NEURAL NETWORK ACCELERATION OF NUMERICAL SIMULATION OF METHANE COMBUSTION IN A GAS TURBINE ENGINE

For more than two decades, Alstom Power Inc. (Alstom) has developed a range of low cost, infurnace technologies for NOx emissions control for the domestic U.S. pulverized coal fired boiler market. This includes Alstom's internally developed TFS 2000{trademark} firing system, and various enhancements to it developed in concert with the U.S. Department of Energy. As of the date of this report, more than 270 units representing approximately 80,000 MWe of domestic coal fired capacity have been retrofit with Alstom low NOx technology. Best of class emissions range from 0.18 lb/MMBtu for bituminous coal to 0.10 lb/MMBtu for subbituminous coal, with typical levels at 0.24 lb/MMBtu and 0.13 lb/MMBtu, respectively. Despite these gains, NOx emissions limits in the U.S. continue to ratchet down for new and existing boiler equipment. On March 10, 2005, the Environmental Protection Agency (EPA) announced the Clean Air Interstate Rule (CAIR). CAIR requires 25 Eastern states to reduce NOx emissions from the power generation sector by 1.7 million tons in 2009 and 2.0 million tons by 2015. Low cost solutions to meet such regulations, and in particular those that can avoid the need for a costly selective catalytic reduction system (SCR), provide a strong incentive to continue to improve low NOx firing system technology to meet current and anticipated NOx control regulations. The overall objective of the work is to develop an enhanced combustion, low NOx pulverized coal burner, which, when integrated with Alstom's state-of-the-art, globally air staged low NOx firing systems will provide a means to achieve: Less than 0.15 lb/MMBtu NOx emissions when firing a high volatile Eastern or Western bituminous coal, Less than 0.10 lb/MMBtu NOx emissions when firing a subbituminous coal, NOx reduction costs at least 25% lower than the costs of an SCR, Validation of the NOx control technology developed through large (15 MWt) pilot scale demonstration, and Documentation required for economic evaluation and commercial application. During the project performance period, Alstom performed computational fluid dynamics (CFD) modeling and large pilot scale combustion testing in its Industrial Scale Burner Facility (ISBF) at its U.S. Power Plant Laboratories facility in Windsor, Connecticut in support of these objectives. The NOx reduction approach was to optimize near-field combustion to ensure that minimum NOx emissions are achieved with minimal impact on unburned carbon in ash, slagging and fouling, corrosion, and flame stability/turn-down. Several iterations of CFD and combustion testing on a Midwest coal led to an optimized design, which was extensively combustion tested on a range of coals. The data from these tests were then used to validate system costs and benefits versus SCR. Three coals were evaluated during the bench-scale and large pilot-scale testing tasks. The three coals ranged from a very reactive subbituminous coal to a moderately reactive Western bituminous coal to a much less reactive Midwest bituminous coal. Bench-scale testing was comprised of standard ASTM properties evaluation, plus more detailed characterization of fuel properties through drop tube furnace testing and thermogravimetric analysis. Bench-scale characterization of the three test coals showed that both NOx emissions and combustion performance are a strong function of coal properties. The more reactive coals evolved more of their fuel bound nitrogen in the substoichiometric main burner zone than less reactive coal, resulting in the potential for lower NOx emissions. From a combustion point of view, the more reactive coals also showed lower carbon in ash and CO values than the less reactive coal at any given main burner zone stoichiometry. According to bench-scale results, the subbituminous coal was found to be the most amenable to both low NOx, and acceptably low combustibles in the flue gas, in an air staged low NOx system. The Midwest bituminous coal, by contrast, was predicted to be the most challenging of the three coals, with the Western bituminous coal predicted to behave in-between the subbituminous coal and the Midwest bituminous coal. CFD modeling was used to gain insight into the mechanisms governing nozzle tip performance with respect to NOx emissions. The CFD simulations were run as steady state, turbulent, non-reacting flow with heat transfer and focused on predicting the near field mixing and particle dispersion rates. CFD results were used to refine the proposed tip concepts before they were built, as well as to help identify and evaluate possible improvements to the tips for subsequent test weeks.

To meet aggressive NOx reduction requirements, a range of NOx reduction strategies are currently available for application to pulverized coal fired furnaces. Utilities must assess the benefits and drawbacks of each viable NOx control technology to develop the best strategy for unit specific NOx control that fits within the utilities’ overall compliance plan. The installation of high capital and operating cost NOx reduction technologies, such as selective catalytic reduction, is cost prohibitive on many units. Lower cost technologies, although not capable of SCR level NOx reductions, can provide a more cost-effective approach and still achieve compliance over the fleet. This paper describes how computational fluid dynamic (CFD) modeling has been utilized by an experienced group of combustion engineers to evaluate and design cost effective NOx reduction strategies applied to a relatively unique PC fired unit, a B&W 150 MW roof-fired furnace. The unit fires bituminous coal through 10 multi-tip burners and is equipped with 10 NOx ports located below the burners. A baseline CFD model was first constructed and the predicted model results were compared with available data including NOx and CO emissions, as well as unburned carbon in fly ash. Upon completion of the baseline model, combustion alterations, including deeper staging, were evaluated. Specific burner adjustments were evaluated to allow for the deeper staging without significantly increasing unburned carbon in the fly ash, CO emissions, or near burner slagging. The CFD model was also utilized to evaluate the impact of water injection. AEP has previously utilized water injection to reduce peak combustion temperatures and thermal NOx formation rates in coal fired units for incremental NOx reductions. It is crucial that the NOx production zones in the downstream portion combustion field be identified, since these regions are most likely to produce NOx that will not be subsequently reduced prior to exiting the furnace. The CFD model was utilized to identify the most appropriate regions for water injection combined with the other combustion alterations. The results showed that NOx emissions could be reduced in this unit by approximately 37% from baseline full load emissions with no associated increase in unburned carbon in the fly ash or furnace exit CO. Burner alterations and water injection equipment based on the CFD model evaluation are currently being installed. Comparisons between the model predictions and the post retrofit performance will be provided.

A Predictive Emission Monitoring (PEM) model for predicting NOx emission from a gas turbine combustor has been developed by employing an optimized Neural Network (NN) architecture. The Neural Network was trained by using actual field test data and predicted results of a Computational Fluid Dynamics (CFD) model of the combustor. The field tests were performed at a natural gas compressor station driven by a General Electric (GE) LM1600 conventional gas turbine. The model takes eight fundamental parameters (operating and ambient) as input, and predicts NO and NOx as outputs. The data used for training the model covers the entire operating ranges of power and ambient temperature for the site. The CFD model employs a non-equilibrium (flamelet) combustion scheme and a set of 8 reactions including the Zeldovich mechanism for thermal NOx, and an empirical correlation for prompt NOx formation. The results predicted by the CFD model were within 15% of the measured values. Results of the field tests demonstrated that the spool speed ratio of the gas turbine remained constant throughout the tests, the power output of the engine was linearly proportional to the spool speeds, and the NOx emission was proportional to the site power output. A Multi Layer Perceptron type Neural Network with two hidden layers, each with four neurons was found to be the optimum architecture for the model. The NO levels predicted by the PEM model based on the optimized NN had a maximum absolute error of approximately 7%, mean absolute error of 2.3% and standard deviation of 1.97%. One year operating data for the site was submitted to the trained NN model with ambient temperatures varying from −29.9 °C to 35.7 °C and output powers from 5.8 MW to 17 MW. It was found that the model produced consistent contours of NO emissions. As expected, the NO levels were found to increase with increasing power and/or ambient temperature.

The use of hydrogen as derived fuel for low emission gas turbine is a crucial issue of clean coal technology power plant based on IGCC (Integrated Gasification Combined Cycle) technology. Control of NOx emissions in gas turbines supplied by natural gas is effectively achieved by lean premixed combustion technology; conversely, its application to NOx emission reduction in high hydrogen content fuels is not a reliable practice yet. Since the hydrogen premixed flame is featured by considerably higher flame speed than natural gas, very high air velocity values are required to prevent flash-back phenomena, with obvious negative repercussions on combustor pressure drop. In this context, the characterization of hydrogen lean premixed combustion via experimental and modeling analysis has a special interest for the development of hydrogen low NOx combustors. This paper describes the experimental and numerical investigations carried-out on a lean premixed burner prototype supplied by methane-hydrogen mixture with an hydrogen content up to 100%. The experimental activities were performed with the aim to collect practical data about the effect of the hydrogen content in the fuel on combustion parameters as: air velocity flash-back limit, heat release distribution, NOx emissions. This preliminary data set represents the starting point for a more ambitious project which foresees the upgrading of the hydrogen gas turbine combustor installed by ENEL in Fusina (Italy). The same data will be used also for building a computational fluid dynamic (CFD) model usable for assisting the design of the upgraded combustor. Starting from an existing heavy-duty gas turbine burner, a burner prototype was designed by means of CFD modeling and hot-wire measurements. The geometry of the new premixer was defined in order to control turbulent phenomena that could promote the flame moving-back into the duct, to increase the premixer outlet velocity and to produce a stable central recirculation zone in front of the burner. The burner prototype was then investigated during a test campaign performed at the ENEL’s TAO test facility in Livorno (Italy) which allows combustion test at atmospheric pressure with application of optical diagnostic techniques. In-flame temperature profiles, pollutant emissions and OH* chemiluminescence were measured over a wide range of the main operating parameters for three fuels with different hydrogen content (0, 75% and 100% by vol.). Flame control on burner prototype fired by pure hydrogen was achieved by managing both the premixing degree and the air discharge velocity, affecting the NOx emissions and combustor pressure losses respectively. A CFD model of the above-mentioned combustion test rig was developed with the aim to validate the model prediction capabilities and to help the experimental data analysis. Detailed simulations, performed by a CFD 3-D RANS commercial code, were focused on air/fuel mixing process, temperature field, flame position and NOx emission estimation.

The flameless oxyfuel combustion technology has been proven to be a promising new method to reduce the fuel consumption and pollutants in industrial applications [...]

Landfills and anaerobic digesters in the waste treatment processes generate biogas. Biogas can be used as a fuel and excess biogas is typically burned in a flare to reduce the greenhouse effect. However, burning biogas produces several pollutants, including CO2, NOx, and SO2. To minimize these emissions, the amount of excess air used in the combustion process needs to be considered, which has a significant impact on NOx emissions. This study developed a Computational Fluid Dynamics (CFD) model to simulate a small-scale biogas combustion system and analyses the effect of excess air on heat output and NOx emissions during biogas combustion. The GRI-Mech reaction mechanism was used to simulate reactions, and the model was validated by comparing it to experimental data from the DLR-Stuttgart CH4/H2/N2 Jet Flame. To reduce computational costs, a Tabulation of Dynamic Adaptive Chemistry (TDAC) algorithm was used to dynamically adapt the reaction mechanism in real time. Turbulence in the DLR flame was simulated using Reynolds-Averaged Navier-Stokes (RANS). The CFD model used a co-flow of a natural draft to provide additional air, while the air was premixed with fuel. The CFD model was used to simulate various premixed equivalent ratios, and the resulting emissions and heat outputs were compared. The study found that the optimal premixed equivalent ratio for the studied system was between 0.85 and 1.1, as this range produced the highest temperature and lowest NOx emissions. This model facilitates emission analysis of gas-phase combustion systems.

The study focuses on the influence of steam boiler load and air excess ratio on NOX emissions and efficiency. Experimental measurements of flue gas temperatures and oxygen concentrations were gathered for various load conditions. Adiabatic flame temperatures were estimated using enthalpy-temperature diagrams and Gaseq software, while the Zeldovich model was employed to estimate NOX emissions. It was observed that increasing the air excess ratio from 5% to 20% reduced the combustion temperature by approximately 180°C, which in turn decreased NOX emissions from 389 ppm (≈732 mg∙Nm−3) down to 46 ppm (≈86 mg∙Nm−3). However, this also led to a reduction in boiler efficiency, from 95.2% at optimal conditions to 92.3% at higher excess air. The analysis showed that maintaining an excess air level of 10–15% at partial loads and 15–20% at full load achieves compliance with NOX limits while sustaining efficiency above 93%. These results quantitatively confirm the trade-off between emission reduction and efficiency in converted gas-fired steam boilers. The study concludes that finding the optimal excess air level is essential to balance efficiency and NOX emissions in gas-fired steam boilers. Higher excess air reduces NOX emissions but lowers the efficiency, while lower excess air improves efficiency but may increase NOX emissions despite the significantly reduced availability of oxygen in the process. The relationship between the excess air and NOX emissions is complex and depends on load conditions. The findings highlight the need for comprehensive data collection and consideration of various factors in optimizing boiler performance.

The Salt Disposition Integration (SDI) portfolio of projects provides the infrastructure within existing Liquid Waste facilities to support the startup and long term operation of the Salt Waste Processing Facility (SWPF). Within SDI, the Blend and Feed Project will equip existing waste tanks in the Tank Farms to serve as Blend Tanks where 300,000-800,000 gallons of salt solution will be blended in 1.3 million gallon tanks and qualified for use as feedstock for SWPF. Blending requires the miscible salt solutions from potentially multiple source tanks per batch to be well mixed without disturbing settled sludge solids that may be present in a Blend Tank. Disturbing solids may be problematic both from a feed quality perspective as well as from a process safety perspective where hydrogen release from the sludge is a potential flammability concern. To develop the necessary technical basis for the design and operation of blending equipment, Savannah River National Laboratory (SRNL) completed scaled blending and transfer pump tests and computational fluid dynamics (CFD) modeling. A 94 inch diameter pilot-scale blending tank, including tank internals such as the blending pump, transfer pump, removable cooling coils, and center column, were used in this research. The test tank represents a 1/10.85 scaled version of an 85 foot diameter, Type IIIA, nuclear waste tank that may be typical of Blend Tanks used in SDI. Specifically, Tank 50 was selected as the tank to be modeled per the SRR, Project Engineering Manager. SRNL blending tests investigated various fixed position, non-rotating, dual nozzle pump designs, including a blending pump model provided by the blend pump vendor, Curtiss Wright (CW). Primary research goals were to assess blending times and to evaluate incipient sludge disturbance for waste tanks. Incipient sludge disturbance was defined by SRR and SRNL as minor blending of settled sludge from the tank bottom into suspension due to blending pump operation, where the sludge level was shown to remain constant. To experimentally model the sludge layer, a very thin, pourable, sludge simulant was conservatively used for all testing. To experimentally model the liquid, supernate layer above the sludge in waste tanks, two salt solution simulants were used, which provided a bounding range of supernate properties. One solution was water (H{sub 2}O + NaOH), and the other was an inhibited, more viscous salt solution. The research performed and data obtained significantly advances the understanding of fluid mechanics, mixing theory and CFD modeling for nuclear waste tanks by benchmarking CFD results to actual experimental data. This research significantly bridges the gap between previous CFD models and actual field experiences in real waste tanks. A finding of the 2009, DOE, Slurry Retrieval, Pipeline Transport and Plugging, and Mixing Workshop was that CFD models were inadequate to assess blending processes in nuclear waste tanks. One recommendation from that Workshop was that a validation, or bench marking program be performed for CFD modeling versus experiment. This research provided experimental data to validate and correct CFD models as they apply to mixing and blending in nuclear waste tanks. Extensive SDI research was a significant step toward bench marking and applying CFD modeling. This research showed that CFD models not only agreed with experiment, but demonstrated that the large variance in actual experimental data accounts for misunderstood discrepancies between CFD models and experiments. Having documented this finding, SRNL was able to provide correction factors to be used with CFD models to statistically bound full scale CFD results. Through the use of pilot scale tests performed for both types of pumps and available engineering literature, SRNL demonstrated how to effectively apply CFD results to salt batch mixing in full scale waste tanks. In other words, CFD models were in error prior to development of experimental correction factors determined during this research, which provided a technique to use CFD models for salt batch mixing and transfer pump operations. This major scientific advance in mixing technology resulted in multi-million dollar cost savings to SRR. New techniques were developed for both experiment and analysis to complete this research. Supporting this success, research findings are summarized in the Conclusions section of this report, and technical recommendations for design and operation are included in this section of the report.

Integrated Gasification Combined Cycle (IGCC) combines gasifier, gas turbine, and steam turbine to increase the electricity production efficiency while having lower emissions compared to conventional coal fired power plants. The syngas produced from coal gasification differs from natural gas in terms of composition, heating value, as well as combustion characteristics. Typically, syngas has much lower heating value than natural gas, thus the flow rates of the syngas are higher than that of natural gas for a similar size gas turbine. In addition, the hydrogen in the syngas may lead to more rapid combustion and higher flame temperature compared to natural gas, which may result it more NOx emission. Thus, to address these issues, syngas could be diluted with nitrogen, steam or carbon dioxides to lower the flame speed and temperature. The effects of different diluents on the fuel economy and emissions are investigated by a combined thermodynamic and computational fluid dynamics (CFD) model. The thermodynamic model was first established and validated by the industrial operational data. More power output and better fuel economy can be achieved using N2 and CO2 as diluent instead of steam from calculation with the thermodynamic model. A numerical case study was done to estimate the profit using nitrogen instead of the steam considering in industrial operation conditions as well as all other costs. Next, the CFD model was employed to further examine the combustion stability and NOx emissions. The results show that changing diluent from steam to nitrogen will not impact the combustion stability and may lead to slightly lower NOx emissions. Finally, the partial replacement of steam by nitrogen as diluent has been realized and the industrial operational performance has also been reported.

Predictions of CO and NOx emissions from steam cracking furnaces using GRI2.11 detailed reaction mechanism – A CFD investigation

Multi-objective optimization of the performance for a marine methanol-diesel dual-fuel engine

Computational fluid dynamics modeling of abutment scour under steady current using the level set method

Experimental and theoretical analysis of effects of N2, O2 and Ar in excess air on combustion and NOx emissions of a turbocharged NG engine

Numerical analysis of NOx formation mechanisms and emission characteristics with different types of reactants dilution during MILD combustion of methane and coke oven gas

Combustion characteristic study with a flue gas internal and external double recirculation burner