Ertan Yilmaz

Low Emissions Combustion System Development for the GE Energy High Hydrogen Turbine Program

Progress on the joint GE Energy/US Department of Energy (DOE) High Hydrogen Turbine Program is presented. A summary of GE’s current integrated gasification combined cycle (IGCC) experience is provided. The Phase I approach is discussed with selected results included. The program follows the well-established GE approach to introducing new technology through: fundamental laboratory testing and analysis; subscale demonstration; full-scale development; full-scale verification. Advancements towards the ultimate goal of ultralow NOx emissions with coal derived pre-combustion carbon capture fuels are presented. Feasibility of diluent-free low NOx combustion is demonstrated experimentally at gas turbine conditions with representative fuel compositions. Phase II design challenges are highlighted within the framework of Phase I results.© 2008 ASME

Fuel-Flexible Combustion System for Co-production Plant Applications

Future high-efficiency, low-emission generation plants that produce electric power, transportation fuels, and/or chemicals from fossil fuel feed stocks require a new class of fuel-flexible combustors. In this program, a validated combustor approach was developed which enables single-digit NO{sub x} operation for a future generation plants with low-Btu off gas and allows the flexibility of process-independent backup with natural gas. This combustion technology overcomes the limitations of current syngas gas turbine combustion systems, which are designed on a site-by-site basis, and enable improved future co-generation plant designs. In this capacity, the fuel-flexible combustor enhances the efficiency and productivity of future co-production plants. In task 2, a summary of market requested fuel gas compositions was created and the syngas fuel space was characterized. Additionally, a technology matrix and chemical kinetic models were used to evaluate various combustion technologies and to select two combustor concepts. In task 4 systems analysis of a co-production plant in conjunction with chemical kinetic analysis was performed to determine the desired combustor operating conditions for the burner concepts. Task 5 discusses the experimental evaluation of three syngas capable combustor designs. The hybrid combustor, Prototype-1 utilized a diffusion flame approach for syngas fuels with a lean premixed swirl concept for natural gas fuels for both syngas and natural gas fuels at FA+e gas turbine conditions. The hybrid nozzle was sized to accommodate syngas fuels ranging from {approx}100 to 280 btu/scf and with a diffusion tip geometry optimized for Early Entry Co-generation Plant (EECP) fuel compositions. The swozzle concept utilized existing GE DLN design methodologies to eliminate flow separation and enhance fuel-air mixing. With changing business priorities, a fully premixed natural gas & syngas nozzle, Protoytpe-1N, was also developed later in the program. It did not have the diluent requirements of Prototype-1 and was demonstrated at targeted gas turbine conditions. The TVC combustor, Prototype-2, premixes the syngas with air for low emission performance. The combustor was designed for operation with syngas and no additional diluents. The combustor was successfully operated at targeted gas turbine conditions. Another goal of the program was to advance the status of development tools for syngas systems. In Task 3 a syngas flame evaluation facility was developed. Fundamental data on syngas flame speeds and flame strain were obtained at pressure for a wide range of syngas fuels with preheated air. Several promising reduced order kinetic mechanisms were compared with the results from the evaluation facility. The mechanism with the best agreement was selected for application to syngas combustor modeling studies in Task 6. Prototype-1 was modeled using an advanced LES combustion code. The tools and combustor technology development culminate in a full-scale demonstration of the most promising technology in Task 8. The combustor was operated at engine conditions and evaluated against the various engine performance requirements.

The Effect of Fuel Density on Mixing Profiles in a DACRS Type Premixer: Experiments and Simulation

A combined experimental and computational study was conducted to investigate the effect of fuel density variations on mixing from a double annular counter-rotating swirl (DACRS) nozzle operated at atmospheric pressure under non-reacting conditions using either helium (He) or a mixture of He and CO2 as fuel simulants. A small probe traversed through the flow collecting gas samples that were sent to gas analyzers measuring the concentration profiles. The resulting measurements are then used to validate the computational fluid dynamics (CFD) model. A commercial CFD code (CFX 10) with a Reynolds averaged Navier-Stokes (RANS) formulation was used to simulate the experiment. Multiple turbulence closures, such as standard and realizable k-e and SSG Reynolds stress model were evaluated. Additionally, several geometrical considerations, such as modeling a 72° sector versus a full 360°, were tested. While at high fuel-to-air momentum flux ratios (J) the fuel simulant concentration profiles were outward-peaked, and at low J the profiles were center-peaked. An analysis of the experimental results clearly indicate the momentum flux ratio is the most influential parameter controlling mixing in a DACRS nozzle. The simulations produced quantitative agreement with the experimental measurements using the realizable k-e turbulence closure and only modeling a 72° sector of the nozzle. The complexity of the studied problem required a considerable refinement of the grid to produce an accurate and grid independent solution. The validated model may now be used to explore the design space for optimization of a nozzle for utilization in a syngas application.© 2007 ASME

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

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.Copyright