GE Oil & Gas Aeroderivative Gas Turbine: Emission Reduction Techniques DLE1.0 System

GE Oil & Gas
Aeroderivative Gas Turbine

Emission Reduction
Techniques
DLE1.0 system
Imagination at work.
Emission Reduction Techniques
Why?
Low environmental impacts
Local Government restrictions
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Gas Turbine Emissions
Typical concentration
Major species Source
(% volume)
Nitrogen (N2) 66-72 Inlet air
Oxygen (O2) 12-18 Inlet air
Carbon dioxide (CO2) 12-18 Oxidation of fuel carbon
Water vapor (H2O) 12-18 Oxidation of fuel hydrogen
Typical concentration
Minor species pollutants Source
(PPMV)
Nitric oxide (NO) 20-220 Oxidation of atmosphere nitrogen
Nitrogen dioxide (NO2) 2-20 Oxidation of fuel bound organic nitrogen
Carbon monoxide (CO) 5-330 Incomplete oxidation of fuel carbon
Sulfur dioxide (SO2) Trace-100 Oxidation of fuel bound organic solfur
Sulfur trioxide (SO3) Trace-4 Oxidation of fuel bound organic solfur
Unburned hydrocarbons (UHC) 5-300 Incomplete oxidation of fuel or intermediates
Particulate matter smoke Trace-25 Inlet ingestion, fuel ash, hot gas path
attrition, incomplete oxidation of fuel
or intermediates
Gas turbine emissions burning conventional fuels

Characteristics of Conventional Combustion Systems
NOx (ppmvd/ppmvw-methane)
Stoichiometric flame
Fuel 1765°F/963°C-2020°F/1104°C
temperature
Firing temperature
Methanol 0.417-0.617 0.489/0.501
increasing Methane 1.000 1.000/1.000 Increasing

flame NOx
temperature Butane 1.280 1.608/1.661 emissions
values
Propane 1.300 1.555/1.606
No. 2 oil 1.667 1.567/1.647
Hydrogen 2.067 3.966/4.029
Carbon Monoxide 2.067 3.835/3.928
The higher the flame temperature,

the greater the NOx emission is.

Equivalence Ratio
The equivalence ratio is defined as:
Ga /Gf α
λ= = λ < 1 means excess of fuel (rich mixture)
αs αs
where: λ > 1 means excess of air (lean mixture)
• Ga is the air mass flow

• Gf is the fuel mass flow
• 𝛼𝛼 is the actual air-to-fuel ratio, (Ga /Gf )
• 𝛼𝛼s is the stoichiometric air-to-fuel ratio, i.e. represents a mixture where
theoretically all the oxygen in the air reacts with the fuel
Methane (CH4 ): 𝛼𝛼s = 17.23

Equivalence Ratio
Away from the stoichiometric

flame, the formation of NOx
quickly decreases.
(excess of fuel) Stoichiometric (excess of air)

conditions

CO & NOx emissions typical trends
Desired
Desired Operating
CO & NOx Operating Range
Emissions Range 100 25
(λ≈1,7)
NOx 80 20
CO NOx
emissions emissions
(ppmv) 60 15 (ppmv)
NOx
40 CO 10
20 5
CO
1100 1200 1300 1400 1500 1600 1700
Flame Temperature (°C)
1,2 1,3 1,4 1,5 1,6 1,7 1,8 CO and NOx emissions can be both
Equivalence Ratio (λ) minimized, but only in a narrow flame
Rich Lean
temperature range.

Standard vs. DLN combustion systems
Standard Diffusion Combustor: A/F Poorly Mixed
Max Temp. Dry

Flame Temp
NOx
Lean A/F Lean A/F
Rich A/F Rich A/F Rich A/F
Lean A/F Lean A/F

Rich A/F Dry Wet
Wet
A/F Flame Temp
DLE Combustor: A/F Premixed

Flame Temp
NOx
Max Temp.
Mixing Zone – Lean A/F

No Reaction Mixture
A/F Flame Temp

Diffusive flame vs. premixed flame
Diffusion Combustion System Premixed Combustion System
Fuel and air are injected separately in the Fuel and air are mixed before being injected
combustion chambers in the combustion chambers
The flame of a candle is a classic example of The flame of a welding torch is a classic
a diffusive flame. example of a premixed flame.
Candle Blowtorch
Diffusive flame vs. premixed flame
Diffusion Combustion System Premixed Combustion System
ADVANTAGES ADVANTAGES
Stable behaviour within a large range of Possibility to manage the air-to-fuel
equivalence ratio (λ) values equivalence ratio (λ) in the combustors
Simple combustion control system Low NOx emissions
DRAWBACKS DRAWBACKS
Difficulties to limit the flame temperature Combustion stable and efficient only in a
and thus to control NOx emissions narrow range of air-to-fuel ratios
Pressure oscillations in the combustion
chambers may occur
More complex combustion and control
systems are needed

DLE Combustion System Hardware
Overview
LM2500/LM2500+ DLE combustion system

features a lean premixer combustion system
designed to operate with natural gas fuel
Features
Number of chambers 1
Comb. Chamber type annular flow
Total number of fuel injectors 75
Max Firing Temperature > 1200 °C
NOx Emissions ≤ 25 ppmv @15%O2
(75% ÷ 100% load)
Materials
Combustor liner Hastelloy X & Haynes 188
material (cobalt-base superalloy)
protected from high combustion
heat by circumferencial film-cooling

SAC Vs. DLE
Single Annular Combustor Emission Control Technology
Water Injection
25ppmv NOx (gas fuel)
42ppmv NOx (liquid fuel)
Steam Injection
Dry Low Emissions (DLE) Combustor

15ppmv NOx (gas fuel) under development
100ppmv NOx (liquid fuel)
Triple Annular Combustor

Compressor Rear Frame (PGT25/PGT25+ DLE)
The Compressor Rear Frame supports:

B sump, Hub and outer casing
(the latter held in position by 10 struts)
1st stg HPT nozzle
combustion chamber and fuel premixers
Compressor Rear Frame is

made of Inconel 718

Compressor Rear Frame
CRF STRUT POSITIONS
VIEW FROM AFT

LOOKING FORWARD

The triple annular design allows the combustor to

operate in uniformly premixed, lean air-to-fuel ratio
throughout the entire power range, minimizing
emissions even at partial loads.
compressor
discharge
diffuser

Outer ring (A) 30 cups Pilot ring (B) 30 cups Inner ring (C) 15 cups

DLE Fuel Manifold
Gas fuel is introduced into the combustor via 75 air/gas premixers packaged in 30 externally
removable and field replaceable modules.
Half of the modules have two premixers and the other half have three premixers.
A three ring tubular manifold supplies gas fuel to the premixers via flexible fuel hoses.

DLE Fuel Premixers
High outlet speeds

avoid flashback
Fuel
Air
> 90 m/s

DLE Fuel Premixers
Shroud
The premixer produces an

homogeneous lean
Swirler fuel/air mixture
Axial counter-rotating swirlers

enhance fuel/air mixing

ELBO Fuel
The system operation is also

enhanced using a lean blow-out
(ELBO) circuit.
ELBO fuel is diffusively burnt to
stabilize the flame

Heat Shields
After looking forward
Heat shields
forms three
burning rings
Separating
fins

Combustor Domes
The premixers are supported by

proper structure, which is cooled
by compressor discharge air
Forward looking after

DLE-1.0 Combustion System Operation
DLE Combustor Staging
As the need for fuel increases,

more combustor rings are fired,
increasing the firing temperature
while ensuring that proper flame
conditions are locally met.

DLE Combustor Operating Modes
2. B + C/2 Mode
39 premixers
1. B Mode Idle to 5% load
30 premixers
Start to Idle 3. B + C Mode
45 premixers
5 ÷ 25% load
4. A + B Mode 5. A + B + C Mode
60 premixers 75 premixers
25 ÷ 50% load 50 ÷ 100% load

Fuel Staging Valves
DLE-1.0 system installs

11 fuel staging valves
(mounted on the gas
manifold) to properly
control fuel distribution
to the three
combustion domes

DLE Fuel System Configuration
2 shut-off valves
3 fuel metering valves
11 staging valves

Gas Fuel System
Ring B (pilot) has 1 staging

valve that feeds the pilot
fuel of 15 cups (ELBO)
Ring C has 5 staging valves
Ring A has 5 staging valves

Bulk Flame Temperature
Bulk Flame Temperature is the average flame temperature in the domes that are supposed to be burning
(active domes).
It is a calculated parameter (not measured), starting from:
Airflow in the active domes (calculated from HP turbine flow and assumed airflow distribution in the
combustor)
Total fuel flow
TFLAME ≈ T3 * LHV * (Gfuel/Gair)
The bulk flame temperature is expected to be always within the following two limits:
TFLMAX: is the max allowable average flame temperature: operating the gas turbine above this value can
result in excessive NOx emissions and/or extensive damage to the combustor.
TFLMIN: is the min allowable average flame temperature: operating the gas turbine below this value can
lead to flame blowouts.

Bulk Flame Temperature
DLE operation
is not possible
in this range!
The operating power range for

each combustor configuration
is limited within the min and
max bulk flame temperatures

A+B+C
COMBUSTOR EXIT TEMPERATURE
A+B
B+C
Bleeding some compressor

B+C/2 air, it becomes possible to fill
the ‘gaps’ between the DLE
combustor operating modes
B
POWER

DLE Combustor Operating Window
Max Bulk Flame Temperature /

Fuel Flow Limit “staging up”
transition point
Max Bleed
Increasing Tflame
Decreasing Bleed
Zero Bleed
“staging down”
transition point
Min Bulk Flame Temperature /
Fuel Flow Limit As power increases, the Control
System adjusts the bleed valve
position in order to maintain the bulk
flame temperature within the limits

DLE Compressor Bleed
Compressor discharge air

is bled through CRF struts
and one bleed valve

A+B+C
COMBUSTOR EXIT TEMPERATURE
A+B
B+C
B+C/2
POWER

Ring Flame Temperature
Ring (or “Dome”) Flame Temperatures are the temperature of hot gases in the specific domes.
Both A and C ring flame temperatures are calculated (not measured), starting from:
Airflow in the individual dome
Fuel flow delivered to individual dome
T3
Lower heating value (LHV)
The flame temperatures in the A and C rings are independently controlled to avoid high dynamic pressure
(combustor acoustics).
While the bulk flame temperature is controlled to stay within the lower and upper limits, A and C ring flame
temperatures are scheduled as a function of T3 and combustor configuration.

Ring Flame Temperature Distribution: Piston Analogy
B
A B C
A C
Bulk Flame
Temp
Same Bulk Temperature
A & C colder - B hotter Uniform Distribution
Having fixed the bulk flame temperature,

unlimited combinations of ring flame
temperature distributions are available

TFLMAX
TFLMAX: max bulk flame temperature limit

TFLMIN: min bulk flame temperature limit
TFL INNER: C ring flame temperature schedule
TFLMIN
TFL OUTER: A ring flame temperature schedule
TFLMAX
TFLMAX
TFLMIN
TFLMIN
TFL INNER
TFL INNER

TFLMAX
TFLMIN
TFL OUTER
TFL INNER
TFLMAX
TFLMIN
TFL OUTER

Combustor Acoustics (Dynamic Pressure Fluctuation)
Interaction of unsteady heat release with the acoustic of the

system is a self-sustaining mechanism
Heat release
Flow and mixture perturbation Pressure dynamics
If pressure and heat release are in favorable phase relation, a self

amplification of the oscillation occurs

Acoustic Baffles (Elk horns)
Acoustic baffles dump pressure

dynamics inside the combustor
Baffles have different shape and
dimension to attenuate all the
acoustic frequencies

Acoustic and Blowout Avoidance (ABAL) System
Why is Acoustic and Blowout Avoidance (ABAL) system required?

• the margin between a blowout and acoustics condition is often small
• acoustics or blowout boundaries drift with time
• it is not desirable to have to constantly remap engines
ABAL automatically lowers or raises A or C ring temperatures (or bulk flame temperature
when in B mode) when high combustor acoustics or partial blowouts are detected.
ABAL can also reduce the high combustor acoustics or partial blowouts that are common
when transitioning to a new combustor mode.

Two sensors, mounted on the compressor rear

frame, measure the combustor acoustics as a
dynamic pressure level (peak-to-peak psi).

TFLMAX
Adjustment ABAL corrective action for high acoustics or partial blowouts
Acoustic
Sensors
TFLMIN B mode
Adjustment TFLMAX and TFLMIN decreased for high acoustics
ABAL TFLMAX and TFLMIN increased for partial blowouts
System TFL INNER
BC/2 and BC mode
Adjustment
Logic TFL INNER (C ring) reference decreased for high acoustics
TFL INNER (C ring) reference increased for partial blowouts
TFL OUTER
Blowout
Adjustment
Detection AB mode
Logic TFL OUTER (A ring) reference decreased for high acoustics
TFL OUTER (A ring) reference increased for partial blowouts
ABC mode
Partial blowouts are not so easy to detect TFL OUTER, then TFL INNER reference decreased for high acoustics
and certainly can’t be directly measured TFL OUTER, then TFL INNER reference increased for partial blowouts
A model-based blowout detection (BOD)
algorithm is used.

Thank you.
Questions & Answers
46
Introduction & General Overview
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GE Oil & Gas

Aeroderivative Gas Turbine

Low environmental impacts

Local Government restrictions

April 15 GE Proprietary Information | All Rights Reserved Page 2

Gas turbine emissions burning conventional fuels

April 15 GE Proprietary Information | All Rights Reserved Page 4

increasing Methane 1.000 1.000/1.000 Increasing

No. 2 oil 1.667 1.567/1.647

Hydrogen 2.067 3.966/4.029

Carbon Monoxide 2.067 3.835/3.928

The higher the flame temperature,

April 15 GE Proprietary Information | All Rights Reserved Page 5

The equivalence ratio is defined as:

where: λ > 1 means excess of air (lean mixture)

• Ga is the air mass flow

Methane (CH4 ): 𝛼𝛼s = 17.23

April 15 GE Proprietary Information | All Rights Reserved Page 6

Away from the stoichiometric

(excess of fuel) Stoichiometric (excess of air)

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1100 1200 1300 1400 1500 1600 1700

Flame Temperature (°C)

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Standard Diffusion Combustor: A/F Poorly Mixed

Max Temp. Dry

Lean A/F Lean A/F

DLE Combustor: A/F Premixed

Mixing Zone – Lean A/F

A/F Flame Temp

April 15 GE Proprietary Information | All Rights Reserved Page 9

Diffusion Combustion System Premixed Combustion System

Diffusion Combustion System Premixed Combustion System

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LM2500/LM2500+ DLE combustion system

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Single Annular Combustor Emission Control Technology

Dry Low Emissions (DLE) Combustor

Triple Annular Combustor

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The Compressor Rear Frame supports:

Compressor Rear Frame is

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CRF STRUT POSITIONS

VIEW FROM AFT

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The triple annular design allows the combustor to

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April 15 GE Proprietary Information | All Rights Reserved Page 19

High outlet speeds

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The premixer produces an

Axial counter-rotating swirlers

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The system operation is also

April 15 GE Proprietary Information | All Rights Reserved Page 22

April 15 GE Proprietary Information | All Rights Reserved Page 23

The premixers are supported by

Forward looking after

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As the need for fuel increases,

April 15 GE Proprietary Information | All Rights Reserved Page 26