3 2 GE Emissions-Tech-Juan-Nogales PDF

Genera 2015
Technical Solutions for Emissions Reduction
Juan Nogales
GE Power & Water
Madrid, February 24, 2015
© 2015 General Electric Company. All rights reserved.
This material may not be copied or distributed in whole or in part without prior permission of the copyright owner.
LM1600®, LM2500®, LM6000®, LMS100® and LM5000® are registered trademarks of the General Electric Company (USA)
Combustion Principles
Flame Types
DIFFUSION FLAME PREMIXED FLAME
(Yellow & Sooty) (Blue)
Fuel and air (reactants) are not mixed, fuel and air are Fuel and air (reactants) are uniformly mixed
injected separately into the combustion environment. to a molecular scale upstream of the flame.
Air and fuel diffuse together at the boundaries. Flame occurs downstream of premixing.
Application Application
Examples Examples
 candle flame  spark ignition
 torch engine
 diesel engine  oxy-acetylene
 all types of welding torch
furnaces  Dry Low NOx
 standard combustor
combustors
© 2015 General Electric Company. All rights reserved. Subject to the restrictions on cover page
Diffusion vs. Premixed Flame
DIFFUSION PREMIXED
 Very Robust and Stable Flame  Very Narrow Operating Window
 Typically Operable Over a 1100°C (2000°F)  Typically Operable Over a 110-165°C
Temp. Rise Range (200-300°F) Temp. Rise Range
 High NOx Emissions Without Diluent  Can Achieve Very Low NOx Emissions
 Low CO Emissions Without Diluent
 Low CO Emissions Can Be Difficult
Flame
Temperature
Diffusion Flame
Temp. Range Diffusion
Premixed Flame Lean

Premixed
Temp. Range
Lean Blow ø=1 Rich Blow
Out Out
Lean Fuel/Air ratio (f) Rich
Combustion Chambers
Primary Purpose To Ensure Flame Stability Througout All Operating
Phases
ANNULAR CHAMBER
Axial development
Direct Flow
Low Aerodynamic
resistance
Jet Derivative
CAN SYSTEM CHAMBER
Radial developement
Reverse Flow
Easier Maintenance
Heavy Duty
Can System Design
Main Components Casing
Liner
Cover
Cross Fire Tubes
Spark Plug
Fuel Nozzle
Aeroderivative combustors
Single-Annular Combustor (SAC) Dry-Low-Emissions (DLE) Combusto
NOx Reduction: premixing
Premixed combustors operate with lean mixture reducing the flame temperature down to the
lower flammability limit (Lean Blow Out).
Standard Diffusion
Combustor
NOx
Standard
Temperature
Diffusion Combustor
NOx
Flame
Premixer example
Lean DLN Comb •Fuel is injected into airstream
Premixed
ø =1 •Turning vanes swirl air to
Lean Blow Rich Blow
Out Out Lean Premixed increase turbulence.
Lean Fuel/Air ratio (f) Rich Flame Temperature
DLN1 Combustor
Combustor Evolution: DLN
Diffusion
NOx
Standard Comb
Diffusion
Flame
Temperature NOx
CO
Lean DLN Comb
Premixed
Lean Blow
ø =1 Rich Blow
Out Out Lean Premixed CO
Lean Rich Flame Temperature
Fuel/Air
Standard Combustor
Regions of Rich and Lean
L Reactions
R L
R
R
L
Turbine Inlet
Fuel Dry Low NOx

Fuel/Air Homogeneous
Premixer Lean Premixed Combustor
Air Lean Premixed
Flame
Comparison of Diffusion & DLN
Fuel/Air
Premixers
Tflame
Lean Premixed
Flame
Dilution Air
Temperature
Homogeneous F/A
Diffusion Flame Low Tflame
High Tflame Low NOx
Tflame Seal leakage
High NOx Seal leakage
Tfire CO Burnout Tfire
Tcd Tcd
Premixer Example
Fuel injected into airstream
Turning vanes swirl air Fuel and air mix before

Entering flame zone
Technological Summary
Standard combustors (Diffusion) DLE/DLN Combustors (Premix)
-water/steam: NOx ~50 -1.0/1.5/2.X: Nox  50-10 mg/Nm3

mg/Nm3 CO  30 mg/Nm3
CO  ~ 30
mg/Nm3 -DLE Commercial op.: 1995 /
operating hours: ~15 MM
+5% heat rate increase vs dry,
lower exhaust temp. -DLN Commercial op.: 1991 /
operating hours: ~150 MM
-Combustor/HS wear/thermal stress
-Water source ~0.25 tons/hr/MWe
DLE upgrades examples
LM2500 SAC (diffusion): 2011
NOx: 383 mg/Nm3 - GT hardware upgrade
CO: 7 mg/Nm3 - Fuel System upgrade
- Control systems upgrade
- Engineering package
- Installation
LM2500 DLE (Premix):
NOx: 50 mg/Nm3 - 12 months lead time (Order to
CO: 30 mg/Nm3 Delivery)
- Outage time: 28 days, 7 days start
up
DLN upgrades examples
2011
Frame 6B (diffusion): - GT hardware upgrade
NOx: 400 mg/Nm3 - Fuel System upgrade
CO: 7 mg/Nm3 - Control systems upgrade
- Engineering package
- Installation
Frame 6B DLN (Premix):
NOx: 50 mg/Nm3 - 12 months lead time (Order to
CO: 30 mg/Nm3 Delivery)
- Outage time: 49 days
Genera 2015
Technical Back up slides
Juan Nogales
GE Power & Water
DLN Fuel Staging
DLN Operational Modes:
Primary Mode Transfer Mode
Diffusion Flame Diffusion Flame
100% Primary Fuel 100% Secondary Fuel
Ignition - 19% Load 50% Load
Diffusion
Diff /Premix
Lean-Lean Mode Premixed Mode

Diffusion Flame Premixed Flame / Diffusion Pilot
~60% Primary / 40% Secondary Fuel 81% Primary / 19% Secondary Fuel
19% - 50% Load 50% - 100% Load
F/A
Diffusion
Mixing
Diffusion/Premix
Premix
Primary Zone Dual Purpose: 1. Low Load Diffusion Flame 2. High Load Premixing Chamber
Typical DLE Burner Modes
Starting configuration Idle - 5% load 5 - 25% load
B reaction zone (30 cups) BC/2 reaction zone (39) BC reaction zone (45)
25 - 35% load 35 - 50% load 50% to full load

BC + 2A reaction zone AB reaction zone (60) ABC reaction zone (75)
(57 – LM6000 only)
Flame Types
PREMIXED FLAME DIFFUSION FLAME
(Blue) (Yellow & Sooty)
Fuel and air (reactants) are uniformly mixed Fuel and air (reactants) are not mixed, fuel and air are
to a molecular scale upstream of the flame. injected separately into the combustion environment.
Flame occurs downstream of premixing. Air and fuel diffuse together at the boundaries.
Application
Application
Examples
Examples
 spark ignition
 candle flame
engine
 torch
 oxy-acetylene
 diesel engine
welding torch
 all types of
 Dry Low NOx
furnaces
combustor
 standard
combustors
Diffusion vs. Premixed Flame
DIFFUSION PREMIXED
 Very Robust and Stable Flame  Very Narrow Operating Window
 Typically Operable Over a 1100°C (2000°F)  Typically Operable Over a 110-165°C
Temp. Rise Range (200-300°F) Temp. Rise Range
 High NOx Emissions Without Diluent  Can Achieve Very Low NOx Emissions
 Low CO Emissions Without Diluent
 Low CO Emissions Can Be Difficult
Flame
Temperature
Diffusion Flame
Temp. Range Diffusion
Premixed Flame Lean

Premixed
Temp. Range
Lean Blow ø=1 Rich Blow
Out Out
Lean Fuel/Air ratio (f) Rich
Pollutants: Nitrogen Oxides
Nitrogen oxides are to be limited by laws because their polluting effects include: lungs
affecting and lower resistance to respiratory infections, greenhouse effect, photochemical
smog, acid rains, depletion of stratospheric ozone.
Nitrogen oxides (NOx) usually refers to NO and NO2. Since NO in contact with O2 is quickly
converted into NO2, NOx measurements mainly consider NO2 only.
NOX Gas Characteristics
NO: odorless and colorless gas.

NO2: red-brown gas with strong odor,
highly toxic and corrosive.
NOx production is caused by 3 main

mechanism:
1. Thermal NO
2. Prompt NO
3. Fuel bound NO
Pollutants: Nitrogen Oxides
The major part of NO produced during combustion processes belongs to the Thermal NO,
produced by the Zeldovich mechanism.
Thermal NO increases exponentially with the flame

temperature and proportionally to the residence time.
Temperature, K
Temperature, K
Solutions to reduce NOx content include:
1. premixed burner/combustor to assure lean

combustion -> lower temperature;
2. steam/water/air injection to cool down combustion
primary zone -> lower temperature;
3. short combustor -> lower residence time.
NOx production rate
f=1
Equivalence ratio
Pollutants: Carbon Monoxides
Carbon monoxide (CO) gas is a by-product of combustion systems; cars and trucks are the
source of nearly two-thirds of this pollutant.
When inhaled, CO blocks the transport of oxygen to the brain, heart, and other vital organs in
the human body. Symptoms of mild poisoning include headaches and dizziness at
concentrations less than 100 ppm. In the United States, OSHA limits long-term workplace
exposure levels to 50 ppm.
CO Gasses Characteristics
CO : odorless and colorless gas.

CO production is caused by 3 main mechanism:
1. Inadequate burning rates due to too low

f/a ratio and/or insufficient residence time.
2. Inadequate mixing of fuel and air, which
produce local rich regions that generate
high local concentrations of CO.
3. Quenching of post flame products by
entrainment with liner cooling air.
Pollutants: Carbon Monoxides
CO main zones of production are located:
•at high f (rich mixture) where lack of oxygen leads to incomplete reaction from CO to CO2.
•at very low f (very lean mixture) combustion processes reaction rate is limited by low
temperature and consequent no development from CO to CO2.
•at stoichiometric condition the high temperature activates the equilibrium CO reactions.
T,degrees K
3000 1.00E+00
Relative NOx
Production Rate
Relative CO
Production Rate
Solution to reduce CO include:
2500 1.00E-01
2000 1.00E-02
1. reducing of cold spots in the
combustion chamber (film
Temperature, K
1500 1.00E-03
cooling, water injection).
CO NOx
2. use of mixing devices to
1000 1.00E-04
reduce rich regions.

500 1.00E-05
3. operation at adequate
0 1.00E-06
burning rates.
0.20 0.40 0.60 0.80 1.00 1.20 1.40 1.60 1.80 2.00
Equivalence Ratio
Pollutants: UHC and VOC
Un-burned HydroCarbons (UHCs) and Volatile Organic Compounds (VOCs) result from incomplete
combustion, then some fuel and fuel derived compounds are present into combustion products. UHCs are
toxic and react with NO to generate ozone (O3) which, at ground level, is a pollutant element, causing eyes
and respiratory issues and large ageing problems to plants.
VOCs effect on environment is highly dependent on the type of compound, the most known and dangerous
is benzene, which is carcinogenic.
Typical emission trend for UHCs production is normally associated

conventional gas turbine
with:
combustor
1. poor atomization of fuel
2. inadequate burning rate
3. chilling effects of film cooling.
Then UHC production trend is

similar
to that of CO.
Note: power is proportional to flame temperature
Pollutants: Sulfure Dioxide
Sulfur dioxide (SO2) is caused mainly by the combustion of fuel containing sulfur
compounds, like diesel, sour gas, etc.
SO2 acts as an acid. Inhalation results in laboured breathing, coughing, and/or a sore throat
and may cause permanent pulmonary damage. When mixed with water and contacted by skin,
frostbite may occur. When it makes contact with eyes, redness and pain will occur. SO2 is also
responsible for acid rains.
Combustion reactions Solutions to reduce SO2

S8 + 8 O2 → 8 SO2 emission include:
2 H2S(g) + 3 O2(g) → 2 H2O(g) + 2 SO2(g) •fuel desulfurization
•flue gas desulfurization
Typical desulfurization reaction
SO2 + 2 NaOH → Na2SO3 + H2O
Pollutants: Smoke and Particulate
Smoke is a general term that refers to the black, impure carbon particles resulting from the
incomplete combustion of a hydrocarbon fuels.
Smoke is a product of incomplete combustion processes, it is primarily produced in region of
high fuel concentration (f > 1) and high temperature which promotes pyrolysis and growth
processes.
Most of the smoke produced in the flame zone is destroyed in downstream zones with high
oxygen unless some rich regions remain unmixed or are cooled prematurely.
Liquid fuels
If liquid fuel is not pre-
vaporized, sprays tend to
produce local zone of rich
combustion, and consequent
high production of smoke and
Droplet
size
particulate.
Solutions include sprays with
smaller droplet size in order to
enhance vaporization and
Equivalence ratio (f)
mixing.
Pollutants: summary
Modern combustors show many characteristics in order to reduce pollutant emissions and
match nowadays restrictions.
•air injection
NOx •steam/water injection

•premixed burner
•combustor design
CO •catalytic reduction
UHC & VOC •combustor design
SOx •control fuel sulfur content
•combustor design
Smoke •fuel composition
&Particulate •liquid fuel atomization
Pollutants: summary
NOx and CO production trends versus equivalent ratio sets the operative window between
0.40 and 0.50-0.60. A control of the effective flame fuel/air ratio can be obtained by use of
premixed flame, where air/fuel proportion are set upstream combustion zone.
Object of premixing is to maximize the

amount of fuel burned at lean
equivalence ratios where NOx is low, but
flame is not cold enough to “freeze” the
CO to CO2 reaction

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Genera 2015

Technical Solutions for Emissions Reduction

 candle flame  spark ignition

 diesel engine  oxy-acetylene

 all types of welding torch

furnaces  Dry Low NOx

Premixed Flame Lean

Lean Fuel/Air ratio (f) Rich

Cross Fire Tubes

Lean Fuel/Air ratio (f) Rich Flame Temperature

Fuel Dry Low NOx

Tfire CO Burnout Tfire

Fuel injected into airstream

Turning vanes swirl air Fuel and air mix before

-water/steam: NOx ~50 -1.0/1.5/2.X: Nox  50-10 mg/Nm3

-Water source ~0.25 tons/hr/MWe

Lean-Lean Mode Premixed Mode

25 - 35% load 35 - 50% load 50% to full load

Premixed Flame Lean

Lean Fuel/Air ratio (f) Rich

NOX Gas Characteristics

NO: odorless and colorless gas.

NOx production is caused by 3 main

Thermal NO increases exponentially with the flame

Solutions to reduce NOx content include:

1. premixed burner/combustor to assure lean

CO : odorless and colorless gas.

1. Inadequate burning rates due to too low

reduce rich regions.

Typical emission trend for UHCs production is normally associated

Then UHC production trend is

Combustion reactions Solutions to reduce SO2

NOx •steam/water injection

UHC & VOC •combustor design

SOx •control fuel sulfur content

Object of premixing is to maximize the

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