Superheated Steam Injection for Gas Turbine Combustors

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Solution Overview

Problem

The sudden increase in variation of gas properties when switching between natural gas fuel and highly reactive fuels like ethane affects the operability of gas turbine combustors, leading to increased combustion dynamics and emissions compliance issues, requiring a system to adjust the Modified Wobbe Index (MWI) without significant temperature changes or additional hardware.

Innovation Solution

A system that injects superheated steam from a Heat Recovery Steam Generator into the gas fuel supply line upstream of the combustion system, modulating the MWI by mixing it with the fuel to adjust its properties, and includes a controller to manage steam flow rates based on turbine cycle conditions and fuel composition.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Use of energy by moving object

If highly reactive fuels (HRFs) such as ethane are substituted for natural gas fuel in gas turbine combustors, then the heating value and energy output increase, but the combustor operability deteriorates due to increased combustion dynamics and emissions compliance issues

Engineering Contradiction:
Improveheating valueVSAvoidcombustor operability
Core Design Contradiction:
Use of energy by moving objectVSReliability

Solution Approach 1:

The patent applies parameter changes by injecting steam into the fuel stream to modify the Wobbe Index of the fuel mixture. By controlling the steam injection rate, the system dynamically adjusts the fuel properties (heating value, specific gravity) to maintain combustor operability within acceptable ranges while utilizing high-energy HRFs. This resolves the contradiction by transforming the fuel parameters to match combustor requirements.

Inventive Principle:
Principle #35Parameter changes

Solution Approach 2:

Steam acts as an intermediary substance that mediates between the high-energy HRF and the combustor. The steam injection system introduces a controllable diluent that adjusts the fuel's energy content and flow characteristics, allowing the combustor to operate reliably with HRFs that would otherwise cause combustion instability and emissions problems.

Inventive Principle:
Principle #24Intermediary (Mediator)

2Reliability

If HRFs are diluted with inert gases such as nitrogen to reduce the Wobbe Number, then the combustor operability is maintained, but the system cost increases and competitiveness decreases

Engineering Contradiction:
Improvecombustor operabilityVSAvoidsystem cost
Core Design Contradiction:
ReliabilityVSEase of manufacture

Solution Approach 1:

Instead of using expensive inert gases like nitrogen for dilution, the patent changes the approach by injecting steam - a byproduct of the heat recovery process - into the fuel stream. This modifies the fuel's Wobbe Index and heating value to match combustor requirements without incurring additional material costs, thereby maintaining operability while reducing system costs.

Inventive Principle:
Principle #35Parameter changes

Solution Approach 2:

The patent converts the typically wasted heat from turbine exhaust into useful steam that serves as a fuel modifier. By generating steam through heat recovery and using it to adjust fuel properties, the system transforms a waste product into a valuable resource that maintains combustor operability without requiring expensive inert gas purchases or additional processing equipment.

Inventive Principle:
Principle #22Blessing in disguise (Convert harm into benefit)

3Adaptability or versatility

If the Wobbe Index of HRF is reduced to match natural gas properties, then fuel interchangeability is achieved, but the energy efficiency and productivity decrease

Engineering Contradiction:
Improvefuel interchangeabilityVSAvoidenergy efficiency
Core Design Contradiction:
Adaptability or versatilityVSProductivity

Solution Approach 1:

The patent applies partial action by injecting only the necessary amount of steam to achieve the target Wobbe Index range, rather than fully diluting the HRF to natural gas properties. This partial modification maintains fuel interchangeability while preserving more of the HRF's inherent high energy content, thereby improving energy efficiency compared to complete dilution approaches.

Inventive Principle:
Principle #16Partial or excessive action

Solution Approach 2:

The system dynamically adjusts fuel parameters (Wobbe Index, heating value, specific gravity) through controlled steam injection to achieve interchangeability with natural gas. By making precise parameter adjustments rather than complete transformations, the system maintains compatibility with existing combustors while retaining the energy advantages of HRFs.

Inventive Principle:
Principle #35Parameter changes

4Adaptability or versatility

If steam is injected into the fuel supply line to modulate the MWI, then the operability range is broadened, but the steam consumption and operational costs increase

Engineering Contradiction:
Improveoperability rangeVSAvoidsteam consumption
Core Design Contradiction:
Adaptability or versatilityVSQuantity of substance

Solution Approach 1:

The system implements self-service by using steam generated from the turbine's own exhaust heat to modify the fuel properties. The heat recovery steam generator produces steam that is then recirculated to the fuel injection system, creating a self-sustaining loop where the system's waste heat serves the dual purpose of power generation and fuel modification, minimizing external resource requirements.

Inventive Principle:
Principle #25Self-service

Solution Approach 2:

The patent converts the waste heat from turbine exhaust - which would otherwise be discarded - into useful steam for fuel modification. This transforms a harmful waste product into a beneficial resource that broadens operability range without requiring additional steam generation capacity or external energy inputs.

Inventive Principle:
Principle #22Blessing in disguise (Convert harm into benefit)

Applied Scientific Principles

This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.

Function Achieved in This Case

Broadens the operability range of gas turbine combustors, reduces the risk of flame holding, and maintains emissions compliance by effectively adjusting the MWI, while minimizing steam usage and costs compared to traditional methods.

Implementation Method 1

mixing it with the fuel to adjust its properties

Methodology Applied
Scientific EffectMixing:

Implementation Method 2

injects superheated steam from a Heat Recovery Steam Generator

Methodology Applied
Scientific EffectSuperheating: Superheating

Data Source

PatentEP4234905B1Method for providing highly reactive fuels to a combustor
Publication Date: 2025.10.01 GENERAL ELECTRIC TECH GMBH
  • EP4234905B1 patent drawingFigure 1
  • EP4234905B1 patent drawingFigure 2
  • EP4234905B1 patent drawingFigure 3

AI summary

A system and related method for providing a highly reactive fuel to a combustor of a gas turbine are disclosed herein. The system includes a fuel supply system that is in fluid communication with a fuel supply. The fuel supply system includes multiple fuel circuits. Each fuel circuit individually feeds fuel to a corresponding fuel distribution manifold. The system further includes a steam injection system. The steam injection system includes at least one flow control valve that is in fluid communication with at least one of the fuel circuits. The flow control valve provides for fluid communication between a superheated steam source and the fuel circuit during both fueled operation and during non-fueled operation of the corresponding fuel circuit.