methanol as a low cost alternative fuel for emission
TRANSCRIPT
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Methanol as a low cost
alternative fuel for
emission reduction in
gas turbines
Joint Venture between
IEC and Dor Chemicals
THE 11TH ISRAELI SYMPOSIUM ON JET ENGINES
AND GAS TURBINES
Thursday, October 25, 2012 (9:00-17:00)
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The Need for Methanol
Dramatic increase in regulatory requirements for
reduced emissions.
Traditional methods of reducing NOx emissions, such
as:
modification of the firing system (DLN – Dry Low NOx)
injection of water into the firing system (WLN – Wet Low NOx)
post combustion treatment of the flue gas to remove NOx
(such as SCR – Selective Catalitic Reduction)
All are very expensive!
Low cost alternatives should be checked!
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Methanol is a synthetic alcohol
Properties:
• Chemical Formula CH3OH
• Molecular weight 32.04
• Flash point 12 C (to 41 C)
• Auto-ignition temperature 464 C
• Combustion (Adiabatic) temperature 2045 C
• Low heating value 4777 kcal/kg
• Density 793 kg/ M3 at 30 C
Methanol as an Option
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Methanol is Attractive Option
Methanol can achieve:
Reduced NOx emissions - lower flame temperature and no Fuel-Bound Nitrogen (FBN)
No SO2 emissions - has no sulfur
Clean heat surfaces and lower maintenance - clean burning characteristics of methanol (better than with HFO or even with LFO)
Higher power output relative to NG and FO - higher mass flow in GT engines
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Methanol Firing at FT4C
TWIN PAC 50 MW GT Unit
Two stage tests:
1 – to prove feasibility (Caesarea)
2 – to restore capacity and gain
operational experience (Eilat)
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Caesarea Power Plant Site
Tested unit
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TP -1 Base Plate Assembly
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FT4 – Engine & Power Turbine
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Liner
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Fuel Spraying Nozzles
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FO Atomizer Assembly
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Predicting the NOx Formation Calculated Flame Temperature
Distribution at 100% Load
Flame temperture distribution through liner length
1400
1450
1500
1550
1600
1650
1700
1750
1800
1850
1900
1950
0 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26
Calculation zone number
Tem
pera
ture
, C
Fuel oil#2
Methanol
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Predicting the NOx Formation Liner Wall Temperature Calculated
Distribution at 100% Load
Relative liner wall metal temperature reduction during
methanol burning
0.5
0.6
0.7
0.8
0.9
1
0 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26
Calculation zone number
Meta
no
l to
FO
#2 w
all
meta
l
tem
pera
ture
rati
o
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Predicting the NOx Formation Formation Through Liner NOx CalculatedComparison of
Length for FO#2 and for Methanol Firing at 100% Load
NOx emission formation through liner length
0
50
100
150
200
250
300
350
400
450
0 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26
Calculation zone number
NO
x,m
g/d
Nm
3 @
15
% O
2,
Fuel oil#2, calculated
Methanol, calculated
Fuel oil#2, measured
Log. (Fuel oil#2, calculated)
Log. (Methanol, calculated)
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Diagram for Methanol Firing Test
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Methanol Tank With Dike
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Methanol Connection Junction
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Emission Measurements Instruments
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Test Results
TT7
Average TT7 as function of GT load
Tamb=22-24C
800825850875900925950975
100010251050107511001125115011751200
0 5 10 15 20 25 30
GT load, Mw
TT
7, F
Oil#2 Methanol Power (Oil#2) Linear (Methanol)
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Test Results
Temperature Spread
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Test Results
Heat Rate
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Test Results
NOx Reduction
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Test Results
CO
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Test results
Oxygen
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Test Results
Particulates
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Test Results
SO2
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Test Results
Formaldehyde
Formaldehyde as function of GT load
0
5
10
15
20
25
0 5 10 15 20 25 30
GT load, Mw
Fo
rmald
eh
yd
e,
mg
/dN
m3@
15%
O2
Methanol
Formaldehyde Limit
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Following Stage
Modification for a Long-Term
Methanol Firing Test in Eilat
The Plan
A project to convert FT4C TWIN PAC 50 MW GT Unit in Eilat to
Methanol firing (identical to the unit in Caesarea).
Objectives
To restore the full capacity of the machine and to gain long-term
operating experience of working with methanol-fueled GT.
Schedule
Following summers for two years.
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How To Restore Capacity?
The flow must be doubled.
There are a few bottle necks, as follows:
HP pumps (Gear Box Driven) – external pumps assembled on a skid
Modulating Valve – omitted – flows are controlled by a Variable
Speed Drive (VSD)
Pressure & Dump (P&D) valves – replacement of strainer
Firing nozzles – Excello Nozzles are replaced by set of High Flow
Delevan Nozzles (which were developed for water injection to
enable doubling the flow).
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Two-Phase Test (in Eilat)
Short-term:
Check feasibility of the system and validate performance
and low emissions (2-3 weeks).
Long-term:
Gain operational experience and confidence in the system
(2-3 years, 1500-2000 hours each year).
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Fuel oil
Methanol
Filters By others
psi
psi
Fuel SOVs (shut-off valves)
gpm
gpm
75 HP VSD
Engine
80 gpm pump
40 gpm pump
Control House
Mixing Block
30 HP VSD
PEPCO Fuel Control Proposal for dual methanol
system (one skid)
1.5” SS pipe
1.25” SS pipe Inlet piping both fuels 3”
400V 50Hz ~75KVA
Control Air 250-110 psi
Motor power wire from VSD
Control wires: 2 digital outputs 2 analog inputs
2 analog outputs
PEPCO Fuel Control
Control wires: 2 digital outputs
6 digital inputs 5 analog inputs
Restoring Capacity – Fuel Control & External Pumps
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External High-Pressure Pumps
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Replacing Nozzles to
Delevan High Flow
Excello Nozzles Delevan Nozzles
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Adapting Fuel Unloading
and Storage System
New unloading piping
Tank adaptation – floating roof
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Adapting Fire-Fighting System
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Fuel Unloading Platform
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Summary
The results presented here clearly show that with minor
low cost fuel system retrofit, methanol firing leads to
significant NOx, SO2, and particulates emission
reduction, without affecting performance.
We believe that the results of the present work can be
applied to other boilers and gas turbines.