Abstract:
The invention provides a new path of combustion technology for gas turbine operation with multifuel capability, low emissions of NO and CO and high thermal efficiency. Further to the present invention providing a method for operating a combustor for a gas turbine and a combustor for a gas turbine are disclosed. The combustor includes a first combustion chamber with a wide operating range, a subsequent deflection unit for deflecting the hot gas flow of the first combustion chamber at least in circumferential direction and components for injecting and mixing additional air and/or fuel, and a sequential combustion chamber with a short residence time, where the temperature of the hot gases reaches its maximum.

Description:
CROSS-REFERENCE TO RELATED APPLICATIONS 
       [0001]    This application claims priority to European application 13006011.4 filed Dec. 24, 2013, the contents of which are hereby incorporated in its entirety. 
       TECHNICAL FIELD 
       [0002]    The invention relates to a method for operating a combustor for a gas turbine with multifuel capability, an increased thermal efficiency and reduced emissions of NO x  and not fully oxidized fuel, particularly CO. In addition, the invention relates to a combustor for a gas turbine. 
       BACKGROUND 
       [0003]    In known gas turbines—both aircraft engines and stationary gas turbines for generation of electricity—the fuel is more or less completely converted into combustion products, mainly CO 2  and H 2 O, within the combustion chamber. In a guide vane row, downstream of the combustion chamber, the exhaust gases are accelerated and deflected towards at least one blade row to perform mechanical work. Usually a couple of vane and blade row stages are subsequently arranged to exploit the kinetic and thermal energy of the hot gas flow. 
         [0004]    The maximum temperature reached in the combustion chamber and the residence time of the combustion products in the combustion chamber dictate the undesired production of NO x  and CO. Less important parameters for the generation of nitrogen oxides are the pressure in the combustion chamber and the fuel composition. 
         [0005]    It is known per se to achieve a substantial local reduction of the maximum combustion temperature and the residence time at this temperature and thus the formation of undesired nitrogen oxides by improving the quality of mixing of fuel and air, including homogenization of fuel and air mixture within a premixing burner or swirl generator elements or between individual burners or swirl generator elements, or by reducing the leakage of air and heat loss of the combustion chamber or by reducing the residence time of the hot combustion gases in the combustion chamber. Such improvement measures become increasingly challenging and the achievable NO x  reductions become smaller. 
         [0006]    The reduction of NO x -formation through a reduction in the residence time is limited, because CO-emissions increase at part load. 
         [0007]    One way for reducing the combustion temperature while maintaining the same rotor inlet temperature is to cool the turbine vanes with a closed cooling circuit, using steam as a coolant. 
         [0008]    Disadvantages of this method are the complexity of an additional cooling management, the additional costs and a to a certain degree lower reliability and availability of the system. 
         [0009]    WO 2006/053825 and DE 10043933 describe a combustor to achieve reduced pollutant emissions, particularly NO x , by a first combustion chamber with a relatively low residence time with the consequence of an incomplete burnout, a first vane row downstream of the first combustion chamber, and following a second combustion zone, a sequential combustion chamber, with or without injection of additional fuel and with sufficient residence time for complete burnout. Said first vane row aligns the flow of the hot combustion gases in axial direction. In addition, the gas flow is accelerated with the consequence of a significant reduction of its temperature. Accordingly, the temperature in the second combustion zone is lower than in the first combustion chamber. This lower temperature level is matched with the parameters of NOx-formation. In this way, a significant reduction of NOx-formation is reached. 
         [0010]    WO 2011/061059 relates to a reheat combustor for a gas turbine. This document discloses features, how to cool the first and the sequential combustion chamber by cooling air, which is subsequently supplied to the combustion chamber and premixed with fuel. The goal is to reduce the difference between combustor exit temperature and the maximum temperature in the premixed flame to a minimum, thus reducing the strongly temperature dependent NO x -formation. 
       SUMMARY 
       [0011]    The invention provides a new functional principle of sequential combustion technology for gas turbine operation, based on premixed combustion with multifuel capability, that allows combustion with very low emissions of NO x  and very low emissions of not fully oxidized fuel, particularly CO, at high outlet temperatures of 1820 K or more at the sequential combustion chamber. 
         [0012]    According to the present invention a method for operating a combustor for a gas turbine and a combustor for a gas turbine are disclosed, the combustor at least comprising a first combustion chamber with a wide operating range, a subsequent deflection unit for deflecting the hot gas flow of the first combustion chamber at least in circumferential direction and including means for injecting and mixing additional air and/or fuel, and a sequential combustion chamber, where the temperature of the hot gases reaches its maximum, whereby in the first combustion chamber the premixed fuel air mixture is combusted in a stable flame at an average flame temperature in the range between 1400K and 1800K to allow CO-emissions and NOx-emissions below 10 vppmd at the exit of the first combustion chamber, at the downstream end of the first combustion chamber a mass flow of additional air is injected into the hot gas flow in order to reduce the temperature below 1400 K, preferably below 1350 K, which allows the injection of additional fuel downstream of said air injection, generating a mixture of hot exhaust gas, air and fuel with auto ignition times between 1 ms and 10 ms, wherein said mixture enters the deflection unit and is deflected there at least in a circumferential direction, but is not reacting until reaching the sequential combustion chamber, where the mixture is burned by auto-ignition and/or a combination of auto-ignition and recirculation of hot reaction products. 
         [0013]    According to a first preferred embodiment the first combustion chamber is a premix combustor with an operating range between 1550 K and 1800 K (relating to the average flame temperature), more preferably between 1600 K and 1800 K. 
         [0014]    According to another embodiment the residence time in the first combustion chamber is 15 ms to 30 ms. 
         [0015]    According to a particularly preferred embodiment the residence time in the first combustion chamber is approximately two to five times longer than the residence time in the sequential combustion chamber with a residence time of about 3 ms to 10 ms. 
         [0016]    According to a first aspect, the injection of additional air in the exit area of the first combustion chamber allows an operation of this first combustor at high enough temperatures for stable CO emissions on a low level. 
         [0017]    According to a second aspect, this injection moderates the temperature of the exhaust gas to a temperature level low enough to avoid an immediate autoignition within 1 ms, but high enough to have an autoignition within 3 ms to 10 ms, with the consequence of an autoignition not before reaching the sequential combustion chamber. 
         [0018]    According to a third aspect, this reduction of the hot gas temperature in front of the deflecting and accelerating vanes in the deflection unit makes it possible to eject only very small amounts of cooling air into the through flow in a range of less than 4% of the through flow. As a consequence the aerodynamic losses in the deflecting and accelerating vanes can be reduced to a minimum (reduced mixing losses, thinner trailing edges of the vanes). 
         [0019]    According to another important embodiment downstream of the mixing section, i.e. in an upstream section of the sequential combustion chamber, the hot gas flow (mixture of exhaust, air and fuel) passes an area of a sudden cross-sectional enlargement, such as a backwards facing step. A reverse flow zone is generated after the step, wherein this reverse flow zone defines a flame anchoring point at the entry into the sequential combustion chamber. 
         [0020]    The generation of a recirculation zone in the upstream section of the auto ignited sequential combustion chamber allows that, apart from the auto ignited reaction front, propagating flame fronts which mix reaction products with the unreacted educts of the mixture of exhaust, fuel and air are generated. As a consequence the location of heat release in the sequential combustion chamber is more stable in time as well as in space and in addition shows less variance for a varying fuel composition or first combustor exit temperature. 
         [0021]    All these effects allow a very broad operation range of the combustion system with reference to pressure, inlet and outlet temperature variation, fuel composition). 
         [0022]    The high entry temperature level in the sequential combustion chamber allows complete combustion of the mixture of fuel and air and exhaust from the first combustor within a very short residence time. As a consequence, the NO x - and CO-levels at the end of the sequential combustor are at the same level as at the end of the first combustor, i.e. CO emissions &lt;10 vppmd or at equilibrium CO levels and NOx emissions &lt;10 vppmd. 
         [0023]    Regarding multifuel capability of the combustion system according to the invention there are options: both the first combustor and the second combustor are operated with gaseous fuel as well as with liquid fuel or both the first combustor and the second combustor are operated with gaseous fuel and the first combustor may additionally be operated with liquid fuel or both the first combustor ( 1 ) and the second combustor ( 3 ) are operated with liquid fuel and the first combustor ( 1 ) may additionally be operated with gaseous fuel. 
     
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         [0024]    In the following the invention will be described in greater detail by means of exemplary embodiments with reference to the accompanying drawings, in which: 
           [0025]      FIG. 1  illustrates in a schematic way a first embodiment of a combustion chamber with an integrated deflection unit; 
           [0026]      FIG. 2  shows a another embodiment of a combustion chamber according to the invention; 
           [0027]      FIGS. 3   a  and  3   b  show vanes with a corrugated ( FIG. 3   a ) or lobed ( FIG. 3   b ) trailing edge for enhancing the formation of vortices in the hot gas flow; 
           [0028]      FIG. 4  illustrates schematically a combustion chamber with step expansion into the sequential combustor; 
           [0029]      FIGS. 5   a  and  5   b  show in more detail embodiments of a sudden enlargement of the flow cross section. 
       
    
    
     DETAILED DESCRIPTION 
       [0030]      FIG. 1  shows in a schematic way a longitudinal sectional view of a gas turbine with a reheat combustion system. The gas turbine comprises a compressor, the combustion system  1 ,  2 ,  3 ,  4 ,  5 ,  6 ,  9 ,  10  and a turbine  19 , extending circumferentially around a rotor  23  with a rotational axis  18  and at least a first row of turbine blades  8 . The combustion system comprises an integrated deflection unit  2  between a first combustion chamber  1  and a sequential combustion chamber  3 . The first combustion chamber  1  is a premix combustor with a number of annularly arranged premixing burners  4 , each burner  4  connected to a plenum for supplying combustion air  5  and to one or more fuel supply lines  6  for liquid and/or gaseous fuel. The sequential combustion chamber  3  is based on auto-ignition. The first vane row  11  of the turbine  19  is integrated into the combustion system in a position far upstream from the first blade row  8 . In this position the first vane row  11  separates the sequential combustion chamber  3  from the first combustion chamber  1 . This first vane row  11  acts as deflection and mixing unit  2 , as described below. As can be seen from  FIGS. 1 and 2  the first vane row  11  is positioned on a significantly larger radius (compared to the rotational axis  18 ) than the first turbine blade row  8  and the sequential combustion chamber  3  is used as a transition piece to compensate the difference in the radii. 
         [0031]    In operation of the gas turbine combustion air is compressed by the compressor and supplied to the premixing burners  4 , fuel is injected into the air and a fuel-air mixture is generated and burnt downstream of the burners  4  in a combustion zone  7  of the first combustion chamber  1 . The temperature of the reaction products at the exit of the first combustion chamber  1  is in the range between about 1450 K and 1780 K, which allows a stable combustion with low emissions (NO x &lt;10 vppmd and CO&lt;10 vppmd) over the entire operating range and which is suitable for both gaseous fuels (natural gas, hydrogen, synthesis gas, etc.) and liquid fuels (oils). The combustor residence time is preferably below 30 ms. 
         [0032]    At a downstream end of the first combustion chamber  1  and upstream of the first vane row  11  means are positioned for injecting a mass flow of additional air  9  into the hot gas flow (see  FIG. 2 ). By this additional mass flow of fresh air  9  the temperature of the resulting exhaust-air mixture is significantly reduced at the outlet of the first combustion chamber  1 . 
         [0033]    In the subsequent deflection unit  2  the mixture of exhaust and air passes the first vane row  11  and is deflected in at least a circumferential direction. To reduce the thermal stress of the vanes  11 , they are made of a high temperature resistant material, e.g. a ceramic coating, and in addition they are equipped with an internal cooling system. Cooling of the vanes  11  may be realized with convective cooling inside the vane  11  and/or film cooling and/or impingement cooling, as known per se from state of the art turbine vanes. Alternatively, embodiments with closed cooling systems, e.g. with steam or air as a coolant, are possible. 
         [0034]    As a consequence of the injection of additional air  9  and the heat transfer from the hot gas flow to the components in the deflection unit  2 , the addition of approximately 3% to 5% of cooling and leakage air to the hot gas flow and acceleration in the deflection unit  2 , the static temperature of the hot gas flow is significantly reduced to a level of less than 1350 K. This reduced temperature allows the injection of a mass flow of additional fuel  10 , generating an exhaust-air-fuel mixture with auto ignition times between 1 ms and 10 ms such that this mixture is not reacting until it reaches the sequential combustion chamber  3 , where it is burnt by auto ignition or a combination of auto ignition and recirculation of hot reaction products. 
         [0035]    A fuel injection system  10 ,  24  and an aerodynamic mixing device  12 ,  13  with a subsequent mixing passage  26  are integrated into the deflection unit  2 . 
         [0036]    In order to improve the penetration depth of the jets of the additional fuel  10  a system of supporting air jets may be used. There is also the option to enclose the individual fuel jets in jets of air to prevent the ignition of the fuel prior to mixing with the exhaust gas from the first combustion chamber  1 . Due to the high temperature, the mixture ignites due to auto-ignition and burns completely within a few milliseconds, typically within less than 10 ms. 
         [0037]    Options for fuel injection  10  include
       Injection from the trailing edge of the deflection vanes  11  (see  FIG. 3   a ,  3   b )   Injection from the pressure or suction side of the guide vanes  11     Injection from the hub side or housing side of the flow channel within the deflection section  2     Injection from a separate fuel injection system  24 ,  25 , integrated into the deflection unit  2 , preferably directly upstream of the guide vane row  11  ( FIG. 4 ). Such fuel injection means  24 ,  25  are known per se. They may be designed as streamlined bodies extending across the entire flow cross section. Such means are disclosed, for example, in patent application WO 2011/054757.       
 
         [0042]    Combinations of two or more of these listed options are possible. 
         [0043]    The mixture quality of the hot gas, the additional air  9  (from cooling air, carrier air, support air) and the additional fuel  10  is improved by the generation of vortices, preferably vortices with a vortex axis in flow direction. These vortices can be generated by different methods in or directly downstream of the deflection section  2 , namely
       Use of vanes  11  with a corrugated trailing edge  12  (see  FIG. 3   a )   Use of vanes  11  with a lobed trailing edge  13  (see  FIG. 3   b )   Use of vortex generators, e.g. tetrahedrons on the hub side or casing side of the flow channel contour within deflection section  2  downstream of the vanes  11     Aerodynamic design of the vanes  11  such that the secondary vortex flows occurring anyway due to the flow deflection are strengthened. Unlike a deflection design without fuel injection (in which the secondary vortex is avoided, if possible), the secondary vortices are amplified by the shape of the vane and the boundary contour on hub and casing side.       
 
         [0048]    To expand the operating range a sudden cross-sectional enlargement  16  of the hot gas flow channel, such as a backwards facing step  20  or a recessed ring channel  31  in the flow channel contour  15  is arranged after the mixing section  26  in the inlet section of the sequential combustion chamber  3  (see  FIGS. 4 and 5 ). 
         [0049]    A reverse flow zone  17  is generated at the step  16 . By forming a reaction zone  30  this reverse flow zone  17  defines a flame anchoring point at the inlet to the sequential combustion chamber  3  and thus a wide operating range in temperature, pressure, flow rate, oxygen content, fuels with different ignition properties etc. is achieved. 
         [0050]    According to a preferred embodiment the said step of sudden flow cross-section enlargement comprises an expansion of flow cross-section of at least 10%. 
         [0051]    To further enhance the operation range another fuel injection system  21  can be included into the backward facing step  16  or recessed ring channel  31  at the entry into the second combustor  3  ( FIG. 4 ). By injecting fuel in this recirculation zone  17  downstream of the backward facing step  16  or into the recessed ring channel  31  the temperature in the recirculation zone  17  is increased by combustion of the additionally injected fuel  21 . 
         [0052]    The sequential combustion chamber  3  is preferably cooled by convective heat transfer, i.e. the combustor walls are cooled on the side opposite to the hot gas with cooling medium, preferably air, not directly flowing into the combustion chamber, as known per se. 
         [0053]    The sequential combustion chamber  3  is advantageously designed as an annular combustion chamber. A can type combustor as sequential combustion chamber  3  would have a number of disadvantages, such as a larger surface to be cooled, larger leakages and the flow to the rotating turbine blades  8  would be disturbed by the wakes of the can side walls. 
         [0054]    According to a preferred embodiment of the invention the first combustion chamber  1  is designed as an annular combustor and the sequential combustion chamber  3  is designed as an annular combustor too. 
         [0055]    According to an alternative embodiment the first combustion chamber  1  is designed in a can combustor configuration and the sequential combustion chamber  3  is designed as an annular combustion chamber. 
         [0056]    The deflection unit  2  including the mixing system can be implemented either as an annular ring around the turbine axis  18  or as individual burners or cans arranged around the turbine axis  18 . 
         [0057]    In order to reduce the axial length of the sequential combustor  3 , the flow can be decelerated without generating flow separation in a diffuser-like combustor shape and then be accelerated again before entry into the turbine  19  rotor. 
         [0058]    In the sequential combustion chamber  3  the temperature of the hot gases reaches its maximum. Therefore, the residence time in the combustion chamber  3  needs to be kept small, preferably less than 10 ms to reduce NO x  formation. 
         [0059]    Another way to reduce NO x  formation in the combustion chamber is the reduction of the oxygen content in the hot combustion gases. This may be achieved by another option, namely exhaust gas recirculation. For example, partial mass flow of the exhaust gas is withdrawn after the turbine  19  or the heat recovery steam generator (not shown), is cooled down and afterwards mixed into the inlet air flows  5 ,  9  of the gas turbine. 
         [0060]    For an optimization of the aerodynamics, i.e. lower pressure losses, it is advantageous to place the deflection unit  2 , therewith the first vane row  11  on a significantly larger diameter (relating to the turbine axis  18 ) than the first turbine blade row  8  and to use the sequential combustor  3  as a transition piece to compensate the difference in the radii between deflection unit  2  and first turbine blade row  8 . This measure results in the additional advantage that the circumferential velocity increases inversely with the radius, obeying the conversation of swirl, for the same axial velocity and thus the flow angle or deflection at the rotor inlet is substantially larger than the deflection in the deflection unit  2 . Since the flow losses depend strongly on the deflection in the guide vanes  11 , the losses can be reduced while maintaining a constant flow angle at the turbine rotor inlet. 
         [0061]    Alternatively, the flow velocity in the deflection unit  2  is reduced proportionally in the radially outwardly offset guide baffle for the radius ratio for the same deflection tangential to axial velocity ratio. 
         [0062]    Since heat transfer decreases approximately proportional to the flow rate, this embodiment requires less cooling of the components of the deflection unit  2 . 
         [0063]    At gas turbine start-up the first combustion chamber  1  is ignited by an ignition device and running up—by applying commonly used methods of operation, like increase in combustion temperature and increased mass flow rate—to a combustor exit temperature suitable for the ignition of the sequential combustor. Due to the wide controllable range of the first combustion chamber  1 , variations in the auto-ignition characteristics of the fuel can be compensated by a higher or lower inlet temperature into the deflection unit  2 , e.g. allowing operation on typically more reactive fuel. 
         [0064]    To simplify the system, operation on liquid backup fuel may be limited to the first combustion chamber  1  at the expense of a certain power loss. If liquid fuel is used as the main fuel, the combustor may be built exclusively for liquid fuel.