US3797231A - Low emissions catalytic combustion system - Google Patents

Low emissions catalytic combustion system Download PDF

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US3797231A
US3797231A US00276875A US3797231DA US3797231A US 3797231 A US3797231 A US 3797231A US 00276875 A US00276875 A US 00276875A US 3797231D A US3797231D A US 3797231DA US 3797231 A US3797231 A US 3797231A
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air
mixture
fuel
combustion
stream
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Lean A Mc
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Ford Motor Co
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Ford Motor Co
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    • FMECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F02COMBUSTION ENGINES; HOT-GAS OR COMBUSTION-PRODUCT ENGINE PLANTS
    • F02CGAS-TURBINE PLANTS; AIR INTAKES FOR JET-PROPULSION PLANTS; CONTROLLING FUEL SUPPLY IN AIR-BREATHING JET-PROPULSION PLANTS
    • F02C7/00Features, components parts, details or accessories, not provided for in, or of interest apart form groups F02C1/00 - F02C6/00; Air intakes for jet-propulsion plants
    • F02C7/08Heating air supply before combustion, e.g. by exhaust gases
    • F02C7/10Heating air supply before combustion, e.g. by exhaust gases by means of regenerative heat-exchangers
    • F02C7/105Heating air supply before combustion, e.g. by exhaust gases by means of regenerative heat-exchangers of the rotary type
    • FMECHANICAL ENGINEERING; LIGHTING; HEATING; WEAPONS; BLASTING
    • F23COMBUSTION APPARATUS; COMBUSTION PROCESSES
    • F23RGENERATING COMBUSTION PRODUCTS OF HIGH PRESSURE OR HIGH VELOCITY, e.g. GAS-TURBINE COMBUSTION CHAMBERS
    • F23R3/00Continuous combustion chambers using liquid or gaseous fuel
    • F23R3/40Continuous combustion chambers using liquid or gaseous fuel characterised by the use of catalytic means
    • YGENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y02TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
    • Y02EREDUCTION OF GREENHOUSE GAS [GHG] EMISSIONS, RELATED TO ENERGY GENERATION, TRANSMISSION OR DISTRIBUTION
    • Y02E20/00Combustion technologies with mitigation potential
    • Y02E20/34Indirect CO2mitigation, i.e. by acting on non CO2directly related matters of the process, e.g. pre-heating or heat recovery

Definitions

  • Catalysis as a means of supporting combustion without a flame and without entering chemically into the combustion reaction, is well known and is the'foundation of many useful industrial applications. But there has been little or no practical applications of catalysis as the primary means for adding working heat in continuous combustion engines, particularly in gas turbine engines. Appropriate utilization of a catalytic combustion mechanism, as taught by this invention, provides immediate advantages including: reduction of unwanted emissions such as nitrogen oxide compounds to levels below two parts per million; provision of a more even temperature gradient across the hot gases generated by catalysis for driving a turbine wheel and thereby increasing engine life.
  • the air/fuel ratio must be between 8:1 to 30:1 at the point of combustion to hold a flame upon ignition and thereby provide some initial prewarming mechanism to bring the heat exchanger and air/fuel mixture up to normal operating conditions to sustain catalytic combustion.
  • This invention provides an apparatus for adding primary heat to a continuous combustion process using a catalystic combustion mechanism effective to promote sustained-combustion with lean or exceptionally lean air/fuel mixtures, the mixture being prewarmed by a regenerative means transferring heat from combusted gases to the unburned mixture.
  • preheating means is employed to divide the air supply and introduce fuel to this divided portion for regulating andpromoting a predetermined air/fuel mixture effective to support a flame when ignited.
  • This divided mixture in one embodiment can be passed through a predetermined radial region of the regenerator operating as a rotating disc, the mixture being ignited to support flaming combustion adjacent to the regenerator.
  • the flame is anchored on the regenerator by a surrounding cylinder of air and the flame is effective to bring the system up to a normal operating temperature.
  • the divided mixture in another embodimenucan be ignited considerably downstream of the regenerator heat extraction zone in an auxiliary combustor assembly effective to flamingly burn substantially all or majorly the air/fuel mixture air/fuel ratio (at or below 30:1) for supporting a preheating flame at ambient air temperatures and consuming the mixture flowing from the duct.
  • the duct mixture is directed through a regenerator matrix which insures totality of fuel vaporization; to prevent carryover of any unvaporized fuel beyond the heat extraction zone of the regenerator, the duct is located off center from a D-shaped passage communicating with one half of the rotating regenerator for defining the heat extraction zone. The offset is in a counterclockwise direction relative to the direction of rotation of the regenerator.
  • remixing of the divided portions can be promoted in a plenum zone upstream of the catalytic combustor but downstream of the-regenerator. This is facilitated by the use of swirl vanes or vortex generators introducing a secondary air supply to the plenum zone.
  • FIG. 1 is a schematic sectional view of a portion of one engine embodying this invention employing a midradial region duct 'for dividing the primary air flow;
  • FIG. 2 is a graphical illustration comparing air stream temperature-to air/fuel ratio
  • FIG. 3 is a schematic illustration of another embodiment employing an auxiliary combustion chamber as a flow divider.
  • a continuous combustion system is illustrated with reference to a preferred gas turbine engine comprising a housing assembly 10 for defining a flow system 8 through the engine; the housing has an air inlet 11 at one end generally aligned with the axis 12 of the flow system.
  • a centrifugal compressor 13 is mounted inside air inlet 11 for generating a supply of compressed air; the compressor is connected by a shaft 14 to a compressor turbine wheel 15, the wheel being suitably supported in housing 10 for rotation.
  • a power turbine wheel 16, constituting the working element of the system is rotatably mounted behind compressor turbine wheel 15 and is independently connected to an output shaft 17.
  • the flow system is arranged to act upon both turbine wheels immediately following the combustion zone 9.
  • Means for adding heat and fuel to the stream of air flowing from said inlet 11 broadlycomprisemeans for providing catalytic combustion A, preheating means 13, regenerator C, and fuel supply means D.
  • the housing and cooperating internal walls 19 define a flow path through the system into which the means A, B, C and D project.
  • housing 10 extends radially outwardly from the tips of the blades of compressor l3 (and a diffuser element not shown) and extends curvingly backward over the forward half-circular portion 20a of disc 20.
  • Disc 20 constitutes a disc-type regenerator (means C) preferably made of ceramic material for providing a matrix or plurality of small passages running therethrough in a direction generally aligned parallel to the rotational axis 21 of the disc.
  • the housing after having curved backward over the forward semi-circular portion 20a then curves inward along a diameter of disc 20 perpendicular to axis 21 to form path portion 22.
  • the flow portion 22 is D-shaped so as to enter one-half the circular area of disc 20.
  • a system path portion 23 is defined by ceramic internal walls 19 disposed downstream of the regenerators 20 having an opening 24 therein for operatively and nestably receiving said rotatable turbine wheels and 16; path portion 23 traverses the rear semi-circular portion b of discs 20.
  • the catalytic combustion means A comprises a honeycomb ceramic element 25 which can be conically or cylindrically shaped to occupy a major region of the plenum area 26.
  • the ceramic honeycomb is coated with a suitable catalyst for promoting combustion of an air/fuel mixture at temperatures contemplated herein.
  • the honeycomb has a configuration effective to cover the total throat area 53 for providing an effective and uniform temperature gradient thereacross.
  • the preheating means B comprises in part a duct of curved tubular construction having a circular inlet 31 in a central location of path portion 22.
  • An outlet 32 of the duct is juxtaposed surface 33 of the ceramic regenerator disc 20.
  • the duct is effective to divide a portion of the primary air, approximately in a proportion of Va to and directs this separated or divided portion to flow through a mid-radial region 34 of the regenerator.
  • Duct outlet 32 may be offset in a direction upwardly from the plane of the paper of FIG. 1; the offset would thus be in a counterclockwise direction of the disc 20 if rotating as arrows indicate in the figure. This offset decreases the possibility that fuel will be rotationally carried by the disc into the flow downstream of the turbine wheels without passing'through the combustion zone.
  • An ignitor 38 extends into the plenum area 26 and is arranged to ignite the air/fuel mixture flowing out of the radial region 34 of the regenerator.
  • the resulting flame will be localized and is anchored at a slight distance (about 2-3 mils) off of surface 39 of the regenerator; anchoring of the flame is assured by the cylinder of air (containing no fuel) passing through other regions of the regenerator.
  • Heat produced by the localized flame 40 is absorbed in part by the forward portion 20a of the regenerator and absorbed in part by the flow which conducts heat to the downstream portion of the regenerator.
  • Regenerator means C should be of the rotating type because normal inlet temperatures to sustain catalytic combustion may become excessive for'stationary types. Depending on the nature of the ceramic matrix of the regenerator, it usually must be kept at a temperature below 1950F to avoid minute cracking resulting from excessive expansion; this is facilitated by rotation which assures a more rapid heat exchange preventing excessive temperature buildup. It also is important for efficiency that all fuel be vaporized in the interstices of the regenerator and be homogeneously mixed with air. The offset location of duct 30 relative to the regenerator facilitates the latter. Air not divided and not passing through duct 30 will pass freely through the outer regions of the regenerator forming a cylinder of air in plenum area 26 about the mixture emitted from duct 30.
  • the cylinder of air is mixed with the duct mixture and together enter the catalytic combustion means A. This may be accomplished by swirl vanes or vortex guides 50 receiving secondary air from a channel source 51 so as to introduce the secondary air to turbulently mix the remainder of primary air with the fuel mixture.
  • the fuel supply means D which functions for the total support of both initial combustion and sustained catalytic combustion has an outlet 41 extending through the housing 10 into duct 30 whereby fuel droplets may be dispersed effectively inside the duct possessing air at a relatively low temperature even at normal operating conditions (150F). This low temperature location promotes the use of low cost fuel nozzles such as the pintle type which is characterized by excellent atomization.
  • Control valve 42 is provided to interrupt full fuel flow to extinguish the localized flame 40 when catalytic operating temperatures are reached.
  • the entrance face 28 to the catalytic combustion means is preferably adapted to operate with the incoming fuel mixture preheated to the temperature range between 1500F to 1700F. Fuel mixtures at lower temperatures passing into the matrix of the catalytic combustor will sustain continuous combustion but engine efficiency is affected.
  • the air/fuel ratio of the mixture passing through face 28 can be in an exceedingly high range such as l000:1 although practical limitations of air supply appropriately place the ratio at to 250:1.
  • the outlet temperature of emissions from the catalytic combustor is preferably about 2000F and any excess temperature should be controlled to be less than 2800F which is the maximum limit over which the catalytic matrix will be stressed; moreover at 3000-3200F, undesirable nitrogen oxide compounds will form in sizable amounts. Combustion gases having a temperature above 2000 may unduly stress the material of which the turbine wheels are constituted requiring an air quench immediately between the entrance to the turbine wheels and the catalytic combustor.
  • the engine of FIG. 1 is started by introducing ambient air to the inlet 11 of housing 10 wherein it is compressed by centrifugal compressor 13 and caused to flow along path portion 22 where it becomes divided by duct 30 into predetermined proportions, the portion passing through duct 30 having a supply of fuel added to it by fuel supply means D.
  • the divided portion within duct 30 is conveyed to a midradial region of the regenerator to exit also at a substantially mid-radial region from the surface of the regenerator.
  • other portions of the air pass through the outer and inner radial regions of the regenerator forming somewhat a cylinder about the mixture centrally located therein.
  • Fuel added to the duct is measured to provide an air/fuel ratio that will meet the conditions as illustrated in FIG. 2.
  • Combustion can take place with or without an ignition source (spark) depending on the temperature and chemical constituency of the mixture.
  • spark an ignition source
  • no flaming combustion will be sustained even with an ignitor (areas outside the horizontal hatched area of FIG. 2 enclosed by line 45 and lean blow-out line 46).
  • Test data indicates that at typical ambient temperatures conditions (50F) the limits of air/fuel must lie within 8/ l to 30/1 to support a continuous flame.
  • a high degree of reliability in ignition can be obtained by utilizing a mixture in the area bounded by line 47 (/1 to 25/1).
  • the duct 30 should be related to the fuel supplied to provide a mixture ranging between 15:1 to 25:1 to be absolutely assured of preheating when starting from cold conditions.
  • the ratio should be maintained close to the lean blow-out line 46, hereby being closer to 30:1.
  • lgnitor means D is employed to spark a flame as the mixture exits from the regenerator to combust the mixture.
  • the flame at certain points may have a temperature as high as 3500F which provides a quick source of preheat.
  • catalytic combustor means A is not functioning other than-to pass air and fuel/air mixtures therethrough. It is also not important at this stage whether the cylinder of air is homogeneously mixed with the combusted mixture in that the immediate aim is to raise the operating temperature of the regenerator as well as the air flow ultimately contacting other portions of the regenerator; this can be effectively accomplished by conduction irrespective of mixing. Typically it takes a period of 6-9 seconds for the temperature rise to exceed the level of 400F (which is the minimum temperature condition for sustaining typical catalysis see FIG. 2). After suitable signals have indicated that the target temperature (of the air stream passing through the catalytic combustor) has been reached, controls (not shown) are employed to extinguish the flame by temporarily cutting off the fuel supply. Such controls can at the same time determine the combustion activity of the catalytic means A before such flame is extinguished.
  • the total air supply be turbulently mixed downstream of the regenerator so that the available fuel (derived from the fuel supply means D injecting into the duct 30) can obtain a relatively homogeneous and uniform mixture with other air portions prior to entrance into the catalytic combustion means.
  • swirl vanes or vortex generators disposed in the walls of the plenum area can introduce a secondary air supply at this stage of the operation.
  • Conventional means may be utilized to increase or decrease the fuel supply rate as well as the speed of the compressor 13 to maintain a uniform catalytic combustion temperature in conformity with a desired speed of the working turbine 16.
  • FIG. 3 An alternative embodiment is illustrated in FIG. 3 which essentially provides an auxiliary combustion chamber 49 to support flaming combustion in advance of the catalytic combustion means and acts as the flow divider per se. More particularly this gas turbine engine provides for an intake of air through an inlet duct 53 directed in a radially inward direction of the engine and is disposed rearwardly of the primary combustion chamber 54. Interior wall system 55 defines a flow path 56 which enters a centrifugal compressor 57 disposed at a central inner region about axis 58. Flow from the compressor returns radially outwardly through a diffuser 59 and the air stream communicates to both sides of the engine at which regenerative rotating discs are located.
  • Inner walls 55 conduct the compressed air to the forward half of the regenerative disc permitting it to pass therethrough similar in function to that of the preferred embodiment.
  • Interior wall 61 and the outer surface of the cylinder 62 carry the compressed air to the most forward portion of the engine to enter the conical dome 63 of the auxiliary combustion chamber 49 (this would normally be a primary combustion chamber in typical prior art).
  • the combustion chamber 49 may have a diameter substantially equal to the outer diameters of twin turbines 64 and 65 (with adjacent stators 77 and 78) disposed at the exit thereof.
  • a pilot auxiliary chamber 66 (shown in phantom outline) may alternatively be used inside of dome 63 to restrict flame by virtue of a lesser diameter and is disposed inwardly of the outer chamber 49.
  • Fuel supply means 67 is located so as to inject a conventional supply of fuel into the area of dome 63 or into the pilot auxiliary chamber 66 if used; an ignition means 68 is employed to spark in the region of the dome 63 or inside chamber 66 if used.
  • the primary air needed to support the preheating flaming combustion, enters the auxiliary chamber 49 through ports 69 adjacent the fuel supply means, and a divided air flow portion enters somewhat downstream at ports 70 to mix and generate turbulence within the auxiliary combustion chamber.
  • the fuel supply means is interrupted so as to extinguish the flame 71 in the auxiliary combustion chamber 49 or pilot chamber 66, and then reopened to provide a leaner air/fuel mixture than that used during preheating combustion.
  • Secondary air, as well as the divided pri mary air is then conveyed to the primary combustion chamber 54 where a catalytic combustor means 73 is located forward of the entrance 75 to the twin turbine wheels.
  • a still further divided portion of the primary air may be admitted through ports 74 to create air dilution and quenching.
  • Yet another modification of the preferred embodiment may be obtained by utilizing a vane plate 76 (see FIG. 1, shown in phantom outline) in place of the duct, the flow is divided proportionally to one forward side of the plate with fuel supplied only to this divided por- 1 tion.
  • a vane plate 76 see FIG. 1, shown in phantom outline
  • apparatus for adding heat and fuel to the stream of compressed air comprising:
  • catalytic combustion means effective to sustain continuous, flameless oxidation of said mixture at a predetermined temperature, thereby generating said hot gases
  • heat exchange means for transferring heat from said hot gases to the stream of compressed air, said heat exchange means being comprised of a perforate rotating member having surfaces effective to contact separately both said hot gases and air stream during a single rotation for transferring heat therebetween,
  • preheating means located upstream of said catalytic combustion means for raising the temperature of said mixture to said predetermined temperature in advance of sustained catalytic combustion by regulating said air/fuel mixture for supporting independent flaming combustion of said mixture upstream of said catalytic combustion means, said preheating means comprising a duct effective to separate a portion of said air stream and direct said portion through one radial region of said member, said preheating means being adapted to add fuel solely to said portion, said preheating means also having ignition means for igniting said regulated mixture and having control means for extinguishing said flaming combustion when said mixture attains said predetermined temperature for sustaining catalytic combustion, the ignition means being located proximate to at least one surface of said perforate member for igniting said mixture immediately downstream of said member.
  • said perforate member is particularly defined as a disc having a ceramic matrix with flow passages therethrough disposed generally transverse to the axis of rotation of said disc, and said preheating means being arranged to anchor said flame to one side of said disc immediately adjacent the passages thereof which carry said mixture from said duct.
  • apparatus for adding heat and fuel to the stream of compressed air comprising:
  • catalytic combustion means effective to sustain continuous, flameless oxidation of said mixture at a predetermined temperature thereby generating said hot gases
  • preheating means located upstream of said catalytic combustion means for raising the temperature of said mixture to said predetermined temperature in advance of sustained catalytic combustion

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  • Engineering & Computer Science (AREA)
  • Chemical & Material Sciences (AREA)
  • Combustion & Propulsion (AREA)
  • Mechanical Engineering (AREA)
  • General Engineering & Computer Science (AREA)
  • Chemical Kinetics & Catalysis (AREA)
  • Combustion Of Fluid Fuel (AREA)
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US00276875A 1972-07-31 1972-07-31 Low emissions catalytic combustion system Expired - Lifetime US3797231A (en)

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JP (1) JPS529765B2 (enrdf_load_stackoverflow)
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US4062190A (en) * 1974-03-26 1977-12-13 Rolls-Royce Limited Gas turbine engine
US4081958A (en) * 1973-11-01 1978-04-04 The Garrett Corporation Low nitric oxide emission combustion system for gas turbines
US4112675A (en) * 1975-09-16 1978-09-12 Westinghouse Electric Corp. Apparatus and method for starting a large gas turbine having a catalytic combustor
EP0059855A1 (en) * 1981-03-05 1982-09-15 Westinghouse Electric Corporation Catalytic combustor having secondary fuel injection for low NOx stationary combustion turbines
US4534165A (en) * 1980-08-28 1985-08-13 General Electric Co. Catalytic combustion system
US4754607A (en) * 1986-12-12 1988-07-05 Allied-Signal Inc. Power generating system
US4850862A (en) * 1988-05-03 1989-07-25 Consolidated Natural Gas Service Company, Inc. Porous body combustor/regenerator
US5165224A (en) * 1991-05-15 1992-11-24 United Technologies Corporation Method and system for lean premixed/prevaporized combustion
US5232358A (en) * 1988-07-08 1993-08-03 Nippon Chemical Plant Consultant Co., Ltd. Combustion apparatus
US5235804A (en) * 1991-05-15 1993-08-17 United Technologies Corporation Method and system for combusting hydrocarbon fuels with low pollutant emissions by controllably extracting heat from the catalytic oxidation stage
US5376345A (en) * 1988-11-18 1994-12-27 Pfefferle; William C. Catalytic method and apparatus
US5623819A (en) * 1994-06-07 1997-04-29 Westinghouse Electric Corporation Method and apparatus for sequentially staged combustion using a catalyst
US5685156A (en) * 1996-05-20 1997-11-11 Capstone Turbine Corporation Catalytic combustion system
US5697211A (en) * 1994-12-21 1997-12-16 Toyota Jidosha Kabushiki Kaisha Exhaust gas purification device
WO1999045251A1 (en) * 1998-03-04 1999-09-10 Solo Energy Corporation Multi-shaft reheat turbine
EP0889289A3 (de) * 1997-06-30 2000-07-12 Abb Research Ltd. Gasturbinenaufbau
US6453658B1 (en) 2000-02-24 2002-09-24 Capstone Turbine Corporation Multi-stage multi-plane combustion system for a gas turbine engine
JP2002339763A (ja) * 2001-05-14 2002-11-27 Toshiba Corp ガスタービンシステム
US6532743B1 (en) 2001-04-30 2003-03-18 Pratt & Whitney Canada Corp. Ultra low NOx emissions combustion system for gas turbine engines
US20050103023A1 (en) * 2003-01-23 2005-05-19 Pratt & Whitney Canada Corp. Ultra low Nox emissions combustions system for gas turbine engines
US20100139282A1 (en) * 2008-12-08 2010-06-10 Edan Prabhu Oxidizing Fuel in Multiple Operating Modes
US20100275611A1 (en) * 2009-05-01 2010-11-04 Edan Prabhu Distributing Fuel Flow in a Reaction Chamber
US8393160B2 (en) 2007-10-23 2013-03-12 Flex Power Generation, Inc. Managing leaks in a gas turbine system
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US8844473B2 (en) 2012-03-09 2014-09-30 Ener-Core Power, Inc. Gradual oxidation with reciprocating engine
US20140298814A1 (en) * 2013-04-08 2014-10-09 General Electric Company Catalytic combustion air heating system
US8893468B2 (en) 2010-03-15 2014-11-25 Ener-Core Power, Inc. Processing fuel and water
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US9017618B2 (en) 2012-03-09 2015-04-28 Ener-Core Power, Inc. Gradual oxidation with heat exchange media
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US9273606B2 (en) 2011-11-04 2016-03-01 Ener-Core Power, Inc. Controls for multi-combustor turbine
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US9534780B2 (en) 2012-03-09 2017-01-03 Ener-Core Power, Inc. Hybrid gradual oxidation
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DE3742891A1 (de) * 1987-12-17 1989-06-29 Bayerische Motoren Werke Ag Gasturbinenanlage

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GB741506A (en) * 1953-06-23 1955-12-07 English Electric Co Ltd Improvements in and relating to open cycle gas turbine power plants
US3191659A (en) * 1958-04-07 1965-06-29 American Thermocatalytic Corp Radiant gas burner
US3182472A (en) * 1962-12-14 1965-05-11 Rolls Royce Catalytic igniters for combustion equipment
US3563031A (en) * 1969-01-13 1971-02-16 Ford Motor Co Gas turbine engine heat exchanger and combustion system
US3641763A (en) * 1970-09-08 1972-02-15 Gen Motors Corp Gas turbine catalytic exhaust system

Cited By (61)

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Publication number Priority date Publication date Assignee Title
US4081958A (en) * 1973-11-01 1978-04-04 The Garrett Corporation Low nitric oxide emission combustion system for gas turbines
US4062190A (en) * 1974-03-26 1977-12-13 Rolls-Royce Limited Gas turbine engine
USRE30629E (en) * 1974-03-26 1981-06-02 Rolls-Royce Limited Gas turbine engine
US4112675A (en) * 1975-09-16 1978-09-12 Westinghouse Electric Corp. Apparatus and method for starting a large gas turbine having a catalytic combustor
US4534165A (en) * 1980-08-28 1985-08-13 General Electric Co. Catalytic combustion system
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