Beruflich Dokumente
Kultur Dokumente
Torsten Strand
Senior Gas Turbine Specialist
ABB STAL, R&D Dept El III 1 1111 lip 111 111
S-612 82 Finspong
Sweden
ABSTRACT
It is shown that emissions are becoming significant development route has been directed to Dry Low NOx
performance parameters. Dry Low NOx combustion Combustion systems with a 25 ppmv NOx target.
is favourably evaluated in terms of fuel consumption In 1991 such a system was introduced on a GTIO based
when compared to NOx abatement with water combined cycle plant in Sweden, which became the reference
Injection or SCR. plant for a whole series of low emission combined cycle
The conversion of two industrial gas turbines to Dry plants in Europe.
Low NOx (DLN) Combustion summarised. The development processes, introduction and operation
Four years experience of commissioning and experiences of these combustion systems will be highlighted.
operation of a number of DLN gas turbines is
described.
Emission Regulations & Guarantees
Emission levels around 25 ppmv NOx on gas has
been achieved. Operation on natural gas is generally Regulations on or taxations of NOx emissions from power
very reliable, but some initial problems were plants are becoming common all over the world. The general
encountered. target levels are in the range of 25-50 ppmv NOx in the
Emission measurements and especially continuos exhaust gas. The "best available technology at reasonable
emission monitoring have proved to be unreliable cost" philosophy has become the base for regulations in many
and caused a lot of trouble during the countries, which has made emissions an important or even the
commissioning of some plants. most important purchasing parameter. NOx taxation of
course has made emissions an operating cost parameter
comparable to fuel consumption.
INTRODUCTION
Generally the emission regulations have come earlier to the
From an environmental point of view, when designing a
power generation sector than in the gas transmission area.
thermal power plant, there are three main areas to consider
However, for pipe line compressor sets in Europe and North
• effective use of the fuel
America there are today requirements for 'emission levels
• choice of fuel
comparable to those of power plants.
• emissions (exhaust gases and noise)
ABB has therefore developed For marine propulsion the allowed NOx levels are still high,
• cogeneration and combined cycle plants, in which the adjusted to the emission capability of the diesel engine.
fuel is utilised to 85 - 95 % Special port and route emission fees are introduced in the US
• natural gas fired gas turbine combustion systems with high and Scandinavia, turning emissions into a cost factor, which
efficiency and low emissions will increase the interest for low emission systems.
Presented at the International Gas Turbine and Aeroengine Congress & Exhibition
Birmingham,
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<x ppmv, mg/MJ or mg/Nrn 3 at the nominal operating point
measured at the performance verification test only, to the most Gas 9aner616, Cambusben chambers
013 Nu
pH, Iv
complex T 725
—16
THE ABB STAL GT35 and GT10 LIGHT INDUSTRIAL Dry Low NOx Combustor Development Targets
GAS TURBINES In retrofitting DLN combustors to the GT35 and GTIO
turbines the targets were
The GT35 is a three shaft and GT10 a two shaft gas turbine * NOx on natural gas, dry 25 ppmv
with the nominal performances described in the figures * NOx on oil with water injection 42 ppmv
below. * combustion efficiency > 99.9 %
* no major changes to existing turbine geometry
2
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in combination with all the conventional combustor load. Some sort of combustion control at part load is
requirements, such as required.
• turbine inlet temperature profile better than before The low flame temperature combustion requires a mixing of.
• combustor pressure drop as before air and fuel in a homogeneous way upstream of the flame.
• fuel change over capability on load After mixing, the medium is explosive and auto ignition or
• full "load drop" capability flash back can occur if conditions (temperature, velocity and
• design life > 40000 hit turbulence) are right
the risk for flash back puts special requirements on the
Lean Premix Combustion Fundamentals burner design.
The two most important emission relations are illustrated in
fig 2. NOx and CO production are functions of flame CHOICE OF TECHNOLOGY
temperature, residence time and to some extent-combustor Thus there are three main areas for technology decisions
pressure. • burner
• combustion chamber
• part load combustion efficiency control method
EV-bumer
For the lean premix burners, which is the key component,
there was an obvious choice since the ABB patented EV
burner was already experimentally proven in advanced
laboratory tests at ABB Corporate Research in Baden,
Switzerland, fig 3.
SOD 2 000
AdaDatc flame temporaturo • degree K
DESIGN PROCEDURE
Fig.5 0T35 Combustor with 3 EV burners Since the components for the GT35 and 0110 design were
fairly well known, the computational phases were rather
Combustion Control short. The main efforts were concentrated on experimental
For the part load combustion control several different ways verification programs, comprising
were contemplated and a few tested. Initially, the thought was - single burner atmospheric and pressure tests
that there were two methods to assure full CO burn out at part - atmospheric full scale combustor tests
load - four burner sector pressure tests (GTIO)
* to keep the flame temperature at high enough level - engine testing
* to modify the flame from premix to diffusion type
Engine Testing
Today it is recognised that the only working method to avoid Three Swedish GTIO plants with Low NOx Combustion were
CO is the first one. However a pilot flame of diffusion type put into commercial operation in December 1991
may anyway be required at start up and low load operation, * a Combined Cycle Plant for City of Angelholm
since the combustor is operated below the blow out limit of * a Cogeneration Plant for City of Lund
the premix flame. * a Combined Cycle Plant for City of Karlskoga
For single shaft turbines the flame temperature can be kept operating on LPG
constant over a reasonable load range by controlling the air All the plants are producing electricity and hot water for
flow with the compressor variable inlet guide vanes. municipal district heating during the heating season
(November to April). The first two plants were installed with
5
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Continued Operating Experience There have in some cases been a dispute of what is included
With several plants in operation for a total of more than in the guaranteed figures
150000hrs, the experiences gained can be summarised as - the real gas turbine emissions or
follows: - the recorded figures of the (inaccurate) monitoring system
Integrity
Emission Results The GTIO combustor wall cooling has come out very well. ,
After the introduction of the bypass system on the GTI 0 unit The outer wall seemed however already after the first season
the emission results on several units has been recorded and of operation to have a somewhat too small margin to local
summarised in fig. 7. overheating. Even after a slight cooling flow modification,
The results show that the GTIO is capable to produce spot wise overheatings due to occasional flame distortions
• NOx values in the range of 17-22 ppmv at full load have appeared. After applying a thin thermal barrier coating,
during performance test conditions the 40000 hrs design life will however be reached.
• NOx values <25 ppmv during continuous operation in The GT35 combustors are very robust and will easily reach
the 60-100% load range design life. A redesign of the fuel piping due to vibration
• CO values < 40 ppmv at full load and <100 ppmv in the problems had to be made after the first engine tests.
65-100% load range
Functionality
The operation of the 0T35 and GTI 0 units have not changed
by the introduction of the dry low NOx combustion systems.
50
At commissioning there is of course one new task, the
45-
40-
emission tuning, which in the beginning required special
35-
personnel at site. Now it usually is handled by the regular
> 30- commissioning crew together with a local emission
a. 25- ........................ measurement consultant.
20- ............ The GTI 0 variable dilution air control valves were for some
15- time a weak point, since the air motors used to drive the
10- valves were sensitive to the combination of compressed air
5- quality and hot environment. A one motor link system, similar
0 to the compressor IGV control, has now replaced the original
i
so 55 60 65 70 75
1 80 85
1 90 95 100 individual motor system.
Load (%)
The GT35 part load control system still has potential for
Fig. 7. Emission results from GT1 0 measurements on natural further fine tuning by optimising burner staging and pilot fuel
gas operation.
The dry low NOx systems used on the 0T35 and GTIO have
combustors very similar to the conventional ones. The EV REFERENCES
burners are basically simpler than the conventional fuel
injectors. However, the fuel supply systems have become Hellat et al: Dual Burner
somewhat more complex US Patent No 4781030 Nov.I .1988
- one extra fuel control valve and fuel distribution manifold Jeffs, Eric: Environmentally Effective Gas Turbine
for the pilot fuel (GT35 and GTIO) Turbomachinery International
- two extra fuel valves and fuel distribution manifolds for the Jan/Feb. 1992
burner staging (0T35) Strand, Torsten: Retrofitting a Dry Low Emission
On GTI 0 there is also the motor for by pass valve operation. Combustors to a Twin Shaft Gas
The extra equipment of the control system is restricted to an Turbines
extra "NOx card" in the Master Control system. CIMAC GT-013, 1993