Zero Stage Introduction
- 1. Zero Stage, Inc. 918-605-6702 Gas turbine emission reduction & resultant performance enhancement thru inlet air density modification Advanced technology for reducing emissions from stationary engines used in; Compressor Drives Power Generation thru inlet air pressurization and cooling.
- 2. Emissions Reduction Value The ZSI system allows the existing engine to operate continuously at the point of lowest emissions, at any power level. The reduction is thru inlet air density modification, using external air pressurization and inter-cooling. Increased mass flow improves combustion & mixing efficiency, which lowers CO emissions. Increased mass flow & reduced fuel use lowers combustion temperature, reducing thermal NOx. Improved engine performance & efficiency, and horsepower substitution reduces GHG emissions
- 3. Lower Emissions by Design Point Matching & Horsepower Substitution Every engine has a design point at which the combustion process is optimized. Most of the time, the plant location & changing ambient conditions keep the engine from operating at this point. ZSI has developed a system that keeps the combustion optimized for operation at the lowest emissions level , at any site location, ambient temperature and power level. Boost fan HP adds to the cycle power, with no emission component, just like electrical driven compression. R&D testing of the ZSI system shows that running at this point reduces the tons per year as much as 40% from uncontrolled conditions.
- 4. Associated Performance Improvement During emission limiting operation, the ZSI system can increase site rated HP of your existing gas turbine as much as 50%, up to the OEM limit, every day, in any ambient condition, at any site. Additional unit capacity results in the ability to shutdown other stations to match demand, with associated emissions & fuel reductions.
- 5. Improved Efficiency The ZSI technology increases the engine efficiency as much as 5%, every running hour , resulting in a significant reduction in fuel, CO and GHG emissions. In a heat recovery application of the ZSI system, the engine-compressor, or engine-generator, will operate with combined cycle efficiency, showing as much as a 30% improvement over the simple cycle, pre-ZSI, conditions. This improvement comes without the cost of adding a second compressor or generator to the plant.
- 6. Improved Engine Longevity Operation of the ZSI modified system will result in lower combustion temperatures, at any HP. These lower temperatures result in longer Time-Between-Overhaul increments, along with lower NOx, CO and GHG production. Inlet boost compensates for degraded air seals within the turbine, delaying overhauls.
- 7. Technology The ZSI process has been developed over a period of 20 years, and is currently “Patent Applied For”. The Technology Demonstration Project was installed on a Saturn compressor set, in West Texas, operational & tested in March 2010. Hot weather performance & emission testing is currently underway.
- 8. Application The ZSI system can be used on any gas turbine, new or old, at any site. ZSI technology works with other add-on, exhaust emissions clean-up systems, like SCR’s. - Because the engine is boosted, it can operate with a higher backpressure, reducing the size & cost of the SCR installation. - Lower tons/yr from the unit improves the operating cost of the SCR, thru lower ammonia usage. - ZSI boost recovers the performance losses normally associated with these systems & enhances the overall performance of the station.
- 9. System Integration No modification of the engine controls is required, and the engine operates within OEM parameters. The ZSI process uses PLC logic and is easily integrated into existing SCADA systems for local operation or remote dispatch, without the need for on-site operators. The system components are pre-assembled & tested to minimize station outage time. Typical installation and commissioning time is 2–3 days from arrival on site, for a Saturn application.
- 10. R&D Demonstration Site 1980 Saturn Engine/Compressor Set
- 11. R&D Demonstration Site The ZSI Inlet Boost Unit installs between the turbine inlet air duct and the air filter house