MULTI-MODE PLASMA IGNITERS AND PILOTS FOR AEROSPACE

AND INDUSTRIAL APPLICATIONS

Presentedby

Dr. Igor MatveevApplied Plasma Technologies

September 19, 2006

PRESENTATION OBJECTIVES

Overview of existing plasma systems forignition and combustion stabilizationDescribe perspective non-thermal and multi-mode plasma ignition and flame control technologies

CONTENT

Chronology Technical DiscussionPerspective TechnologiesSummary

PLASMA SYSTEMS CHRONOLOGY1979 - Began plasma technology R&D1981 - Developed and tested first plasma fuel nozzle1983 - Started 1st gas turbine engine (10 MW)1985 - Began mass production of plasma ignition systems1987 - Developed direct plasma ignition system for Naval gas

turbine generator (1.6 MW)1989 - Conducted 1st high altitude tests on aircraft turbine

for MIG interceptor1990 - Established privately owned company PlasmaTechnika2000 – Presented technology to Pratt & Whitney, Unison,

DOE (NETL, BNL, LANL), etc.2002 – CRDF grant for Plasma-Fuel Nozzle tests2002 – The first plasma system sold in USA (NETL)

CHRONOLOGY (cont.)2003 – International Patent Application on Vortex Reactor (joint with

Drexel University); Plasma Ignition System high altitude testsfor Suhoi-30/33/37 interceptor; established AppliedPlasma Technologies (USA)

2004 - US patent application on Reverse Vortex Combustor,Variety of Plasma Assisted Combustion Systems,technology validation tests for Siemens turbines

2005 - APT has initiated and became a participant in a joint, DOEfunded, three- year multi-million dollar internationalproject focused on research and development of a novel plasma assisted combustion technology.SBIR Phase 1 award.

To Date - Over 1,200 operating plasma ignition systems

TECHNICAL DISCUSSIONBackgroundThermal Plasma Systems:- Plasma Igniters - Plasma Torch Parameters- Plasma Nozzles Non - Thermal Plasma Systems:- Non-thermal Plasmatron Parameters- Multi-mode Plasma Igniter-Pilot

INDUSTRIAL PLASMA IGNITION SYSTEM SAMPLES

INDUSTRIAL AND MARINE PLASMA IGNITION SYSTEM

Over 1200 systems are installed and operating all over the world

PLASMA IGNITER(laminar mode)

PLASMA TORCH(turbulent mode)

PLASMA TORCH PARAMETERSPower (kW) 0.5 - 3Dimensions (mm)– length 20 - 50– diameter 10 -15

Velocity (m/sec) 50 - 300Temperature (o C) 2,000 - 3,000Air Pressure– turbulent igniter (Bar) 0.1 - 0.6– laminar igniter (mm H2O) 20 – 3,000

Air Flow Rate (g/sec) 0.01 – 1.0

PLASMA IGNITION SYSTEM PARAMETERS

Coefficient of Performance (COP) 0.3 - 0.75Cathode Life (cycles, 45 sec. each) - for thermal arc systems 500 – 4,000- for non-thermal arc systems no limitsWeight (kg)– 3X240V, 60 Hz or 3X380V, 50 Hz 6 - 21– 1X115V 400 Hz network 3 – 5– 24-27V DC 1.5 - 2.5

CONTEMPORARY POWER SUPPLY

PLASMA STABILIZATION SYSTEMSPLASMA FUEL NOZZLE

PLASMA NATURAL GAS NOZZLE

PLASMA FUEL NOZZLE PARAMETERS

Power (kW) 0.5 – 2.0Dimensions (mm)– length 100– diameter 30Air Pressure for Plasma Formation (PF)– turbulent plasmatron (Bar) 0.1 - 0.6– laminar plasmatron (mm H2O) 20 – 3,000Air Flow Rate for PF (g/sec) 0.01 - 0.5Liquid Fuel Flow Rate (g/sec) 10 and upChannels for Various Fuels 2 and up

PLASMA FUEL NOZZLE ADVANTAGES

Dramatically increased ignition reliabilityMuch wider equivalence ratio or alpha rangeSignificant decrease in T3 (RIT) jump at the point of fuel ignitionUtilization as a pilot burnerUtilization for hydrogen enriched gas generation

PLASMA FUEL NOZZLE ADVANTAGES (cont)

Reduction of a combustion zone geometryReduction of the combustion chamber walls temperatureIncrease of a combustion efficiency (COP)Achieving smokeless operation Simultaneous burning of several fuelsSmooth regulation in a wider turn down ratio

NON-THERMAL AND MULTI-MODE PLASMA SYSTEMS

Objectives:Increase life timeReduce power consumptionUtilize fuels to increase torch powerProvide continuous (thousands of hours) flame controlCombine advantages of thermal and non-thermal plasma generators

2020

OPERATION PRINCIPLESOF THE PLASMA PILOT

Pressure sensor

PowerSupply

I = f (P2)

Air

2121

PRESSURE DIFFERENTIAL ON THE COMBUSTOR WALL DEPENDING ON

THE TURBINE OPERATION MODE

15 100 100

6000

0

2000

4000

6000

8000

1 2 3 4Operation mode

Pres

sure

diff

eren

tial,

mm

of H

2O

1 - 2 – Ignition, ∆ P = 15 – 100 mm H2O, τ = 3 – 5 min2 – 3 – Yield (heating), ∆ P = const, τ = 10 – 15 min3 – 4 – Load, ∆ P = 100 – 6,000 mm H2O, τ = 3 min – ∞

2222

ARC CHARACTERISTICSVolt - current characteristics

0

500

1000

1500

2000

2500

50 100 150 200 250

Current, mA

Volta

ge, V

G a = 0.31 g/s

G a = 0.70 g/sG a = 1.24 g/s

G a = 1.99 g/s

G a = 2.89 g/s

Power - current characteristics

050

100150200250300350

50 100 150 200 250

Current, mA

Pow

er, W

G a = 0.31 g/s

G a = 0.70 g/s

G a = 1.24 g/s

G a = 1.99 g/s

G a = 2.89 g/s

2323

ALPHA versus POWER

00.10.20.30.40.50.60.70.80.9

1

0 100 200 300 400

Arc power, Watt

Alfa

G a = 3.1 g/s

G a = 2.1 g/s

G a = 1.27 g/s

G a = 0.71 g/s

2424

NON-THERMAL PLASMA TORCH PARAMETERS

Power (kW) 0.04 - 1Dimensions (mm)– length 100– diameter 24

Plasma torch velocity (m/sec) 50 – 900Plasma torch temperature (o C) 100 - 3,000Air Pressure Differential (mm H2O) 15 – 10,000Air Flow Rate (g/sec) 0.1 – 3.5

2525

NON-THERMAL PLASMA TORCH OPERATION

2626

SPATIAL ARC

ADVANTAGES New quality - generates non-equilibrium plasmaDramatically increased life time of both electrodesDoes not need cooling of electrodes and nozzleWider range of power regulation (from a few W to several kW)Utilizes different plasma feedstock gases and blends: air,N2,

Ar, water steam, air/CH4, N2/CH4, N2/H4, steam/methane blends, etc.No rare materialsNo soot formation inside the arc chamberFlexible designSimple and reliable

MULTI-MODE PLASMA TORCHES

2929

NON-THERMAL PLASMA PILOT AND GAS IONIZER

PLASMA PILOT FOR AEROSPACE APPLICATION

3131

FUTURE WORKS

Conduct high pressure pilot tests on a real turbineDevelop a power supply with programmable output depending on the engine’s operation modeRun the life time testsDevelop prototypes of plasma pilots and nozzles for subsonic and supersonic applications

SUMMARYEnergy, environmental and security challenges open new markets for advanced plasma technologiesNew plasma generators can assist in capturing new markets: gas turbines, scramjets, boilers, internal combustion engines, tools, residential appliances, environment security systems, etc.Acceleration of new technologies development could be reached by combining research, development and marketing efforts