The invention relates generally to gas turbine combustors, and more specifically to an electrical discharge device used to improve lean blow-out limits and reduce combustion instabilities of a gas turbine combustor.
Fully premixed lean-combustion is a key enabler of low nitric-oxide (NOx) emissions at high firing rates. This is also referred to as dry-low-NOx (DLN) combustion, as it achieves low NOx emissions without the addition of steam or water to keep peak combustion temperatures down. One of the issues that arises in lean premixed combustion is the occurrence of thermo-acoustic instabilities or combustion dynamics, which if left unchecked, can cause large enough pressure fluctuations to damage gas turbine hardware. Plasma-assisted combustion is one technology that has been identified as a potential technology to affect or control the combustion process (the effective reaction rates and/or flame stabilization) so as to be able to counteract the acoustic/thermal feedback loop which drives combustion dynamics.
Another challenge associated with gas turbines is turn-down. During the daily off-peak hours of operation, gas turbine operators (power generation companies) turn down the power output of their machines due to the lower electricity demand. A complete shut-down of the machine on a daily basis is undesirable as it causes early cycle fatigue of the gas turbine components. Further, there is a cost associated with the shut-down and start-up processes. These costs are traded for the operating costs of running the gas turbine during times of low demand (and therefore low-value electricity generation).
Generally, DLN systems are unable to turn down below ˜40-50% of base load while in fully premixed mode. Methods to turn down below this level (e.g. decreasing the fuel-to-air ratio, staging the fuel to only a portion of the nozzles, or turning on a diffusion pilot flame) incur undesirable side effects (e.g. flame instabilities at lean flammability limits, high carbon monoxide (CO) emissions due to incomplete combustion, and high NOx due to high diffusion flame temperatures).
Yet another challenge associated with gas turbines is combustion ignition, both in land-based gas turbines and for aircraft engines at high altitudes.
Challenges associated with applying plasma-assisted combustion technology in gas turbines include without limitation difficulties associated with generating electrical discharges at elevated gas densities and isolating high voltage electrodes inside a combustion chamber.
Known techniques for addressing some of the foregoing challenges have included 1) gas turbine turndown achieved by fuel staging among several nozzles within a combustor can, undesirably producing high CO emissions, 2) staged combustion, and 3) transition to partially premixed or non-premixed combustion, also undesirably producing high NOx emissions.
In view of the foregoing, it would be both advantageous and beneficial to provide a system and method of improving lean blow-out limits of a gas turbine combustor. It would be further advantageous if the system and method could be easily configured for use as an ignition source and as a means to reduce combustion instabilities.
Briefly, in accordance with one embodiment, a plasma enhanced pilot comprises a swirler mechanism disposed substantially within the pilot and configured to receive pilot fuel and pilot air and swirl the pilot fuel and pilot air substantially within the swirler to provide a premixed, pre-swirled fuel/air mixture, the pilot being disposed substantially within the centerbody of a premixed fuel/air nozzle portion of a gas turbine combustor.
In some embodiments, the swirler mechanism is disposed solely within the pilot. In other embodiments, the swirler mechanism is configured to receive pilot fuel and pilot air and swirl the pilot fuel and pilot air solely within the swirler mechanism. In yet other embodiments, the pilot is disposed solely within the centerbody of a premixed fuel/air nozzle portion of a gas turbine combustor.
According to another embodiment, a plasma enhanced pilot comprises a swirler mechanism, the pilot configured to be inserted into an existing blank (purge air) or liquid fuel (dual fuel) cartridge space within the centerbody of a lean, premixed land-based gas turbine combustor fuel nozzle.
According to yet another embodiment, a method of generating a gas turbine combustor pilot flame comprises:
providing a swirler mechanism disposed substantially within a pilot disposed solely within the centerbody of a premixed fuel/air nozzle portion of a gas turbine combustor;
premixing and pre-swirling a fuel/air mixture substantially within the swirler mechanism; and
igniting the premixed, pre-swirled fuel/air mixture exiting the pilot to form plasma enhanced pilot flame gases substantially within a pilot flame region within a main combustion zone within the gas turbine combustor.
According to still another embodiment, a plasma enhanced pilot is disposed within an existing blank (purge air) or liquid fuel (dual fuel) cartridge space within the centerbody of a lean, premixed land-based gas turbine combustor fuel nozzle, the plasma enhanced pilot comprising a high voltage electrode disposed at least partially within a dielectric barrier, wherein the dielectric barrier is configured to prevent high current flow during electrical discharge of the high voltage electrode to provide a cold or non-equilibrium plasma having NOx emissions below that generated by hot or thermalized (equilibrium) plasmas.
According to still another embodiment, a plasma enhanced pilot is disposed solely within an existing blank (purge air) or liquid fuel (dual fuel) cartridge space within the centerbody of a lean, premixed land-based gas turbine combustor fuel nozzle, the pilot being configured to generate a cold or non-equilibrium plasma within the pilot having NOx emissions below that generated by hot or thermalized (equilibrium) plasmas.
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:
While the above-identified drawing figures set forth alternative embodiments, other embodiments of the present invention are also contemplated, as noted in the discussion. In all cases, this disclosure presents illustrated embodiments of the present invention by way of representation and not limitation. Numerous other modifications and embodiments can be devised by those skilled in the art which fall within the scope and spirit of the principles of this invention.
The embodiments described herein below with reference to the Figures are directed to a pilot that includes a mechanism to swirl air and fuel or a fuel/air mixture to provide a premixed, pre-swirled plasma-assisted (enhanced) pilot flame suitable for use with a gas turbine combustor. According to one embodiment, the pilot is located in the centerbody of a premixed fuel/air nozzle of a gas turbine combustor and operates to improve lean blow-out limits (LBO) of the combustor. The pilot can also function, without limitation, as an ignition source and/or as a means to reduce combustion instabilities.
Looking now at
The swirling, reacting, radical-enhanced fuel/air mixture exits the pilot 10 and enters into the main combustion zone (described herein below with reference to
In lean turn-down conditions, the pilot 10 can act to improve the lean blow-out limits of the combustor by stabilizing a lean main fuel/air mixture that is otherwise unstable or beyond the lean blow-out limits. Further, in situations where thermo-acoustic instabilities are driving combustion dynamics, the pilot 10 can again act as a stabilizing mechanism for the main flame; or it can be modulated to counteract the specific dynamic combustion tones.
The pilot embodiments described herein can operate to provide plasma-assisted, premixed piloted combustion to enhance the combustion process at low turn-down conditions while avoiding the undesirable effects discussed above. Chemical activation of a portion of the fuel, air, or fuel/air mixture may enhance the overall reaction processes of the combustor, by generating reactive species and high temperatures that stabilize the main premixed fuel-air flow. Thus, the lean flammability limits of the whole combustor are extended to lower fuel-to-air ratios. The present inventors recognized that turbulent mixing of the reacting pilot gases with the main premixed fuel/air flow should enhance the reactivity of the whole combustor, enabling faster burnout rates of the CO, and that a lean or rich premixed pilot avoids the peak flame temperatures, and therefore the NOx generation which occurs in a diffusion flame pilot.
Particular pilot embodiments described herein can also act, for example, as an integral igniter in each fuel nozzle for a can combustor system to eliminate cross-fire tubes, if so desired. Further, particular embodiments described herein may also enlarge the overall ignition envelope for both can and annular combustors. Particular embodiments of the pilot described herein also allow integration and use of plasma technology in a gas turbine fuel nozzle, thus overcoming challenges associated with incorporating isolated high voltage electrodes into a combustion chamber.
Moving now to
Pilot air enters through a pilot air entry port 12 and therefrom flows into the pilot swirler mechanism 20. Pilot fuel enters through one or more pilot fuel entry ports 32 and therefrom also flows into the pilot swirler mechanism 20 via a swirler fuel entry port 42 that is positioned substantially downstream from the pilot fuel entry port 32. Although separate flowpaths are not depicted for the main and pilot fuel, these two fuel circuits can optionally be separate and independently controlled. The fuel and air are together swirled within swirler mechanism 20 to provide a premixed, pre-swirled fuel/air combination that exits the pilot 10 and is passed into the combustion zone 44 where it is ignited along with the main premixed fuel to generate a premixed, plasma-enhanced pilot flame 46 within the main premixed flame.
According to one embodiment, the main premixed fuel is mixed solely with its own main supply air, while the premixed, pre-swirled pilot fuel is mixed solely with its own pilot supply air to more accurately control and achieve a desired premixed, plasma-enhanced pilot flame within the combustion zone 44. The premixed fuel/air mixture in the pilot can be comprised such that it is a fuel-lean mixture (one which includes excess air), a fuel-rich mixture (one which has insufficient air for combustion), or a stoichiometric mixture (a mixture having the exact required ratio of fuel and air for complete combustion). Further, the ratio of the flow rate of premixed, pre-swirled, plasma-enhanced pilot fuel/air mixture and the flow rate of additional non-premixed purge air in the centerbody of the fuel nozzle can be adjusted in various ways to optimize the performance of the plasma-enhanced pilot flame in igniting and stabilizing the combustion of the main premixed fuel/air mixture in the combustor. Alternative embodiments can be configured such that 1) the pilot air and fuel are fully premixed upstream of the fuel nozzle, 2) the pilot fuel enters the pilot air upstream of the swirler, 3) the pilot fuel enters the pilot air as part of the swirler, 4) the pilot fuel enters the pilot air downstream of the swirler.)
Advantages provided by the DLN gas turbine nozzle 30 comprising a premixed, pre-swirled, plasma-assisted pilot 10 include without limitation:
provision of a premixed fuel and air in the pilot flame that avoids the NOx created by high temperatures found in diffusion pilot flames;
a small annular discharge gap distance (electrical discharge passage height ˜1.5-3 mm, enumerated 22 in
provision of an annular discharge passage that naturally fits into a swirl-stabilized fuel/air nozzle;
provision of an annular discharge passage that contributes to a uniform electric field in which the discharge occurs, thus providing an increased likelihood that a uniformly distributed discharge is created;
provision of a swirled pilot flow that provides inherent aerodynamic stabilization such that in certain circumstances the pilot may function without turning on the plasma;
provision of a turbulent swirling flow that will enhance mixing of the pilot flame gases with the main swirling premixed flow;
provision of a turbulent swirling flow within the pilot discharge volume that contributes to a better distribution of the discharge streamers and/or diffuse glow volume;
provision of a structure that permits the inner high voltage electrode to be electrically insulated from the machine by use of high voltage insulating feedthroughs in which the outer electrode is grounded to the fuel nozzle in which it is inserted;
provision of a dielectric barrier capability according to one aspect that includes encapsulation of the inner electrode by a dielectric material (e.g., high temperature ceramic) to provide a colder plasma by preventing high current flow during the discharge process, a feature that is advantageous since hot or thermalized plasmas have been shown to create their own NOx;
provision of a structure having the ability to operate with both pulsed high voltage power as well as more conventional AC high voltage power in which the electrical power can be applied at 10-50 kHz frequencies or modulated at frequencies of interest in the combustor (10's to 1000's of Hz) to counteract combustion dynamic tones;
provision of a plasma discharge that is located just upstream of and inside the pilot flame front region, placing the discharge right at the entrance into the flame zone, a feature that is more critical at high pressures, where active species will more quickly be collisionally quenched; and
provision of a pilot that is inserted into existing space within the centerbody of a land-based gas turbine combustor fuel nozzle (e.g., DLN system) in which the pilot can take the place of a blank (purge air) or liquid fuel (dual fuel) cartridge that currently is installed in the centerbody. Thus, the main premixed fuel/air combustion is enhanced without making any modifications to the critical premixed burner tube area where flashback and flameholding are challenges to be avoided.
Moving now to
The pilot 50 disposed within the centerbody of the DLN gas turbine nozzle 70 can be seen to include a high voltage electrode 16 such as discussed herein before. A more detailed depiction of the plasma-assisted, premixed pilot 50 is shown in
Pilot 50 further includes in addition to the high voltage electrode 16, a pilot outer body/outer electrode 14 that is grounded to the gas turbine, a dielectric insulator 18 such as discussed above, and a swirler mechanism 20 disposed downstream of the air and fuel or premixed fuel/air entry port 12 and upstream from the plasma region 72. The present embodiments are not so limited, and it will be appreciated that fuel can be injected anywhere in the pilot cartridge, such that it premixes upstream of the plasma region.
A dielectric barrier 18, depicted also in
A workable dielectric barrier, enumerated 18 in
In summary explanation, particular embodiments have been described for a plasma-assisted premixed pilot that improves lean turn-down capabilities of a gas turbine combustor, and that can be implemented as a retrofit for existing fuel nozzles and machines. The pilot generates a swirled, premixed, plasma-enhanced pilot flame that is applied to solve combustion challenges including without limitation, lean turn down, dynamics, and ignition. Particular embodiments are directed to a specific geometry that is integrated inside the centerbody of a DLN nozzle to generate a premixed plasma-enhanced pilot flame.
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.