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Development and Testing of a Low NOX Micromix Combustion Chamber for an Industrial Gas Turbine
(2017)
The Micromix combustion principle, based on cross-flow mixing of air and hydrogen, promises low emission applications in future gas turbines. The Micromix combustion takes place in several hundreds of miniaturized diffusion-type micro-flames. The major advantage is the inherent safety against flash-back and low NOx-emissions due to a very short residence time of reactants in the flame region. The paper gives insight into the Micromix design and scaling procedure for different energy densities and the interaction of scaling laws and key design drivers in gas turbine integration. Numerical studies, experimental testing, gas turbine integration and interface considerations are evaluated. The aerodynamic stabilization of the miniaturized flamelets and the resulting flow field, flame structure and NOx formation are analysed experimentally and numerically. The results show and confirm the successful adaption of the low NOx Micromix characteristics for a range of different nozzle sizes, energy densities and thermal power output.
For fuel flexibility enhancement hydrogen represents a possible alternative gas turbine fuel within future low emission power generation, in case of hydrogen production by the use of renewable energy sources such as wind energy or biomass. Kawasaki Heavy Industries, Ltd. (KHI) has research and development projects for future hydrogen society; production of hydrogen gas, refinement and liquefaction for transportation and storage, and utilization with gas turbine / gas engine for the generation of electricity. In the development of hydrogen gas turbines, a key technology is the stable and low NOx hydrogen combustion, especially Dry Low Emission (DLE) or Dry Low NOx (DLN) hydrogen combustion. Due to the large difference in the physical properties of hydrogen compared to other fuels such as natural gas, well established gas turbine combustion systems cannot be directly applied for DLE hydrogen combustion. Thus, the development of DLE hydrogen combustion technologies is an essential and challenging task for the future of hydrogen fueled gas turbines. The DLE Micro-Mix combustion principle for hydrogen fuel has been in development for many years to significantly reduce NOx emissions. This combustion principle is based on cross-flow mixing of air and gaseous hydrogen which reacts in multiple miniaturized “diffusion-type” flames. The major advantages of this combustion principle are the inherent safety against flashback and the low NOx-emissions due to a very short residence time of the reactants in the flame region of the micro-flames.
The Dry Low NOx (DLN) Micromix combustion principle with increased energy density is adapted for the industrial gas turbine APU GTCP 36-300 using hydrogen and hydrogen-rich syngas with a composition of 90%-Vol. hydrogen (H₂) and 10%-Vol. carbon-monoxide (CO). Experimental and numerical studies of several combustor geometries for hydrogen and syngas show the successful advance of the DLN Micromix combustion from pure hydrogen to hydrogen-rich syngas. The impact of the different fuel properties on the combustion principle and aerodynamic flame stabilization design laws, flow field, flame structure and emission characteristics is investigated by numerical analysis using a hybrid Eddy Break Up combustion model and validated against experimental results.
Combined with the use of renewable energy sources for its production, hydrogen represents a possible alternative gas turbine fuel for future low-emission power generation. Due to the difference in the physical properties of hydrogen compared to other fuels such as natural gas, well-established gas turbine combustion systems cannot be directly applied to dry low NOₓ (DLN) hydrogen combustion. The DLN micromix combustion of hydrogen has been under development for many years, since it has the promise to significantly reduce NOₓ emissions. This combustion principle for air-breathing engines is based on crossflow mixing of air and gaseous hydrogen. Air and hydrogen react in multiple miniaturized diffusion-type flames with an inherent safety against flashback and with low NOₓ emissions due to a very short residence time of the reactants in the flame region. The paper presents an advanced DLN micromix hydrogen application. The experimental and numerical study shows a combustor configuration with a significantly reduced number of enlarged fuel injectors with high-thermal power output at constant energy density. Larger fuel injectors reduce manufacturing costs, are more robust and less sensitive to fuel contamination and blockage in industrial environments. The experimental and numerical results confirm the successful application of high-energy injectors, while the DLN micromix characteristics of the design point, under part-load conditions, and under off-design operation are maintained. Atmospheric test rig data on NOₓ emissions, optical flame-structure, and combustor material temperatures are compared to numerical simulations and show good agreement. The impact of the applied scaling and design laws on the miniaturized micromix flamelets is particularly investigated numerically for the resulting flow field, the flame-structure, and NOₓ formation.
Flexible fuel operation of a Dry-Low-NOx Micromix Combustor with Variable Hydrogen Methane Mixture
(2022)
The role of hydrogen (H2) as a carbon-free energy carrier is discussed since decades for reducing greenhouse gas emissions. As bridge technology towards a hydrogen-based energy supply, fuel mixtures of natural gas or methane (CH4) and hydrogen are possible.
The paper presents the first test results of a low-emission Micromix combustor designed for flexible-fuel operation with variable H2/CH4 mixtures. The numerical and experimental approach for considering variable fuel mixtures instead of recently investigated pure hydrogen is described.
In the experimental studies, a first generation FuelFlex Micromix combustor geometry is tested at atmospheric pressure at gas turbine operating conditions corresponding to part- and full-load. The H2/CH4 fuel mixture composition is varied between 57 and 100 vol.% hydrogen content.
Despite the challenges flexible-fuel operation poses onto the design of a combustion system, the evaluated FuelFlex Micromix prototype shows a significant low NOx performance