Abstract: A gas turbine combustor (23) includes a catalytic combustion stage (22) receiving a first portion (18) of a total oxidizer flow (16) and a first portion (30) of a total fuel flow (29) and discharging a partially oxidized fuel/oxidizer mixture (40) into a post catalytic combustion stage (24) defined by a combustion liner (58). The combustor further includes an injector scoop (54) having an injector scoop inlet (56) in fluid communication with an opening (56) in the combustion liner for receiving a second portion (20) of the oxidizer flow. A fuel outlet (e.g. 64) selectively supplies a second portion (42) of the total fuel flow into the second portion of the oxidizer flow.

Abstract: A method used for combustion of a fuel-oxidizer mixture in a combustion chamber of a turbogroup, in particular of a power plant wherein total oxidizer flow is divided into a main oxidizer flow and a secondary oxidizer flow. The main oxidizer flow is lean mixed with a main fuel flow in a premix burner, and the mixture is fully oxidized in the combustion chamber. The secondary oxidizer flow is divided into a pilot oxidizer flow and a heat-exchanging oxidizer flow. The pilot oxidizer flow is rich mixed with a pilot fuel flow, and the mixture is partially oxidized in a catalyst, with hydrogen being formed. Downstream of the catalyst, the partially oxidized pilot fuel-oxidizer mixture and the heat-exchanging oxidizer flow are together introduced into at least one zone which is suitable for stabilizing the combustion of the main fuel-oxidizer mixture.

Abstract: Method of preparing and introducing fuel into the combustors of a gas turbine in which a hydrocarbon containing feed, oxygen and steam are introduced into a catalytic partial oxidation reactor to produce a product stream. The hydrocarbon containing feed contains no less than about 15 percent by volume on a dry basis of hydrocarbons with at least two carbon atoms and/or at least about 3 percent by volume of olefins. The reactant mixture formed of the hydrocarbon containing feed, oxygen and steam has an oxygen to carbon ratio of between about 0.08 and about 0.25 and a water to carbon ratio of between about 0.05 to about 0.5. The hydrocarbon containing feed is introduced into the reactor alone or with a steam at a temperature no greater than 600° C. and the product stream is produced at a temperature of between about 600° C. and 860° C. and contains less than about 0.5 percent of olefins and less than 10 percent of hydrocarbons with two or more carbon atoms on a dry basis.

Abstract: Method of preparing and introducing fuel into the combustors of a gas turbine in which a hydrocarbon containing feed, oxygen and steam are introduced into a catalytic partial oxidation reactor to produce a product stream. The hydrocarbon containing feed contains no less than about 15 percent by volume on a dry basis of hydrocarbons with at least two carbon atoms and/or at least about 3 percent by volume of olefins. The reactant mixture formed of the hydrocarbon containing feed, oxygen and steam has an oxygen to carbon ratio of between about 0.08 and about 0.25 and a water to carbon ratio of between about 0.05 to about 0.5. The hydrocarbon containing feed is introduced into the reactor alone or with a steam at a temperature no greater than 600° C. and the product stream is produced at a temperature of between about 600° C. and 860° C. and contains less than about 0.5 percent of olefins and less than 10 percent of hydrocarbons with two or more carbon atoms on a dry basis.

Abstract: The present invention discloses a hybrid combustor, such as an anode tailgas oxidizer (ATO), for fuel processing applications which combines both flame and catalytic type burners. The hybrid combustor of the present invention combines the advantages of both flame and catalytic type burners. The flame burner component of the hybrid combustor is used during start-up for the preheating of the catalytic burner component. As soon as the catalytic burner bed is preheated or lit off, the flame burner will be shut off. Optionally, the hybrid combustor may also include an integrated heat recovery unit located downstream of the catalytic burner for steam generation and for the preheating of the feed for a reformer, such as an autothermal reformer.

Abstract: According to one aspect, a method of controlling a multi-combustor catalytic combustion system is provided for determining a characteristic of a fuel-air mixture downstream of a preburner associated with a catalytic combustor and adjusting the fuel flow to the preburner based on the characteristic. The characteristic may include, for example, a measurement of the preburner or catalyst outlet temperature or a determination of the position of the homogeneous combustion wave in the burnout zone of the combustor.

Abstract: A control system for a catalytic combustion system on a gas turbine includes a flame preburner, a fuel injector positioned downstream of the preburner and a catalyst positioned downstream of the fuel injector. In such systems, a portion of the fuel combusts within the catalyst itself and the remainder of the fuel combusts in a homogeneous combustion process wave downstream of the catalyst. A sensor in communication with the control system monitors the homogeneous combustion process wave and adjusts the gas temperature at the catalyst inlet to a preferred value based on a predetermined schedule that relates the catalyst inlet gas temperature to operating fundamentals such as adiabatic combustion temperature or the gas turbine's exhaust gas temperature.

Abstract: Aspects according to the invention relate to a catalytic combustor system for a turbine engine and an associated method. Catalytic combustors are used in connection with turbine engines because they can minimize the formation of oxides of nitrogen during combustion. Despite this emissions advantage, catalytic combustion systems can increase the level of CO in the turbine exhaust. According to aspects of the invention, vortex formation devices includes vortex generators, swirlers and mixers can be placed downstream of each catalytic module surrounding the pilot nozzle so as to form one or more vortices in the otherwise substantially laminar flow exiting the modules. The vortices can create a suction so that a portion of the flow exiting the pilot nozzles is mixed with the flow exiting the catalyst modules. The introduction of the higher temperature pilot flow can accelerate the catalytic reaction time, promoting burnout of the CO formed during combustion.

Abstract: Disclosed is a unique fuel and air premixing system for a gas turbine catalytic combustion system. The mixer utilizes a multi-channel counter-rotating swirler with aerodynamically shaped fuel pegs located upstream of the swirler. The premixing system provides the downstream catalyst with a fuel-air mixture sufficiently uniform for proper catalyst operation and wide operating limits. Features have been incorporated in the system to make it resistant to flameholding.

Abstract: The present embodiment relates to a catalytic combustor for reducing the pollutant emissions of combustion. The catalytic combustor described herein employs a novel heat exchange system for rapidly and economically bringing the combustor to a temperature wherein catalytic combustion may occur with minimal production of toxic products.

Abstract: A gas turbo group has a combustion chamber comprising a catalytic burner stage (2), a preburner stage (1) located upstream from the catalytic burner stage, as well as a non-catalytic burner stage (11, 5, 6) located downstream from the catalytic burner stage. The preburner stage serves to always maintain a temperature (T1) at the inlet into the catalytic stage that corresponds at least to a minimum temperature (TMIN) necessary for operating the catalytic burner stage. According to the invention, the gas turbo group is operated so that the burner stage located downstream from the catalytic combustion chamber is taken into operation only when the temperature (T2) at the outlet from the catalytic stage has reached an upper limit in the presence of a maximum combustion air mass flow.

Abstract: A recuperated gas turbine engine system and associated method employing catalytic combustion, wherein the combustor inlet temperature can be controlled to remain above the minimum required catalyst operating temperature at a wide range of operating conditions from full-load to part-load and from hot-day to cold-day conditions. The fuel is passed through the compressor along with the air and a portion of the exhaust gases from the turbine. The recirculated exhaust gas flow rate is controlled to control combustor inlet temperature.

Abstract: Provided is a combustion engine having a combustion chamber. The combustion engine comprises an engine housing having an air intake port, a mixed conductor, a water intake port, an exhaust turbine and a hydrogen compressor assembly. The air intake port provides air to the mixed conductor which provides an oxygen-pure fraction of air to the combustion chamber by conducting oxygen ions in the air from a retentate side to a permeate side when the oxygen partial pressure on the permeate side is less than that on the retentate side. The water intake port provides water to the combustion chamber for combustion with hydrocarbon fuel and the oxygen-pure fraction of the air to produce exhaust fluid. The exhaust fluid expands in the exhaust turbine causing the turbine rotor to rotate producing mechanical energy. The hydrogen compressor assembly extracts hydrogen from the exhaust fluid and provides hydrogen to the exhaust turbine.

Abstract: A microturbine engine operable to combust a flow of VOCs without a combustor. The microturbine engine comprising a compressor having an inlet, the inlet receiving a mixture of air and VOCs, the compressor operable to produce a flow of compressed air and VOCs. The invention also includes a reaction chamber including a reactor bed. The flow of compressed air and VOCs is combusted within the reactor bed to produce a flow of products of combustion. The invention includes a turbine driven by the flow of products of combustion from the combustor and a generator coupled to the turbine. The generator is driven by the turbine at a speed to produce electrical power.

Abstract: A method of controlling a catalytic combustion system comprising a flame burner or a heat exchanger, a fuel injector positioned downstream of the flame burner or heat exchanger and a catalyst positioned downstream of the fuel injector, wherein a portion of the fuel combusts within the catalyst and the remainder of the fuel combusts in the region downstream of the catalyst comprising: measuring the exhaust gas temperature; and adjusting the catalyst inlet gas temperature to a preferred value based upon a predetermined schedule that relates the catalyst inlet gas temperature to the difference between the measured exhaust gas temperature and the calculated exhaust gas temperature at full load.

Abstract: According to one aspect, a method of controlling a multi-combustor catalytic combustion system is provided for determining a characteristic of a fuel-air mixture downstream of a preburner associated with a catalytic combustor and adjusting the fuel flow to the preburner based on the characteristic. The characteristic may include, for example, a measurement of the preburner or catalyst outlet temperature or a determination of the position of the homogeneous combustion wave in the burnout zone of the combustor.

Abstract: The present additional control strategy has been developed to allow the gas turbine to operate at lower load or at other conditions where the total fuel required by the gas turbine is not optimum for full combustion of the fuel. The present invention manages air that bypasses the catalytic combustor and air that bleeds off of the compressor discharge. The bypass system changes the fuel air ratio of the catalytic combustor without affecting the overall gas turbine power output. The bleed system also changes the fuel air ratio of the catalytic combustor but at the cost of reducing the overall gas turbine efficiency. The key advantage of a catalytic combustor with a bypass and bleed system and the inventive control strategy is that it can maintain the catalyst at optimum low emissions operating conditions over a wider load range than a catalytic combustor without such a system.

Abstract: A catalytic combustor 30 includes a frame 32 and catalyst support plate assemblies 34 carried by the frame. A catalyst support plate assembly 34 includes a pair of opposing plates 36A, 36B, at least one having ridges 38A, 38B that define passageways 40 between the pair of opposing plates. A catalyst 44 is carried by the catalyst support plate assemblies 34. Both of the opposing plates 36A, 36B may have ridges 38A, 38B with valleys 42A, 42B between adjacent ridges. A pair of opposing plates 36A, 36B may be aligned and connected at opposing ridges 38A, 38B so that opposing valleys 42A, 42B define air passageways having predetermined shapes. The catalyst support plate assemblies 34 may be arranged in back-to-back relation so that adjacent pairs of catalyst support plate assemblies 34 define fuel/air passageways 46. Adjacent pairs of catalyst support plate assemblies 34 may be offset from one another to define a nested configuration.

Abstract: The present invention provides a method for sustained catalytic combustion of low BTU fuels in a gas-turbine engine, and applications thereof. The method comprises ingesting fuel and combustion air into a catalytic reactor to produce thermal energy and converting the thermal energy to mechanical energy with a turbine. The fuel and the combustion air are mixed to form a fuel-air mixture. The ingested combustion air is used to oxidize the ingested fuel. Fuels having a higher heating value in a range of between 1000 and 5 BTU/scf are mixed with the combustion air and oxidized using the catalytic reactor.

Abstract: The invention is a method and apparatus for use therewith for a main burner of a gas turbine. The method employs catalytic combustion to support main combustion. More specifically, a rich fuel/air mixture is catalytically oxidized with the resulting reacted mixture being made lean by having additional air added thereto. The resulting lean mixture is then combusted in the presence of the main mixture that is also lean thereby supporting combustion of the main mixture. The method allows for enhanced turndown of a lean main mixture.

Abstract: The invention provides integrated turbogenerators having a turbine wheel, a compressor impeller, and a motor generator mounted to or mechanically constrained to a common shaft, and improved components and configurations thereof.

Abstract: The present additional control strategy has been developed to allow the gas turbine to operate at lower load or at other conditions where the total fuel required by the gas turbine is not optimum for full combustion of the fuel. The present invention manages air that bypasses the catalytic combustor and air that bleeds off of the compressor discharge. The bypass system changes the fuel air ratio of the catalytic combustor without affecting the overall gas turbine power output. The bleed system also changes the fuel air ratio of the catalytic combustor but at the cost of reducing the overall gas turbine efficiency. The key advantage of a catalytic combustor with a bypass and bleed system and the inventive control strategy is that it can maintain the catalyst at optimum low emissions operating conditions over a wider load range than a catalytic combustor without such a system.

Abstract: Described is a premix burner arrangement as well as a method for operating the same, comprising a pilot fuel feeding means for operating a combustion chamber of a gas turbine arrangement, a premix burner, wherein at least one fuel addition unit as well as supply air openings have been provided in such a way that gaseous and/or liquid fuel can be mixed with combustion supply air inside the premix burner and form a fuel/air mixture, which exits from the premix burner downstream in the direction towards the combustion chamber positioned after the premix burner arrangement and which can be ignited inside the combustion chamber in the form of a spatially largely stationary flame.

Abstract: A combustor for a gas powered turbine which employs a hypergolic or high energy air stream and an injector design to mix fuel with the high energy hypergolic air stream faster than the combustion rate of the fuel. A heat exchanger and a catalyst combusts a first portion of fuel in air without the production of undesired chemical species. A gas powered turbine requires expanding gases to power the turbine fans or blades. Fuel is generally combusted to produce the required gases. A catalyst is employed to lower the combustion temperature of the fuel. The catalyst is placed on a set of tubes in a heat exchanger such that a portion of the thermal energy may be transferred to the air before it engages the catalyst. After encountering the catalyst, the fuel that was combusted increases the temperature of the air to an auto-ignition temperature so that no other ignition source is needed to combust additional fuel added later.

Abstract: Internal combustion engines produce a number of emissions including oxides of nitrogen, NOx. One manner of reducing NOx production used in gas turbine engines is through the use of catalytic reactors. Catalytic reactors reduce the ignition temperatures required for complete combustion of a fuel air mixture. However, high temperatures present in catalytic reactors cause sintering of the substrate, vaporization of the catalyst, and sintering of catalyst and metal substrate. The present invention is directed at controlling the temperature of a catalytic reactor in an internal combustion engine. An exothermic catalyst coats a first side of a substrate in the catalytic reactor. An endothermic catalyst coats a second side of the substrate.

Abstract: A system and method of combusting a hydrocarbon fuel is disclosed. The system combines the accuracy and controllability of an air staging system with the ultra-low emissions achieved by catalytic combustion systems without the need for a pre-heater. The result is a system and method that is mechanically simple and offers ultra-low emissions over a wide range of power levels, fuel properties and ambient operating conditions.

Abstract: A combustor for a gas powered turbine which employs a heat exchanger and a catalyst to combust a fuel without the emission of undesired chemical species. A gas powered turbine requires expanding gases to power the turbine blades. Fuel is combusted to produce the required gases. A catalyst is employed to lower the combustion temperature of the fuel. The catalyst is placed on a set of tubes in the heat exchanger such that a portion of the thermal energy may be transferred to the air before it engages the catalyst. After encountering the catalyst, the combusted fuel increases the temperature of the air to an auto-ignition temperature so that no other ignition source is needed to combust additional fuel.

Abstract: A combustor for a gas powered turbine which employs a heat exchanger and a catalyst to combust a fuel without the emission of undesired chemical species. A gas powered turbine requires expanding gases to power the turbine blades. Fuel is combusted to produce the required gases. A catalyst is employed to lower the combustion temperature of the fuel. The catalyst is placed on a set of tubes in the heat exchanger such that a portion of the thermal energy may be transferred to the air before it engages the catalyst. After encountering the catalyst, the combusted fuel increases the temperature of the air to an auto-ignition temperature so that no other ignition source is needed to combust additional fuel.

Abstract: A method for fabricating a three-dimensional turbine engine combustor liner model includes coupling at least a first member to a second member to form an assembly that has an inner surface. The assembly inner surface simulates an inner surface of the aircraft engine combustor liner. The first member is at least one of a pre-formed conical member and a pre-formed cylindrical member, and the second portion is at least one of a pre-formed conical member and a pre-formed cylindrical member. The method also includes coupling the assembly to a baseplate, and coupling a plurality of templates to the assembly.

Abstract: A premix burner arrangement with catalytic combustion provides a fuel/air mixture to a combustion chamber of a gas turbine arrangement. The premix burner arrangement includes a premix burner, at least one fuel addition unit, and air inlet openings arranged in such a way that at least one of gaseous and liquid fuel can be mixed with combustion inlet air inside the premix burner to form a fuel/air mixture. The fuel/air mixture exits from the premix burner downstream in the direction towards a combustion chamber positioned after the premix burner arrangement and can be ignited inside the combustion chamber. A catalyzer unit is provided before the entrance of the fuel/air mixture into the combustion chamber. Part of the fuel/air mixture can be introduced into and passed through the catalyzer unit before the catalyzed part of the fuel/air mixture flows together with the remaining portion of the fuel/air mixture into the combustion chamber.

Abstract: Methods and apparatus for control of NOx in catalytic combustion systems, and more particularly to control of thermal or/and prompt NOx produced during combustion of liquid or gaseous fuels in the combustor sections of catalytic combustor-type gas turbines, by controlled injection of water in liquid or vapor form at selected locations, orientations, amounts, rates, temperatures, phases, forms and manners in the compressor and combustor sections of gas turbines. The ratio of thermal NOx ppm reduction to water addition, in weight %, is on the order of 4-20, with % NOx reduction on the order of up to about 50-80% and NOx of below 2 ppm. Liquid water, steam or superheated steam can be used to reduce NOx in combustion systems operating at reaction zone temperatures above 900° C., preferably 1400° C. to 1700° C. The amount of water added is sufficient to provide a concentration of water in the range of from about 0.

Abstract: A system and method of combusting a hydrocarbon fuel is disclosed. The system and method combines the accuracy and controllability of an air staging system with the ultra-low emissions achieved by catalytic combustion systems. The present invention can achieve ultra-low emissions while maintaining the combustion system pressure drop constant over a wide range of power levels, with essentially no consequent impact on engine efficiency. Also, the present technology is easily applied to a multitude of different systems, such as conventional lean operating catalysts. One aspect of the invention is a system for combusting hydrocarbon fuel, which includes an air supply for supplying air from a compressor to the air inlet, an air inlet for entrance of an air mixture from the compressor, at least one air staging valve that directs air to a catalyst module and a bypass manifold. The catalyst module receives fuel and air, which mixes with a catalyst contained therein.

Abstract: A catalytic combustor (34) for a gas turbine engine (30). A fuel-air mixture (50) is reacted on a catalytic surface (54) of a catalytic heat exchanger module (36) to partially combust the fuel (48) to form heat energy. The fuel-air mixture is formed using compressed air (44) that has been pre-heated to above a reaction-initiation temperature in a non-catalytic cooling passage (46) of the catalytic heat exchanger module (36). Because the non-catalytic cooling passages (46) provide the necessary pre-heating of the combustion air, no separate pre-heat burner is required. Fuel (48) is added to the pre-heated air (44) downstream of the non-catalytic cooling passage (46) and upstream of the catalytic surface (54), thereby eliminating the possibility of flashback of flame into the cooling passages (46). Both can-type (60) and annular (80) combustors utilizing such a combustion system are described.

Abstract: A catalytic combustor (34) for a gas turbine engine (30). A fuel-air mixture (50) is reacted on a catalytic surface (54) of a catalytic heat exchanger module (36) to partially combust the fuel (48) to form heat energy. The fuel-air mixture is formed using compressed air (44) that has been pre-heated to above a reaction-initiation temperature in a non-catalytic cooling passage (46) of the catalytic heat exchanger module (36). Because the non-catalytic cooling passages (46) provide the necessary pre-heating of the combustion air, no separate pre-heat burner is required. Fuel (48) is added to the pre-heated air (44) downstream of the non-catalytic cooling passage (46) and upstream of the catalytic surface (54), thereby eliminating the possibility of flashback of flame into the cooling passages (46). Both can-type (60) and annular (80) combustors utilizing such a combustion system are described.

Abstract: A combustion catalyst coating (36) applied to the surface of a ceramic thermal barrier coating (34) which is supported by a metal substrate (32). The microstructure of the thermal barrier coating surface provides the necessary turbulent flow and surface area for interaction of the catalyst and a fuel-air mixture in a catalytic combustor of a gas turbine engine. The temperature gradient developed across the thermal barrier coating protects the underlying metal substrate from a high temperature combustion process occurring at the catalyst surface. The thermal barrier coating deposition process may be controlled to form a microstructure having at least one feature suitable to interdict a flow of fuel-air mixture and cause the flow to become more turbulent than if such feature did not exist.

Abstract: A combustion system for a gas turbine engine includes a Catalyst (CAT) combustion sub-system for generating combustion products under a lean premixed fuel/air condition in the presence of a Catalyst and a Dry-Low-Emissions (DLE) combustion sub-system, for generating combustion products under a lean premixed fuel/air condition. Gaseous and liquid fuels are used for the DLE combustion sub-system while only gaseous fuel is used for the CAT combustion system. The engine operates at start-up and under low load conditions with the DLE combustion system and switches over the combustion process to the CAT combustion sub-system under high load conditions. Thus the combustion system according to the invention combines the advantages of DLE and CAT combustion processes so that the gas turbine engine operates over an entire operating range thereof at high engine efficiency while minimizing emissions of nitrogen oxides and carbon monoxide from the engine.

Abstract: The invention provides integrated turbogenerators having a turbine wheel, a compressor impeller, and a motor generator mounted to or mechanically constrained to a common shaft, and improved components and configurations thereof.

Abstract: A device for conditioning the flow of hot gas in a catalytic combustor in preparation for entry into a catalytic reactor. The device is composed of at least one and most preferably two or more disks that are secured to a shroud so as to be disposed in a plane generally perpendicular to the hot gas flow direction. Each disk is composed of a plurality of small cells oriented so that flow channels therethrough are axially disposed. The cells linearize the gas flow and exert drag on the gas flow therethrough. This generates a static pressure gradient in the flow fields upstream and downstream of the honeycomb disk, which in turn causes flow adjustments so as to produce a more uniform axial flow field. This results in a more uniform fuel/air concentration distribution and velocity distribution at the catalytic reactor inlet.

Abstract: An improved metal catalytic tube includes an elongated metal member formed at least partially of metal particles and including a catalytic enhancement incorporated into the metal member. The metal member is formed with a cavity and includes an inner surface defined by the cavity and an outer surface opposite the inner surface. The metal member has a porosity at the outer surface that is greater than the porosity at the inner surface. The porosity at the inner surface is sufficiently low that the metal member can carry a quantity of gas through the cavity without the gas leaking through the inner surface of the metal member. The abstract shall not be used for interpreting the scope of the claims.

Abstract: A bypass air injection scheme for a combustor of a gas turbine. Combustor includes a body with an inner liner and a casing enclosing the body with a passageway defined therebetween. A predetermined amount of the compressor discharge air passing through the passageway is extracted through a manifold. A conduit feeds the extracted air into an injection manifold having a plurality of injection tubes for injecting the extracted air into the combustor bypassing the reactor. The injection tubes and the injection manifold are disposed in a substantially common axial plane.

Abstract: Methods and apparatus, both devices and systems, for control of Zeldovich (thermal) NOx production in catalytic combustion systems during combustion of liquid or gaseous fuels in the post catalytic sections of gas turbines by reducing combustion residence time in the HC zone through control of the HC Wave, principally by adjusting the catalyst inlet temperature. As the fuel/air mixture inlet temperature (to the catalyst) is reduced, the HC Wave moves downstream (longer ignition delay time), shortens the residence time at high temperature, thereby reducing thermal NOx production. The countervailing increase in CO production by longer ignition delay times can be limited by selectively locating the HC Wave so that thermal NOx is reduced while power output and low CO production is maintained. NOx is reduced to on the order of <3 ppm, and preferably <2 ppm, while CO is maintained <100 ppm, typically <50 ppm, and preferably <5-10 ppm.