NTPC Workshop

Dry Low NOx (DLN) Systems

Vamsi Duraibabu
September 14, 2010
Hyderabad
India
2
General Electric Company
2010 General Electric Company. All Rights Reserved. This material may not be copied
or distributed in whole or in part, without prior permission of the copyright owner.
Copyright 2010 General Electric Company. Proprietary.
All Rights Reserved. No part of this document may be reproduced,
transmitted, stored in a retrieval system nor translated into any human or
computer language, in any form or by any means, electronic, mechanical,
magnetic, optical, chemical, manual, or otherwise, without the prior written
permission of the General Electric Company.
GE Energy
3
General Electric Company
2010 General Electric Company. All Rights Reserved. This material may not be copied
or distributed in whole or in part, without prior permission of the copyright owner.
Emissions Technology Advancement
N
O
x
(

p
p
m

)
Technology Enablers
3D Reacting Flow
Advanced Materials / Coatings
Active Fuel Staging
Smart GT Controls
85 90 10 95
DLN +
DLN +
DLN - Dry Low NOx
DLN - Dry Low NOx
25 PPM 25 PPM
Water Injected
Water Injected
42 PPM 42 PPM
9 PPM 9 PPM
15 PPM 15 PPM
< 5 PPM < 5 PPM
Leader in Low Emissions Technology
4
General Electric Company
2010 General Electric Company. All Rights Reserved. This material may not be copied
or distributed in whole or in part, without prior permission of the copyright owner.
Dry Low NOx (DLN) Technology Evolution
NOx
CO
Stability
&
Premix
Range
Reliability
&
Component
Life
DLN 1.0
( 6B / 9E )
DLN 1.0+
( 7EA )
DLN 2.0
( 9FA )
DLN 2.6
( 6FA )
DLN 2.0+
( 9FA+e )
DLN 2.6+
( 9FB )
DLN Design
A Four
Sided Box
DLN Technology 30 years of Design Evolution
5
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2010 General Electric Company. All Rights Reserved. This material may not be copied
or distributed in whole or in part, without prior permission of the copyright owner.
DLN Combustion System - Summary
1327
1411
1327
1327
1288
1135
Firing
Temp
(
o
C )
9FA+e
9FBA
9FA+e
6FA+e
9FA
6B
9E
GT Model
40%
38%
30 mg/Nm
3
30 mg/Nm
3
4 DLN 2.6+
60% 50 mg/Nm
3
3 DLN 2.0+
50% 30 mg/Nm
3
4 DLN 2.6
60% 50 mg/Nm
3
4 DLN 2.0
#
65%
75%
30 mg/Nm
3
2 DLN 1.0
Turndown *
( % GT Load )
Emission
(NOx 15% O
2
)
No. of
Fuel
Circuits
DLN Type
#
Not Offered for New units
* ISO Day ( 15
o
C , 60% RH )
6
General Electric Company
2010 General Electric Company. All Rights Reserved. This material may not be copied
or distributed in whole or in part, without prior permission of the copyright owner.
DLN 1.0 System Frame 6B & 9E
The original Dry Low NOx
Combustion System, first fielded
in early 80s.
Operates in Diffusion mode,
Piloted-premixed mode, and
Fully premixed mode.
Can be retrofitted on to existing
turbines to replace Diffusion
flame combustors
Second largest single-digit NOx
DLN fleet, behind the 7FA+e.
Lean Premixed System
FUEL STAGING
7
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2010 General Electric Company. All Rights Reserved. This material may not be copied
or distributed in whole or in part, without prior permission of the copyright owner.
DLN 2.0+ System - Frame 9FA+e
Premix
PM1
PM4
PM4
PM4 PM4
Diffusion
D5
D5
D5
D5
D5
Sub Piloted Premix
D5
D5
D5
D5
D5
PM1
Piloted Premix
D5
D5
D5
D5
D5
PM1
PM4
PM4
PM4
PM4
Premix
PM1
PM4
PM4
PM4 PM4
Diffusion
D5
D5
D5
D5
D5
Sub Piloted Premix
D5
D5
D5
D5
D5
PM1
Piloted Premix
D5
D5
D5
D5
D5
PM1
PM4
PM4
PM4
PM4
FUEL STAGING
Ignition - 95% Speed
95% Speed - 10% Load
10% - 50% Load
50% - 100% Load
DLN-2+ retains the basic architecture of
the DLN-2
Fuel nozzle ( Swozzle Design ) redesigned
with cleaner aerodynamics for improved
Flame Holding Margin & Pressure drop.
Accept fuels with wide wobbe Index
ranging from 28 to 52.
Swirl-Stabilized Premixed System
8
General Electric Company
2010 General Electric Company. All Rights Reserved. This material may not be copied
or distributed in whole or in part, without prior permission of the copyright owner.
DLN 2.6+ System - Frame 9FA+e / 9FB
Diffusion
D5
D5
D5
D5
D5 D5
Sub Piloted Premix
D5
D5
D5
D5
PM1
D5
D5
Piloted Premix
D5
D5
D5
D5
D5
PM3
PM3
PM3
PM1
Sub Premix
PM3
PM3 PM3
PM1
D5
Premix
PM3
PM2
PM3 PM3
PM1
PM2
Diffusion
D5
D5
D5
D5
D5 D5
Sub Piloted Premix
D5
D5
D5
D5
PM1
D5
D5
Piloted Premix
D5
D5
D5
D5
D5
PM3
PM3
PM3
PM1
Sub Premix
PM3
PM3 PM3
PM1
D5
Premix
PM3
PM2
PM3 PM3
PM1
PM2
Diffusion
D5
D5
D5
D5
D5 D5
Sub Piloted Premix
D5
D5
D5
D5
PM1
D5
D5
Piloted Premix
D5
D5
D5
D5
D5
PM3
PM3
PM3
PM1
Sub Premix
PM3
PM3 PM3
PM1
D5
Premix
PM3
PM2
PM3 PM3
PM1
PM2
Ignition - 95% Speed
95% Speed - 20% Load
FUEL STAGING
20% - 30% Load
30% - 40% Load
40% - 100% Load
Based on the DLN 2+ fuel nozzle with DLN 2.6
architecture
Designed for Sub 9 ppm NOx / CO Emissions
Fuel Staging Flexibility Solution for Yellow plume
New Unit or Retrofit
Advanced Swirl-stabilized System
9
General Electric Company
2010 General Electric Company. All Rights Reserved. This material may not be copied
or distributed in whole or in part, without prior permission of the copyright owner.
DLN2.6+ System w/ OpFlex AutoTune
Model Based Control Technology
Applications
Fuel flexibility
Wobbe index variation
Eliminates combustion
retuning requirement
Performance enhancement
Output & efficiency
Fuel Supply pressure
reduction
Start-up fuel flexibility
Larger start up fuel
variances
Start-up emissions
improvements
Lower start up NOx
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t
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ARES - Parameter
Estimation
Engine Model
Virtual
Sensors
Sensors
Effectors
Physics-Based
Boundary Models
L
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S
c
h
e
d
u
l
i
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g
CDM
Direct boundary control
Accommodates deterioration
Tuning schedules are adjusted
automatically
Key Features
10
General Electric Company
2010 General Electric Company. All Rights Reserved. This material may not be copied
or distributed in whole or in part, without prior permission of the copyright owner.
Gas Turbine Combustion Laboratory
10 Test stands for testing and
validating all DLN Systems
Capability of blending NG with
H2, CO, CO2, N2 and Steam
Advanced monitoring and
diagnostic instrumentation (upto
400 sensors) for component
validation
Up to 230 High Pressure / High
Temperature Tests conducted
per year
World Class DLN Combustor Test Facility
CameraPremixed Flame
Overview
Appendix
12
General Electric Company
2010 General Electric Company. All Rights Reserved. This material may not be copied
or distributed in whole or in part, without prior permission of the copyright owner.
DLN 2.6+ System - Frame 9FA/FA+e /FB
Super B
Thermal
Barrier
Coating
(TBC)
Extended Interval (EI) transition
piece cooling and sealing
DLN 2.6 style nozzle
arrangement (5+1)
Fuel flexibility retained
from DLN 2+
9FA+e (9351FA)
20/20 mg/Nm
3
NOx/CO to 50% load
30/30 mg/Nm
3
NOx/CO to 35% load
1
24k combustion interval
9FA (9311FA)
30/30 mg/Nm
3
NOx/CO to 50% load
24k combustion interval
9FB (9371FA)
30/12.5 mg/Nm
3
NOx/CO to 38% load
12k combustion interval
9FA+e (9351FA)
20/20 mg/Nm
3
NOx/CO to 50% load
30/30 mg/Nm
3
NOx/CO to 35% load
1
24k combustion interval
9FA (9311FA)
30/30 mg/Nm
3
NOx/CO to 50% load
24k combustion interval
9FB (9371FA)
30/12.5 mg/Nm
3
NOx/CO to 38% load
12k combustion interval
9FA+e launch in 2005
(12 operating, 7 ordered)
9FB launch in 2007
(18 operating, 32 ordered)
9FA (9311FA) launch in 2009
(1 operating, 4 ordered)
Dual fuel and wide wobbe
capable
9FA+e launch in 2005
(12 operating, 7 ordered)
9FB launch in 2007
(18 operating, 32 ordered)
9FA (9311FA) launch in 2009
(1 operating, 4 ordered)
Dual fuel and wide wobbe
capable
1
With OpFlex Extended Turndown software
13
General Electric Company
2010 General Electric Company. All Rights Reserved. This material may not be copied
or distributed in whole or in part, without prior permission of the copyright owner.
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Sensors
Effectors
Control
Control Schedules
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Sensors
Effectors
Control
Control Schedules
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L
o
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p

S
e
l
e
c
t
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o
n

S
t
r
u
c
t
u
r
e
ARES - Parameter
Estimation
Engine Model
Virtual
Sensors
Sensors
Effectors
Physics-Based
Boundary Models
L
i
m
i
t

S
c
h
e
d
u
l
i
n
g
CDM
Good: Schedule-Based
Indirect boundary control
No explicit deterioration
accommodation
Coupled effectors
Better: Model-Based
Direct boundary
control
Accommodates
deterioration
De-coupled effectors
A different control paradigm