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)
1
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!
2
Methanol as an Option
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
3
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
5
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)
6
Caesarea Power Plant Site
Tested unit
7
TP -1 Base Plate Assembly
8
FT4 – Engine & Power Turbine
9
Liner
10
Fuel Spraying Nozzles
11
FO Atomizer Assembly
12
Predicting the NOx Formation
Calculated Flame Temperature
Distribution at 100% Load
Flame temperture distribution through liner length
1950
1900
1850
1800
Temperature, C
1750
1700 Fuel oil#2
1650 Methanol
1600
1550
1500
1450
1400
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
13
Predicting the NOx Formation
Calculated Liner Wall Temperature
Distribution at 100% Load
Relative liner wall metal temperature reduction during
methanol burning
1
Metanol to FO#2 wall metal
0.9
temperature ratio
0.8
0.7
0.6
0.5
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
14
Predicting the NOx Formation
Comparison of Calculated NOx Formation Through Liner
Length for FO#2 and for Methanol Firing at 100% Load
NOx emission formation through liner length
450
400
NOx,mg/dNm3 @15% O2,
350
300
Fuel oil#2, calculated
250 Methanol, calculated
Fuel oil#2, measured
200 Log. (Fuel oil#2, calculated)
Log. (Methanol, calculated)
150
100
50
0
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
15
Diagram for Methanol Firing Test
16
Methanol Tank With Dike
17
Methanol Connection Junction
18
Emission Measurements Instruments
19
Test Results
TT7
Average TT7 as function of GT load
Tamb=22-24C
1200
1175
1150
1125
1100
1075
1050
TT7, F
1025
1000
975
950
925
900
875
850
825
800
0 5 10 15 20 25 30
GT load, Mw
Oil#2 Methanol Power (Oil#2) Linear (Methanol)
20
Test Results
Temperature Spread
21
Test Results
Heat Rate
22
Test Results
NOx Reduction
23
Test Results
CO
24
Test results
Oxygen
25
Test Results
Particulates
26
Test Results
SO2
27
Test Results
Formaldehyde
Formaldehyde as function of GT load
25
Formaldehyde Limit
mg/dNm3@15%O2
20
Formaldehyde,
15
10
0
0 5 10 15 20 25 30
GT load, Mw
Methanol
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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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Restoring Capacity – Fuel Control & External Pumps
PEPCO Fuel Control
Fuel SOVs
Proposal for dual methanol Engine (shut-off valves)
system (one skid)
Control Air 250-
110 psi
Mixing Block
40 gpm
Fuel oil pump gpm
1.25” SS pipe
Inlet piping psi
both fuels 3”
Methanol 80 gpm gpm
pump
1.5” SS pipe
psi
Control wires:
Filters Motor power 2 digital outputs
By others wire from VSD 6 digital inputs
Control wires: 5 analog inputs
2 digital outputs
2 analog inputs
400V 50Hz 75 HP 30 HP 2 analog outputs
~75KVA VSD VSD
Control House
PEPCO
Fuel Control
32
External High-Pressure Pumps
33
Replacing Nozzles to
Delevan High Flow
Delevan Nozzles Excello Nozzles
34
Adapting Fuel Unloading
and Storage System
New unloading piping
Tank adaptation – floating roof
35
Adapting Fire-Fighting System
36
Fuel Unloading Platform
37
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.
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