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This paper describes the progress made in developing an external ultra-low oxides of nitrogen (NOx) ‘Green Thumb’ combustor for the Allison Engine Company’s 501-K series engines. A lean premixed approach is being pursued to meet the emissions goals of 9 ppm NOx, 50 ppm carbon monoxide (CO), and 10 ppm unburned hydrocarbon (UHC). Several lean premixed (LPM) module configurations were identified computationally for the best NOx-CO trade-off by varying the location of fuel injection and the swirl angle of the module. These configurations were fabricated and screened under atmospheric conditions by direct visualization through a quartz liner; measurement of the stoichiometry at lean blow out (LBO); measurement of the fuel/air mixing efficiency at the module exit; and emissions measurements at the combustor exit, as well as velocity measurements. The influence of liner residence time on emissions was also examined. An LPM module featuring a radial inflow swirler demonstrated efficient fuel-air mixing and subsequent low NOx and CO production in extensive atmospheric bench and simulated engine testing. Measurements show the fuel concentration distribution at the module exit impacts the trade-off between NOx and CO emissions. The effect of varying the swirl angle of the module also has a similar effect with the gains in NOx emissions reduction being traded for increased CO emissions. A uniform fuel-air mixture (± 2.5% azimuthal variation) at the exit of the module yields low NOx (5–10 ppm) at inlet conditions of 1 MPa (∼10 atmospheres) and temperatures as high as 616 K (650°F). The combustion efficiency at the above conditions was also good (> 99.9%) with CO and UHC emissions below 76 ppm and 39 ppm, respectively. This LPM module was resistant to flashback, and stability was good as LBO was observed below ϕ = 0.50. Tests with multiple modules in a single liner indicate a strong intermodule interaction and show lower NOx and CO emissions. The close proximity of adjacent modules and lower confinement in the liner most likely reduces the size of the recirculation zone associated with each module, thereby reducing the NOx formed therein. The CO emissions are probably lowered due to the reduced cool liner surface area per module resulting when several modules feed into the same liner.

This paper describes the development of an ultra-low emissions combustion system for Allison’s Advanced Turbine System (ATS) engine, which is being developed in cooperation with the U.S. Department of Energy. The simple cycle engine is designed to have a thermal efficiency that is 15% better than today’s best in class engine, and exhaust emissions of 9 ppm NOx, 20 ppm CO, and 20 ppm UHC. The approach taken to meet the low emissions goals is based on ultra-lean premixed fuel-air combustion supported by a catalyst. The progress toward development and integration of lean premix (LPM), catalytic and post-catalytic stages, and the combustor-to-turbine transition duct into an overall ATS combustion system is presented. A parametric computational fluid dynamics (CFD) study was conducted on the performance of lean premix modules at ATS conditions. Various lean premix modules were tested extensively under atmospheric conditions to determine airflow capacity, flashback propensity, lean blowout (LBO) fuel-air ratios, and fuel concentration profiles at the module exit. Kinetic modeling using the GRI mechanism has been used to estimate ignition delay times in the post-catalytic zone. Comparison between the modeling results and experimental data at high pressure shows good agreement. A detailed computational analysis was performed to design the combustion-to-turbine transition duct. The results indicate that the scroll duct configuration produces an acceptable mass flow uniformity and swirl angle exiting the duct into the turbine section. High pressure sector rig tests have been performed to evaluate staging interaction issues. The results indicate that the series staged approach can facilitate incorporation of the catalytic combustion system by expanding the operability range. NOx emissions levels of 9 ppm or less can be sustained over a wide range of equivalence ratios.

This paper describes the progress made in developing an external ultralow oxides of nitrogen (NOx) “Green Thumb” combustor for the Allison Engine Company’s 501-K series engines. A lean premixed approach is being pursued to meet the emissions goals of 9 ppm NOx, 50 ppm carbon monoxide (CO), and 10 ppm unburned hydrocarbon (UHC). Several lean premixed (LPM) module configurations were identified computationally for the best NOx–CO trade-off by varying the location of fuel injection and the swirl angle of the module. These configurations were fabricated and screened under atmospheric conditions by direct visualization through a quartz liner; measurement of the stoichiometry at lean blow out (LBO); measurement of the fuel–air mixing efficiency at the module exit; and emissions measurements at the combustor exit, as well as velocity measurements. The influence of linear residence time on emissions was also examined. An LPM module featuring a radial inflow swirler demonstrated efficient fuel-air mixing and subsequent low NOx and CO production in extensive atmospheric bench and simulated engine testing. Measurements show the fuel concentration distribution at the module exit impacts the tradeoff between NOx and CO emissions. The effect of varying the swirl angle of the module also has a similar effect with the gains in NOx emissions reduction being traded for increased CO emissions. A uniform fuel-air mixture (±2.5 percent azimuthal variation) at the exit of the module yields low NOx (5–10 ppm) at inlet conditions of 1 MPa (~10 atm) and temperatures as high as 616 K (650°F). The combustion efficiency at these conditions was also good (>99.9 percent) with CO and UHC emissions below 76 ppm and 39 ppm, respectively. This LPM module was resistant to flashback, and stability was good as LBO was observed below φ = 0.50. Tests with multiple modules in a single liner indicate a strong intermodule interaction and show lower NOx and CO emissions. The close proximity of adjacent modules and lower confinement in the liner most likely reduces the size of the recirculation zone associated with each module, thereby reducing the NOx formed therein. The CO emissions are probably lowered due to the reduced cool liner surface area per module resulting when several modules feed into the same liner.