Single-Digit Emissions in a Full Scale Catalytic Combustor

Catalytic combustion offers the possibility of attaining the firing temperatures of current and next generation gas turbines [up to ∼1450°C (2640°F)] with nitrogen oxides (NOx) production as low as 1 part per million by volume (ppmv). Such catalytic combustion technology has been under development at Catalytica for several years, and the first full scale test of the technology took place at the General Electric Company under TEPCO sponsorship in 1992. The results of the most recent and most successful full scale test in this program are reported in this paper. The catalytic combustor system was designed for the GE Model MS9001E gas turbine fired with natural gas fuel. The 508-mm (20-in) diameter catalytic reactor was operated at conditions representative of the startup and load cycle of that machine. It was verified that the observed NOx levels were produced not in the catalyst, but in the diffusinn flame of the preburner used to start the system and maintain the necessary catalyst inlet temperature. Even so, NOx levels below 5 ppmv (at 15% O2) were achieved at the simulated base load operating point. Carbon monoxide (CO) and unburned hydrocarbons (UHC) emissions were likewise below 10 ppmv at that condition. Single digit emissions levels also were recorded at conditions representative of the combustor operating at 78% load, the first such demonstration of the turndown capability of this system. Throughout the test, dynamic pressure measurements showed the catalytic combustor to be quieter than even the diffusion flame combustors currently in commercial service.

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

Volume 3: Coal, Biomass and Alternative Fuels; Combustion and Fuels; Oil and Gas Applications; Cycle Innovations ◽

10.1115/96-gt-485 ◽

1996 ◽

Cited By ~ 5

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

Journal of Engineering for Gas Turbines and Power ◽

10.1115/1.2817063 ◽

1997 ◽

Vol 119 (4) ◽

pp. 844-851 ◽

Cited By ~ 15

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.

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Hybrid Catalytic Combustion for Stationary Gas Turbine: Concept and Small Scale Test Results

Volume 3: Coal, Biomass and Alternative Fuels; Combustion and Fuels; Oil and Gas Applications; Cycle Innovations ◽

10.1115/87-gt-99 ◽

1987 ◽

Cited By ~ 6

Author(s):

Tomiaki Furuya ◽

Terunobu Hayata ◽

Susumu Yamanaka ◽

Junji Koezuka ◽

Toshiyuki Yoshine ◽

...

Keyword(s):

Gas Turbine ◽

Gas Phase ◽

Gas Turbines ◽

Catalytic Combustion ◽

Small Scale ◽

Inlet Temperature ◽

Test Results ◽

Turbine Inlet Temperature ◽

Scale Test ◽

Near Future

Catalytic combustion for gas turbine applications has been investigated. Its significant advantages in reducing combustor emissions, particularly nitrogen oxides (NOx), have been shown. One of the main problems in regard to developing a catalytic combustor is the durability of catalysts, because the catalysts deteriorate during high temperature operation, which is normal for current gas turbines and near future gas turbines. The hybrid catalytic combustion concept has advantages concerned with catalyst durability. This paper shows its concept and small scale test results. This hybrid catalytic combustion concept comprises the following steps; premix fuel and air for a catalyst-packed zone; operate catalysts at rather low temperatures, to prolong catalyst life; add fresh fuel into the stream at the catalyst-packed zone outlet, where gas phase combustion occurs completely without a catalyst; add dilution air into the stream at the gas phase combustion zone outlet with a by-pass valve. Experimental data and analyses indicated that this hybrid catalytic combustion has a potential of being applicable to current gas turbines (turbine inlet temperature is about 1100°C) and near future gas turbines (turbine inlet temperature is about 1300°C).

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Full-Scale Test on Coupled Thermo-Hydro-Mechanical Processes in Engineered Barrier System

Journal of Nuclear Fuel Cycle and Environment ◽

10.3327/jnuce.1.77 ◽

1994 ◽

Vol 1 (1) ◽

pp. 77-83

Author(s):

Yoshiji Moro ◽

Tomoo Fujita ◽

Takeshi Kanno ◽

Akira Kobayashi

Keyword(s):

Full Scale ◽

Full Scale Test ◽

Scale Test ◽

Engineered Barrier

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The assessment of particulate matter (PM2.5) removal efficiency on air cleaner products through full scale test in Korea

Journal of Odor and Indoor Environment ◽

10.15250/joie.2019.18.1.76 ◽

2019 ◽

Vol 18 (1) ◽

pp. 76-80 ◽

Cited By ~ 2

Author(s):

Kichul Kim ◽

Pil-Ju Park ◽

Soomi Eo ◽

Seungmi Kwon ◽

Kwangrae Kim ◽

...

Keyword(s):

Particulate Matter ◽

Removal Efficiency ◽

Full Scale ◽

Full Scale Test ◽

Air Cleaner ◽

Scale Test

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Reaction to fire tests. Fire growth. Full-scale test for stairs and stair coverings

10.3403/30098024 ◽

2007 ◽

Keyword(s):

Full Scale ◽

Fire Tests ◽

Fire Growth ◽

Full Scale Test ◽

Scale Test

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Predicting Roof Diaphragm and Endwall Stiffness From Full-Scale Test Results of a Metal-Clad, Post-Frame Building

Transactions of the ASAE ◽

10.13031/2013.28690 ◽

1992 ◽

Vol 35 (3) ◽

pp. 977-985 ◽

Cited By ~ 2

Author(s):

K. G. Gebremedhin ◽

J. A. Bartsch ◽

M. C. Jorgensen

Keyword(s):

Full Scale ◽

Test Results ◽

Full Scale Test ◽

Frame Building ◽

Scale Test

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Numerical evaluation of contaminants mixing uniformity in a full-scale test chamber with mixing fan

Indoor and Built Environment ◽

10.1177/1420326x20979021 ◽

2020 ◽

pp. 1420326X2097902

Author(s):

Hai-Xia Xu ◽

Yu-Tong Mu ◽

Yin-Ping Zhang ◽

Wen-Quan Tao

Keyword(s):

Concentration Distribution ◽

Test Chamber ◽

Full Scale ◽

Numerical Results ◽

Test Method ◽

Test Accuracy ◽

Full Scale Test ◽

Concentration Region ◽

Airflow Field ◽

Scale Test

Most existing models and standards for volatile organic compounds emission assume that contaminants are uniform in the testing devices. In this study, a three-dimensional transient numerical model was proposed to simulate the mass transport process based on a full-scale test chamber with a mixing fan, and the airflow field and contaminants concentration distribution were obtained within the chamber under airtight and ventilated conditions. The model was validated by comparing the numerical results with experimental data. The numerical results show that the contaminant source position and the airflow field characteristics have significant impact on the contaminant mixing, and the fan rotation has an important role in accelerating mixing. In the initial mixing stage, the concentration distribution is obviously uneven; as the mixing progresses, it gradually reaches acceptable uniformity except for some sensitive regions, such as high concentration region at the injection point of the contaminants and low concentration region at the air inlet. To ensure test accuracy, the monitor should avoid above sensitive regions; and some special regions are recommended where contaminant concentration uniformity can be reached sooner. The ventilated chamber results indicate that the mixture of contaminants in the chamber is actually better than the results shown by conventional test method.

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