Combined heat & power plant at FUJAIRAH (UAE)

for desalinating sea water

By : JC. Gauthier (Head of RnD Dept., PILLARD Marseilles - F)
In 2001, Doosan Heavy Industries & Combustion (South Korea) was awarded the contract for the largest sea water
desalination plant of the world (1 200 000 people supplied with fresh water, 45 000 m
3
per day), located in the Fujairah
Emirates (U.A.E.). Such a plant uses a combined cycle plant of 660 MW.
The plant comprises 4 gas turbine (GT)/HRSG/ steam turbine units). The HRSGs are equipped for postcombustion.
The supply of the postcombustion burners (four x 212 MW units) fuel preparation sets (for natural gas and diesel oil) and the
BMS and CCS was awarded by Doosan to PILLARD. It was delivered mid 2002. The starting up with diesel oil was completed
in June 2003. Natural gas will only be available in 2004.
1 - POSTCOMBUSTION
The postcombustion burners are of PILLARD GRC INDUCT dual fuel type. They are located downstream of the GT
diverter, at the base of the HRSGs inlet duct.
Main characteristics :
- Gas turbine (GT) : GE FRAME 9 110 MWe
- HRSG : 420 t/h steam at 71 bar/520C
Flue gases to at HRSGs inlet = 840 C (max)
- Turbine exhaust gas (TEG) : Design flow 402 kg/sec at 425C
O
2
content = 12,8 to 15,6 % (vol, wet basis)
H
2
O content = 6,4 to 10,8 % (vol)
- Burners PILLARD : Number = 4
GRC INDUCT type Number of combustion heads per burner = 10, arranged in 2 columns of 5
Fuels = Diesel-oil or natural gas
- Heat release per burner : 120 MW
(without additional air)
- Heat release per burner on TEG : 212 MW i.e. 21,2 MW per burner head
(with additional air)
- Turndown ratio : 1 to 5 per burner head
1 to 50 per burner (of 10 heads)

Fig. 1 : General view

2 - GUARANTEED EMISSIONS
Data concerning turbine emissions
(upstream to the burners)
Guaranteed emissions
(downstream from the burners)
NAT GAS D.O. NAT GAS D.O.
NOx ppm vd @15%O
2
25 58 NOx ppm vd @15%O
2
29 58
mg/Nm
3
@15%O
2
51 120 mg/Nm
3
@15%O
2
60 120
CO ppm vd @15%O
2
15 20 CO ppm vd @15%O
2
40 40
mg/Nm
3
@15%O
2
19 25 mg/Nm
3
@15%O
2
50 50
We can point out that the burner must not produce any NOx emission (if converted to 15% dO
2
).

Fig. 2 : General arrangement of a HRSG

Additional
air fan
postcombustion
burner
HRSG
turbine vent
(diverter)
stack
3 - COMBUSTION TECHNIQUE APPLIED
10 PILLARD burners heads GRC INDUCT dual fuel type (patent PILLARD 97/02586) are located in the duct, in 2 columns of 5
(Fig. 3, 4).
Each burner head is laterally adjustable in position and removable for maintenance thanks to a system of rails and a side door.
The rails are supported by a central pillar (cooled by natural draft) which can be seen in the above. A system of deflectors
allows to adapt and adjust the TEG velocity through the burner.
Such technical solutions aim at obtaining :
- A very high flame stability
- A low pressure drop (< 30 daPa)
- Low NOx and CO emissions.
The Diesel oil atomization is by steam (at 12 bar, 295 C, useful flow 10 % of the D.O. flow). Each diesel oil gun can
be removed from the side of the duct even in operation (Fig. 5). The burner head may continue gas firing during such a
removal.
The corresponding principle is patented by PILLARD (n EU 98430005.3).

Fig. 3 : Positioning of the burner heads in the duct Fig. 4 : Internal view of stage 3, 4 and 5
Fig. 5 : One burner head
Fig. 7 : Internal view : 2 burner heads in operation Fig. 6 : External view of stages 1 and 2
4 - FLOW AND HRSG INLET TEMPERATURE OPTIMIZATION
A modelization thanks to the FLUENT

software has been used to improve the velocity distribution through the burner
(Fig. 8, 9, 10). Deflectors and a perforated plate have been added. The combustion modelizing allowed to optimize the
position and angle of the burner heads in order to reduce the temperature variation at the HRSG inlet to less than 80C
(Fig. 11, 12, 13).
5 - DESIGN OF THE FAILSAFE BMS/CCS SYSTEM
We call the reliability target run-safe. It obliges to master safety as well as availability.
CPU and failsafe I/O cards have been made redundant in order to maintain the required safety level, even in case of a CPU
failure.
The chosen programmable controller (HIMA) is also redundant, and TV approved.
The resistance to high ambient temperature is ensured by the use of military components. It is possible to replace the I/O
cards and CPU whilst energised. The cabinets and flame detection panels have been located inside a marine container close
to the burners and air conditioned. The computing time is reduced in order to comply with the max safety time to close the
fuel shut-off valves.
It is possible to operate each unit from its container thanks to an operator interface located on the front face, and to use local
panels for any maintenance operation. However normal operation is achieved from the control room located about one
hundred meters from the containers.

Fig. 11 : Temperature field (side view) Fig. 12 : Temperature field

(seen from above)
Fig. 13 : Temperature field at HRSG inlet
Fig. 10 : Final result Fig. 9 : Deflectors + perforated plate Fig. 8 : Before correction
Fig. 15 : Inside of a container Fig. 14 : View of container
6 - EMISSIONS AS VERIFIED AT SITE
The emission performances have been verified with Doosan on unit n 1, further to the adjustment of the turbine emissions
thanks to the water injection system.
Line n 1 - August 10
th
, 2003
Turbine 105,8 MWe on diesel oil (8,33 kg/sec)
(with water injection)
TEG at burner inlet
572C
O
2
= 14,7 % (vol, dry) @ 15 % O
2
(vol, dry) Doosan's guarantee
CO = 0 ppm 0 ppm 0 mg/Nm
3
25 mg/Nm
3
NOx = 53 ppm 50,5 ppm 104 mg/Nm
3
120 mg/Nm
3
Burner 9 014 kg/hr diesel oil on 10 heads
Flue gas at stack
740C
(697-797C)
O
2
= 13,1 % (vol, dry) @ 15 % O
2
(vol, dry) PLLARD guarantee
CO = 45 ppm 34 ppm 43 mg/Nm
3
50 mg/Nm
3
NOx = 38 ppm 29 ppm 59 mg/Nm
3
120 mg/Nm
3
7 - CONCLUSION
The emissions comply with the guaranteed ones :
- CO < 50 mg/Nm
3
@15%O
2
- NOx < 120 mg/Nm
3
@15%O
2
with NOx emitted by the turbine complying with the specification.
The NOx emissions due to the burner are lower than those of the turbine : The mass flow of NOx is reduced by 10 to
20 % thanks to the reburning effect.
Such a plant confirms the reliability of the GRC INDUCT dual fuel burners as well as the possibility to use them for diesel
oil firing at a high heat release rate with short flames and with a homogeneous temperature distribution at the HRSG inlet
without hot spot points.