Low emission combustion process and apparatus

Claim 2

A combustion process for producing exhaust gases having a low content of carbon monoxide and nitrogen oxides, said process comprising: introducing a mixture of hydrocarbon fuel and air into a combustion zone having a volume which is sufficient to support stable combustion under the desired combustion conditions, with the mixture being premixed to a sufficient extent to provide a substantially uniform and homogeneous mixture within the combustion zone; igniting and burning the mixture within the combustion zone; maintaining the combustion temperature at about 3000° F. or less to reduce the content of nitrogen oxides in the exhaust gases to a level of about 1.5 grams or less for each kilogram of consumed fuel; controlling the fuel-to-air ratio in the combustion zone at lean fuel-to-air ratios of about 0.0035 to about 0.035 under stable combustion conditions which exceed lean blowout to a sufficient extent to reduce the carbon monoxide levels in the exhaust gases to about 12.0 grams or less per kilogram of consumed fuel, and maintaining the flow rate of the fuel-air mixture into the combustion zone at a level which exceeds the turbulent flame velocity within the combustion zone to prevent flashback to the point of introduction of the combustible mixture.

Claim 3

A combustion process for producing exhaust gases having a low content of carbon monoxide and nitrogen oxides, said process comprising: introducing a mixture of hydrocarbon fuel and air into a combustion zone having a volume which is sufficient to support stable combustion under the desired combustion conditions, with the mixture being premixed to a sufficient extent to provide a substantially uniform and homogeneous mixture within the combustion zone; igniting and burning the mixture within the combustion zone; maintaining the walls which define the combustion zone at temperatures which are sufficiently close to the combustion temperature to prevent quenching of the combustion reaction in the regions adjacent the walls to an extent which forms excessive quantities of carbon moxoxide and unburned hydrocarbons adjacent the burner walls; providing a dilution zone which is positioned downstream from the combustion zone and in flow communication with the combustion zone; splitting the incoming stream of air into a first stream which is introduced into the combustion zone and a second stream which is introduced into the dilution zone; controlling the flow split of the said first stream to provide a ratio of fuel to air within the combustion zone at lean fuel-to-air ratios of about 0.0035 to about 0.035 under stable combustion conditions which exceed lean blowout to a sufficient extent to reduce the carbon monoxide levels in the exhaust gases to about 12.0 grams or less per kilogram of consumed fuel while maintaining the combustion temperature at about 3,000° F. or less to reduce the content of nitrogen oxides in the exhaust gases to a level of about 1.5 grams or less for each kilogram of consumed fuel, and maintaining the flow rate of the fuel-air mixture into the combustion zone at a level which exceeds the turbulent flame velocity within the combustion zone to prevent flashback to the point of introduction of the combustible mixture.

Claim 4

A combustion process for producing exhaust gases having a low content of carbon monoxide and nitrogen oxides, said process comprising: introducing a mixture of hydrocarbon fuel and air into a combustion zone having a volume which is sufficient to support stable combustion under the desired combustion conditions, with the mixture being premixed to a sufficient extent to provide a substantially uniform and homogeneous mixture within the combustion zone; igniting and burning the mixture within the combustion zone; maintaining the walls which define the combustion zone at temperatures which are sufficiently close to the combustion temperature to prevent quenching of the combustion reaction in the regions adjacent the walls to an extent which forms excessive quantities of carbon moxoxide and unburned hydrocarbons adjacent the burner walls; providing a dilution zone which is positioned downstream from the combustion zone and in flow communication with the combustion zone; splitting the incoming stream of air into a first stream which is introduced into the combustion zone and a second stream which is introduced into the dilution zone; controlling the flow split of the said first stream to provide a ratio of fuel to air within the combustion zone at lean fuel-to-air ratios of about 0.0035 to about 0.035 under stable combustion conditions which exceed lean blowout to a sufficient extent to reduce the carbon monoxide levels in the exhaust gases to about 12.0 grams or less per kilogram of consumed fuel while maintaining the combustion temperature at about 3,000° F. or less to reduce the content of nitrogen oxides in the exhaust gases to a level of about 1.5 grams or less for each kilogram of consumed fuel, and maintaining the flow rate of the fuel-air mixture into the combustion zone at a level which exceeds the turbulent flame velocity within the combustion zone to prevent flashback to the point of introduction of the combustible mixture.

Claim 5

The process of claim 2 wherein the fuel is vaporized prior to its introduction into the combustion zone.

Claim 6

The process of claim 2 wherein the combustion zone temperature is maintained between about 2,100° to about 3,000° F.

Claim 7

The process of claim 2 wherein the hydrocarbon fuel is propane, nautral gas, lpg, or a fuel in the gasoline to diesel boiling range.

Claim 8

The process of claim 2 including the step of heating the incoming stream of air prior to its introduction into the combustion zone.

Claim 9

The process of claim 2 wherein the fuel-to-air ratio within the combustion zone is varied in controlling the combustion in response to variations in the fuel flow to the combustion zone or variations in the flow rate of incoming air.

Claim 10

The process of claim 2, including the steps of admixing water with the fuel and vaporizing the water with the quantity of water and the extend of water vaporization controlled to form a sufficient quantity of water vapor or carry the fuel into the combustion zone in the form of microscopic fuel droplets of a sufficiently small size to provide an essentially homogeneous combustible mixture within the combustion zone.

Claim 11

The process of claim 2, including sensing the content of nitrogen oxides or carbon monoxide, or both, in the exhaust gases; providing a signal or force that is proportional to the said level of nitrogen oxides or carbon monoxide or both, and splitting the incoming stream of air in response to the signal or force to control the flow rate of the first stream at a level which reduces the nitrogen oxide levels in the exhaust gases to about 1.5 grams or less for each kilogram of consumed fuel and the carbon monoxide levels in the exhaust gases to about 12.0 grams or less for each kilogram of consumed fuel, or reduces both the nitrogen oxide content and the carbon monoxide content to said levels.

Claim 12

A process for operating a gas turbine to reduce the content of carbon monoxide and nitrogen oxides in the turbine exhaust gases, said process comprising: introducing a mixture of a hydrocarbon fuel and air into a combustion zone having a volume sufficient to support stable combustion under the desired combustion conditions and burning the mixture with the combustible mixture being well mixed to provide a substantially uniform and homogeneous mixture within the combustion zone; maintaining the combustion temperature within the combustion zone at a level of about 3,000° F or less to reduce the nitrogen oxides content in the exhaust gases to a level of about 1.5 grams or less for each kilogram of consumed fuel; maintaining a lean fuel-to-air ratio in the combustion zone of about 0.0035 to about 0.035 under stable combustion conditions and at a sufficient level above lean blowout to reduce the carbon monoxide level in the exhaust gases to about 12.0 grams or less per kilogram of consumed fuel; maintaining the flow rate of the fuel-air mixture into the combustion zone at a level in excess of the turbulent flame velocity in the combustion zone to prevent flashback to the point of introduction of the combustible mixture, and conveying the exhaust gases from the combustion zone to a turbine rotor to drive the rotor in producing power.

Claim 13

A process for operating a gas turbine to reduce the content of carbon monoxide and nitrogen oxides in the turbine exhaust gases, said process comprising: introducing a mixture of a hydrocarbon fuel and air into a combustion zone having a volume sufficient to support stable combustion under the desired combustion conditions and burning the mixture with the combustible mixture being well mixed to provide a substantially uniform and homogeneous mixture within the combustion zone; maintaining the combustion temperature within the combustion zone at a level of about 3,000° F or less to reduce the nitrogen oxides content in the exhaust gases to a level of about 1.5 grams or less for each kilogram of consumed fuel; maintaining a lean fuel-to-air ratio in the combustion zone of about 0.0035 to about 0.035 under stable combustion conditions and at a sufficient level above lean blowout to reduce the carbon monoxide level in the exhaust gases to about 12.0 grams or less per kilogram of consumed fuel; maintaining the flow rate of the fuel-air mixture into the combustion zone at a level in excess of the turbulent flame velocity in the combustion zone to prevent flashback to the point of introduction of the combustible mixture, and conveying the exhaust gases from the combustion zone to a turbine rotor to drive the rotor in producing power.

Claim 14

A process for operating a gas turbine to reduce the content of carbon monoxide and nitrogen oxides in the turbine exhaust gases, said process comprising: introducing a mixture of a hydrocarbon fuel and air into a combustion zone having a volume sufficient to support stable combustion under the desired combustion conditions and burning the mixture with the combustible mixture being well mixed to provide a substantially uniform and homogeneous mixture within the combustion zone; providing a dilution zone which is positioned downstream of the combustion zone in flow communication with the combustion zone; splitting the incoming stream of air into a first stream which is introduced into the combustion zone and a second stream which is introduced into the dilution zone; controlling the flow split of the first stream to maintain the combustion temperature within the combustion zone at a level of about 3,000° F. or less to reduce the nitrogen oxides content in the exhaust gases to a level of about 1.5 grams or less for each kilogram of consumed fuel while maintaining a lean fuel-to-air ratio in the combustion zone of about 0.0035 to about 0.035 under stable combustion conditions at a sufficient level above lean flowout to reduce the carbon monoxide level in the exhaust gases to about 12.0 grams or less per kilogram of consumed fuel; maintaining the flow rate of the fuel-air mixture into the combustion zone at a level in excess of the turbulent flame velocity in the combustion zone to prevent flashback to the point of introduction of the combustible mixture; and conveying the exhaust gases from the combustion zone to a turbine rotor to drive the rotor in producing power.

Claim 15

A process for operating a gas turbine to reduce the content of carbon monoxide and nitrogen oxides in the turbine exhaust gases, said process comprising: introducing a mixture of a hydrocarbon fuel and air into a combustion zone having a volume sufficient to support stable combustion under the desired combustion conditions and burning the mixture with the combustible mixture being well mixed to provide a substantially uniform and homogeneous mixture within the combustion zone; providing a dilution zone which is positioned downstream of the combustion zone in flow communication with the combustion zone; splitting the incoming stream of air into a first stream which is introduced into the combustion zone and a second stream which is introduced into the dilution zone; controlling the flow split of the first stream to maintain the combustion temperature within the combustion zone at a level of about 3,000° F. or less to reduce the nitrogen oxides content in the exhaust gases to a level of about 1.5 grams or less for each kilogram of consumed fuel while maintaining a lean fuel-to-air ratio in the combustion zone of about 0.0035 to about 0.035 under stable combustion conditions at a sufficient level above lean flowout to reduce the carbon monoxide level in the exhaust gases to about 12.0 grams or less per kilogram of consumed fuel; maintaining the flow rate of the fuel-air mixture into the combustion zone at a level in excess of the turbulent flame velocity in the combustion zone to prevent flashback to the point of introduction of the combustible mixture; and conveying the exhaust gases from the combustion zone to a turbine rotor to drive the rotor in producing power.

Claim 16

The process of claim 11, including the step of prevaporizing the fuel prior to its introduction into the combustion zone.

Claim 17

The process of claim 12, including the step of compressing the incoming stream of air by passing the incoming stream through a compressor driven by the turbine rotor.

Claim 18

The process of claim 12, including the step of transferring heat from the exhaust gases to the stream of incoming air to preheat the incoming stream prior to its introduction into the combustion zone.

Claim 19

The process of claim 12, including the step of transferring heat from the exhaust gases to the incoming fuel with the heat transfer being carried out at a temperature below the decomposition temperature of the fuel.

Claim 20

The process of claim 15, including the step of removing excess heat from the exhaust gases when the heat transfer from the exhaust gases would cause the incoming fuel to reach a temperature above the decomposition temperature of the fuel.

Claim 21

The process of claim 16, including the step of transferring the excess heat removed from the exhaust gases to the incoming stream of air.

Claim 22

The process of claim 11, including the steps of admixing water with the fuel and vaporizing the water with the quantity of water and the extent of water vaporization controlled to form a sufficient quantity of water vapor to carry the fuel into the combustion zone in the form of microscopic fuel droplets of a sufficiently small size to provide an essentially homogeneous combustible mixture within the combustion zone.

Claim 23

The process of claim 11, including the steps of sensing the content of nitrogen oxides or carbon monoxide in the exhaust gases, or both the content of nitrogen oxides and carbon monoxide in the exhaust gases; providing a signal or force that is proportional to the said content of nitrogen oxides or carbon monoxide, or both, and splitting the incoming stream of air in response to the signal or force to control the flow rate of the first stream at a level which reduces the nitrogen oxide levels in the exhaust gases to about 1.5 grams or less for each kilogram of consumed fuel or the carbon monoxide levels in the exhaust gases to about 12.0 grams or less for each kilogram of consumed fuel, or reduces both the nitrogen oxide and carbon monoxide content to said levels.

Claim 24

The process of claim 11 wherein the hydrocarbon fuel is propane, natural gas, lpg, or a fuel in the gasoline to diesel boiling range.

Claim 25

The process of claim 11 wherein the combustion zone temperature is maintained between about 2,000° F. to about 3,000° F.

Claim 26

The process of claim 2 including: sensing the actual temperature in the combustion zone; sensing the fuel flow rate to the combustion zone and the flow rate of the incoming stream of air and determining a set combustion temperature required to maintain a selected nitrogen oxides level in the exhaust gases; comparing the set combustion temperature with the actual combustion temperature, and varying the splitting of the incoming stream of air in response to the difference between the set combustion temperature and the actual combustion temperature to bring the actual combustion temperature into correspondence with the set combustion temperature.

Claim 27

The process of claim 2 including: sensing actual temperature in the combustion zone; sensing the inlet air temperature, the pressure in the combustion zone, the fuel flow rate and the flow rate of the incoming stream of air and determining a set combustion temperature required to maintain a selected level of carbon monoxide in the exhaust gases at the sensed conditions; comparing the set combustion temperature with the actual combustion temperature, and splitting the incoming stream of air in response to the set combustion temperature and the actual combustion temperature to bring the actual combustion temperature into correspondence with the set combustion temperature.

Claim 28

The process of claim 2 including: sensing the flow rate of the incoming stream of air, the fuel flow rate, the temperature of the incoming stream of air and the flow split of the incoming stream of air into said first and second streams and determining the actual combustion temperature within the combustion zone; determining a set combustion temperature from the fuel flow rate and the flow rate of the incoming stream of air that is required to maintain a selected nitrogen oxides level in the exhaust gases; comparing the set combustion temperature with the actual combustion temperature, and varying the splitting of the incoming stream of air in response to the difference between the combustion temperature and the actual combustion temperature to bring the actual combustion temperature into correspondence with the set combustion temperature.

Claim 29

The process of claim 2 including: sensing the flow rate of the incoming stream of air, the fuel flow rate, the temperature of the incoming stream of air and the flow split of the incoming stream of air into said first and second streams and determining the actual combustion temperature within the combustion zone; sensing the inlet air temperature, the pressure in the combustion zone, the fuel flow rate and the flow rate of the incoming stream of air and determining a set combustion temperature required to maintain a selected level of carbon monoxide in the exhaust gases at the sense combustions, comparing the set combustion temperature with the actual combustion temperature, and splitting the incoming stream of air in response to the difference between the set combustion temperature and the actual combustion temperature to bring the actual combustion temperature into correspondence with the set combustion temperature.

Claim 30

The process of claim 2 including: sensing the fuel flow rate to the combustion zone and the flow rate of the incoming stream of air and determining a set combustion temperature required to maintain a selected nitrogen oxides level in the exhaust gases; sensing the temperature of the incoming air stream and determining the difference between the temperature of the incoming air stream and the set combustion temperature; determining the required fuel-to-air ratio in the combustion zone to raise the temperature of the air entering the combustion zone to the set combustion temperature; sensing the fuel flow rate and the flow rate of the incoming stream of air and determining the fuel-to-air ratio; comparing the required fuel-to-air ratio in the combustion zone with the fuel-to-air ratio to determine the required flow split of the incoming air stream to provide the set combustion temperature; sensing the actual flow split of the incoming stream of air, and changing the actual flow split to bring it into correspondence with the required flow split of the incoming air stream.

Claim 31

The process of claim 2 including: sensing the inlet air temperature, the pressure in the combustion zone, the fuel flow rate and the flow rate of the incoming stream of air and determining a set combustion temperature required to maintain a selected level of carbon monoxide in the exhaust gases at the sensed conditions; sensing the temperature of the incoming air stream and determining the difference between the temperature of the incoming air stream and the set combustion temperature; determining the required fuel-to-air ratio in the combustion zone to raise the temperature of the air entering the combustion zone to the set combustion temperature; sensing the fuel flow rate and the flow rate of the incoming stream of air and determining the fuel-to-air ratio; comparing the required fuel-to-air ratio in the combustion zone with the fuel-to-air ratio to determine the required flow split of the incoming air stream to provide the set combustion temperature; sensing the actual flow split of the incoming stream of air, and changing the actual flow split to bring it into correspondence with the required flow split of the incoming air stream.