Full Scale Catalytic Burner Testing With No. 2 Oil for Combustion Turbine Application

1982 ◽  
Author(s):  
Paul E. Scheihing ◽  
Paul W. Pillsbury ◽  
Thomas A. Piaia ◽  
Omer Kitaplioglu
Keyword(s):  
Laboratory Tests ◽  
Fuel Injection ◽  
Full Scale ◽  
Inlet Temperature ◽  
Nox Emissions ◽  
Catalytic Burner ◽  
Westinghouse Electric Corporation ◽  
Reduce Emissions ◽  
Westinghouse Electric ◽  
Distillate Fuel

Full scale laboratory tests were performed by the Combustion Turbine Systems Division of the Westinghouse Electric Corporation to explore the feasibility of using catalytic burners in industrial combustion turbines to reduce emissions. Catalytic elements were provided by the Engelhard Industries Division of Engelhard Corporation, and No. 2 distillate fuel was burned in single combustor rig tests at the pressure, airflow, and inlet temperature equivalent to those in a large combustion turbine. Variations of a concept that employed a conventional preburner upstream of a catalytic secondary, and sidewall fuel injection were tested and evaluated for fuel/air presentation to the catalyst. Results indicated ultra-low NOx emissions and that, with development in secondary fuel/air preparation, the concept is technically feasible.

scholarly journals Reduced NOx Emissions Using Low Radial Swirler Vane Angles

1991 ◽  
Author(s):  
H. S. Alkabie ◽  
G. E. Andrews
Keyword(s):  
Gas Turbines ◽  
Fuel Injection ◽  
Combustion Efficiency ◽  
Inlet Temperature ◽  
Nox Emissions ◽  
Primary Zone ◽  
Industrial Gas Turbines ◽  
Curved Blade ◽  
Swirl Vane ◽  
Vane Angle

The influence of vane angle and hence swirl number of a radial swirler on the weak extinction, combustion inefficiency and NOx emissions was investigated at lean gas turbine combustor primary zone conditions. A 140mm diameter atmospheric pressure low NOx combustor primary zone was developed with a Mach number simulation of 30% and 43% of the combustor air flow into the primary zone through a curved blade radial swirler. The range of radial swirler vane angles was 0–60 degrees and central radially outward fuel injection was used throughout with a 600K inlet temperature. For zero vane angle radially inward jets were formed that impinged and generated a strong outer recirculation. This was found to have much lower NOx characteristics compared with a 45 degree swirler at the same pressure loss. However, the lean stability and combustion efficiency in the near weak extinction region was not as good. With swirl the central recirculation zone enhanced the combustion efficiency. For all the swirl vane angles there was little difference in combustion inefficiency between the swirlers. However, the NOx emissions were reduced at the lowest swirl angles and vane angles in the range 20–30 degrees were considered to be the optimum for central injection. NOx emissions for central injection as low as 5ppm at 15% oxygen and 1 bar were demonstrated for zero swirl and 20 degree swirler vane angle. This would scale to well under 25 ppm at pressure for all current industrial gas turbines.

Full-Scale Demonstration of Surface-Stabilized Fuel Injectors for Sub-Three ppm NOx Emissions

2004 ◽  
Author(s):  
Steven J. Greenberg ◽  
Neil K. McDougald ◽  
Leonel O. Arellano
Keyword(s):  
Pressure Ratio ◽  
Full Scale ◽  
Low Flow ◽  
Stable Operation ◽  
Inlet Temperature ◽  
Nox Emissions ◽  
Fuel Injectors ◽  
Air Inlet ◽  
Radial Profiles ◽  
Developed Surface

ALZETA Corporation has developed surface-stabilized fuel injectors for use with lean premixed combustors which provide extended turndown and ultra-low NOx emission performance. These injectors use a patented technique to form interacting high-flow and low-flow flame zones immediately above a selectively-perforated porous metal surface. This allows stable operation at low reaction temperatures. This technology has been given the product name nanoSTAR™. Previous work involved the development of nanoSTAR technology from the proof-of-concept stage to prototype testing. Rig testing of single injectors and of two injectors simulating a sector of an annular combustion liner have been completed for pressure ratios up to 17 and combustion air inlet temperatures up to 700 K (800°F). This paper presents results from the first ever full-scale demonstration of surface-stabilized fuel injectors. An annular combustion liner, fitted with twelve nanoSTAR injectors was successfully tested up to a pressure ratio of 12 and combustion air inlet temperature of 700 K (800°F). NOx emissions were 2 ppm with CO emissions of 3 ppm both corrected to 15% O2. The combustion system exhibited excellent temperature uniformity around the annular combustor outlet with a maximum pattern factor of 0.16 and engine-appropriate radial profiles.

Development of a Phenomenological Combustion Simulation for a Dual Fuel Engine

2001 ◽  
Author(s):  
Yafeng Liu ◽  
Stuart R. Bell ◽  
K. Clark Midkiff
Keyword(s):  
Natural Gas ◽  
Diesel Fuel ◽  
Fuel Injection ◽  
Air Entrainment ◽  
Dual Fuel ◽  
Nox Emissions ◽  
Cycle Simulation ◽  
Specific Performance ◽  
Combustion Simulation ◽  
Reduce Emissions

Abstract A phenomenological cycle simulation for a dual fuel engine has been developed to mathematically simulate the significant processes of the engine cycle, to predict specific performance parameters for the engine, and to investigate approaches to improve performance and reduce emissions. The simulation employs two zones (crevice and unburned) during the processes of exhaust, intake, compression before fuel injection starts, and expansion after combustion ends. From the start of fuel injection to the end of combustion, several, zones are utilized to account for crevice flow, diesel fuel spray, air entrainment, diesel fuel droplet evaporation, ignition delay, flame propagation, and combustion quenching. The crevice zone absorbs charge gas from the cylinder as pressure increases, and releases mass back into the chamber as pressure decreases. Some crevice mass released during late combustion may not be oxidized, resulting in emissions of hydrocarbon and carbon monoxide. Quenching ahead of the flame front may leave additional charge unburned, yielding high methane emissions. Potential reduction of engine-out NOx emissions with natural gas fueling has also been investigated. The higher substitution of natural gas in the engine produces less engine-out NOx emissions. This paper presents the development of the model, baseline predictions, and comparisons to experimental measurements performed in a single-cylinder Caterpillar 3400 series engine.

Effects of Swirler Configurations on Flow Structures and Combustion Characteristics

2004 ◽  
Author(s):  
Guoqiang Li ◽  
Ephraim J. Gutmark
Keyword(s):  
Fuel Injection ◽  
Vortex Breakdown ◽  
Swirling Flow ◽  
Combustion Characteristics ◽  
Pollutant Emissions ◽  
Flow Structures ◽  
Inlet Temperature ◽  
Nox Emissions ◽  
Atmospheric Conditions ◽  
Fuel Injector

Modern gas turbine combustion technologies are driven by stringent regulations on pollutant emissions such as CO and NOx. A combustion system of multiple swirlers coupled with distributed fuel injection was studied as a new concept for reducing NOx emissions by application of Lean Direct Injection (LDI) combustion. The present paper investigates the effects of swirler configurations on the flow structures in isothermal flow and combustion cases using a multiple-swirlers fuel injector at atmospheric conditions. The swirling flow field within the combustor was characterized by a central recirculation zone formed after vortex breakdown. The differences between the tangential and axial velocity profiles, the shape of the recirculation zones and the turbulence intensity distribution for the different fuel injector configurations impacted the flame structure, the temperature distribution and the emission characteristics both for gaseous and liquid fuels. Co-swirling configuration was shown to have the lowest NOx emission level compared with the counter-swirling ones for both types of fuels with lower inlet temperature. In contrast to this, the swirl configuration had less effect on the combustion characteristics in the case of gaseous fuel with high air inlet temperature. The differences in NOx emissions were shown to be closely related to the Damkohler number or the degree to which the flame resembled well-mixed combustion, which is the foundation for LDI combustion.

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.

Jet Shear Layer Size and Number Influences on Grid Plate Direct Fuel Injection Shear Layer Mixing Low NOx Gas Turbine Combustion With Fuel Staging for Power Turn Down

2008 ◽  
Author(s):  
Gordon E. Andrews ◽  
S. A. R. Ahmed
Keyword(s):  
Shear Layer ◽  
Gas Turbine ◽  
Fuel Injection ◽  
Scale Up ◽  
Shear Layers ◽  
Inlet Temperature ◽  
Nox Emissions ◽  
Round Jet ◽  
Fuel Staging ◽  
Four Levels

The scale up of jet shear layer low NOx concepts for compact gas turbine applications is considered using natural gas as the fuel with all experiments at one atmosphere pressure and 600K air inlet temperature. A 76mm diameter cylindrical combustor with 4 round jet shear layers was compared with a near double scale combustor with 140mm diameter and 4 round jet shear layers with the same total blockage as for the smaller combustor. This is compared with 16 round jet shear layers of the same diameter as for the smaller combustor. The shear layer air holes were fuelled by eight radial inward fuel injection holes in each shear layer jet. All three designs had acceptable combustion efficiencies, but the NOx emissions were considerably higher for the 4 shear layer design in the larger combustion. When the same shear layer hole size was used and the number increased in the larger combustor the NOx emissions were identical. Changing the shape of the hole from circulat to slot for the same area, considerably reduced the NOx in the four hole 76mm combustor, but had little effect on the 16 hole 140mm combustor. Fuel staging within the array of shear layers was successfully demonstrated for four levels of fuel staging. There was some intermixing of air from the unfuelled jets, but this had only a small effect on the combustion efficiency and flame stability. A practical range of simulated power turndown was demonstrated with little NOx penalty. This was achieved with no wall between the staged shear layer regions and hence leads to very compact combustor designs.

A New 150-MW High-Efficiency Heavy-Duty Combustion Turbine

1989 ◽  
Vol 111 (2) ◽  
pp. 211-217 ◽  
Author(s):  
A. J. Scalzo ◽  
L. D. McLaurin ◽  
G. S. Howard ◽  
Y. Mori ◽  
H. Hiura ◽  
...  
Keyword(s):  
High Efficiency ◽  
Combined Cycle ◽  
Full Scale ◽  
Heavy Duty ◽  
Component Testing ◽  
Evolutionary Changes ◽  
Long Line ◽  
Westinghouse Electric Corporation ◽  
And Performance ◽  
Westinghouse Electric

The 501F 60-Hz Combustion Turbine has been developed jointly by Westinghouse Electric Corporation and Mitsubishi Heavy Industries, Ltd. It continues a long line of large heavy-duty single-shaft combustion turbines by combining the proven efficient and reliable concepts of the W501D5 with the low NOx technology of the MW701D, together with the experience of the advanced cooled MF111. The new engine is described along with the improved evolutionary changes made from previous engines. Planned design and performance verification programs including model, full-scale component testing, and full-load engine tests are described. Mature output and efficiency in simple cycle mode will be 145 MW and 34 percent, respectively, with expected combined cycle efficiencies in excess of 50 percent.

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

1997 ◽  
Vol 119 (4) ◽  
pp. 844-851 ◽  
Author(s):  
R. A. Dalla Betta ◽  
J. C. Schlatter ◽  
S. G. Nickolas ◽  
M. B. Cutrone ◽  
K. 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 diluent injection in the combustor reaction zone, and lean premixed Dry Low NOx (DLN) combustion. For ultralow 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 MS9OO1E 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-dia 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 nonuniformities that 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 MS9OO1E 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 baseload 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.

scholarly journals Ultra Low NOx Emissions for Gas and Liquid Fuels Using Radial Swirlers

1989 ◽  
Author(s):  
H. S. Alkabie ◽  
G. E. Andrews
Keyword(s):  
Gas Turbines ◽  
Fuel Injection ◽  
Air Flow ◽  
Combustion Efficiency ◽  
Liquid Fuels ◽  
Inlet Temperature ◽  
Flame Stability ◽  
Nox Emissions ◽  
Gas Oil ◽  
Industrial Gas Turbines

Curved blade radial swirlers using all the primary air were investigated with applications to lean burning gas turbine combustor primary zones with low NOx emissions. Two modes of fuel injection were compared, central and radial swirler pássage injection for gaseous and liquid fuels. Both fuel systems produced low NOx emissions but the upstream mixing in the swirler passages resulted in ultra low NOx emissions. A 140mm diameter atmospheric pressure combustor was used with 43% of the combustor air flow into the primary zone through the radial swirler. Radial gas composition measurements at various axial distances were made and these showed that the flame stability and NOx emissions were controlled by differences in local mixing at the base of the swirling shear layer downstream of the swirler outlet. For radial passage fuel injection it was found that a very high combustion efficiency was obtained for both propane and liquid fuels at 400K and 600K inlet temperatures. The flame stability, although worse than for central fuel injection was considerably better than for a premixed system. The NOx emissions at one bar pressure and 600K inlet temperature, compatible with a high combustion efficiency, for propane and kerosene were 3 and 6 ppm at 15% oxygen. For Gas Oil the NOx emissions were higher, but were still very low at 12ppm. Assuming a square root dependence of NOx on pressure these results indicate that NOx emissions of 48ppm for Gas Oil and less than 12ppm for gaseous fuels could be achieved at 16 bar pressure, which is typical of recent industrial gas turbines. High air flow radial swirlers with passage fuel injection have the potential for a dry solution to the NOx emissions regulations.

Radial Swirlers With Peripheral Fuel Injection for Ultra-Low NOx Emissions

1990 ◽  
Author(s):  
H. S. Al Kabie ◽  
G. E. Andrews
Keyword(s):  
Natural Gas ◽  
Recirculation Zone ◽  
Fuel Injection ◽  
Air Flow ◽  
Inlet Temperature ◽  
Nox Emissions ◽  
Gas Oil ◽  
Primary Zone ◽  
Wall Injection

A 76mm outlet diameter radial swirler with a dump expansion into a 140mm diameter combustor was investigated with a simulated 43% primary zone air flow at a 600K inlet temperature and one bar pressure. Two modes of peripheral fuel injection were investigated: at the 76mm swirler outlet and at the 140mm combustor wall just downstream of the swirler. This 140mm wall injector resulted in fuel injection into the swirler expansion outer recirculation zone. It was shown that the 140mm wall injection gave much higher NOx emissions than for the 76mm swirler outlet injector. These results were compared with other methods of fuel injection and the 76mm peripheral injection was shown to have superior NOx emissions than vane passage injection for all fuels except gas oil. Ultra low NOx emissions of 1ppm with 20 ppm CO, both at 15% oxygen, were demonstrated for propane and natural gas.

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