The invention relates generally to a combustion system, and more particularly, to a fuel-flexible combustion system and method of operation.
Various types of combustors are known and are in use in systems such as in combined cycle power plants. Typically, the combustors for such systems are designed to minimize emissions such as NOx and carbon monoxide emissions. In most natural gas fired systems, the combustors are operated using lean premixed flames. In these systems fuel is mixed with air upstream of the reaction zone for creating a premixed flame at lean conditions to reduce emissions from the combustion system. Unfortunately, the window of operability is very small for such combustion systems. Further, it is desirable to avoid combustion dynamics while keeping NOx low and avoiding lean blow out of the flame. Designs are typically targeted for a narrow fuel composition range, thereby making a system designed for natural gas incompatible with a system designed to use gasified coal or synthesis gas fuel.
Certain other systems employ diffusion combustion to minimize emissions through diluent augmentation in the reaction zone. For example, in an integrated coal gasification combined cycle (IGCC) system, steam or nitrogen may be employed as a diluent to facilitate the combustion and reduce the emissions from the combustor. Typically, for an IGCC system, the combustor is designed to operate in a diffusion mode using a coal gasified fuel and may have a backup firing mode using natural gas in a diffusion mode. However, it is challenging to design a combustor that can operate on coal gasified fuels having varying calorific heating values while maintaining low emissions. The current IGCC combustors employ diffusion combustion and are designed on a site-by-site basis according to the gasified fuel stock. This results in specific combustion systems that have limited fuel flexibility in order to meet emission requirements.
Accordingly, there is a need for a combustion system that will work on a variety of fuels while maintaining reduced emissions. It would also be advantageous to provide a combustion system that has sustained low emission firing with a backup fuel and is adaptable to different power plant configurations while maintaining the overall power plant efficiency.
Briefly, according to one embodiment a combustion nozzle is provided. The combustor nozzle includes a first fuel system configured to introduce a hydrocarbon fuel into a combustion chamber to enable lean premixed combustion within the combustion chamber and a second fuel system configured to introduce a syngas fuel, a hydrocarbon fuel and diluents into the combustion chamber to enable diffusion combustion within the combustion chamber.
In another embodiment, a fuel-flexible combustion system is provided. The combustion system includes a combustor nozzle configured to introduce a fuel stream within the combustion system and a combustion chamber configured to combust the fuel stream and air through a combustion mode selected based upon a fuel type of the fuel stream. The combustor nozzle includes a first fuel system configured to introduce a hydrocarbon fuel into the combustion chamber to enable a first combustion mode within the combustion chamber and a second fuel system configured to introduce a syngas fuel, nitrogen, CO2, steam and hydrocarbon fuel into the combustion chamber to enable a second combustion mode within the combustion chamber.
In another embodiment, an integrated coal gasification combined cycle (IGCC) system is provided. The system includes a gasifier configured to produce a syngas fuel from coal and a gas turbine configured to receive the syngas fuel from the gasifier and to combust the syngas fuel and air within a combustion system to produce electrical energy. The combustion system includes a combustion nozzle having first, second and third co-annular passages for introducing the syngas fuel, hydrocarbon fuel and diluents within the combustion system and a combustion chamber configured to combust the fuel, diluent, and air through diffusion combustion.
In another embodiment, a method of operating a fuel-flexible combustion system is provided. The method includes introducing a fuel stream within the combustion system via a combustor nozzle and combusting a back-up fuel stream in a low emission combustion mode and combusting syngas in a second combustion mode. The method also includes switching the second combustor mode based on the calorific heating value of the syngas and combusting the fuel stream and air through the low emission combustion mode, or the second combustion mode, or combinations thereof.
These and other features, aspects, and advantages of the present invention will become better understood when the following detailed description is read with reference to the accompanying drawings in which like characters represent like parts throughout the drawings, wherein:
As discussed in detail below, embodiments of the present technique function to provide a fuel-flexible combustion system that will work with a variety of fuels while having reduced emissions. In particular, the present technique employs a combustor nozzle that operates with, for example, natural gas and a wide range of syngas fuels by switching between lean premixed and diffusion combustion modes based upon a desired or required volumetric flow rate of the fuel feedstock. Turning now to the drawings and referring first to
In operation, the gasifier 12 receives a fuel feedstock 20 along with oxygen 22 that is typically produced in an on-site air separation unit (not shown). In the illustrated embodiment, the fuel feedstock 20 includes coal. In other embodiments, the fuel feedstock 20 can include any Low Value Fuel (LVT) for example, coal, biomass, waste, oil sands, municipal waste, coke and the like. The fuel feedstock 20 and oxygen 22 are reacted in the gasifier 12 to produce synthesis gas (syngas) 24 that is enriched with carbon monoxide (CO) and hydrogen (H2). Further, feedstock minerals are converted into a slag product 26 that may be utilized in roadbeds, landfill cover and other applications.
The syngas 24 generated by the gasifier 12 is directed to a gas cooling and cleaning unit 28 where the syngas 24 is cooled and contaminants 30 are removed to generate purified syngas 32. In the illustrated embodiment, the contaminants 30 include, for example, sulfur, mercury, or carbon dioxide. Further, the purified syngas 32 is combusted in the gas turbine 14 to produce electrical energy. In this exemplary embodiment, an incoming flow of air 34 is compressed via a compressor 36 and the compressed air is directed to the combustion system 16 for combusting the syngas 32 from the gasifier 12. Further, the combustor gas stream from the combustion system 16 is expanded through a turbine 38 to drive a generator 40 for generating electrical energy 42 that may be directed to a power grid 44 for further use. In certain embodiments, the fuel-flexible combustion system 16 utilizes natural gas 46 for a lean premixed combustion, typically as a backup mode of operation.
In the illustrated embodiment, exhaust gases 48 from the gas turbine 14 are directed to a heat recovery steam generator 50 and are utilized to boil water to create steam 52 for the steam turbine 18. Further, in certain embodiments, heat 54 from the steam turbine may be coupled to the heat recovery steam generator 50 for enhancing efficiency of the heat recovery steam generator 50. In addition, a portion of steam 56 from the heat recovery steam generator 50 may be introduced into the gasifier 12 to control the H2:CO ratio of the generated syngas 24 from the gasifier 12. The steam turbine 18 drives a generator 58 for generating electrical energy 42 that is again directed to the power grid 44 for further use.
The fuel-flexible combustion system 16 employed in the IGCC system 10 described above may be operated in a lean premixed or a diffusion combustion mode. In particular, the combustion system 16 includes a combustor nozzle having individual fuel systems for introducing, for example, natural gas or syngas fuel within the combustion system 16 and the combustion mode is selected based upon the fuel type and a fuel calorific heating value of the fuel feedstock 20. The combustor nozzle employed in the combustion system 16 will be described in detail below with reference to
In this exemplary embodiment, the combustion system 64 includes a combustor nozzle 72 that is configured to introduce a fuel stream within the combustion system 64. In particular, the combustor nozzle 72 includes a first fuel system 74 configured to introduce a hydrocarbon fuel into the combustion system 64 and a second fuel system 76 configured to introduce a syngas fuel, or a hydrocarbon fuel and diluents into the combustion system 64. Further, the combustion system 64 includes a combustion chamber 78 for combusting the fuel stream from the first or second fuel systems 74 and 76 through a combustion mode selected based upon a fuel type of the fuel stream. In certain embodiments, the combustion system 64 may be co-fired through simultaneous operation of the first and second fuel systems 74 and 76.
In one embodiment, the combustion system 64 is operated in a lean premixed combustion mode or a low emission combustion mode by employing a hydrocarbon fuel received from the first fuel system 74. Alternatively, the combustion system 64 is operated in a diffusion mode by employing the syngas fuel received from the second fuel system 76. The operation of the first and second fuel systems 74 and 76 employed in the combustion system 64 will be described in detail below with
The combustor nozzle 90 also includes a controller (not shown) coupled to the first and second fuel systems 74 and 76 for selecting a combustion mode based upon a fuel type, or a fuel calorific heating value of the fuel stream. Further, the controller is configured to control the flow through the injection orifices 96, 98 and 100 of the second fuel system 76 based upon a required volumetric flow of the syngas fuel. The control of the fuel flows through the inner, outer and middle passages through injection orifices 96, 98 and 100 will be described in detail with reference to
Further, as described earlier the combustor nozzle 110 includes the second fuel system 76 having the inner, middle and outer co-annular passages with injection orifices 96, 98 and 100 for introducing the syngas fuel, hydrocarbon fuel and diluents within the nozzle 110. The control of flow of the syngas fuel, hydrocarbon fuel and diluents within the nozzle 110 will be described in detail below.
The first, second and third passages 132, 134 and 136 are designed so that the combustor nozzle 130 may be employed with either oxygen-enhanced or with traditional gasification units. As will be appreciated by one skilled in the art in the traditional gasification units, steam from the gasification units may be utilized as a diluent to facilitate combustion. However, in the oxygen enhanced gasification units nitrogen from an air separation unit may be employed as an additional diluent for enhancing the overall plant efficiency.
In a present embodiment, the first, second and third passages 132, 134 and 136 are designed based upon a desired range of calorific heating values of the fuel produced from the coal gasification units. In this embodiment, the fuel calorific value of the syngas fuel is less than about 310 BTU/scf. In one embodiment, the fuel calorific value of the syngas fuel is about between 130 BTU/scf to about 230 BTU/scf. For example, the passage for flowing syngas fuel may be designed to account for introducing low heating value fuel that requires a large volumetric flow rate. Similarly, the passage for flowing diluents may be designed according to higher heating value fuel that require relatively greater diluent flow to meet desired performance levels.
In an exemplary embodiment, the first, second and third passages 132, 134 and 136 have a tangential injection angle of about 0 degrees to about 75 degrees and a radial injection angle of about 0 degrees to about 75 degrees. In one embodiment, the second and third passages 134 and 136 have a tangential injection angle of about 40 degrees and the first and second passages 132 and 134 have a radial injection angle of about 45 degrees. Further, in one embodiment, the flow of syngas fuel and nitrogen in the second and third passages 134 and 136 is counter swirled with respect to the air swirl generated by the vanes 92 to facilitate enhanced mixing, decreased flame length, reduced emissions and increased flame front pattern factors. Moreover, as described above, a controller may be coupled to the first, second and third passages 132, 134, 136 to control the flow of syngas fuel, hydrocarbon fuel, steam and nitrogen and CO2 within the passages 132, 134 and 136 based upon the fuel calorific heating value of the syngas fuel as described below.
In an exemplary embodiment, while operating with a low heating value fuel, the nozzle feed system may be reconfigured to flow syngas through the second and third passages 134 and 136 to account for the increased volumetric flow requirement, while providing substantial diluent capability through the first passage 132. Furthermore, once the heating value of the fuel decreases to a value where diluent augmentation is not required and the volumetric flow of the fuel becomes substantially large to efficiently flow through a single passage then the fuel may be simultaneously flowed through the first, second and third passages 132, 134 and 136 thereby maintaining the performance of the system.
In an alternate embodiment, while operating with higher heating value syngas fuels, the desired volumetric flow rate of the fuel is substantially small and the diluents requirements increase to reduce emissions. In this particular condition, the nozzle may be reconfigured to flow steam through the passage 136 to account for the required diluent augmentation. Further, a substantially small amount of nitrogen may be added to the syngas fuel through the second passage 134. In addition, the remaining nitrogen from the air separation unit may be flowed through the first passage 132. As will be appreciated by one skilled in the art for air gasification units the diluents requirements may be met by flowing steam through the second and third passages 134 and 136 thereby decreasing flow and efficiency losses. Thus, the combustion nozzle design enables a wide range of flexibility in operating and fueling through the control mechanism described above.
For example, in a system with ASU, for a cofiring mode with a fuel LHV of about less than 90 BTU, the nozzle may be configured to flow natural gas and syngas through the inner passage and to flow syngas through the middle and outer passages, as represented by Mode 1. Alternatively, for a fuel LHV of about 176 BTU to about 285 BTU, the nozzle may be configured to flow steam through the inner passage, syngas through the middle passage and nitrogen or steam through the outer passage, as represented by Mode 5. Similarly, for a fuel LHV of about greater than 330 BTU, the nozzle may be configured to flow nitrogen through the inner passage, steam through the middle passage and syngas or nitrogen through the outer passage, as represented by Mode 8. Thus, a plurality of modes may be envisaged based upon the fuel LHV of the fuel stream thereby resulting in a fuel-flexible combustion system that works with a variety of fuels. Additionally, the combustion system described above has sustained low emission firing with a backup fuel.
The various aspects of the method described hereinabove have utility in different applications such as combustion systems employed in IGCC systems. As noted above, the fuel-flexible combustion system works with a variety of fuels while having reduced emissions. Further, the combustion system has sustained low emission firing with a backup fuel and is adaptable to different power plant configurations while maintaining the overall power plant efficiency. In particular, the present technique employs a combustor nozzle that operates with natural gas and a wide range of syngas fuels by switching between lean premixed and diffusion combustion modes based upon a desired volumetric flow rate of the fuel feedstock. Thus, the combustion system has significantly enhanced fuel flexibility while maintaining reduced emissions and may be operated with different power plant configurations while maintaining the overall power plant efficiency.
While only certain features of the invention have been illustrated and described herein, many modifications and changes will occur to those skilled in the art. It is, therefore, to be understood that the appended claims are intended to cover all such modifications and changes as fall within the true spirit of the invention.
This invention was made with Government support under contract number DE-FC26-03NT41776 awarded by the U.S. Department of Energy. The Government has certain rights in the invention.