Texas Technology Showcase March 2003 Houston, TX

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Franklin Rose
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1 Texas Technology Showcase March 2003 Houston, TX

2 Overview Who Is Kawasaki Gas Turbines? What Causes NOx? How Can We Control NOx? Field Results Summary

3 Kawasaki Gas Turbine History 1943 Built First Aircraft Gas Turbine Engine 1950 s Service Operations - US Military 1972 Started Development of Industrial Gas Turbines Engines 1974 First S1A-01 (200 kw) Gas Turbine Engine 1977 First Gas Turbine Generator Set Delivered 1979 First Mobile Gas Turbine Genset Delivered 1984 First Co-generation System Delivered 1988 First Cheng-cycle Co-generation System Delivered 1988 Developed M1A-13 Gas Turbine (High Efficiency) Engine 1993 Developed M7A-01 Gas Turbine (High Efficiency) Engine 1995 Developed M1A-13D with Dry Low NOx System 1997 Over 5,000 Gas Turbine Engines Delivered 1999 Ceramic Gas Turbine 302, World Record Efficiency 42.1% 2000 Introduced Catalytic Combustion - World s Cleanest Turbine 2001 Introduction Of L20A 2002 Over 7,000 Gas Turbine Engines Delivered More To Come!!

4 Kawasaki Aircraft Turbines Risk Share Partner Pratt & Whitney GE Rolls Royce Etc

5 Kawasaki Aircraft Turbines Pratt & Whitney F100 F-15 Eagle F-16 Falcon PW4000 Airbus A300/A310/A330 Boeing B747/767/777 V2500 Airbus A319/A320/A321 MD-90

6 Kawasaki Industrial Turbines

7 Kawasaki Industrial Turbines GPB07D GPB15D GPB15X GPB60D GPB70D GPB180D 650 kwe 1434 kwe 1423 kwe 5265 kwe 6500 kwe 17,000 kwe

8 Overview Who Is Kawasaki Gas Turbines? What Causes NOx? How Can We Control NOx? Field Results Summary

9 NOx Caused By High Temperatures F NOx (ppm) Temperature required for turbine Inlet Temperature required for flame C Reaction Temperature

10 Overview Who Is Kawasaki Gas Turbines? What Causes NOx? How Can We Control NOx? Field Results Summary

11 Kawasaki s Combustion Technology Dry Low Emissions (DLE) Catalytic Combustors

12 Kawasaki s Combustion Technology Dry Low Emissions (DLE) Current State Of The Art

13 Kawasaki s Combustion Technology Dry Low Emissions (DLE) Design Concept Lean, Pre-mixed Combustion Multiple Fuel Nozzles Fuel Nozzle Staging

14 Kawasaki s Combustion Technology DLE Combustor

15 Kawasaki s Combustion Technology DLE Burner Assembly

16 Kawasaki s Combustion Technology Guaranteed NOx Emissions With DLE Less than 25ppm On Larger Machines Less than 14ppm On Smaller Machine Low NOx power range - 85 to 100% load

17 Kawasaki s Combustion Technology Catalytic Combustors

18 Kawasaki s Combustion Technology Catalytic Combustion In Development Since 1982 ASME Paper Published 1987 Verified Module Durability 1999 Development Complete 2000 First Commercial Order 2000 Delivered First Commercial Units 2001 Demonstrated In Practice 2002

19 Flame Combustion System Fuel 1800 o C 350 o C Bypass Air 1300 o C Exhaust NOx ~ 25 ppm Compressor Drive Turbine

20 Catalytic Combustion System Main Fuel 1300 o C Catalyst Module Air Preburner Fuel 350 o C 1300 o C Exhaust NOx < 2.5 ppm Compressor Drive Turbine

21 Catalytic Combustion System Control Systems (not shown)

22 Catalytic Combustion System Preburner Module Keeps catalyst in operating window Allows engine start-up Source of NOx

23 Catalytic Combustion System Pre-mixer Improves catalyst fuel and air uniformity to prevent higher temperature regions in catalyst

24 Catalytic Combustion System Burn Out Zone Complete combustion of remaining fuel (homogenous combustion) Complete CO and UHC burnout

25 Catalytic Combustion System Bypass System Increases load turndown capability Keeps catalyst in operating window

26 Catalytic Combustion System

27 Catalytic Combustion System Traditional Approach CH 4 / Air Mixture Temperature1300 ( o C) 800 Surface Gas 350 Catalyst surface temp rapidly approaches 1300 o C At 1300 o C, damage to catalyst will occur Noble metal vaporization Loss of surface area

28 Catalytic Combustion System All of fuel All of air Inlet catalyst Outlet catalyst Homogeneous combustion Surface Tad Temperature Gas High activity Low lightoff T Designed for low wall T Higher wall T (design limits max wall T) High outlet gas T Sufficient time to: Complete CH 4 combustion Complete UHC and CO burnout

29 Catalytic Combustion System 330 C 630 F 450 C 840 F 1300 C 2370 F 1010 C 1850 F Compressor Pr eburner Fuel Inject or Cat alyst Bur n out zone Turbine Bypass/dilution air Preburner provides required catalyst inlet temperature Catalyst fuel injector produces a uniform fuel/air mixture for the catalyst High post catalyst temperature oxidizes CO to < 10 ppm Bypass and dilution air provides required turbine inlet temperature

30 Catalytic Combustion System Integral Heat Exchange Limits Catalyst Temp Bulk flow Boundary layer Catalyst Foil substrate Reactants Products Rxn heat T s = T in + ²T ad 2 Boundary layer Bulk flow Rxn heat Solid cross-section essentially isothermal Equal heat transferred to catalyzed and non-catalyzed channels Maximum conversion = 50% Maximum wall temperature = T in + 1 ² T ad 2 Example: Inlet gas T = 700 C (1290 F) Tad = 1300 C (2370 F) non-ihe wall T = 1300 C(2370 F) IHE wall T = 1000 C (1830 F)

31 Catalytic Combustion System Catalyst designed to control its own temperature: Active form Inactive form High Temp 1 PdO Pd + O 2 2 Low Temp

32 Catalytic Combustion System

33 Overview Who Is Kawasaki Gas Turbines? What Causes NOx? How Can We Control NOx? Field Results Silicon Valley Power Sonoma Development Center Summary

34 Field Results - Silicon Valley Power

35 Field Results - Silicon Valley Power RAMD: Reliability, Availability, Maintainability, Durability Performance Criteria Results Operating Hours > NOx emissions < 2.5 ppm (corrected to 15% O2) CO emissions < 6 ppm (corrected to 15% O2) VOC emissions < 2 ppm Reliability 1 > 98% Reliability 2 > 99% 1 Total turbine engine and catalytic combustor system reliability 2 Catalytic combustion system reliability

36 Field Results - Sonoma Development Center

37 Field Results - Sonoma Development 50 Center 40 Emissions (ppm) _ NOx HC CO Load (%kw)

38 Field Results - Sonoma Development Center We re obviously within the legal limits as far as the BAAQMD is concerned and it reads down as far as it needs to. But we would like to be able to read it exactly so everybody can see what we re doing. Mary Lavin, Environmental Specialist Sonoma Development Center

39 Field Results - Sonoma Development Center About the only problem is that we don t have another one sitting right next to it. Ron Johnson, Chief Engineer Sonoma Development Center

40 Overview Who Is Kawasaki Gas Turbines? What Causes NOx? How Can We Control NOx? Field Results Summary

41 Summary Turbines With Catalytic Combustion No Black Magic Known Maintenance and Repair Requirements VERY Low Exhaust Emissions Similar To Fuel Cells % Load Completely Environmentally Friendly No SCR Required (No Ammonia Storage) No Oil Changes No Coolant Required

42 Summary How clean is clean??? Industry Example Environmental Example

43 Summary Equivalent NOx - 100% Load, 2.5 PPM Guarantee Natural Gas Fuel, ISO Conditions Equivalent NOx (lbs/mw-hr) Kawasaki GPB15X Equivalent NOx Output Proposed Equivalent NOx Limit Total Efficiency (%) Eq. NOx (lbs/mw-hr) NOx Lim. (lbs/mw-hr)

44 Summary

45 Summary A single lightning strike makes as much NOx in an instant as a Kawasaki Gas Turbine with catalytic combustion does in an entire year!!

46 Summary Catalytic Combustion Available Next Generation Of Combustion Technology Low Risk Cost Effective In Production

47 Summary Our third goal is to promote energy independence for our country, while dramatically improving the environment. George W. Bush State-Of-The-Union Energy Independence Goals

48 Kawasaki Gas Turbines - Americas A Division Of Kawasaki Motors Corp., U.S.A. Grand Rapids, MI

KAWASAKI VAM Abatement System

Coal Mining Methane Abatement Seminar KAWASAKI VAM Abatement System Kawasaki Heavy Industries, Ltd. Gas Turbines & Machinery Company Gas turbine Division 1 4 th September, 2012 InterContinental Hotel,