Syngas and Hydrogen

Combustion in GT
State of art about the use
of H2 rich Syngas in GTs,
in the prospect of
Hydrogen Economy

S.Giammartini

Syngas
With this acronym we are use to indicate a gas of varying composition
that can be produced by gasification of coal, biomass, waste or by
petrolchemical / metallurgical industry
Syngas consists mainly of carbon monoxide and hydrogen,
and has less than half the energy density of natural gas
Opportunity gases, coming from wastes, petrochemical and metallurgical
industry, and even more the prospects of the hydrogen economy
put in evidence the problem of :

how we can burn these fuels in GTs?

Summary
three steps:
1. Industrial experiences about syngas with
low percentage content of H2 (< 20 %)
2. Syngas with high content of H2
(up to ~ 100%)
3. Future prospects and new advanced technologies

Summary:
1. Industrial experiences about syngas with
low percentage content of H2 (< 20 %)
2. Syngas with high content of H2
(up to ~ 100%)
3. Future prospects and new advanced technologies

Future H2-based energy concepts will require 90 100% H2 as fuel,

but now it can involve intermediate H2 concentrations
Generally, to minimize the high costs of a new project, a low BTU burner is
derived from a premixed burner for NG, operated in diffusive mode
two are the elements that can characterize a not convenctional fuel:
Low CalorificValue (LHV) and volume ratio H2/CO
For conventional fuels, the effects that phisical/chemical parameters deviation can
induce on GT combustion, are negligible.
On the contrary, for non-conventional fuels, effects of H2 content are very significant
About syngas reactivity, the only parameter that we can determine analytically
is the laminar flame velocity, defined as:

vfuel
SL = 2( +1)
u

where:

K
=
u cpu

(Diffusivity factor)

= cinematic viscosity; u = unburned density

From the formula: SL increases if H2 percentage increases, because the
density of the mixture can be very low respect to the density of NG.

ANSALDO Energia experiences

A tipical modified Low BTU diffusive burner, developed by ANSALDO
Energia, is shown in figure (starting from a V94-K)
Respect to the convenctional burner, the low BTU version has enlarged channels to
permit the feeding with syngas diluted with steam, to reduce reactivity of fuel and NOx
emissions
FuelOil
Cooling
Air

Low BTUFuel

Air

2
4

Natural Gas

Main components are:

1. A diffusive line (1-yellow) feeded with NG, for

the start-up and for going up the power, up to
Syngas commutation (change over point);
2. A pilot line (2-orange), with NG, to prevent the
extinction;
3. A diagonal swirler (3) for secondary
combustion air;
4. The diffusive low BTU fuel line (4 - green)
to feed GT in the power range:
change over base load.
6. Primary swirled air
by P.Gobbo - Ansaldo Energia

About the practice

FuelOil
Cooling
Air

Low BTUFuel

Air

At the start up the burner is feeded by NG in the diffusive

Line (1). Power is increased with NG up to the change over
point (50% of the base load), before to switch at the Low
BTU line;

2
4

The start up with NG is imposed by the high laminar flame

velocity of H2 (SLH2 ~ 350 cm/s; SL CH4 ~ 43 cm/s),
infact low flow rates can determine ignition in zones near
the internals of the burner

Natural Gas

During the switch phase (15-20 min), machine is runned with NG (in 1) and
Syngas (in 4);
A configuration like this can be easily modified to be adapted at different syngas
compositions and characteristics

by P.Gobbo - Ansaldo Energia

SL (cm/s)

Effecs of H2 percentace increase

on the syngas flame velocity,
and mitigation effects of the dilution with air

NG + 40% H2
SL(40%H2)

SL(NG)
NG

Lambda

SL(40%H2)~1,5 SL(NG)

by P.Gobbo - Ansaldo Energia

3
Effecs of H2 percentace increase
on Flash Back margins in Premixed mode (F-class machine V94-3A)
Red lines represent flash back limits in function of H2 %
Flash Back limits

No Overheating

Air/Fuel ratio

40% H2

Risk of
Overheating

dp/p (Air Flow Rate)

Enlargement of
the overheating zone
Pilot feeded with H2 (40% from premixed line + 10% from pilot)
reduces stability limits and safety margin on flash back further on
by P.Gobbo - Ansaldo Energia

Results
Tests of Flash Back, carried out with mixture of NG + H2 (max 50% vol),
put in evidence the following results:
No overheating in diffusive conditions;
In premixed mode safety margin on flash back is very reduced, respect
to NG;
Pilot flame feeded with H2 reduces stability limits and safety margin
on flash back;
In diffusive mode, no significant effect of H2 on flash back is observed;
An increase of 20 30 % of NOx is evaluated in premixed mode, for
mixture of 40% vol of H2.

by P.Gobbo - Ansaldo Energia

ENEL results
Stability limits and NOx emissions in
premixed combustion

Increasing Stability

in weight

in function of pilot flame percentage (P/T %) and H2 % content

Results: Combustion stability, burning NG only, requires pilot flame in DLN burner.
The addition of H2 gives a wider flame stability range, and consequently allows to work at
very low values of the P/T ratio without any problem.
At P/T level less than 4% the concentration of the NOx emissions falls
From G.Benelli et al. ENEL Ricerche

Conclusions
Different experimental campaigns demonstrate the feasibility of burning
Hydrogen enriched flame within industrial DLN Gas Turbine burners.
A 10% addition in weight of hydrogen allows to operate, using DLN
combustor, at almost full premixed mode with NOx emissions below
10 ppm@15%O2

Summary:
1. Industrial experiences about syngas with
low percentage content of H2 (< 20 %)
2. Syngas with high content of H2
(up to ~ 100%)
3. Future prospects and new advanced technologies

Hydrogen Economy
The hydrogen economy founds its appeal on the advantages of this fuel,
mainly :

No generation of CO2; SOx; CO; UHC; VOC

Radical solution of the greenhouse effecs
In this scenario it is generally admitted that:

Gas Turbine is one of the most promising prime movers

for H2 applications

Hydrogen-fuelled Gas Turbine

Today Hydrogen is not terra incognita (unknown land) for Gas Turbine:
a considerable number of E-class machines are burning H2 actually

Actual experience:
- In Spain about 20 Frame 6B, erected in 90s are burning 10 70% H2
- In UK a Frame 9E is burning 48-55 % of H2
- In Korea a 40 MW GT (Daesan, a petrolchemical complex) is operated with
combustion of over 97% H2

The Daesan plant boastes some records :

from september 1997,over 10 years of experience with content of 85-97% of H2
availability has been 96,5%
Always the start up is feeded with NG

H2-air flames: General Considerations

H2 is a dual-faced fuel, due to
its very low density, respect NG:

LHV

Volume basis

Mass basis

CH4

35.500 kJ/Nm3

50.030 kJ/kg

H2

10.770 kJ/Nm3

120.650 kJ/kg

Resuming: combustion properties of H2 in Air respect CH4

350

~ 40 times

~ 8 times ~ half
43

Effects of increasing H2 percentage

exposure time=1 s, f# = 5

exposure time=1 s, f# = 5

50 mm

About swirled
diffusive burner

100% NG
exposure time=1 s, f# = 5

80% H2

40% H2
exposure time=1 s, f# = 3.4

100% H2

Results:
the increase of H2 percentage, determines the progressive reduction of flame
dimensions that means significat reduction of combustion chamber
dimensions for burners of new design.

Effects of increasing H2 % on flame stability

Global equivalence
Phi globale ratio,

0.7

100% NG

STABLE

0.6

90% NG +10% H2

0.5

80% NG +20% H2

0.4
0.3
0.2

BLOWOUT

0.1

0
90

130

170

210

250

290

330

370

410

& airH2
0%
m& f m
10% H2
&
&
m
m
( f 30%
air ) H2
stoich
450

490

530

Strain parameter, Uair/dburner, 1/s

The increase of H2 % content has the effect to enlarge the stability region
Swirled burner can be operated at very lean equivalence ratio, and greater
Reynolds number (Uair), when fed with fuel mixture of Natural Gas + H2

Diffusive combustion

ENEL experiences

Effects of H2 concentration increase

on the longitudinal profile of the liner temperature
shorter H2 flame
higher local wall temp.

Radiation: absence of soot contribution

is compensed by higher H2O

Increase of H2 content

Results: H2 content has effect only in the zone between the dome and the primary holes of dilution.
Respect to the case of NG combustion, the maximum of temperature move back towards the dome.
This displacement is almost independent from combustion pressure, and mixture composition.
After primary combustion zone, T profiles are equivalent, so we can conclude that reduction of soot
is belanced by higher H2O radiation
From G.Benelli et al. ENEL Ricerche

H2-air flames: Combustion effecs

1. Flames Short & Fast:

As an effect of very simple chain reaction respect CH4

H2-air flames: Combustion effecs

1. Flame Short & Fast:

Very simple chain reaction respect CH4

High diffusivity and reactivity (due to radicals H; OH; ..) :
H2 is 15 times lighter than air, so 3 times more diffusive than air
High Flash Back risk at the present no premix combustion technology
is available for GTs

H2% increase
produces shorter
and stronger flames

From G.Benelli et al. ENEL Ricerche

H2-air flames: Combustion effecs

1. Flame Short & Fast:

Very simple chain reaction respect CH4

High diffusivity /reactivity of intermediate species / radicals (H; OH; ..)
- H2 is 15 times lighter than air, 3 times more diffusive than air
High Flash Back risks at the present no premix combustion technology
is available for GTs

2. Very Hot flames:

Only a molecule (H2O) as combustion product, per molecule of fuel (H2):
that determines very increased radiation effects on the liner

From M.Moliere GE Energy

H2-air flames: Combustion effecs

2. Very Hot Flame:
Only a molecule of combustion product (H2O) per molecule of fuel (H2)
Adiabatic Stoichiometric Comb. Temp. (Tas) of H2 ~ Tas of CH4+150C

Diffusive flame: NOx increases with (adiabatic) combustion temperature

DeNOx Steam/Water injection has the effects: (i) to degrade efficiency;
(ii) to amplify the H2O radiative effects
From G.Benelli et al. ENEL Ricerche

H2-air flames: Combustion effecs

1. Flame Short & Fast:

Very simple chain reaction respect CH4

High diffusivity /reactivity of intermediate species / radicals (H; OH; ..)
- H2 is 15 times lighter than air, 3 times more diffusive than air
High Flash Back risks at the present no premix combustion technology
is available for GTs

2. Very Hot Flame:

Only a molecule of combustion product (H2O) per molecule of fuel (H2)
Tas (adiabatic stoichiometric combustion Temperature) of H2 ~ Tas (CH4)+150C

3. Very Stable Combustion:

Very large Flammability Range
(LFL = 4% vol UFL = 75% vol)
and lower Auto-ignition Temp.

H2-air flames: Combustion effecs

4. Radiative & Aerothermal effects
Enhanced heat transfer with H2O rich hot gas:
Produces radiation & convection severe impact on metal temperature
Moreover:
An extremely turbulent hot gas (1400 1700 K) impacts the 1 stage
turbine nozzles, so they undergo the highest temperature and
mechanical stress, partially mitigated by the dilution air and by the
cooling air from the 1 stage nozzles
Future prospects about this aspect:
Actual E-class GTs are characterized by Tf = 1100 - 1150 C
Future H2 based power applications will require higher Tf (1300 1400 C)

From M.Moliere GE Energy

SIEMENS Experiences
In the last years significant test campaigns have been
completed. Results indicate that:

Generally connected
Industrial plants
to gasification
operating with high H2 %

Significant
percentage of H2
TG Siemens/Ansaldo

Resuming

Fuel properties
considered
3 are the
driving forces
of H2 as fuel

These facts
determine:

It is necessary
To carry out
actions
to promote:

Need to prevent pre-ignition

Particular care for avoiding flash back To reduce risk of flashback
and NOx emissions
Mixing of fuel and air within shortest possible time

by SIEMENS

% increase of SL respect to NG

V94-3K

by SIEMENS

Diffusion or DLN Combustion

respect to the Flash Back risk ( H2 diluted with N2)

Increase dilution and gas

velocity

by SIEMENS

Conclusions
GTs are well positioned for H2-based generation in the medium / large
power range
Experiences accumulated with E-class GT provides solid milestones
in terms of feasibility / safety / reliability
Pending aspects exist, expecially for advanced H2-fuelled GTs:
- H2 compatibility of materials
- Development of Ultra Lean burners, flash back free
- Blade material for higher TiT
- Global safety policy for H2 storage/transport and leak detection
Diluted H2-mixture (H2-N2) is likely to alleviate most issues:
- New combustion chambers or use of available IGCC GT chambers
- NOx: as an effect of lower combustion temperature
- Safety: in terms of mitigation of high flammability issues
- Radiative: lesser H2O content in the combustion gas

Summary:
1. Industrial experiences about syngas with
low percentage content of H2 (< 20 %)
2. Syngas with high content of H2
(up to ~ 100%)
3. Future prospectives and new advanced technologies

Our traditional experiences about combustion, related to

natural events, every day life or techological applications,
are relative to two foundamental way to burn:
diffusive combustion (> 90% of industrial applications)
premixed combustion (tipical of GTs).
High temperature of reactants and low concentration
of oxygen make possible another way:

FLAMELESS COMBUSTION

Flammability limits: temperature effect

threshold flameless
900
800

Temperature C

700

stoichiometry

600
500
400

300

Upper (rich)
flammability
limit

Lower (lean)
flammability
limit

200
100
0
0

10

15

20

25

-100

CH4 concentration in mixture with air

Fuel in air is flammable within a specific range of concentration (lower and upper limits) under
self-ignition temperature.
Over the self-ignition (auto-ignition) temperature these limits tend to vanish,
and mixture burns anyway even if not necessarily with flame front.

Flameless Combustion
2000
stable
flame
front
at the
burner

1750

Temperature
C
temperature
C

1500

stable flameless
combustion

Lifted flames

1250
1000
Self-ignition temperature

750
500

No stable flame risk of explosion

Kv = PdCric / Airinput

250
0
0
21

1
O2 %

2
3
Kv
Flue
recirculation
ratio
Flue
recirculation
ratio
Kv
17

13

4
9

5
5

Graphic representation of combustion regimes in function of Temp. and Recirc. Factor.

4 regions are evident :
a zone of convenctional combustion caracterized by a limited mixing with entrained recirculated flue gases
a zone of unstable flame, under self-ignition (auto-ignition) temperature (high risk of explosion)
a zone of lifted flame, over self-ignition (auto-ignition) temperature;
a stable combustion zone, without flame front, caracterized by presence of reactants,hot combustion products
and hot flue gases.
Condition for stable combustion is Kv > 2-3

Flameless combustion with oil: an evidence

No flame front !
only IR emissions

Burner 100kW: BTZ oil; Air 250C;

O2% = 21%

Burner 100kW: BTZ oil; Air 500C;

O2% = 12%
Ansaldo Caldaie:
Gioia del Colle station

Comparison between Flame and Flameless

combustion
Furnace at 1200 C
2000

T adiab

1800

FLAMELESS

Gas temperature C

1600
1400

flameless mode
1200

flame mode
1000

T rec

In Flameless mode, temperature

goes up very softly, as effect of
premixig with flue gases.
Above self-ignition temperature
we have a moderate gradient,
up to the adiabatic temperature,
suitable of the recirculation rate
(GREEN LINE)

800

no reaction

600

Tair = 400 C

self-ignition

400
200
0
0,0

1,0

2,0

3,0

4,0

In Flame mode, temperature,

starting from Tair, goes up with
a high gradient, up to the Adiabatic
Temperature. (BROWN LINE)

5,0

recirculation rate Kv

In Flameless mode we reduce the maximum of temperature

because we dont have flame front !

Cortesia WS

Flameless combustion:
some experimental evidences
(y = 0 : burner axis)
.1450,0

T (C)

1400,0

Temperature
profiles

flox 1250C
flame 1250C

1350,0
1300,0
1250,0
1200,0
0,00

250,00

0,20

0,40

0,60

furnace axis (x/L)

0,80

NOx
emissions

mg/Nm3 (3% O2)

Temperature
profiles
Temperature profiles

NOx emissions in flue gas

200,00
150,00

flame
MILD

100,00
50,00
0,00
950

1000

1050

1100

1150
C

From the microscopic point of view

In flame we have high gradients
of temperature and
concentration of species
(reactants + products of
combustion)
In flameless mode we can observe
the general smoothing of these
quantities

Flameless combustion: practical realization

preheated air
1000 C

Limited recirculation (Kv < 1)

Traditional

fuel gas

Staged burner

furnace wall
preheated air
1000 C

enhanced recirculation (Kv > 3)

air jet

((

reaction zone

Flameless combustion is obtained:

Increasing the entrainment of

combustion products .

fuel gas

the effects are;

Great temperature uniformity

flue gas

Reduced production of thermal NOx

FL592B-E

How we can realize

Flameless Combustion in GT burner ?

Trapped Vortex Combustion Strategy

can be a solution for Flameless

Create a stable vortex system in a cavity,

where fuel and oxidant are injected, mixed and burn
with minimum pressure drop

The anchorage of
the flame is
assured
by recirculation of
hot combustion
products
First cavity

Second cavity

CFD simulations
of Syngas combustion
in a TV burner
Flameless combustion
is stable and anchored
in the first cavity
Temperature + velocity maps

Component

Volume
fraction [%]

H2

40

CH4

CO

15

CO2

35

N2

Temperature map
Dati

FLOX Turbogas combustor CFD

simulation
A conceptual design,
proposed by DLR and WS (Ge)
Temperature

CO Mole Fraction

TV Burner exp. tests

Trapped Vortex seems

to represent a real possibility
to realize Flameless Combustion
in Gas Turbines

Thank you
for yor
attention !