zero nox gas turbine combustion

10November2003NearNear--ZeroNOxZeroNOxGasTurbineCombustionGasTurbineCombustionVivekKhannaSolarTurbinesIncorporatedSanDiego,California2ndDistributedEnergyPeerReviewDecember2-4,2003WashingtonD.C.10November2003OutlineOutline•Programstructure•Projectgoals•Programmilestonesandschedule•Technicalresultsandcurrentactivities•Keytechnicalhurdlesandplanstoovercome•Projectrisk•OtherlowNOxtechnologyefforts•ImpactonDER10November2003PRECISIONPRECISIONCOMBUSTIONCOMBUSTIONDOEDOESOLARSOLARSBIRNear-ZeroNOxProgramStructureProgramStructure10November2003TheDevelopmentTeamTheDevelopmentTeam•ProgramSponsor–U.S.DepartmentofEnergy(DOE)OfficeofDistributedEnergy,Washington,DC•DebbieHaught,MerrillSmith•DOEProjectManagement–DOEChicagoOperationsOffice,Argonne,IL•DaleDietzel,SteveWaslo–DOEGoldenFieldOffice,Golden,CO•PaulBakke10November2003ProgramGoalsProgramGoals•Assessandadvanceanultra-lowNOxR/LcombustionsystemforGTs–Seekingacost-effectivealternativetoSCR•Lowerelectricitycost•Noammoniastorage/slipissues•EasiercitingofGTs10November2003TechnicalGoalsTechnicalGoals•2.5ppmNOx,10ppmCO,UHC-Naturalgas•8000-hourdurability•Minimumchangetocurrentengine•Fieldreplaceable10November2003TechnicalMilestonesTechnicalMilestones•“Proof-of-concept”rigtests–SinglePCIR/Lmodule•Demonstrateoperabilityinan“engineenvironment”–Saturnenginetest(1MW)•DevelopaGenIImoduledesign–FocusonTaurus70(7.5MW)application–RigtestasingleT70module10November2003LongTermMilestonesLongTermMilestones––BeyondContractEffortBeyondContractEffort•Fullsystemrigtest(12modules)•In-houseenginetest•Long-termfieldtest–Documentmoduledurability10November200320002001200220032004Proof-of-ConceptRigTestSaturnDemoInjectorOptimizationGenIIDesign/TestProgramScheduleProgramSchedule10November2003SingleBurnerModuleSingleBurnerModuleConfigurationConfigurationCatalystFlameholdingConeCombustorLinerReverse-FlowPremixerPost-MixDuct10November2003Rich/LeanCatalyticRich/LeanCatalyticCombustionCombustion10November2003NOx&COEmissionsvs.OperatingCondition12/10/01RCLtest@Solar;Tin=810F,Pin=16atm0.002.004.006.008.0010.0012.0014.0016.0018.0020.0026002650270027502800285029002950AdiabaticFlameTemperature(F)atCatalystModuleExitCO(ppm,15%O2dry)0.000.501.001.502.002.503.003.504.004.505.00NOx(ppm,15%O2dry)CONOxSingleInjectorTestsSingleInjectorTests––T70T70OperatingConditionsOperatingConditions•Well-mixed,leanstablecombustionachieved.•NOx3ppm@16atmpforflametemp2875°F.•CO10ppmforflametemp2660°F.•Pressuredrop5%•Capableofhighfiringtemperatureoperation.•Dynamicpressureoscillations1/4%•Extremelyquietoperationachieved,overwideoperatingrange.10November2003SaturnEngineTestSaturnEngineTest•Shorttermdemonstrationinan“engineenvironment”(1MW)–“Externalcan”combustionsystem–Fourmodule“cluster”–Assesstransientoperability10November2003SaturnTestFacilitySaturnTestFacilityCombustorPZAirDilutionAirTurbineExhaust(Muffler)10November2003SaturnModuleConstructionSaturnModuleConstruction10November20034R/LModulesSaturnCombustorAssemblySaturnCombustorAssembly10November2003SaturnEngineOperationSaturnEngineOperation05010015020025030035040045050012:36:0012:43:1212:50:2412:57:3613:04:48TimeFuelmassflow(Wf,pph)0102030405060708090100Gasproducershaftspeed(Ngp,%)PreburnerFuel(Wf_pbn)RCLStageAFuel(Wf_A)RCLStageBFuel(Wf_B)ShaftSpeed(Ngp)coldcrankidleNgpWf_AWf_Bpreburnerfuelon@29%Ngpincreasepreburnerfuel(RCLinlettemp)tolight-offcatalyststurnpreburnerfueloff@80%Ngp--catalystsremainactive(litoff)Wf_pbnfuelRCLmodules,ignitecombustion,accelto65%NgpAdjustcombustorairvalvesforbestemissions10November2003SaturnEngineTestResultsSaturnEngineTestResults•NOx3ppmandCO10ppmachievedbetween82%NGPand89.7%NGP•Maximumspeedlimitedbylimitsonscrolltemperature•SystemresponsetoloadchangesandenginecontrolverysimilartoSoLoNOxsystems0246810121481838587899193%NGPEmissionscorrectedto15%O2(ppm)COHCNOx10November2003CurrentTechnicalActivityCurrentTechnicalActivity•GenIImoduleindesign–Incorporatesapilotburner–Improvedflamestabilizer–Morerobusttubebundledesign•Combustorcasingandlinermodsbeingdefined10November2003TechnicalHurdlesTechnicalHurdles•Catalystdurability•Catalyticelementretention•Catalyticreactorresonance•Pilotperformance•COemissionsvslinervolume10November2003PlanstoOvercomePlanstoOvercomeTechnicalHurdlesTechnicalHurdles•CompleteGenIIdesign•RigtestsofasingleGenIImodule–Demonstratepilotburnerperformance•IntegrateactivitieswithPCISBIR–Demonstratecatalystdurability–Multi-burnerrigandenginetests10November2003ProjectRiskProjectRisk•Allmilestonesexceptthelastcompletedsuccessfully•Minimaltechnicalriskinvolvedinthesuccessfulcompletionoftheprogram•Shortfalloreliminationoffuturefundingcancurtailthetechnicaleffort10November2003OtherLowNOxTechnologyEffortsOtherLowNOxTechnologyEfforts10November2003TechnologiesTechnologies•SurfaceCombustion(ALZETA)•LeanCatalyticCombustion(CESI)•LowSwirlInjector(LBNL/DOE)•CatalyticPilotforDLN(PCI)10November2003AlzetaSurfaceBurnersAlzetaSurfaceBurners10November2003CESILeanCatalyticCESILeanCatalyticCombustionCombustion10November2003Taurus70LeanCatalyticTaurus7