Rich Catalytic Lean (RCL®) burn catalytic combustion is PCI's patented solution for a near single digit ppm NOx combustor approach for gas turbines. Our systems enable high combustion stability over a wide operating range and from microturbine operating conditions up through F-class firing temperatures. The rich reactor chemistry enables start-up and operation at relatively low temperatures. The lower operating temperature and rich kinetics support long catalytic surface life, lead to controllable catalytic reactions, and enable broad fuel flexibility with even highly reactive fuels.
RCL® technology is suitable for new or existing natural gas-fired F-class power generation machines, both combined cycle and simple cycle, as well as for smaller distributed power engines including microturbines. The design is scalable and can be supplied as an engine subcomponent. It can fit annular can and silo configurations, integrates readily to available engine fuel lines and the air compressor, and can be controlled with conventional DLN control systems. The technology offers strategic and economic value for a power producer:
The system uses a rich catalytic reactor with air cooling and subsequent mixing of the reactor output with the cooling air to form a lean mixture for combustion. In the process, the combustion air stream is split into two parts upstream of the catalyst. One part is mixed with all of the fuel forming a rich fuel/air mixture and contacted with the catalyst, while the second part is used to cool the catalyst. The catalyst is cooled only by primary combustion air, so that no heat is extracted from the system. The rich fuel/air stream undergoes partial fuel oxidation followed by mixing of the partially reacted fuel with the cooling stream to produce a reactive, fuel lean mixture. This lean mixture can then be burned stably in a downstream combustion zone, with the result being lower NOx and CO emissions and greater combustion stability than DLN/DLE technologies.
RCL® technology enables a robust, long life catalytic combustor that can achieve near zero NOx emissions while minimizing combustion dynamics. This enables combustion turbines to directly achieve low single digit ppm NOx emissions, thereby avoiding the substantial capital, operating cost and penalties of post-combustion controls. In addition, the improvement in combustion stability may lead to further reduced hot section O&M costs.
Our compact combustors fit into existing DLN combustor envelopes, providing a low-cost design upgrade.
RCL® catalytic combustors have been demonstrated with natural gas, low BTU gas, syngas, hydrogen, and prevaporized diesel fuels.
PCI is developing its RCL® catalytic combustion technology for a number of applications. PCI's full catalytic combustors seek to minimize NOx emissions from gas turbines, while its catalytic pilot burners are a partially-catalytic design that is easy to implement into existing lean premixed/dry low NOx designs. Our microturbine catalytic combustor addresses the unique needs of microturbines. Our downhole catalytic combustor/steam generator adapts RCL® technology for use downhole in an oil or gas production wellbore to provide thermal stimulation for production of oil and gas. PCI's oxyfuel combustor is directed to achieving effective combustion of oxygen and fuel in the presence of steam in IGCC and related systems.
Contact PCI to learn more about how our solutions may be adapted for your needs.
PCI has developed a compact, lightweight and highly efficient catalytic reactor design offering major performance and cost advantages when compared to conventional state of the art catalytic reactors.
PCI's patented Microlith® technology consists of a series of discrete, ultra-short channel length, metal monoliths with low pressure drop. This combined with our advanced catalytic coating technology enables the simultaneous design of a high cell density, low thermal mass device and smaller, lighter and higher efficiency catalytic reactor. Both mass transfer and heat transfer are significantly increased by the substrate design, allowing more rapid reactor response to gas temperatures as well as improved rates of reactant contact with the surface.
Microlith® technology offers superior attributes, major performance benefits and cost advantages when compared to conventional state-of-the-art catalytic reactor systems.
Additional information can be obtained from the following published papers:
"Development and Performance of Microlith® Light-off Preconverters for LEV/ULEV", 1997 Society of Automotive Engineers, Inc.
"Laboratory Evaluation of Ultra-short Metal Monolith Catalyst", 1998 Society of Automotive Engineers, Inc.
PCI has developed a range of technologies relating to its catalytic reactors and catalytic reactor systems. These include catalyst formulations, coatings and coating processes, unique substrate geometries, materials specifications, catalytic reactor designs, and catalytic reactor systems. The specific technologies vary by product and application. We have developed and patented several technologies that we use for multiple applications which offer breakthrough performance and advantages for targeted applications as compared to other technologies.
Short Contact Time, High Heat and Mass Transfer
Used in fuel reformers, fuel processors, air cleaners, compact burners and oxidation reactors, catalytic converters, and select chemical manufacturing processes. Microlith® technology offers an array of advantages relating to its short contact time and high heat and mass transfer features which provide size and weight benefits among other advantages.
Improved emissions and combustion stability as well as substantial fuel-flexibility.
Used in catalytic combustors for gas turbines, oil and gas production, soil disinfestation, soil remediation, and other large-scale heating applications for improved emissions and combustion stability as well as substantial fuel-flexibility. RCL® technology enables a robust, long life catalytic combustor that can achieve near zero NOx emissions while minimizing combustion dynamics. This enables combustion turbines to directly achieve low single digit ppm NOx emissions, thereby avoiding the substantial capital, operating cost and penalties of post-combustion controls. In addition, the improvement in combustion stability may lead to further reduced hot section O&M costs.
PCI is the exclusive assignee of some 80 issued U.S. patents on its technologies, a portion of which have also been issued in other countries, in addition to licenses of patents held by others. The company also has a number of patents currently applied for in the U.S. Patent and Trademark Office as well as others in non-U.S patent offices. PCI also holds some technology as trade secret.
Contact PCI to learn more about how our solutions may be adapted for your needs.