Patent Application
20170058771
The present invention generally relates to a gas turbine power plant such as a combined cycle or cogeneration power plant having a steam source and a Dry Low NOx (DLN) combustion system. More particularly, the present invention relates to a system and method for generating steam via the gas turbine during low-load conditions.
A gas turbine power plant such as a combined cycle or cogeneration power plant generally includes a gas turbine having a compressor, a combustor and a turbine, a heat recovery steam generator (HRSG) that is disposed downstream from the turbine and a steam turbine in fluid communication with the HRSG. During operation, air enters the compressor via an inlet system and is progressively compressed as it is routed towards a compressor discharge or diffuser casing that at least partially surrounds the combustor. At least a portion of the compressed air is mixed with a fuel and burned within a combustion chamber defined within the combustor, thereby generating high temperature and high pressure combustion gases.
The combustion gases are routed along a hot gas path from the combustor through the turbine where they progressively expand as they flow across alternating stages of stationary vanes and rotatable turbine blades which are coupled to a rotor shaft. Kinetic energy is transferred from the combustion gases to the turbine blades thus causing the rotor shaft to rotate. The rotational energy of the rotor shaft may be converted to electrical energy via a generator. The combustion gases exit the turbine as exhaust gas and the exhaust gas enters the HRSG. Thermal energy from the exhaust gas is transferred to water flowing through one or more heat exchangers of the HRSG, thereby producing superheated steam. The superheated steam is then routed into the steam turbine which may be used to generate additional electricity, thus enhancing overall power plant efficiency.
Regulatory requirements for low emissions from gas turbine based power plants have continually grown more stringent over the years. Environmental agencies throughout the world are now requiring even lower levels of emissions of oxides of nitrogen (NOx) and other pollutants and carbon monoxide (CO) from both new and existing gas turbines. In order to balance fuel efficiency with emissions requirements, various types of gas turbines utilize a Dry Low NOx (DLN) type combustion system which utilizes lean premix combustion technology.
A DLN-1 or DLN-1+ type combustor by General Electric Company, Schenectady, N.Y., is a two-stage pre-mixed combustor designed for use with natural gas fuel and may be capable of operation on liquid fuel. The DLN-1 or DLN-1+ type combustor provides a fuel injection system including a secondary fuel nozzle positioned on the center axis of the combustor surrounded by a plurality of primary fuel nozzles annularly arranged around the secondary fuel nozzle. During base load or peak load, the DLN-1 or DLN-1+ type combustor may be configured to maintain very low exhaust emission levels while maintaining high levels of efficiency using lean premixed fuel/air concepts.
It is generally desirable for operators to turn down the gas turbine during times when power generation is not needed, thus potentially saving fuel and allowing for quick recovery time when power is needed again. However, at low-load levels such as during turndown operation the DLN-1 or DLN-1+ combustion system may operate outside of desired emissions levels. In addition, operation at low-load levels results in decreased exhaust gas temperatures, thus negatively impacting the steam output for the power plant. Accordingly, there is a need to provide a system and method for producing steam while maintaining emissions within desired levels when operating the combustor in turndown or less than base load mode.
Aspects and advantages of the invention are set forth below in the following description, or may be obvious from the description, or may be learned through practice of the invention.
One embodiment of the present invention is a system for generating steam during gas turbine low-load operating conditions. The system includes a gas turbine having, in serial flow order, a compressor including a plurality of inlet guide vanes disposed at an inlet of the compressor, a combustor and a turbine. The gas turbine further comprises at least one bleed air extraction port where the bleed air extraction port is in fluid communication with the compressor, a compressor discharge casing or the combustor. The system further includes a premix duct burner that is positioned downstream from the turbine and upstream from a heat recovery steam generator within an exhaust section of the gas turbine. During operation, the premix duct burner increases temperature of combustion gases flowing from the turbine and into the heat recovery steam generator and compressed air flows out of the bleed air extraction port so as to reduce pressure within the compressor, the compressor discharge casing or the combustor during low-load gas turbine operating conditions.
Another embodiment of the present disclosure includes a method for generating steam during gas turbine low-load operating conditions. The method includes operating a gas turbine in a non-premix mode condition, extracting bleed air from at least one extraction port fluidly coupled to a compressor, combustor or turbine of the gas turbine, increasing thermal energy of combustion exhaust gases flowing from the turbine via a premix duct burner disposed downstream from the turbine and generating steam via the thermal energy from the combustion exhaust gases via a heat recovery steam generator system disposed downstream from the premix duct burner.
Those of ordinary skill in the art will better appreciate the features and aspects of such embodiments, and others, upon review of the specification.
A full and enabling disclosure of the present invention, including the best mode thereof to one skilled in the art, is set forth more particularly in the remainder of the specification, including reference to the accompanying figures, in which:
Reference will now be made in detail to present embodiments of the invention, one or more examples of which are illustrated in the accompanying drawings. The detailed description uses numerical and letter designations to refer to features in the drawings. Like or similar designations in the drawings and description have been used to refer to like or similar parts of the invention. As used herein, the terms “first”, “second”, and “third” may be used interchangeably to distinguish one component from another and are not intended to signify location or importance of the individual components. The terms “upstream” and “downstream” refer to the relative direction with respect to fluid flow in a fluid pathway. For example, “upstream” refers to the direction from which the fluid flows, and “downstream” refers to the direction to which the fluid flows.
The terminology used herein is for the purpose of describing particular embodiments only and is not intended to be limiting of the invention. As used herein, the singular forms “a”, “an” and “the” are intended to include the plural forms as well, unless the context clearly indicates otherwise. It will be further understood that the terms “comprises” and/or “comprising,” when used in this specification, specify the presence of stated features, integers, steps, operations, elements, and/or components, but do not preclude the presence or addition of one or more other features, integers, steps, operations, elements, components, and/or groups thereof.
As used herein, “gas turbine load” or “load” may relate to the power output of a gas turbine's generator(s); “inlet guide vane angle” means the angles of inlet vanes (not shown) relative to axial flow through the inlet system upstream from the compressor; “inlet bleed heat” means the amount of heat in fluid extracted from a downstream portion of the compressor section and inserted into the inlet system or an upstream portion of the compressor section to heat the flow therein; “fuel split” means the amount of fuel sent to different circuits within the combustor and “emissions” or “emissions level” means levels of various exhaust gases including but not limited to oxides of nitrogen (NOx), unburned hydrocarbons and carbon monoxide (CO).
Each example is provided by way of explanation of the invention, not limitation of the invention. In fact, it will be apparent to those skilled in the art that modifications and variations can be made in the present invention without departing from the scope or spirit thereof. For instance, features illustrated or described as part of one embodiment may be used on another embodiment to yield a still further embodiment. Thus, it is intended that the present invention covers such modifications and variations as come within the scope of the appended claims and their equivalents.
An embodiment of the present invention takes the form of a system and method for producing steam while maintaining emissions within desired levels when operating a power plant gas turbine at turndown or less than base load mode. In particular embodiments, the disclosure provides a power plant having a compressor, combustor downstream from the compressor, at least one combustion air or bleed air extraction port in fluid communication with the compressor or the combustor, a premix duct burner disposed within an exhaust section downstream from a turbine portion from the gas turbine and a heat recovery steam generator (HRSG) disposed downstream from the premix duct burner.
In operation the bleed heat or bypass air is routed away from the combustor at low load. The exhaust duct of the gas turbine has a premixed duct burner or combustion system to heat the exhaust flow at low gas turbine loads where the exhaust temperature upstream of the duct burner is not high enough for steam production. The bypass or bleed air is used to allow the combustion system to operate at low fuel flow rates (low loads) while maintaining the required fuel to air ratio needed for combustion stability. This allows for the gas turbine to open inlet guide vanes (IGVs) to increase exhaust flow rate to the level needed for steam production. The system disclosed and claimed herein provided an operator with the ability to generate high levels of steam production independent of gas turbine load level. This allows the operator to not have to generate megawatts in situations where power generation is not desired, but where steam production is desired.
Referring now to the drawings, wherein identical numerals indicate the same elements throughout the figures,
The compressed air 20 is mixed with a fuel 22 such as natural gas from a fuel supply system 24 to form a combustible mixture within one or more combustors 26. The combustible mixture is burned to produce combustion gases as indicated schematically by arrows 28 having a high temperature, pressure and velocity. The combustion gases 28 flow through a turbine 30 of a turbine section to produce work. For example, the turbine 30 may be connected to a shaft 32 so that rotation of the turbine 30 drives the compressor 18 to produce the compressed air 20. Alternately or in addition, the shaft 32 may connect the turbine 30 to a generator 34 for producing electricity.
Exhaust gases 36 from the turbine 30 flow through an exhaust section 38 that connects the turbine 30 to an exhaust stack 40 downstream from the turbine 30. The exhaust section 38 may include, for example, a heat recovery steam generator (HRSG) 42 for cleaning and extracting additional heat from the exhaust gases 36 prior to release to the environment. For example, the HRSG 42 may include one or more heat exchangers 44 in thermal communication with the exhaust gases 36 and which may generate steam or superheated steam as indicated schematically by arrows 46. The steam 46 may then be routed to various components at the power plant 10 such as to one or more steam turbines 48 and/or to various heating systems (not shown).
In various embodiments, the gas turbine 12 may include one or more bleed air extraction ports 50. In particular embodiments, as illustrated in
The bleed air extraction ports 50 may be in fluid communication with various external components. For example, in one embodiment, at least one bleed air extraction port 50 may be in fluid communication with the inlet system 14 via various fluid conduits, couplings, valves and/or at least one bleed air inlet port 54. In this manner, a portion of the compressed air 20 from the compressor 18 and/or the compressor discharge casing 52 may be directed to the inlet system 14 to provide heat to air 16 upstream from the compressor 18 and/or to reduce pressure within the combustor 26 and/or the compressor discharge casing 52.
In particular embodiments, at least one bleed air extraction port 50 may be in fluid communication with the turbine 30 via various fluid conduits, couplings, valves and/or at least one bleed air inlet port 54. In this manner, a portion of the compressed air 20 from the compressor 18 and/or the compressor discharge casing 52 may be routed to the turbine 30 to provide cooling to various components of the turbine 30 and/or to reduce pressure within the combustor 26 and/or the compressor discharge casing 52. In particular embodiments, at least one bleed air extraction port 50 may be in fluid communication with the turbine 30 via various fluid conduits, couplings, valves and/or at least one bleed air inlet port 54. In this manner, a portion of the compressed air 20 from the compressor 18 and/or the compressor discharge casing 52 may be routed to the turbine 30 to provide cooling to various components of the turbine 30 and/or to reduce pressure within the combustor 26 and/or the compressor discharge casing 52.
In particular embodiments, at least one bleed air extraction port 50 may be in fluid communication with the exhaust section 38 via various fluid conduits, couplings, valves and/or at least one bleed air inlet port 54. In this manner, a portion of the compressed air 20 from the compressor 18 and/or the compressor discharge casing 52 may be routed to the exhaust section 38 to provide thermal energy to the HRSG 42 and/or to provide cooling to various components of the exhaust section 38 and/or to reduce pressure within the combustor 26 and/or the compressor discharge casing 52.
In particular embodiments, an oxidation catalyst module or system 56 may be positioned downstream from the turbine 30 and upstream from the exhaust stack 40. The oxidation catalyst system 56 may be used to reduce or potentially eliminate carbon monoxide (CO), unburned hydrocarbons or other undesirable emissions contained within the exhaust gases 36 flowing from the turbine 30.
In various embodiments, the compressor 18 includes a plurality of variable angle inlet guide vanes 58 disposed at an inlet of the compressor 18. The guide vanes 58 may be rotated about a radial axis between an open and a closed positioned. The angle of the inlet guide vanes 58 can be changed to meet the air flow requirements of the engine-operating conditions. For example, the inlet guide vanes 58 may be closed or at least partially closed to restrict air flow to the compressor 18 and the combustor 26 during engine start-up and at low-load or low RPMs. The inlet guide vanes 58 may be progressively opened to increase air flow to the compressor 18 and/or the combustor 26 as the load or RPMs are increased. During start up and at low-load conditions, the angle of attack of the inlet guide vanes 58 is angled so as to avoid stalling the compressor 18.
In various embodiments, a premix duct burner 60 is disposed downstream from the turbine 30 within the exhaust section 38 upstream from the heat exchangers 44 of the HRSG 42. The premix duct burner 60 generally functions by injecting a fuel into the flow of exhaust gases 36 to form a premixed fuel/air combustible mixture. The premixed fuel/air combustible mixture is then burned to reduce NOx. Thermal energy from the burned fuel/air combustible mixture may then be transferred to water flowing through the heat exchangers 44 of the HRSG 42, thus generating steam even at low-load conditions. The premixed fuel/air combustible mixture may be mixed in stoichiometric proportions of fuel and an oxidizer, may be fuel rich or fuel lean as long as the premixed ratio of fuel and air is combustible. It is commonly known to those of ordinary skill in the art that a uniformly premixed fuel/air mixture is desirable.
In various embodiments, the combustor 26 is a Dry Low NOx (DLN) type combustor.
As shown in
The fuel supply system 24 may be configured to provide the same fuel type such as natural gas or liquid fuel to both the primary fuel nozzles 104 and the center fuel nozzle 106. In certain configurations, the fuel supply system 24 may be configured to provide different fuel types such as natural gas and/or a liquid fuel to the primary fuel nozzles 104 and/or the center fuel nozzle 102.
During operation, the combustor 100 operates in and transitions between various modes of operation. These modes of operation are generally related to the load placed on the gas turbine and/or the steam output requirement for the power plant 10. The DLN type combustor 100 as shown in
The primary mode of operation typically occurs from ignition up to about thirty percent of full load. During primary mode of operation the fuel supply system 24 provides one hundred percent of the total fuel flow to the combustor 100 to the primary fuel nozzles 104. As a result, combustion during the primary mode of operation takes place primarily in the primary combustion zones 114. The primary mode of operation is used to ignite, accelerate and operate the gas turbine 12 over low-loads to mid-loads, up to a pre-selected combustion reference temperature.
The lean-lean mode of operation typically occurs from about thirty percent to about seventy percent of full load. During lean-lean operation the fuel supply system 24 may split the total fuel flow between the primary fuel nozzles 104 and the center fuel nozzle 102. For example, the fuel supply system 24 may provide about seventy percent of the total fuel flow to the primary fuel nozzles 104 and about thirty percent of the total fuel flow to the center fuel nozzle 102. As a result, combustion during the lean-lean mode of operation takes place in both the primary combustion zones 114 as well as the secondary combustion zone 118. This mode of operation is used for intermediate loads between two pre-selected combustion reference temperatures.
The secondary mode of operation generally occurs when the combustor 100 transitions between the lean-lean mode of operation and a premix mode of operation. During the secondary mode of operation the fuel supply system 24 may decrease the fuel flow to the primary fuel nozzles 104 from about seventy percent to about zero percent of total fuel flow to the combustor 100 while increasing the fuel flow to the center fuel nozzle 102 from about thirty percent to about one hundred percent of the total fuel flow, thus allowing the flames associated with the primary combustion zones 114 to extinguish while maintaining a flame in the secondary combustion zone 118 which originates from the center fuel nozzle 102. This mode is necessary to extinguish the flame in the primary combustion zones 114.
When the combustor 100 is operating in the premix mode of operation, the fuel split between the primary fuel nozzles 104 and the center fuel nozzle 102 may be modified such that the primary fuel nozzles 104 receive about eighty percent of the total fuel flow to the combustor 100 while the center fuel nozzle 102 may receive about twenty percent of the total fuel flow to the combustor 100. The fuel 22 flowing to the primary fuel nozzles 102 is premixed with the compressed air 20 from the compressor 18 (
The load ranges associated with the primary, lean-lean, secondary and premix modes of operation may shift from the ranges provided above based on various factors. For example, the load ranges may vary with a degree of inlet guide vane (IGV) modulation and, to a smaller extent, with the ambient temperature of air 16. For instance, at ISO ambient, the premix mode of operation operating range may be from about 50% to 100% load with IGV modulation down to about 42°, and about 75% to 100% load with IGV modulation down to about 57°. The various fuel splits provided herein with regards to the various modes of operation are exemplary and not meant to be limiting unless otherwise specified in the claims.
In particular embodiments, as shown in
Each or at least some of the fuel injectors 120 may be configured to provide Late Lean or axial fuel staging capability to the combustor 100. That is, the fuel injectors 120 are each configured to supply a fuel and/or fuel/air mixture to the hot gas path 124 in a direction that is generally transverse to a predominant flow direction of the combustion gases 28 flowing through the hot gas path 124. In so doing, conditions within the combustor 100 and the hot gas path 124 are staged to create local zones of stable combustion while reducing the formation of NOx emissions, thus enhancing overall performance of the combustor 100.
In various embodiments, as shown in
As shown in
The controller 132 may incorporate a General Electric SPEEDTRONIC™ Gas Turbine Control System, such as is described in Rowen, W. I., “SPEEDTRONIC™ Mark V Gas Turbine Control System”, GE-3658D, published by GE Industrial & Power Systems of Schenectady, N.Y. Controller 132 may also incorporate a computer system having a processor(s) that executes programs stored in a memory to control the operation of the gas turbine using sensor inputs and instructions from human operators. The programs executed by controller 132 may include scheduling algorithms for regulating fuel flow to the combustor 100, regulating flow of the diluent 130 to the combustor 100, steam output and for reducing combustion related emissions. The controller 132 may also be programmed to control the various operating parameters of the premix duct burner such as but not limited to fuel flow rate. The commands generated by controller 132 may, for example, cause valves to actuate between open and closed positions to regulate the flow of fuel, bleed air and diluent and may cause actuators to adjust angle of the inlet guide vanes 58.
The controller 132 may regulate the gas turbine 12 based, at least in part, on a database stored in the memory of the controller 132. This database may enable the controller 132 to maintain the NOx and CO emissions in the gas turbine exhaust section 38 to within certain predefined limits, to maintain a predefined steam output and to maintain the combustor 100 within suitable stability boundaries. The controller 132 may set operational parameters such as the gas turbine load, steam production requirements, inlet bleed heat, flow of diluent and combustor fuel split so as to: 1) achieve the desired steam production output rate while operating in a non-premix mode and/or operating between a full speed no load (FSNL) condition up to a base load condition; while 2) staying within desired emissions boundaries.
During base load or peak load, the combustor 100 is operated in the premix mode. While in this operating mode, emissions levels are generally maintained within desired acceptable emissions levels and operation of the HRSG 42 is optimized to provide sufficient steam flow to drive the steam turbine 48 and/or support various secondary operations. During non-peak or base load demand such as during turndown operation, operators may wish to maintain a minimum steam output independent of the gas turbine load level. However, during turndown operation of the gas turbine 12 emissions levels increase. Therefore, in order to meet steam output requirements while maintaining overall emissions compliance for the power plant 10, operators typically operate the gas turbine 12 at base or full load operation or have to accept the increase in overall emissions output.
In order to generate higher levels of steam while operating at reduced emission levels during non-premix mode of operation and/or during turndown operation, bleed air (compressed air 20) may be extracted from one or more of the bleed air extraction ports 50 to achieve maximum turndown. The bleed air may be routed to at least one of the inlet system 14, the turbine 30 or the exhaust section 38. The bleed air reduces the pressure within the combustor 26 and/or the compressor discharge casing 52, thus preventing blow-out of the combustion flames. In addition, the bleed air may be used to heat the inlet air 16 upstream from the compressor 18 and/or may be used to add thermal energy to the exhaust gases 36 upstream from the HRSG 42. The bleed air is used to allow the combustion system to operate at low fuel flow rates (low loads) while maintaining the required fuel to air ratio needed for combustion stability. This allows for the gas turbine to open the inlet guide vanes to increase exhaust gas flow rate to the level needed for steam production. The premix duct burner 60 is engaged to add thermal energy to the exhaust gases 36 upstream from the heat exchangers 44 of the HRSG 42, thus allowing for appropriate steam generation while operating the combustor 100, 26 at reduced or desired emissions levels.
In particular embodiments, the diluent 130 (i.e. steam, water, nitrogen, etc. . . . ) may be injected into the fuel 22 upstream form the primary fuel nozzles 104 and the center fuel nozzle 102 and/or may be injected into the combustion gases 28 within the hot gas path 124 via the diluent supply 128 to reduce NOx production within the hot gas path 124. In addition, the fuel injectors 120 may inject the fuel or fuel/air mixture into the hot gas path 124 downstream from the secondary combustion zone 118, thus reducing NOx within the combustion gases 28. The oxidation catalyst system 56 may be activated to further reduce various undesirable emissions such as carbon monoxide (CO) from the exhaust gases 36 downstream from the premix duct burner 60 at less than base load condition as they flow through the exhaust section 36 towards the exhaust stack 40. In this configuration, desired levels of steam output from the power plant 10 may be maintained while mitigating the emissions levels at less than base load or non-premix operating conditions.
The various embodiments described and shown herein provide for at least one method for generating steam during gas turbine low-load or non-premix mode operating conditions.
In particular embodiments, method 200 may include heating inlet air 16 entering the compressor 18 via the bleed air 20. In particular embodiments, method 200 may include adding thermal energy to the combustion exhaust gases 36 upstream from the premix duct burner 60 via the bleed air 20. In particular embodiments, method 200 may include opening the inlet guide vanes disposed at an inlet to the compressor 18 so as to increase combustion exhaust gas flow rate to the premix duct burner 60. In particular embodiments, method 200 may include injecting the diluent 130 into the combustor 26 upstream from the turbine 30. In particular embodiments, method 200 may include injecting the diluent 130 into the combustor 26 where the diluent 130 comprises at least on of water, steam and nitrogen. In particular embodiments, method 200 may include scrubbing the flow of combustion exhaust gases 36 via an oxidation catalyst system 56 disposed downstream from the premix duct burner 60.
Although specific embodiments have been illustrated and described herein, it should be appreciated that any arrangement, which is calculated to achieve the same purpose, may be substituted for the specific embodiments shown and that the invention has other applications in other environments. This application is intended to cover any adaptations or variations of the present invention. The following claims are in no way intended to limit the scope of the invention to the specific embodiments described herein.
The present application claims filing benefit of U.S. Provisional Patent Application Ser. No. 62/210,624 having a filing date of Aug. 27, 2015, which is incorporated by reference herein in its entirety.
| Number | Date | Country | |
|---|---|---|---|
| 62210624 | Aug 2015 | US |
