Dynamic control system and method for catalytic combustion process and gas turbine engine utilizing same

A method of controlling a catalytic combustion process within a combustor having at least a first pre-burner and at least one catalyst module therein, comprising the steps of:

• calculating a mass flow of air introduced into the combustor;
• monitoring a fuel flow to be combusted within the combustor;
• monitoring a temperature of the air introduced into the combustor;
• calculating an inlet temperature set point for the catalyst module based on the air mass flow and the fuel flow to be combusted;
• controlling at least the first pre-burner to heat the air introduced into the combustor based on the inlet temperature set point, the air mass flow, and the temperature of the air introduced into the combustor;
• and
• said step of calculating a mass flow of air introduced into the combustor comprises the steps of:
• monitoring a pressure of the air introduced into the combustor;
• monitoring a delta pressure across the pre-burner;
• and
• calculating a mass flow of air introduced into the combustor as a function of the temperature of the air introduced into the combustor, the pressure of the air introduced into the combustor, and the delta pressure across the pre-burner.

A method of controlling a catalytic combustion process within a combustor having at least a first pre-burner and at least one catalyst module therein, the combustor being supplied with air from a compressor, comprising the steps of:

• estimating a mass flow of air introduced into the combustor;
• monitoring a fuel flow to be combusted within the combustor;
• monitoring a temperature of the air introduced into the combustor;
• calculating an inlet temperature set point for the catalyst module based on the air mass flow and the fuel flow to be combusted;
• and
• controlling at least the first pre-burner to heat the air introduced into the combustor based on the inlet temperature set point, the air mass flow, and the temperature of the air introduced into the combustor.

A catalytic combustion system for use in a dynamic plant, the plant supplying the catalytic combustion system with a flow of fuel and a supply of air to be mixed and combusted therein, the operation of the plant being controlled by a dynamic plant controller which generates a fuel flow rate demand signal to control the flow of fuel to be combusted in response to dynamic plant demands, the catalytic combustion system being capable of transparently replacing a conventional flame combustion system typically used with such a dynamic plant, comprising:

• a catalytic combustor including at least a first pre-burner and at least one catalyst module therein;
• at least a first fuel control valve;
• a catalytic combustion controller;
• and
• an air inlet temperature sensor positioned to monitor a temperature of the air supplied to the system, said air inlet temperature sensor transmitting sensed inlet temperature information to said controller;
• and
• wherein said controller receives the fuel flow rate demand signal from the plant controller, calculates a mass flow of the air supplied by the plant, and calculates an inlet temperature set point for said catalytic combustor based on said air mass flow and the fuel flow to be combusted, said controller generating at least a first fuel demand signal based on said inlet temperature set point and said sensed inlet temperature;
• wherein said first fuel control valve is responsive to said first fuel demand signal to supply fuel to said first pre-burner;
• and
• wherein said first pre-burner combusts said fuel to heat the air supplied by the plant.

A catalytic combustion system for use in a dynamic plant, the plant supplying the catalytic combustion system with a flow of fuel and a supply of air to be mixed and combusted therein, the operation of the plant being controlled by a dynamic plant controller which generates a fuel flow rate demand signal to control the flow of fuel to be combusted in response to dynamic plant demands, the catalytic combustion system being capable of transparently replacing a conventional flame combustion system typically used with such a dynamic plant, comprising:

• a catalytic combustor including at least a first pre-burner and at least one catalyst module therein;
• at least a first fuel control valve;
• a catalytic combustion controller;
• and
• an air inlet temperature sensor positioned to monitor a temperature of the air supplied to the system, said air inlet temperature sensor transmitting sensed inlet temperature information to said controller;
• and
• wherein said controller receives the fuel flow rate demand signal from the plant controller, calculates a mass flow of the air supplied by the plant, and calculates an inlet temperature set point for said catalytic combustor based on said air mass flow and the fuel flow to be combusted, said controller generating at least a first fuel demand signal based on said inlet temperature set point and said sensed inlet temperature;
• wherein said first fuel control valve is responsive to said first fuel demand signal to supply fuel to said first pre-burner;
• and
• wherein said first pre-burner combusts said fuel to heat the air supplied by the plant;
• an air inlet pressure sensor positioned to monitor a pressure of the air supplied to the system, said air inlet pressure sensor transmitting sensed inlet pressure information to said controller;
• and
• a delta pressure sensor positioned to sense a delta pressure across the pre-burner, said delta pressure sensor transmitting sensed delta pressure information to said controller;
• and
• wherein said controller calculates said mass flow of the air supplied by the plant as a function of said sensed inlet temperature, said sensed inlet pressure, and said sensed delta pressure.

A catalytic combustion system for use in a dynamic plant, the plant supplying the catalytic combustion system with a supply of air from a compressor and a flow of fuel to be mixed and combusted within the system, the operation of the plant being controlled by a dynamic plant controller which generates a fuel flow rate demand signal to control the flow of fuel to be combusted in response to dynamic plant demands, the catalytic combustion system being capable of transparently replacing a conventional flame combustion system typically used with such a dynamic plant, comprising:

• a catalytic combustor including at least a first pre-burner and at least one catalyst module therein;
• at least a first fuel control valve;
• a catalytic combustion controller;
• and
• an ambient air temperature sensor positioned to monitor a temperature of the ambient air entering the compressor, said ambient air temperature sensor transmitting sensed ambient temperature information to said controller;
• a compressor speed sensor positioned to monitor a speed of the compressor, said speed sensor transmitting sensed compressor speed information to said controller;
• and
• wherein said controller receives the fuel flow rate demand signal from the plant controller, estimates a mass flow of the air supplied by the compressor as a function of said sensed ambient temperature, said sensed speed of the compressor, and a known ambient pressure, said controller further calculating an inlet temperature set point for said catalytic combustor based on said air mass flow and the fuel flow to be combusted, said controller generating at least a first fuel demand signal based on said inlet temperature set point and said sensed inlet temperature;
• wherein said first fuel control valve is responsive to said first fuel demand signal to supply fuel to said first pre-burner;
• and
• wherein said first pre-burner combusts said fuel to heat the air supplied by the plant.

A catalytic combustion system for use in a dynamic plant, the plant supplying the catalytic combustion system with a supply of air from a compressor and a flow of fuel to be mixed and combusted within the system, the operation of the plant being controlled by a dynamic plant controller which generates a fuel flow rate demand signal to control the flow of fuel to be combusted in response to dynamic plant demands, the catalytic combustion system being capable of transparently replacing a conventional flame combustion system typically used with such a dynamic plant, comprising:

• a catalytic combustor including at least a first pre-burner and at least one catalyst module therein;
• at least a first fuel control valve;
• a catalytic combustion controller;
• and
• an ambient air temperature sensor positioned to monitor a temperature of the ambient air entering the compressor, said ambient air temperature sensor transmitting sensed ambient temperature information to said controller;
• a compressor speed sensor positioned to monitor a speed of the compressor, said speed sensor transmitting sensed compressor speed information to said controller;
• and
• wherein said controller receives the fuel flow rate demand signal from the plant controller, estimates a mass flow of the air supplied by the compressor as a function of said sensed ambient temperature, said sensed speed of the compressor, and a known ambient pressure, said controller further calculating an inlet temperature set point for said catalytic combustor based on said air mass flow and the fuel flow to be combusted, said controller generating at least a first fuel demand signal based on said inlet temperature set point and said sensed inlet temperature:
• wherein said first fuel control valve is responsive to said first fuel demand signal to supply fuel to said first pre-burner;
• wherein said first pre-burner combusts said fuel to heat the air supplied by the plant;
• an air inlet pressure sensor positioned to monitor a pressure of the air supplied to the system, said air inlet pressure sensor transmitting sensed inlet pressure information to said controller;
• an air inlet temperature sensor positioned to monitor a temperature of the air supplied to the system, said air inlet temperature sensor transmitting sensed inlet temperature information to said controller;
• and
• a delta pressure sensor positioned to sense a delta pressure across the pre-burner, said delta pressure sensor transmitting sensed delta pressure information to said controller;
• and
• wherein said controller calculates said mass flow of the air supplied by the plant as a function of said sensed inlet temperature, said sensed inlet pressure, and said sensed delta pressure;
• and
• wherein said controller enunciates a degradation in compressor air flow when a ratio of said calculated mass flow to said estimated mass flow drops blow a predetermined minimum threshold.

A method of controlling a catalytic combustion system for use in a gas turbine engine system, the gas turbine engine system including a compressor, a turbine, and a fuel supply subsystem, the compressor supplying a flow of air to the catalytic combustion system and the fuel supply subsystem supplying a flow of fuel to be combusted within the catalytic combustion system, the catalytic combustion system including at least one pre-burner and at least one catalyst module, the catalytic combustion system further including at least one temperature sensor positioned to sense temperature of air entering the catalyst module, comprising the steps of:

• purging the catalytic combustion system of combustible gases;
• ramping the turbine to an ignition speed;
• warming-up the catalyst module;
• ramping the turbine to desired speed;
• regulating a flow of fuel to be combusted within the catalytic combustion system to meet a power demand of the gas turbine engine.

A dynamic plant, comprising:

• a catalytic combustor having a compressed air inlet, at least one pre-burner, a fuel-air mixing portion, at least one catalyst module, a combustion burner zone, and a combusted gas outlet;
• a compressor supplying compressed air to said compressed air inlet;
• a fuel delivery system providing fuel to said at least one pre-burner and to said fuel-air mixing portion for combustion within said catalytic combustor;
• a turbine in gaseous communication with said combusted gas outlet;
• and
• a dynamic controller monitoring parameters of the dynamic plant, said controller providing fuel control signals to the fuel delivery system to control a flow of fuel to said at least one pre-burner and said fuel-air mixing portion to meet dynamic plant performance, load, and emissions requirements over an entire range of operating conditions of the dynamic plan.

A dynamic plant, comprising:

• a catalytic combustor having a compressed air inlet, at least one pre-burner, a fuel-air mixing portion, at least one catalyst module, a combustion burner zone, and a combusted gas outlet;
• a compressor supplying compressed air to said compressed air inlet;
• a fuel delivery system providing fuel to said at least one pre-burner and to said fuel-air mixing portion for combustion within said catalytic combustor;
• a turbine in gaseous communication with said combusted gas outlet;
• and
• a dynamic controller monitoring parameters of the dynamic plant, said controller providing fuel control signals to the fuel delivery system to control a flow of fuel to said at least one pre-burner and said fuel-air mixing portion to meet dynamic plant performance, load, and emissions requirements over an entire range of operating conditions of the dynamic plan;
• said controller calculates a primary fuel demand signal to control a speed of said turbine, and determines a mass flow of said compressed air delivered to said catalytic combustor, said controller calculating a secondary fuel demand signal based on said primary fuel signal and said mass flow to control the heating of said compressed air to maintain a temperature of combusted gas at said combusted gas outlet within a predetermined range, and wherein said fuel delivery system provides fuel to said at least one pre-burner in response and in proportion to said secondary fuel demand signal, and provides fuel to said gas-fuel mixing portion in response and in proportion to said primary fuel demand signal;
• an air inlet temperature sensor positioned to monitor a temperature of said compressed air delivered to said catalytic combustor;
• an air inlet pressure sensor positioned to monitor a pressure of said compressed air supplied to said compressed air inlet;
• and
• a delta pressure sensor positioned to sense a delta pressure across said at least one pre-burner;
• and
• wherein said controller determines said mass flow of said compressed air delivered to said catalytic combustor as a function of said sensed inlet temperature, said sensed inlet pressure, and said sensed delta pressure.