Micro-Mixing Lean-Premix System for Ultra-Low Emission Hydrogen/Syngas Combustion

摘要

The focus of this project was to develop the next generation of fuel injection technologies for environmentally friendly, hydrogen syngas combustion in gas turbine engines that satisfy DOE's objectives of reducing NOx emissions to 3 ppm. Building on Parker Hannifin's proven Macrolamination technology for liquid fuels, Parker developed a scalable high-performing multi-point injector that utilizes multiple, small mixing cups in place of a single conventional large-scale premixer. Due to the small size, fuel and air mix rapidly within the cups, providing a well-premixed fuel-air mixture at the cup exit in a short time. Detailed studies and experimentation with single-cup micro-mixing injectors were conducted to elucidate the effects of various injector design attributes and operating conditions on combustion efficiency, lean stability and emissions and strategies were developed to mitigate the impact of flashback. In the final phase of the program, a full-scale 1.3-MWth multi-cup injector was built and tested at pressures from 6.9bar (100psi) to 12.4bar (180psi) and flame temperatures up to 2000K (3150 F) using mixtures of hydrogen and natural gas as fuel with nitrogen and carbon dioxide as diluents. The injector operated without flash back on fuel mixtures ranging from 100% natural gas to 100% hydrogen and emissions were shown to be insensitive to combustor pressure. NOx emissions of 3-ppm were achieved at a flame temperature of 1750K (2690 F) when operating on a fuel mixture containing 50% hydrogen and 50% natural gas by volume with 40% nitrogen dilution and 1.5-ppm NOx was achieved at a flame temperature of 1680K (2564 F) using only 10% nitrogen dilution. NOx emissions of 3.5-ppm were demonstrated at a flame temperature of 1730K (2650 F) with only 10% carbon dioxide dilution. Finally, 3.6-ppm NOx emissions were demonstrated at a flame temperature over 1600K (2420 F) when operating on 100% hydrogen fuel with 30% carbon dioxide dilution. Superior operability was demonstrated for the hydrogen-natural gas fuel. The micro-mixing fuel injectors show great promise for use in future gas turbine engines operating on hydrogen, syngas or other fuel mixtures of various compositions, supporting the Department of Energy goals related to increased energy diversity while reducing greenhouse gases.