scholarly journals Design and Evaluation of a Single-Can Full Scale Catalytic Combustion System for Ultra-Low Emissions Industrial Gas Turbines

1997 ◽  
Author(s):  
P. Dutta ◽  
L. H. Cowell ◽  
D. K. Yee ◽  
R. A. Dalla Betta
Keyword(s):  
Gas Turbines ◽  
Catalytic Combustion ◽  
Catalyst Design ◽  
Full Scale ◽  
Variable Geometry ◽  
Combustion System ◽  
Catalytic Reactor ◽  
Fuel Injector ◽  
Mode Of Operation ◽  
Load Conditions

The goal of the Advanced Turbine Systems (ATS) program is the design and development of high thermal efficiency gas turbines with pollutant emissions at single digit levels, through the development of advanced recuperated gas turbines. Following successful subscale catalytic reactor testing, a full scale catalytic combustion system was designed to be representative of a single can in a multi-can gas turbine combustor configuration. The full scale catalytic combustion system is modular in design and includes a fuel/air premixer upstream of the catalytic reactor and a post catalyst homogeneous combustion zone downstream of the catalyst bed to complete the homogeneous gas-phase reactions. System start-up is accomplished using a lean-premixed (LP) low emissions fuel injector. The system transitions to catalyst operation using a variable geometry valve that diverts air flow into the catalyst at loads greater than 50% of full load. The variable geometry valve is used to operate the catalyst within the narrow operating window due to limited fuel/air turndown allowed by the catalyst. A catalyst design with preferential catalyst coating on a corrugated metal substrate to limit catalyst substrate temperatures was selected for the system. Mean fuel concentration measurements at the inlet to the catalyst bed using an instrumented catalyst module showed the fuel/air premixing to be within catalyst specifications. Preliminary combustion tests on the system were completed. The catalytic combustion system was tested over the 50-to-100% load range. Using variable geometry control, emissions goals (< 5 ppmv NOx, < 10 ppmv CO and UHC corrected to 15% O2) were achieved for catalyst operation between 50-and-100% load conditions. The system was started and operated under part-load conditions using the LP injector. Efforts are under way to accomplish successful transition from LP mode of operation to catalytic mode of operation using the variable geometry system.

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.

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.

Development of a Catalytic Combustor for Industrial Gas Turbines

1994 ◽  
Author(s):  
Luke H. Cowell ◽  
Matthew P. Larkin
Keyword(s):  
Gas Turbines ◽  
Catalytic Combustion ◽  
Nox Emissions ◽  
Combustion System ◽  
Single Digit ◽  
Design Elements ◽  
Part Load ◽  
Lean Premixed ◽  
Industrial Gas Turbines ◽  
Load Conditions

A catalytic combustion system for advanced industrial gas turbines is under long tern development employing recent advances in catalyst and materials technologies. Catalytic combustion is a proven means of burning fuel with single digit NOx emissions levels. However, this technology has yet to be considered for production in an industrial gas turbine for a number of reasons including: limited catalyst durability, demonstration of a system that can operate over all loads and ambient conditions, and market and cost factors. The catalytic combustion system will require extensive modifications to production gas turbines including fuel staging and variable geometry. The combustion system is composed of five elements: a preheat combustor, premixer, catalyst bed, part load injector and post-catalyst combustor. The preheat combustor operates in a lean premixed mode and is used to elevate catalyst inlet air and fuel to operating temperature. The premixer combines fuel and air into a uniform mixture before entering the catalyst. The catalyst bed initiates the fuel-air reactions, elevating the mixture temperature and partially oxidizing the fuel. The part load injector is a lean premixed combustor system that provides fuel and air to the post-catalyst combustor. The post-catalyst combustor is the volume downstream of the catalyst bed where the combustion reactions are completed. At part load conditions a conventional flame bums in this zone. Combustion testing is on-going in a subscale rig to optimize the system and define operating limits. Short duration rig testing has been completed to 9 atmospheres pressure with stable catalytic combustion and NOx emissions down to the 5 ppmv level. Testing was intended to prove-out design elements at representative full load engine conditions. Subscale combustion testing is planned to document performance at part-load conditions. Preliminary full-scale engine design studies are underway.

Experimental Development of On-Line Flame Transfer Function Measurements for Fielded Gas Turbines

2021 ◽  
Author(s):  
Austin Matthews ◽  
Anna Cobb ◽  
Subodh Adhikari ◽  
David Wu ◽  
Tim Lieuwen ◽  
...  
Keyword(s):  
Transfer Function ◽  
Heat Release ◽  
Gas Turbine ◽  
Gas Turbines ◽  
High Speed ◽  
Transfer Functions ◽  
Full Scale ◽  
Fuel Injector ◽  
Experimental Development ◽  
On Line

Abstract Understanding thermoacoustic instabilities is essential for the reliable operation of gas turbine engines. To complicate this understanding, the extreme sensitivity of gas turbine combustors can lead to instability characteristics that differ across a fleet. The capability to monitor flame transfer functions in fielded engines would provide valuable data to improve this understanding and aid in gas turbine operability from R&D to field tuning. This paper presents a new experimental facility used to analyze performance of full-scale gas turbine fuel injector hardware at elevated pressure and temperature. It features a liquid cooled, fiber-coupled probe that provides direct optical access to the heat release zone for high-speed chemiluminescence measurements. The probe was designed with fielded applications in mind. In addition, the combustion chamber includes an acoustic sensor array and a large objective window for verification of the probe using high-speed chemiluminescence imaging. This work experimentally demonstrates the new setup under scaled engine conditions, with a focus on operational zones that yield interesting acoustic tones. Results include a demonstration of the probe, preliminary analysis of acoustic and high speed chemiluminescence data, and high speed chemiluminescence imaging. The novelty of this paper is the deployment of a new test platform that incorporates full-scale engine hardware and provides the ability to directly compare acoustic and heat release response in a high-temperature, high-pressure environment to determine the flame transfer functions. This work is a stepping-stone towards the development of an on-line flame transfer function measurement technique for production engines in the field.

New Catalytic Combustion Technology for Very Low Emissions Gas Turbines

1994 ◽  
Author(s):  
R. A. Dalla Betta ◽  
J. C. Schlatter ◽  
S. G. Nickolas ◽  
D. K. Yee ◽  
T. Shoji
Keyword(s):  
Thermal Shock ◽  
Gas Turbine ◽  
High Temperatures ◽  
Gas Turbines ◽  
Catalytic Combustion ◽  
Combustion Process ◽  
Combustion System ◽  
Gas Turbine Combustors ◽  
Homogeneous Combustion ◽  
Combustion Technology

A catalytic combustion system has been developed which feeds full fuel and air to the catalyst but avoids exposure of the catalyst to the high temperatures responsible for deactivation and thermal shock fracture of the supporting substrate. The combustion process is initiated by the catalyst and is completed by homogeneous combustion in the post catalyst region where the highest temperatures are obtained. This has been demonstrated in subscale test rigs at pressures up to 14 atmospheres and temperatures above 1300°C (2370°F). At pressures and gas linear velocities typical of gas turbine combustors, the measured emissions from the catalytic combustion system are NOx < 1 ppm, CO < 2 ppm and UHC < 2 ppm, demonstrating the capability to achieve ultra low NOx and at the same time low CO and UHC.

scholarly journals Variable Geometry Fuel Injector for Low Emissions Gas Turbines

1999 ◽  
Author(s):  
K. Smith ◽  
R. Steele ◽  
J. Rogers
Keyword(s):  
Gas Turbines ◽  
Field Tests ◽  
Flow Distribution ◽  
Operating Conditions ◽  
Variable Geometry ◽  
Fuel Injector ◽  
System Variable ◽  
Lean Premixed Combustion ◽  
Stable Operating ◽  
Lean Premixed

To extend the stable operating range of a lean premixed combustion system, variable geometry can be used to adjust the combustor air flow distribution as gas turbine operating conditions vary. This paper describes the design and preliminary testing of a lean premixed fuel injector that provides the variable geometry function. Test results from both rig and engine evaluations using natural gas are presented. The variable geometry injector has proven successful in the short-term testing conducted to date. Longer term field tests are planned to demonstrate durability.

Advanced Materials for Mercury™ 50 Gas Turbine Combustion System

2006 ◽  
Author(s):  
Jeffrey Price ◽  
Josh Kimmel ◽  
Xiaoqun Chen ◽  
Arun Bhattacharya ◽  
Anthony Fahme ◽  
...  
Keyword(s):  
Gas Turbine ◽  
Gas Turbines ◽  
Ceramic Matrix Composite ◽  
Field Evaluation ◽  
Ceramic Composites ◽  
Advanced Materials ◽  
Combustion System ◽  
Fuel Injector ◽  
Ods Alloys ◽  
Gas Turbine Combustion

Solar Turbines Incorporated (Solar), under cooperative agreement number DE-FC26-00CH 11049, is improving the durability of gas turbine combustion systems while reducing life cycle costs. This project is part of the Advanced Materials in Advanced Industrial Gas Turbines program in DOE’s Office of Distributed Energy. The targeted engine is the Mercury™ 50 gas turbine, which was developed by Solar under the DOE Advanced Turbine Systems (ATS) program (DOE contract number DE-FC21-95MC31173). The ultimate goal of the program is to demonstrate a fully integrated Mercury 50 combustion system, modified with advanced materials technologies, at a host site for 4,000 hours. The program has focused on a dual path development route to define an optimum mix of technologies for the Mercury 50 turbine and future Solar products. For liner and injector development, multiple concepts including high thermal resistance thermal barrier coatings (TBC), oxide dispersion strengthened (ODS) alloys, continuous fiber ceramic composites (CFCC), and monolithic ceramics were evaluated. An advanced TBC system for the combustor was down-selected for field evaluation. ODS alloys were down-selected for the fuel injector tip application. Preliminary component and sub-scale testing was conducted to determine material properties and demonstrate proof-of-concept. Full-scale rig and engine testing were used to validate engine performance prior to field evaluation. Field evaluation of ceramic matrix composite liners in the Centaur® 50 gas turbine engine [1–3] which was previously conducted under the DOE sponsored Ceramic Stationary Gas Turbine program (DE-AC02-92CE40960), is continuing under this program. This paper is a status review of the program, detailing the current progress of the development and field evaluations.

Dry, Low Emissions for the ‘H’ Heavy-Duty Industrial Gas Turbines: Full-Scale Combustion System Rig Test Results

2003 ◽  
Author(s):  
Geoff Myers ◽  
Dan Tegel ◽  
Markus Feigl ◽  
Fred Setzer ◽  
William Bechtel ◽  
...  
Keyword(s):  
Gas Turbine ◽  
Gas Turbines ◽  
Pressure Ratio ◽  
Combined Cycle ◽  
Full Scale ◽  
Combustion System ◽  
Heavy Duty ◽  
Test Program ◽  
Industrial Gas Turbines ◽  
Inlet Conditions

The lean, premixed DLN2.5H combustion system was designed to deliver low NOx emissions from 50% to 100% load in both the Frame 7H (60 Hz) and Frame 9H (50 Hz) heavy-duty industrial gas turbines. The H machines employ steam cooling in the gas turbine, a 23:1 pressure ratio, and are fired at 1440 C (2600 F) to deliver over-all thermal efficiency for the combined-cycle system near 60%. The DLN2.5H combustor is a modular can-type design, with 14 identical chambers used on the 9H machine, and 12 used on the smaller 7H. On a 9H combined-cycle power plant, both the gas turbine and steam turbine are fired using the 14-chamber DLN2.5H combustion system. An extensive full-scale, full-pressure rig test program developed the fuel-staged dry, low emissions combustion system over a period of more than five years. Rig testing required test stand inlet conditions of over 50 kg/s at 500 C and 28 bar, while firing at up to 1440 C, to simulate combustor operation at base load. The combustion test rig simulated gas path geometry from the discharge of the annular tri-passage diffuser through the can-type combustion liner and transition piece, to the inlet of the first stage turbine nozzle. The present paper describes the combustion system, and reports emissions performance and operability results over the gas turbine load and ambient temperature operating range, as measured during the rig test program.

Development of a Catalytic Combustor for Small Gas Turbines

1987 ◽  
Author(s):  
K. Mori ◽  
J. Kitajima ◽  
S. Kajita ◽  
S. Ichihara
Keyword(s):  
Natural Gas ◽  
Gas Turbines ◽  
Combustion Zone ◽  
Catalytic Combustion ◽  
Liquefied Natural Gas ◽  
Nox Emissions ◽  
Variable Geometry ◽  
Wide Range ◽  
Catalytic Combustor ◽  
Full Scale Tests

To reduce NOx emissions significantly, a catalytic combustor was developed. Full scale tests of catalytic combustors designed for application in Kawasaki S1A-O2 type gas trubines were conducted. The combustor consisted of a pre-combustion zone, a premixing zone, a catalytic combustion zone, and a variable geometry dilution zone. Liquefied Natural Gas (LNG) was burned in combustor rig tests and results indicated low NOx emissions and high combustion efficiencies over a wide range of air/fuel ratios and that the catalytic combustor can be applied to the engine tests.

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.

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