V64.3A Gas Turbine Natural Gas Burner Development

2002 ◽  
Author(s):  
Heinrich Hermsmeyer ◽  
Bernd Prade ◽  
Uwe Gruschka ◽  
Udo Schmitz ◽  
Stefan Hoffmann ◽  
...  
Keyword(s):  
Gas Turbines ◽  
Nox Emissions ◽  
Fuel System ◽  
Combustion System ◽  
Standard Design ◽  
Commercial Operation ◽  
Annular Combustor ◽  
Gas Burner ◽  
Development Approach ◽  
Near Future

From the very first beginning of the V64.3A development the HR3 burner was selected as standard design for this frame. The HR3 burner was originally developed for the Vx4.2 and Vx4.3 fleet featuring silo combustors in order to mitigate the risk of flashback and to improve the NOx-emissions (Prade, Streb, 1996). Due to its favourable performance characteristics in the Vx4.3 family the advanced HR3 burner was adapted to the Vx4.3A series with annular combustor (hybrid burner ring – HBR). This paper reports about the burner development for V64.3A gas turbines to reach NOx emissions below 25 ppmvd and CO emissions below 10 ppmvd. It is described how performance and NOx emissions have been optimised by implementation of fuel system and burner modifications. The development approach, emission results and commercial operation experiences as well are described. The modifications of the combustion system were successfully and reliably demonstrated on commercially running units. NOx emissions considerably below 25ppmvd were achieved at and above design baseload. An outlook to further steps of V64.3A burner development in the near future will be given in this paper.

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.

scholarly journals Field Experience of the Sequential Combustion System for the GT24/GT26 Gas Turbine Family

1998 ◽  
Author(s):  
Franz Joos ◽  
Philipp Brunner ◽  
Marcel Stalder ◽  
Stefan Tschirren
Keyword(s):  
Gas Turbine ◽  
Research Work ◽  
Basic Research ◽  
Test Facility ◽  
Test Results ◽  
Combustion System ◽  
System A ◽  
Commercial Operation ◽  
Near Future

The first units of the Sequential Combustion System gas turbine family are in commercial operation. The first gas turbine GT24 (60Hz, 165MW-class) started the commercial operation, while the first GT26 (50Hz, 265MW-class) demonstrates its performance at the GT test facility. More engines are presently in the commissioning phase or will be in the near future. These turbines are designed to offer increased output at high GT efficiency. To acheive this, the sequential combustion system, a reheat process with two combustors, has been developed. Whereas the first combustor is based on the proven EV-combustor technology, extensive research and development efforts have been carried out in developing the lean premixed self-igniting second combustor (SEV). This paper is a follow-up of the ASME paper 96-GT-315, which described the basic research work concerning the lean premixing SEV-burners with self-ignition. The present paper reports the experience gained during commissioning of the first engines. The performance of the two combustors, as well as the measured emissions, are discussed and compared with the expected values and rig test results. Finally, the potential of the sequential combustion system to reach low NOx levels is demonstrated by unveiling the results of the extensive testing program during the commissioning phase.

From Concept to Commercial Operation: The Tri-Fuel Injector Used for LPG and Naphtha Applications

2001 ◽  
Author(s):  
A. W. Newman ◽  
P. S. Nixon ◽  
R. I. Wilms ◽  
D. M. Taylor ◽  
M. D. Cornwell
Keyword(s):  
Liquid Phase ◽  
Load Shedding ◽  
Dual Fuel ◽  
Fuel System ◽  
Fuel Injector ◽  
Rotary Pump ◽  
Diesel Fuels ◽  
Liquid Petroleum Gas ◽  
Commercial Operation ◽  
Near Future

The tri-fuel injector is an extension of the standard dual fuel multi passage injector to cover additional fuels such as Liquid Petroleum Gas (LPG) and Naphtha at medium pumping pressure (less than 40 Bara). There is an additional passage designed for metering the LPG or Naphtha in liquid phase. The fuel system uses a non-contacting rotary pump with modern inverter technology for the pumping of these fuels. Both tri-fuel injector and fuel system are now in commercial operation on two Tornado engines using LPG, natural gas and diesel fuels. The LPG system is operating just below 30 Bara pumping pressure, and has accumulated about 1029 operating hours on the lead engine. LPG load shedding capability has been proven on one engine. Commercial operation of the Typhoon engine on Naphtha at medium pumping pressures (< 40 Bara), with an improved tri-fuel injector, will commence in the near future.

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.

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.

Burner Development for Flexible Engine Operation of the Newest Siemens Gas Turbines

2003 ◽  
Author(s):  
Bernd Prade ◽  
Ju¨rgen Meisl ◽  
Peter Berenbrink ◽  
Holger Streb ◽  
Stefan Hoffmann
Keyword(s):  
Natural Gas ◽  
Gas Turbines ◽  
Liquid Fuel ◽  
Fuel Quality ◽  
Nox Emissions ◽  
Combustion System ◽  
Engine Operation ◽  
Water Emulsion ◽  
Combustion Dynamics ◽  
Wide Range

The newest Siemens gas turbine family has already been well received by the market. Nevertheless, the market drives continuing development of the family and the combustion system. Central focus is put on further increasing reliability and component lifetime and on increased inspection cycles, as well as increasing the engine power output and efficiency, which is directly linked to higher turbine inlet temperatures. Increasing attention, however, is given to the flexibility concerning fuel quality and according fluctuations. Additionally, more and more strict emission requirements must be considered. This paper especially reports on demonstration of the capability of the Siemens gas turbines with an annular combustion system to fulfil the requirements for the highest operational flexibility. Thus, the combustion system has been tested and qualified for the highest operating flexibility with special fuel requirements such as burning Naphtha, Light Oil #2 and Natural gas with an extremely wide range of heating values as well. Also special operation modes such as fuel changeover, fastest load changes for island grid operation, frequency response and load rejection require this highly flexible combustion system without any hardware exchange. In different frames when fired with natural gas, base load is reached with the NOx emissions ranging well below 25 ppmvd, confirming the high potential of this advanced hybrid burner. In liquid fuel operation, dry NOx emissions of 75ppmvd were demonstrated but by injecting fuel / water emulsion NOx emissions were reduced to below 42 ppmvd with different liquid fuel qualities. Combustion dynamics, unburned Hydrocarbons, CO and soot emissions remained always below the required limits.

Development and Testing of a Low NOx Hydrogen Combustion System for Heavy-Duty Gas Turbines

2013 ◽  
Vol 135 (2) ◽  
Author(s):  
William D. York ◽  
Willy S. Ziminsky ◽  
Ertan Yilmaz
Keyword(s):  
Gas Turbine ◽  
Gas Turbines ◽  
Small Scale ◽  
Nox Emissions ◽  
Combustion System ◽  
Fuel Injector ◽  
Hydrogen Fuel ◽  
Heavy Duty ◽  
High Hydrogen ◽  
Hydrogen Fuels

Interest in hydrogen as a primary fuel stream in heavy-duty gas turbine engines has increased as precombustion carbon capture and sequestration (CCS) has become a viable option for integrated gasification combined cycle (IGCC) power plants. The U.S. Department of Energy has funded the Advanced IGCC/Hydrogen Gas Turbine Program since 2005 with an aggressive plant-level NOx target of 2 ppm at 15% O2 for an advanced gas turbine cycle. Approaching this NOx level with highly reactive hydrogen fuel at the conditions required is a formidable challenge that requires novel combustion technology. This study begins by measuring entitlement NOx emissions from perfectly premixed combustion of the high-hydrogen fuels of interest. A new premixing fuel injector for high-hydrogen fuels was designed to balance reliable flashback-free operation, reasonable pressure drop, and low emissions. The concept relies on small-scale jet-in-crossflow mixing that is a departure from traditional swirl-based premixing concepts. Single nozzle rig experiments were conducted at pressures of 10 atm and 17 atm, with air preheat temperatures of about 650 K. With nitrogen-diluted hydrogen fuel, characteristic of carbon-free syngas, stable operation without flashback was conducted up to flame temperatures of approximately 1850 K. In addition to the effects of pressure, the impacts of nitrogen dilution levels and amounts of minor constituents in the fuel—carbon monoxide, carbon dioxide, and methane—on flame holding in the premixer are presented. The new fuel injector concept has been incorporated into a full-scale, multinozzle combustor can with an energy conversion rate of more than 10 MW at F-class conditions. The full-can testing was conducted at full gas turbine conditions and various fuel compositions of hydrogen, natural gas, and nitrogen. This combustion system has accumulated over 100 h of fired testing at full load with hydrogen comprising over 90% of the reactants by volume. NOx emissions (ppm) have been measured in the single digits with hydrogen-nitrogen fuel at target gas turbine pressure and temperatures. Results of the testing show that small-scale fuel-air mixing can deliver a reliable, low-NOx solution to hydrogen combustion in advanced gas turbines.

Advanced Burner Development for the Vx4.3A Gas Turbines

2001 ◽  
Author(s):  
Holger Streb ◽  
Bernd Prade ◽  
Thomas Hahner ◽  
Stefan Hoffmann
Keyword(s):  
Gas Turbine ◽  
Gas Turbines ◽  
Field Evaluation ◽  
Test Facility ◽  
Nox Emissions ◽  
Exhaust Gas ◽  
Test Results ◽  
Exhaust Gas Emission ◽  
Annular Combustor ◽  
Base Load

The Vx4.3A gas turbine family has already been well received by the market. Nevertheless the market drives technology towards both increased turbine inlet temperatures and reduced emissions. The HR3 burner was originally developed for the V4.2 and Vx4.3 fleet featuring silo combustors in order to mitigate the risk of flashback and to improve the NOx- emissions (Prade, Streb, 1996). Due to its favourable performance characteristics in the Vx4.3 family the advanced HR3 burner was adapted to the Vx4.3A series with annular combustor. The paper reports upon the design, testing and field evaluation steps which were necessary to implement the burner for the 50 and 60 cycle gas turbines. With CFD calculations the flow field and the mixing of natural gas and combustion air have been optimised. A number of tests in the Siemens test facilities confirmed these predictions. The atmospheric 3 burner segment combustion test rig allows to test flame interaction, stability and exhaust gas emission simultaneously. In the Siemens Berlin Test Facility which provides a platform for full scale gas turbine testing 24 HR3-burners were implemented into a V84.3A gas turbine with a base load power output of 184 MW at ISO conditions for prototype testing before introducing this new burner generation into the bigger 50 cycle family V94.3A. Implementation of 24 scaled HR3 burners were installed in the V94.3A of Cottam Development Centre (Great Britain) and demonstrated an excellent performance. The gas turbine reached an ISO base load output of 265 MW with NOx emissions well below 25 ppmvd. Due to the very promising test results in Berlin and Cottam, this burner modification, which can be retrofitted to all VX4.3A gas turbines, was implemented nearly fleet wide.

Operational Flexibility of GE’s F-Class Gas Turbines With the DLN2.6+ Combustion System

2018 ◽  
Author(s):  
William D. York ◽  
Derrick W. Simons ◽  
Yongqiang Fu
Keyword(s):  
Gas Turbine ◽  
Gas Turbines ◽  
Combined Cycle ◽  
Nox Emissions ◽  
Combustion System ◽  
Operational Flexibility ◽  
Start Up ◽  
Wide Range ◽  
Combined Cycle Plant ◽  
Base Load

F-class gas turbines comprise a major part of the heavy-duty gas turbine power generation fleet worldwide, despite increasing penetration of H/J class turbines. F-class gas turbines see a wide range of applications, including simple cycle peaking operation, base load combined cycle, demand following in simple or combined cycle, and cogeneration. Because of the different applications, local power market dynamics, and varied emissions regulations by region or jurisdiction, there is a need for operational flexibility of the gas turbine and the combustion system. In 2015, GE introduced a DLN2.6+ combustion system for new and existing 7F gas turbines. Approximately 50 are now in operation on 7F.04 and 7F.05 turbines, combining for nearly 150,000 fired hours. The system has been demonstrated to deliver 5 ppm NOx emissions @ 15% O2, and it exhibits a wide window of operation without significant thermoacoustic instabilities, owing the capability to premixed pilot flames on the main swirl fuel-air premixers, low system residence time, and air path improvements. Based on the success on the 7F, this combustion system is being applied to the 6F.03 in 2018. This paper highlights the flexibility of the 7F and 6F.03 DLN2.6+ combustion system and the enabling technology features. The advanced OpFlex* AutoTune control system tightly controls NOx emissions, adjusts fuel splits to stay clear of instabilities, and gives operators the ability to prioritize emissions or peak load output. Because of the low-NOx capability of the system, it is often being pushed to higher combustor exit temperatures, 35°C or more above the original target. The gas turbine is still meeting 9 or 15 ppm NOx emissions while delivering nearly 12% additional output in some cases. Single-can rig test and engine field test results show a relatively gentle NOx increase over the large range of combustor exit temperature because of the careful control of the premixed pilot fuel split. The four fuel legs are staged in several modes during startup and shutdown to provide robust operation with fast loading capability and low starting emissions, which are shown with engine data. The performance of a turndown-only fueling mode is highlighted with engine measurements of CO at low load. In this mode, the center premixer is not fueled, trading the NOx headroom for a CO emissions benefit that improves turndown. The combustion system has also demonstrated wide-Wobbe capability in emissions compliance. 7F.04 engine NOx and dynamics data are presented with the target heated gas fuel and also with cold fuel, producing a 24% increase in Modified Wobbe Index. The ability to run unheated fuel at base load may reduce the start-up time for a combined cycle plant. Lastly, there is a discussion of a new OpFlex* Variable Load Path digital solution in development that will allow operators to customize the start-up of a combined cycle plant.

Development and Testing of a Low NOX Hydrogen Combustion System for Heavy Duty Gas Turbines

2012 ◽  
Author(s):  
William D. York ◽  
Willy S. Ziminsky ◽  
Ertan Yilmaz
Keyword(s):  
Gas Turbine ◽  
Gas Turbines ◽  
Small Scale ◽  
Nox Emissions ◽  
Combustion System ◽  
Fuel Injector ◽  
Hydrogen Fuel ◽  
Heavy Duty ◽  
High Hydrogen ◽  
Hydrogen Fuels

Interest in hydrogen as a primary fuel stream in heavy-duty gas turbine engines has increased as pre-combustion carbon capture and sequestration (CCS) has become a viable option for integrated gasification combined cycle (IGCC) power plants. The US Department of Energy has funded the Advanced IGCC/Hydrogen Gas Turbine Program since 2005 with an aggressive plant-level NOx target of 2 ppm @ 15% O2 for an advanced gas turbine cycle. Approaching this NOx level with highly-reactive hydrogen fuel at the conditions required is a formidable challenge that requires novel combustion technology. This study begins by measuring entitlement NOx emissions from perfectly-premixed combustion of the high-hydrogen fuels of interest. A new premixing fuel injector for high-hydrogen fuels was designed to balance reliable, flashback-free operation, reasonable pressure drop, and low emissions. The concept relies on distributed, small-scale jet-in-crossflow mixing that is a departure from traditional swirl-based premixing concepts. Single nozzle rig experiments were conducted at pressures of 10 atm and 17 atm, with air preheat temperatures of about 650K. With nitrogen-diluted hydrogen fuel, characteristic of carbon-free syngas, stable operation without flashback was conducted up to flame temperatures of approximately 1850K. In addition to the effects of operating pressure, the impact of minor constituents in the fuel — carbon monoxide, carbon dioxide, and methane — on flame holding in the premixer is presented. The new fuel injector concept has been incorporated into a full-scale, multi-nozzle combustor can with an energy conversion rate of more than 10 MW at F-class conditions. The full-can testing was conducted at full gas turbine conditions and various fuel compositions of hydrogen, natural gas, and nitrogen. This combustion system has accumulated over 100 hours of fired testing at full-load with hydrogen comprising over 90 percent of the reactants by volume. NOx emissions (ppm) have been measured in the single digits with hydrogen-nitrogen fuel at target gas turbine pressure and temperatures. Results of the testing show that small-scale fuel-air mixing can deliver a reliable, low-NOx solution to hydrogen combustion in advanced gas turbines.

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