operation and full load over various ambient and engine thermal state conditions. To allow for detailed validation, dedicated fully instrumented combustor cans were installed in the GT. Detailed validated air distribution and emission models support the results obtained on the engine. Ignition and ramps up to full speed no load have been validated with large variations of the first combustor stage firing temperature to minimize power consumption and start-up time. The potential of the CPSC with regards to turndown capability, with minimum environmental load (MEL) below 25% GT load while keeping CO levels low has been confirmed. The MEL can be kept low over a wide range of ambient temperature and fuel compositions by adjusting the inlet temperature of the sequential burner. Low NOx values were achieved at baseload and peak firing temperature. The operational flexibility and stability of the premixed first stage combustor over the load range and over a large variation of combustor inlet plenum pressures was as well validated along with the operation concept of the gas turbine.

The Effect of Transient Fuel Staging on Self-Excited Instabilities in a Multi-Nozzle Model Gas Turbine Combustor

2017 ◽  
Author(s):  
Wyatt Culler ◽  
Janith Samarasinghe ◽  
Bryan D. Quay ◽  
Domenic A. Santavicca ◽  
Jacqueline O’Connor
Keyword(s):  
Gas Turbine ◽  
Gas Turbines ◽  
High Speed ◽  
Equivalence Ratio ◽  
Growth Time ◽  
Stable Operation ◽  
Time Constants ◽  
Decay Times ◽  
Fuel Staging ◽  
Passive Techniques

Combustion instability in gas turbines can be mitigated using active techniques or passive techniques, but passive techniques are almost exclusively used in industrial settings. While fuel staging, a common passive technique, is effective in reducing the amplitude of self-excited instabilities in gas turbine combustors at steady-state conditions, the effect of transients in fuel staging on self-excited instabilities is not well understood. This paper examines the effect of fuel staging transients on a laboratory-scale five-nozzle can combustor undergoing self-excited instabilities. The five nozzles are arranged in a four-around-one configuration and fuel staging is accomplished by increasing the center nozzle equivalence ratio. When the global equivalence ratio is φ = 0.70 and all nozzles are fueled equally, the combustor undergoes self-excited oscillations. These oscillations are suppressed when the center nozzle equivalence ratio is increased to φ = 0.80 or φ = 0.85. Two transient staging schedules are used, resulting in transitions from unstable to stable operation, and vice-versa. It is found that the characteristic instability decay times are dependent on the amount of fuel staging in the center nozzle. It is also found that the decay time constants differ from the growth time constants, indicating hysteresis in stability transition points. High speed CH* chemiluminescence images in combination with dynamic pressure measurements are used to determine the instantaneous phase difference between the heat release rate fluctuation and the combustor pressure fluctuation throughout the combustor. This analysis shows that the instability onset process is different from the instability decay process.

scholarly journals Alternate Fuels and the Gas Turbine Catalytic Combustor

1979 ◽  
Author(s):  
W. C. Pfefferle
Keyword(s):  
Nitrogen Oxides ◽  
Gas Turbine ◽  
Gas Turbines ◽  
Soot Formation ◽  
Raw Materials ◽  
Tar Sands ◽  
Aromatic Content ◽  
Percent Conversion ◽  
Catalytic Combustor ◽  
Alternate Fuels

Inasmuch as conventional gas turbine combustors often produce soot even with the present low aromatic content fuels, the production of acceptable liquid turbine fuels from hydrogen deficient raw materials such as coal and tar sands requires large quantities of high cost hydrogen if conventional combustors are to be used. The economics of producing alternate turbine fuels would be improved if high aromatic content fuels could be burned in gas turbines without soot formation. Gas turbines using the catalytic combustor not only can efficiently burn highly aromatic fuels without soot formation but can meet all existing or proposed regulations on emissions of hydrocarbons, carbon monoxide, and nitrogen oxides. Under certain conditions, high fuels can be burned with as little as 10 to 15 percent conversion of the fuel nitrogen to nitrogen oxides. In view of the potential savings, any program for alternate fuels should take into account the opportunities offered by the catalytic combustor.

Rig Testing of the Operability of a Transonic Compressor Blade of an Industrial Gas Turbine

2019 ◽  
Author(s):  
Hyunsu Kang ◽  
Sungjong Ahn ◽  
Kyusic Hwang ◽  
Justin Bock ◽  
Jeongseek Kang ◽  
...  
Keyword(s):  
Gas Turbine ◽  
Gas Turbines ◽  
Large Scale ◽  
Load Condition ◽  
Compressor Blade ◽  
Guide Vanes ◽  
Aerodynamic Damping ◽  
Transonic Compressor ◽  
Full Speed ◽  
Industrial Gas Turbine

Abstract This paper describes the flow and vibrations measured in a 1.5-stage transonic research compressor tested at the Notre Dame Turbomachinery Laboratory. The compressor is a sub-scale version of a large-scale industrial gas turbine. The experiment measured the compressor performance and investigated the operability issues of stall and flow-induced blade vibrations due to buffet and flutter. The buffet was investigated at full-speed with fully-closed inlet guide vanes; the full-speed, no-load condition of gas turbines used for power generation. The flutter was investigated at part-speed conditions with partially closed guide vanes; the part-power condition where stall flutter typically occurs for aero-engines. At both of these conditions the blades operate with high incidence and moderate velocity, which can result in flow-induced vibrations. Aero-elastic simulations were performed to predict the flutter boundary. The flutter analysis predicted positive aerodynamic damping near the operating line, and a decrease in aerodynamic damping as the stall boundary was approached. No flutter was observed in the stable operating range of the compressor. The experimental campaign used blade tip timing to measure the vibrations and unsteady pressure transducers above the compressor blade. These two types of data were correlated to better understand the drivers of vibration. The paper describes the behavior of the aerodynamic drivers of buffet and flutter and the resulting vibration.

One-Dimensional Model to Quantify NOx Reduction in Gas Turbines Using EGR

1998 ◽  
Author(s):  
K. K. Botros ◽  
M. J. de Boer ◽  
G. Kibrya
Keyword(s):  
Gas Turbine ◽  
Thermal Efficiency ◽  
Gas Turbines ◽  
Nox Reduction ◽  
Simulation Software ◽  
Specific Work ◽  
Dimensional Model ◽  
Nox Formation ◽  
One Dimensional ◽  
Thermal Nox

A one dimensional model based on fundamental principles of gas turbine thermodynamics and combustion processes was constructed to quantify the principle of exhaust gas recirculation (EGR) for NOx reduction. The model utilizes the commercial process simulation software ASPEN PLUS®. Employing a set of 8 reactions including the Zeldovich mechanism, the model predicted thermal NOx formation as function of amount of recirculation and the degree of recirculate cooling. Results show that addition of sufficient quantities of uncooled recirculate to the inlet air (i.e. EGR>∼4%) could significantly decrease NOx emissions but at a cost of lower thermal efficiency and specific work. Cooling the recirculate also reduced NOx at lower quantities of recirculation. This has also the benefit of decreasing losses in the thermal efficiency and in the specific work output. Comparison of a ‘rubber’ and ‘non-rubber’ gas turbine confirmed that residence time is one important factor in NOx formation.

scholarly journals Development of a Catalytic Combustor for a Heavy-Duty Utility Gas Turbine

1996 ◽  
Author(s):  
Ralph A. Dalla Betta ◽  
James C. Schlatter ◽  
Sarento G. Nickolas ◽  
Martin B. Cutrone ◽  
Kenneth W. Beebe ◽  
...  
Keyword(s):  
Gas Turbine ◽  
Gas Turbines ◽  
Catalytic Combustion ◽  
Full Scale ◽  
Inlet Temperature ◽  
Nox Emissions ◽  
Combustion System ◽  
Catalytic Reactor ◽  
Heavy Duty ◽  
Catalytic Combustor

The most effective technologies currently available for controlling NOx emissions from heavy-duty industrial gas turbines are either diluent injection in the combustor reaction zone, or lean premixed Dry Low NOx (DLN) combustion. For ultra low emissions requirements, these must be combined with selective catalytic reduction (SCR) DeNOx systems in the gas turbine exhaust. An alternative technology for achieving comparable emissions levels with the potential for lower capital investment and operating cost is catalytic combustion of lean premixed fuel and air within the gas turbine. The design of a catalytic combustion system using natural gas fuel has been prepared for the GE model MS9OOIE gas turbine. This machine has a turbine inlet temperature to the first rotating stage of over 1100°C and produces approximately 105 MW electrical output in simple cycle operation. The 508 mm diameter catalytic combustor designed for this gas turbine was operated at full-scale conditions in tests conducted in 1992 and 1994. The combustor was operated for twelve hours during the 1994 test and demonstrated very low NOx emissions from the catalytic reactor. The total exhaust NOx level was approximately 12–15 ppmv and was produced almost entirely in the preburner ahead of the reactor. A small quantity of steam injected into the preburner reduced the NOx emissions to 5–6 ppmv. Development of the combustion system has continued with the objectives of reducing CO and UHC emissions, understanding the parameters affecting reactor stability and spatial non-uniformities which were observed at low inlet temperature, and improving the structural integrity of the reactor system to a level required for commercial operation of gas turbines. Design modifications were completed and combustion hardware was fabricated for additional full-scale tests of the catalytic combustion system in March 1995 and January 1996. This paper presents a discussion of the combustor design, the catalytic reactor design and the results of full-scale testing of the improved combustor at MS9OOIE cycle conditions in the March 1995 and January 1996 tests. Major improvements in performance were achieved with CO and UHC emissions of 10 ppmv and 0 ppmv at base load conditions. This ongoing program will lead to two additional full-scale combustion system tests in 1996. The results of these tests will be available for discussion at the June 1996 Conference in Birmingham.

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