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Landfill gas and biogas are typical LCV fuels.

The application
Extension of Fuel Flexibility in the for these types of gases as a renewable energy source, instead of
Siemens Dry Low Emissions releasing or flaring to the atmosphere, offers environmental bene-
fits. The reduction in methane as a greenhouse gas is important
SGT-300-1S to Cover a Wobbe Index since this is approximately 21 times more harmful to the atmos-
phere than CO2. The combustion of these LCV fuels using the
Rangeofl5to49MJ/Sm^ SITL DLE combustion system produces significantly lower emis-
sions and reduces the usage of fossil fuels.
Kexin The LCV fuels typically have a lower WI, which is an indicator
of the interchangeability of fuel gases and is defined as the ratio of
e-mail: kexin.liu@siemens.com the lower heating value (LHV) to the square root of the specific
gravity (SG) of the fuel (WI = UW/y/SG). The WI is used for
Varkey Alexander the comparison of the energy release from gaseous fuels with dif-
ferent compositions; for example, if two fuels have identical WIs
Victoria Sanderson then the energy release will also be identical, given the same volu-
metric flow rate. This is used as the primary factor in the evalua-
Ghenadie Bulat tion of the gas fuel flexibility on a gas turbine.
The SGT-300-IS SITL DLE combustion system was extended
Siemens Industrial Turbomachinery Limited, to allow a weak wellhead gas to be used, followed by the use of
Lincoln, LN5 7FD, United Kingdom PLG, the latter with a WI of 30 MJ/Sm^. Significant operational
experience has been achieved with the SITL DLE system across
the product range, including more than 3 x 10^ operating hours on
The extension of gas fuel flexibility in the Siemens SGT-300 single the SGT-300-IS. Maturity in the technology has enabled a lead
shaft (SGT-300-1S) is reported. A successful development program site to operate with an extended variable fuel range with high reli-
has increased the capability of the Siemens Industrial Turbomachi- ability and meets customer's emission guarantee requirements.
nery, Lincoln (STTL) diy low emissions (DLE) burner configuration This experience provided the justification to investigate a further
to a fuel range covering a Wobbe index (Wl)from 15 to 49MJISm^. extension of the range of fuels for the SGT-300-IS.
The WI reported in this paper is at a 15 °C fuel temperature. The The development work has successfully targeted extending
standard SGT-300-1S SITL DLE combustion hardware allows for the range of fuels for the SGT-300-IS to a WI between 15 and
gas and liquid fuels within a specified range typically associated 49 MJ/Sm^. The high pressure air facility (HPAE) used to demon-
with natural gas and diesel, respectively. The range of the WI associ- strate the capability of the combustion system is linked to a plant
ated with natural gas is 37^9 MJ/Sm^. Eietd operation of the stand- capable of mixing the representative gases. Euels with a defined
ard production SGT-300-1S has confinned the reliable operation WI were tested at actual engine conditions in a single SITL DLE
with an extension to the fuels range to include processed landfill gas combustion system. The standard engine hardware was capable of
(PLG) from 30 to 49MJISm^. The further extension of the fuel range covering the range to 23 MJ/Sm^ and the additional extension to
for the SGT-300-1S SITL DLE combustion system was achieved 15MJ/Sm^ was achieved by small modifications to the standard
through high pressure testing of a single combustion system at bumer. These were related to the internal bumer fuel supply since
engine operating conditions and representative fuels. The variations the reduction in the WI results in an increase in fuel mass flow.
in the fuel heating value were achieved by blending natural gas with The modifications were required to maintain a target pressure loss
diluent CO2 and/or N2. Various diagnostics were used to assess the through the bumer and to maintain a consistent level of mixing.
performance of the combustion system, including the measurement This paper provides the background for the fuel extension de-
of combustion dynamics, temperature, fuel supply pressure, and the velopment for the SGT-300-IS by presenting field experience on
emissions of N0„ CO, and unburned hydrocarbons (UHCs). The the reliability of the system in transient loading with standard gas
results of the testing showed that the standard production burner fuel, extended gas fuel ranges, and liquid fuel. This is achieved
can operate for a fuel with a WI as low as 23 MJISm^, which corre- with the SITL DLE combustion system consistently providing
sponds to 35% CO2 (by volume) in the fuel. This range can be low emissions. The results of an extensive test campaign in the
extended to l5MJISm^ (54.5% CO2 in the fuel) with only minor HPAE are then presented to prove the capabilities of the SITL
modification to control losses through the burner and to maintain DLE combustion system to operate with a range of fuels with a
similar fuel injection characteristics. The SITL DLE combustion sys- Wlof 15to49MJ/Sml
tem is able to cover a WI range of 15 to 49MJISm^ in two configura-
tions. The results of testing showed a lowering in the WI, by diluting
with CO2 and/or N2, so that a benefit in the NO,, reduction is The SITL DLE Combustion System
observed. This decrease in the WI may lead to an increased require- The SITL DLE combustion technology is applied across the
ment of the fuel supply pressure. [DOÍ: 10.1115/1.4007730] range of small-scale industrial gas turbines from 4MW to 15MW
(SGT-100 to SGT-400). The operational experience on these DLE
Introduction engines has accumulated more than 20 x 10* hr. The combustion
system consists of three main sections: the pilot bumer, the main
In order to tackle the issues associated with fuel security and bumer, and the combustor; for details refer to Refs. [1-3]. The main
environment, fuel flexibility must be considered for power genera- bumer is a radial swirler with fuel injection in the vane passage.
tion. This presents a design challenge for industrial gas turbines to The swirler number is sufficiently high to create a vortex breakdown
ensure reliability with varying fuels across an operational range. reverse flow feature along the axis of the combustor [1,3]. This flow
In this paper, the extension to the standard gas fuel range is con- feature is called an intemal reverse flow zone or central recircula-
sidered, with lower calorific values (LCVs) than natural gas, and tion zone. In the DLE concept, this reverse flow zone remains
the fuels primarily consist of natural gas diluted with CO2 and/or attached to the pilot surface of the combustor, thereby establishing a
N2. firm aerodynamic base for flame stabilization. Due to the sudden
expansion of the combustor, an extemal reverse flow zone is estab-
'Corresponding author. lished. The flame is stabilized in the aerodynamically generated
Contributed by the Combustion and Fuels Committee for publication in the shear layers around the intemal and extemal reverse flow regions.
JOURNAL OF ENGINEERING FOR GAS TURBINES AND POWER. Manuscript received June 18,
2012; final manuscript received August 16, 2012; published online January 8, 2013. Euel is introduced in two stages with gas and liquid. Eirst, with
Editor; Dilip R. Ballal. the main injection, which has a high degree of premixing and.

Journal of Engineering for Gas Turbines and Power FEBRUARY2013, Vol. 135 / 024502-1
Copyright © 2013 by ASME
hence, low NOx emissions and second, with the pilot, which is
steadily increased as the load demand decreases, in order to ensure
flame stability [1,3].

The SGT-300-1S Standard Engine Performance for WI


From30to49MJ/Sm^
A standard SGT-300-1S engine has been operating at the Uni-
versity of New Hampshire (UNH, USA) since 2006 and has tri-
fuel capability: diesel, natural gas, and PLG. This site is a com-
bined heat power plant with a 10 ppmv (at 15% O2) NO^ guaran-
tee at full load and 25 ppmv down to 49% load; for details refer to
Refs. [1,4].
The raw landfill gas is extracted from more than 300 wells and
compressed miles away from the power plant. The untreated land-
fill gas is further processed, i.e., the removal of the noncombustible
compounds, particularly the volatile organic compounds and silox-
anes. After processing, the landfill gas has 70 to 83% methane by
volume and the rest is balanced by N2, O2, and CO2. The corre-
sponding fuel heating value has a WI between 26 and 34MJ/Sm^.
In the power plant the cleaned landfill gas can be blended with nat-
ural gas to boost its WI value to above 30 MJ/Sm'' prior to combus-
tor entry. The 30MI/Sm'' limit is not the restriction of the
combustion system capability limit, as one can see that the standard
combustion system can operate for a WI as low as 23MI/Sm\ as
tested in the HPAF. This limit is because of the gas compression
limit in the power plant. Hence, either 100% cleaned landfill gas or
the blend with natural gas is used to power the gas turbine, depend-
ing on the landfill gas availability, its calorific value, and engine
power requirements. The WI of the gas is monitored by a gas Chro-
matograph just before entry into the gas turbine skid. 7:00 9:t)0 21:00 23.-00

An intelligent control algorithm has been commissioned in the


power plant [1] and the stable operation of the engine achieving Fig. 1 Standard SGT-300-1S engine continuous operation with
values below 9 ppmv NOx has been achieved at full load for a fuel trifuel flexibility at UNH, showing smooth and stable transient
supply varying between a Wobbe index of 29.7 and 49 MJ/Sm' [1]. operation with fuel change over
Figure 1 shows the standard engine continuous operation with
trifuel flexibility at this site: diesel, natural gas, and PLG on 21 Table 1 Fuel with different WIs and their compositions used in
Oct 2009 over a period of 16hr. The WI, NOx, combustion the rig testing
dynamic pressure, and corresponding engine load are shown. The
NOx emission guarantee has been achieved since the NOx values WI UKNG CO2
are below 10 ppmv at full power for both the natural gas and PLG (MJ/Sm^) (% VO].) (% vol.) (% vol.)
and are below 50 ppmv for liquid fuel. The amplitude of the com-
bustion dynamic pressure is well within the acceptable level for 45 100 0 0
gas turbine operation. Figure 1 also provides a snapshot of the 40 93.2 6.8 0
testing: during this period, the gas turbine experienced both slow 32 78 6 16
and fast transient responses from accepting and rejecting of the 30 77.3 22.7 0
load during changes in fuel composition. The results showed that 30 72.1 0 27.9
27 68.93 22.83 8.24
the transient operation is smooth and stable over the fuel change 25 67.9 32.1 0
over a range of gaseous fuels for a WI from 30 to 49 MJ/Sm^. 23 65 35 0

High Pressure Rig Testing on Standard Burner for WI


From23to49MJ/Sm^ engine performance when the WI is decreased for the same TET
The HPAF includes a mixing plant, which allows the blending is the increase in the power achieved due to the increased mass
of various fuel components to achieve a WI with a target fuel flow of the fuel.
composition. The fuels tested had a range of WIs varying from 23 The impact of the WI on the emissions of NOx, CO, and the
to 45 MJ/Sm"* with natural gas blended with CO2 and/or Ni; the main fuel supply pressure is shown in Fig. 2. The pilot split (the
details of the fuel compositions are listed in Table I. Fuel supply fuel mass flow ratio through the pilot burner to the total fuel con-
pressure limitations precluded testing below 23 MJ/Sm"\ The WI sumed) was the same as the engine standard for a WI range
was measured by a gas Chromatograph and the fuel temperature between 27 MJ/Sm"* and natural gas. The lower WI range of 23
was kept at a constant level. and 25 MJ/Sm"^ required a higher pilot split to maintain the same
Emissions recorded along with other information such as com- low level of combustion dynamics pressure amplitude (the root
bustion dynamics, fuel pressure, and burner and combustor metal mean square pressure pulsation). The NOx reduces as the WI
temperature enabled the combustor design to be evaluated. The decreases over the load range and the gradient for the NO^ reduc-
technique for the emissions measurement was described in Ref. tion, at a lower WI, is higher at part load than that at full load.
[2] and the equipment used is compliant with ISO-11042. The higher level of the NOx at low load is associated with the
The predicted performance of the engine at various load and higher pilot being used in order to enhance the transient reliability
ambient conditions was used to define the test condition parame- of the engine.
ters such as air pressure, temperature, mass flow rate, and turbine There are a number of factors that can contribute to the reduc-
entry temperature (TET). An interesting consideration in the tion in NOx with a decrease in the WI by adding diluents in the

024502-2 / Vol. 135, FEBRUARY 2013 Transactions of the ASiVIE


50

ig
2S--

1 0 0 « load K)%toad
-t-
)^25% & 5% loacfe
s
Wl 27, standmd plot

75% load Wl 23, higher pilot


* • • • « > . . - ,

%lc
• 00
1.4
0 10 20 30 40 SO 60 70 80 90 100 110
Load (%)

Fig. 3 Standard burner test results: burner temperature and


combustion dynamics

gas. The frequencies associated with this amplitude are in the


lower range, which is typical of the lean blow out (LBO) frequency.
Periodic detachment of the flame front from its flame holder near
the LBO limit was observed [17] and the low frequency flame pul-
Fig. 2 Standard burner test results: emissions and main fuel sation was found to be dependent on the pilot split.
supply pressure Bulat et al. [1] showed that the frequency of the pressure pulsa-
tion in engine operation of the SGT-300-1S was in the same
range. The frequency was found to reduce with a decreasing WI
reactants: (a) the reduction in the flame temperature slows the and an increased amplitude. The engine test and the single com-
chemical reaction rate and leads to the reduction in the laminar bustor test showed that the combustion dynamics behaved differ-
flame speed [5-10]; (b) the change in the chemical reaction ently according to the initial amplitudes and the percentage of N2
reduces the size of the O/H/OH radical pool and suppresses the dilution in the fuel [18]. The lOMW engine test results showed
formation of NO^ [11-13]; (c) the increase in the fuel jet penetra- that when the CO2 content was higher than 20%, a higher pilot
tion reduces the level of unmixedness for industrial application split was used [19] and the combustion dynamic pressure ampli-
[14]; (d) the reduction in the burnt gas residence time reduces the tude, for a frequency between 40 to 45 Hz, increased with the
thermal NOx from the Zeldovich mechanism. The details of the increasing CO2 concentration. It was also noticed that the fre-
analysis can be found in Ref. [15]. quency shifts towards the lower value at this particular band,
At full load, CO is unmeasurable, however, it rapidly increases although the author did not mention this finding. Outside of this
as the load is reduced. In general, the CO is seen to increase with frequency band, the CO2 had little effect on the pressure
a reduction in the WI at part loads. The increased production of pulsation.
CO may be due to the dissociation of the CO2 in fuel lean flames Lafay et al. [6] identified the fact that flame instabilities, result-
and a reduced oxygen content to complete the oxidation of CO ing from low frequency pressure oscillation, can appear below a
[16]. The shorter resident time of burnt gas due to the higher mass critical equivalence ratio value when diluting premixed flames
flow could also prevent the CO converting to CO2. The UHC is with CO2. One of the mechanisms which induced instabilities is
less than 10 ppmv at 50% load for all WIs tested [15] and this low linked to the laminar flame speed and flame thickness. An increase
level of the UHC indicates that the combustion efflciency is not of flame thickness can be seen in the CO2 diluted flames: for a
adversely affected by the lower calorific value fuel. given equivalence ratio, the higher the dilution rate, the thicker
The main burner fuel supply pressure was normalized by the the flame [6,7]. A flame diluted with CO2 also shows a weaker an-
fuel supply pressure for natural gas. At a low load (5%), the chorage than for the methane-air flame [20], a reduction in the
impact of the WI variation is insignificant, due to the fact that extinction strain rate [8,16] and a change in the flame position [9].
much of the fuel is in the pilot stream rather than the main stream. The NOx emissions from the standard combustion system tested
At loads of 25% and higher, a reduction in the WI value results in in the HPAF were compared with those from a standard engine
a higher main fuel supply pressure. The main burner pressure operating at site at a WI of 32 MJ/Sm"* and are reported in Ref.
requirement increased by more than 30% for a WI of 23 MJ/Sm"*, [15]. An excellent agreement in the NO^ emissions between the
compared to natural gas for loads between 50% and 100%. HPAF and the engine is achieved. Some effect of the change in
Figure 3 shows the influence of the WI on the burner metal tem- the composition is also observed in the engine test points. The
perature and the combustion dynamic pressure. The burner metal higher content of N2 in the mixture results in higher NOx emis-
temperature was normalized at full load natural gas condition. sions [21,22]. The good agreement between the rig test and engine
The decrease in the burner metal temperature with the WI could performance provides confidence in the translation of the rig
indicate changes in the flame position and/or a reduction in the results presented in this paper to the engine scale.
flame temperature. The combustion dynamic pressure amplitude The SGT-300-1S standard combustion system can operate on
measured over the range of loads is well within the acceptable fuels with a WI as low as 23 MJ/Sm"^. The use of fuels with these
level for gas turbine operation. As aforementioned, only at a WI lower WIs can provide an environmental benefit through the use of
of 23 and 25 MJ/Sm^, a higher pilot split was required to maintain waste gases and by providing power with reduced NOx emissions.
the combustion dynamic amplitude at a level similar for natural The increased mass flow of the fuel with increasing dilution leads

Journal of Engineering for Gas Turbines and Power FEBRUARY2013, Vol. 135 / 024502-3
to a requirement for higher supply pressures. This could have costly higher pilot split required at a low Wl disguises the expected
plant implications if large gas compressors were required to supply reduction in emissions. However, at part loads of 50% and 75%, a
the fuel. A further extension to the fuels capability has therefore significant reduction in NOx can be seen as the WI decreases. This
been achieved with minor modifications to the burner in order to gradient of NOx is also observed at 25% load although the gradi-
maintain the burner supply pressure at an acceptable level. ent is not so steep.
. The CO emissions for part loads greater than 50% are pre-
sented. Full load CO emissions are not included since they were
Development of Burner for WI 15 to 45 insignificant across the range of WIs. The trend observed in the
The increase in the pressure as the WI is reduced is required standard burner is replicated with higher CO emissions as the WI
due to the constant geometry of the burner with the increasing is reduced. For a WI of less than 25 MJ/Sm', 10 ppmv CO cannot
fuel mass flow. An analysis of the losses in the burner allowed a be achieved even at 90% load. As previously discussed, the reduc-
minimum of modifications of the burner to be made in order to tion in the fiame temperature and shorter resident time contribute
maintain lower supply pressures. The modifications were primar- towards the uncompleted conversion from CO to CO2, thus
ily made to the fuel injection holes with the effective area increasing emissions. This will need to be considered during the
increased based on maintaining a pressure drop comparable to nat- project/application technical review.
ural gas. A secondary consideration was to maintain a similar The burner temperature reduces with the reducing WI, which
level of mixing in the burner, indicating fuel jet penetration is to again correlates to the findings on the standard burner shown in
be considered as a design parameter. Fig. 3. The combined effect of the flame moving downstream and
A further test campaign with a modified burner was performed the change in the fiame temperature are believed to cause the
in the HPAF and the range of fuels considered varied between a reduction in temperature with the WI.
WI of 15 MJ/Sm^^ (54.5% CO2 with 45.5% natural gas by volume) The fuel pressure drops across the main burner at full load
and UK natural gas at 45 Ml/Sm"*. In common with the standard APf = {Pf -Pa)/Pa X 100%, which is the normalized pressure
burner, it was found that the normal engine pilot split schedule difference between the fuel supply pressure Pf and the combus-
could be used for a WI of 27 MJ/Sm' and above. Below this value, tion air pressure P„ in the burner. The practical impact of the
the pilot split had to be increased in order to maintain the combus- design change is shown in the supply pressure requirement, which
tion dynamics at the same low level observed with natural gas. is reduced significantly with the modified burner.
The HPAF testing results for the modified burner are shown in
Fig. 4. At full load, the NOx is low and is consistently less than 10 Summary
ppmv for all WIs considered. A gradient is not observed in the Figure 5 is the summary for the standard and modified burners
NOx with a WI at full load due to the effect of the pilot split: the on emissions and burner metal temperatures for the different WI
fuels with only CO2 as a diluent in the natural gas to provide a
more fundamental insight. The metal temperature was normalized
to the standard burner temperature at full load natural gas
condition.

stadanl bwner 75% load


edtHirrar7S%ioad
standard burner 50% lowi
„ modified burner 50% toad
:r^^j2^J «
I 8tàid«dbt»ner 1 0 ^ ^ * * - "-*•**"''^
•-—v
modifKd bumer 100% toad

modffied t>umer50% load

O 75% load
A S0% load 8 A ~~--star»Ùwdbutt«r75%toad
~ modified bumef 75% load
O 25% toad
X 5% toad

0 5 10 IS 20 25 30 35 40 45 50 55 60
10 15 20 30 35 40 45 50

Fig. 5 Summary results: effect of CO2 addition in the fuei on


Fig. 4 Modified burner test resuits the emissions and burner metal temperature

024502-4 / Vol. 135, FEBRUARY 2013 Transactions of the ASME


Generally, NO^ reduces as more CO2 is added into the fuel. At References
the full load condition the modified bumer has a lower NOx and II] Bulat, G.. Liu. K.. Brickwood. C . Satideison, V.. and Igoe. B., 2011,
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|2] Kowkabie, M., Noden, R., atid De Pietro, S., 1997. "The Development of a Dry
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"Biodie.sel as an Alternative Fuel in Siemens Dry Low Emissions Combustors:
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CO2 is less than 25% and the temperature difference between the |4] University of New Hampshire, 2012. "UNH Cogeneration Facility," http://
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[5] Ren, J. Y., Egolfopoulos, F. N., Mak. H., and Tsotsis, T. T., 2002, "NO, Emis-
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bumer at full load may indicate that the aerodynamics feature is Reforming Products," Combust. Sei. Technol., 174, pp. 181-205.
modified due to the fuel jet penetration change caused by the fuel [6] Lafay, Y.. Renou, B., Cabot. G., and Boukhalfa. M., 2007, "Experimental
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The successful development of the SGT-300-1S SITL DLE [8] Ren, J. Y., Qin. W.. Egolfopoulos, F. N., Mak, R, and Tsotsis. T. T., 2001,
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