Retrofitting Duct Burners for CO Control

Richard T. Waibel and Steve Somers

John Zink Company
Tulsa, OK
ABSTRACT
Duct burners are often installed in gas turbine cogeneration or combined cycle systems
to add supplementary heat to the turbine exhaust gas (TEG) stream upstream of the
heat recovery steam generator (HRSG). The turbine exhaust gas usually contains
enough oxygen to sustain combustion and the duct burner is designed to use the TEG
as combustion air. Although duct burners produce relatively low NOx levels due to the
low oxygen content of the TEG, the levels of CO and VOC's can be greatly influenced
by the composition, temperature, velocity and turbulence of the TEG stream.
In some applications, steam is added to the TEG to reduce NOx emissions produced by
the turbine or to augment the power produced by the turbine. This steam further
depresses the oxygen content of the TEG and can lead to increases in combustible
emissions from the duct burners. An improved, low emission duct burner design has
been developed to significantly minimize the effect of steam addition, turbulence and
TEG velocity on combustible emissions. Data are shown for a gas turbine application
that has been retrofitted with the improved design.

INTRODUCTION
Many gas turbine/heat recovery steam generator systems used in cogeneration or
combined cycle applications utilize duct burners to add supplementary heat to the
turbine exhaust gas (TEG) prior to the TEG entering the heat recovery steam generator
(HRSG). In general the oxygen content in the turbine exhaust gas is sufficient for
combustion and duct burners are designed to use TEG as combustion air. While the
composition of the TEG depends on the turbine and the specifics of the application, a
typical composition will fall within the range of 11 to 15% oxygen on a volume percent,
wet basis. Typical TEG temperatures fall within the range of 850F to 1100F. The
duct burner is generally located in the expansion duct between the turbine outlet and
the heat recovery steam generator inlet. The expansion section is needed to provide
the proper TEG velocity through the steam generator. Figure 1 shows a schematic
diagram of a typical turbine/heat recovery steam generator system with duct burners.
The duct burner is designed to distribute the heat as uniformly as possible in the lEG
stream using a series of linear runners extending across the duct at several elevations.
The TEG velocity at the plane of the duct burners is normally in the range of 30 to 60
feet per second, although lower and higher velocities are occasionally encountered.

Heat Recovery
Steam Generator
Inlet

J-.
6... Duct
Distributi on
Grid

Gas Turbine
FLOWe=::::> Out let

FLO We=::::>

ci.. Burn e r
Section
ci.
~
~
~

Figure 1 Schematic Side Elevation View of Expansion Duct with Duct Burners
Unfortunately the gases exiting the turbine are also highly turbulent and poorly
distributed in the outlet. This turbulence and maldistribution of the flow at the turbine
outlet combined with the rapid expansion of the duct cross section between the turbine
outlet and the HRSG inlet leads to a gross maldistribution of the flow in the expansion
duct. A typical application includes a flow distribution grid in order to improve the flow
distribution. However, the flow entering the plane of the duct burners is still far from
perfect. Figure 2 shows an example of a TEG flow distribution with and without a flow
distribution grid. Without any flow distribution device there are significant differences in
the flow (averaged across the width of the duct) at each elevation in the duct. The grid
improves the flow distribution to a minimally acceptable level. Further improvement
would require additional pressure drop or additional real estate. Both of these are at a
premium in a typical installation.

DUCT BURNER OPERATION

A duct burner is unique in that the flow of " combustion air" is well in excess of the
stoichiometric requirements and totally independent of the operation of the burner. The
TEG flow rate is relatively constant and varies primarily in oxygen content as the
turbine operation varies, although duct burners are normally only used when the
turbine is at base load. The duct burner, therefore, is primarily a fuel injection system
and the burner must be designed to mix a varying amount of fuel with a relatively
constant flow of oxidant.

No Flow
Distribution
Devices

8
7
6

c:

5
4

0
;:; 3
cu 2
>

-W

(1)

(1)

--

With Flow
Distribution
Grid

....cu> 8
7

(1)

6
5
4

3
2

1
50

75

100

125

150

Percent Flow Relative to Mean

Figure 2 Comparison of Average Flow at Different Elevations in Duct With and
Without Flow Distribution Devices
The primary concern in duct burner design is to provide for stable ignition over a wide
turndown range, normally 10 to 1, and to prevent quenching of the flame over this
range of operation. Quenching can occur if too much TEG mixes with the flame prior to
completion of combustion. However, rapid mixing between the combustion products
and the remaining TEG flow is desirable, since a uniform temperature is required at the
entrance to the HRSG. The burner design must, therefore, promote enough mixing to
minimize flame length and provide a uniform temperature profile, while precluding
quenching of the flame.
Figure 3 shows a schematic diagram of a John Zink duct burner. The flame holder
provides a zone for ignition and flame stabilization and is perforated to allow a metered
amount of TEG into the base of the flame. The flame holder shape also provides for a

mixing zone. downstream of the burner for completion of combustion and for mixing of
the combustion products and the remainder of the TEG.

TEG Flow
Fuel Injector Spud

\.\.- - - Flame Holder

uel Supply Runner

Figure 3 Schematic Cross-Section of Gas Fired Duct Burner [John Zink LDR-LE]
Turbulence and maldistribution of TEG flow complicate the design problem.
Maldistribution can be in the form of variations in the velocity and mass flow at different
points in the duct cross section as well as variations of the flow vector at different
points in the duct. Mass flow maldistribution can lead to long flames in zones with low
mass flow and velocity and quenching of the flame in zones with high mass flow and
velocity. Mass flow maldistribution can also lead to excessive temperature variations at
the entrance to the HRSG with high temperatures in the zones with low TEG flow and
low temperatures in those zones with high flow. In some cases the fuel injection
pattern has been modified to match the TEG flow distribution in order to provide a more
uniform temperature profile at the HRSG entrance.
It is also desirable to have uniform flow vectors across the duct with the TEG flow
parallel to the axis of the fuel injector spuds. If the TEG flow approaches the burner at
an oblique angle, the fuelfTEG mixing pattern on one side of the burner will be much
more rapid than desired leading to quenching of the combustion reactions. On the
other side of the burner the fuel and TEG will mix much more slowly than desired
leading to poor combustion and consequently combustible emissions.
Some TEG flows exhibit such large scale turbulence that the turbulent fluctuations
actually cause intermittent flow reversals at the duct burner. These are seen as highly
unsteady flames with the flame occasionally moving upstream behind the flame holder.
This also leads to poor combustion, quenching of the flames, elevated combustible
emissions and damage to the burner elements and duct casing .

RETROFIT APPLICATION
In one recent application extremely large turbulence levels were seen including
intermittent flame reversals and detachment of the flame from the flame holders. The
CO emissions were higher than expected both with and without steam injected into the
turbine. Figure 4 shows the CO emissions versus duct burner firing rate with and
without steam injection. The unit was fitted with a flow distribution device and a review
of the flow modeling data showed that time averaged flow distribution was acceptable.
However, the model also showed the turbulence that was found in the field and the
instantaneous flow variations across the plane of the duct burners were highly nonuniform.
60

48

=it
';36
c

0
.;

en

'E

24

(J

12

0
0

50

100

150

200

250

300

350

Duct Burner Fuel Input, MMBtu/hr

~

0 #Is steam

12 #Is steam

Figure 4 CO Emissions Versus Firing Rate with and without Steam Injection
In this case the duct from the turbine outlet expanded at a 50 degree angle up to the
plane of the duct burners and expanded at 30 degrees downstream of the duct burners.
Based on the behavior of the flames it did not appear that the TEG flow vectors were
normal to the axis of the individual burner elements. As a first attempt to overcome the
problem the individual burner runners were rotated to try to ensure that the local lEG
flow was parallel to the axis of each runner. This improved the operation. However the
combustible emissions were still higher than acceptable.
In order to further investigate the problem a four foot section of a full scale runner was
installed in the JZ duct burner test facility. This facility can provide simulated lEG with
the proper composition, temperature and velocity.
Turbulence generators were
installed upstream of the test section to recreate the problem seen in the field. With
sufficient additional turbulence, elevated CO emissions were observed in the test
facility, similar to those seen in the commercial application. Various modifications were
then made to the duct burner flame holder to overcome the effect of the turbulence. A

significant reduction in CO was observed when the flame holder was modified to make
it less sensitive to the flow vector, either time averaged or instantaneous. Figure 5
shows a schematic diagram of the modified burner.

TEG Flow
Inj ecto r Spud

I .e I Supply Runner

Figure 5 Schematic Cross-Section of Modified Duct Burner [John Zink LDRW]

Based on the improvements seen in the test facility the duct burners in the field were
modified. Visual observations of the flames showed improved flame quality with a
significant reduction in flame reversals. Figure 6 is a plot comparing the CO emissions
of the original and modified designs.
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en
'E24L---~~---+~---r----+-----r-~~-----1

12L---~~~~----_r----+_----~---1----~

50

100

150

200

250

300

350

Duct Burner Fuel Input, MMBtu/hr

~

0 #Is steam

12 #Is steam .... 12 #Is steam

Figure 6 Comparison of CO Emissions of Original and Modified Designs

This data shows a significant reduction in CO emissions and reduction in sensitivity to

steam injection. NOx emissions were not adversely impacted by the modifications. In
this case the resulting combustible emissions were well below the requirements of the
application.

CONCLUSIONS
The modified duct burner design has provided significant performance improvements
under adverse conditions. Combustible emissions were reduced without increasing
NOx emissions. The design provides for a more uniform supply of TEG into the flame
stabilization zone and this supply is less influenced by variations in TEG flow. The
modified flame holder performs effectively over an extended range of TEG turbulence,
velocity, composition and flow vector variation. The edges of the flame holders also
provide for less turbulent and more controlled mixing of the bulk TEG flow into the
active flame zone which reduces quenching. In most cases flame lengths are actually
reduced compared with the previous design.
In subsequent applications this modified design has proven to be useful for low CO and
VOC emission requirements in applications with one or more of the following:

flow maldistribution
high steam injection rates
short flame requirements
low TEG flow velocities.

Economic benefits derived from reduced CO emissions in existing units will depend on
the system configuration and operating parameters. Reduced CO emissions may
provide emission "bubble" trade-offs and longer catalyst life, if CO catalyst is used.
More importantly lower CO emissions may allow increased electrical generation at peak
operating points by allowing increased power augmentation steam as well as increased
auxiliary duct burner firing .