Investigation on hydrogen-fueled combustion characteristics and thermal performance in a micro heat-recirculation combustor inserted with block

Numerical investigation on the premixed H₂/air combustion in a micro heat-recirculation combustor inserted with/without block is conducted. Effects of block setting, heat-recirculation, and flow rate on combustion characteristics and thermal performance are depicted and analyzed. The results demonstrate that the block enhances the flame stability and preheating effect, which also reduces the heat loss via exhaust gas, while it shortens reactants residence time. The combustor setting with a transverse block gains a better thermal performance than that inserted with a longitudinal block. With the increase of transverse block height, the high-temperature zone is broadened and radiation is improved. However, the block with a height of 10 mm separates the fluid field and weakens the effects of heat recirculation, leading to a lower outer wall temperature. Furthermore, the appropriate block insertion method and height contribute to the significant improvement of heat transfer, radiant efficiency and further optimization of micro power generator.     

A new calorimetric facility to investigate radiative‐convective heat exchangers for concentrated solar power applications

A new calorimetric facility for the aerothermal assessment of radiative‐convective heat exchangers in concentrating solar power applications has been developed and is described in this paper. The configuration of volumetric solar receivers enables concentrated sunlight to be absorbed and conducted within their solid volume, from where it is gradually transferred by forced convection to a heat transfer fluid flowing through their structure. Current design trends towards higher thermal conversion efficiencies have led to the use of complex intricate geometries to maximise temperatures deep inside the structure. The work presented aims to aid these objectives by commissioning a new experimental facility for the fully integrated evaluation of such components. The facility is composed of a high‐flux solar simulator that provides 1.2 kW of radiative power, a radiation homogeniser, inlet and outlet collector modules, and a working section that can accommodate volumetric receivers up to 80 mm × 80 mm in aperture. Irradiance levels and flow field nondimensional governing parameters are highly representative of on‐sun experiments at larger scales. Results from experiments with a siliconised silicon carbide monolithic honeycomb are presented, conducted at realistic conditions of incident radiative power per unit mass flow rate to validate its design point operation. Measurements conducted include absorber solid temperature distributions, air inlet and outlet temperatures, pressure drop, incident heat flux, and overall thermal efficiency. The relative influence of different sources of thermal loss is analysed and discussed.     

Toluene addition to turbulent H2/natural gas flames in bluff-body burners

A key challenge in the transition towards using hydrogen as an alternative carbon-free fuel is the reduced thermal radiation due to the absence of soot. A novel solution to this may be doping with highly sooting bio-oils. This study investigates the efficacy of toluene as a prevapourised dopant in turbulent pure hydrogen and blended hydrogen/natural gas flames as a means of improving soot loading and radiant heat transfer. All flames are stabilised on bluff-body burners to emulate the recirculation component of many industrial combustors. Total heat flux and illuminance increase non-linearly with toluene concentration for fuel blends and bluff-body diameters. By reducing the bluff-body diameter from 64 mm to 50 mm, a 20/80 (vol%) H₂/natural gas mixture produces a more radiative flame than a 10/90H₂/natural gas mixture in the smaller bluff-body. Opposed-flow flame simulations of soot precursors indicate that as strain rate increases, although overall soot precursor concentration decreases, a 20 vol% hydrogen mixture will produce more soot than a 10 vol% mixture. This suggests the addition of hydrogen up to 20 vol% may be beneficial for soot production in high strain environments.     

Inverse influence of initial diameter on droplet burning rate in cold and hot ambiences: a thermal action of flame in balance with heat loss

Isolated droplet burning were conducted in microgravity ambiences of different temperatures to test the initial diameter influence on droplet burning rate that shows a flame scale effect and represents an overall thermal action of flame in balance with heat loss. The coldest ambience examined was room air, which utilized a heater wire to ignite the droplet. All other ambiences hotter than 633 K were acquired through an electrically heated air chamber in a stainless steel can. An inverse influence of initial droplet diameter on burning rate was demonstrated for the cold and hot ambiences. That is, the burning rate respectively decreased and increased in the former and latter cases with raising the initial droplet diameter. The reversion between the two influences appeared gradual. In the hot ambiences the burning rate increase with increasing the initial droplet diameter was larger at higher temperatures. A “net heat” of flame that denotes the difference between “heat gain” by the droplet and “heat loss” to the flame surrounding was suggested responsible for the results. In low-temperature ambiences there is a negative net heat, and it turns gradually positive as the ambience temperature gets higher and the heat loss becomes less. Relating to luminous flame sizes and soot generation of differently sized droplets clarified that the flame radiation, both non-luminous and luminous, is determinative to the net heat in microgravity conditions. In addition, the work identified two peak values of soot generation during burning, which appeared respectively at the room temperature and at about 1000 K. The increase in ambience temperature made also bigger soot shells. The heat contribution of flame by both radiation and conduction was demonstrated hardly over 40% in the total heat required for droplet vaporization during burning in a hot ambience of 773 K.     

Effect of heat transfer through the release pipe on simulations of cryogenic hydrogen jet fires and hazard distances

Jet flames originated by cryo-compressed ignited hydrogen releases can cause life-threatening conditions in their surroundings. Validated models are needed to accurately predict thermal hazards from a jet fire. Numerical simulations of cryogenic hydrogen flow in the release pipe are performed to assess the effect of heat transfer through the pipe walls on jet parameters. Notional nozzle exit diameter is calculated based on the simulated real nozzle parameters and used in CFD simulations as a boundary condition to model jet fires. The CFD model was previously validated against experiments with vertical cryogenic hydrogen jet fires with release pressures up to 0.5 MPa (abs), release diameter 1.25 mm and temperatures as low as 50 K. This study validates the CFD model in a wider domain of experimental release conditions - horizontal cryogenic jets at exhaust pipe temperature 80 K, pressure up to 2 MPa ab and release diameters up to 4 mm. Simulation results are compared against such experimentally measured parameters as hydrogen mass flow rate, flame length and radiative heat flux at different locations from the jet fire. The CFD model reproduces experiments with reasonable for engineering applications accuracy. Jet fire hazard distances established using three different criteria - temperature, thermal radiation and thermal dose - are compared and discussed based on CFD simulation results.     

Effects of channel length on propagation behaviors of non-premixed H2-air flames in Y-shaped micro combustors

In the present study, dynamics of non-premixed hydrogen-air flames in two Y-shaped cylindrical micro combustors of different horizontal channel lengths (L = 100 and 200 mm) were experimentally compared. The inner diameters of the micro-combustors are 2 mm. Unburned mixture was ignited by heating the near-exit wall with a butane torch. The results show that six and three flame propagation modes in the 200-mm and 100-mm micro-combustors were observed, respectively. Moreover, it is found that the flame oscillation duration is much longer with a larger noise intensity in the 200-mm micro-combustor. As a result, the mean propagation speed under L = 100 mm is much larger. In addition, the edge flame is longer on the lean side under L = 100 mm and almost identical on the rich side for the two combustors. Furthermore, the luminosity of edge flame in the 100-mm micro-combustor is much brighter. Numerical analysis reveals that the deflection of propagating flame in the Y-shaped micro-combustor is determined by the stoichiometric line. In summary, the short combustor has a smaller heat loss ratio and a stronger flame-wall thermal coupling, which can enhance the combustion intensity and increase the flame propagation speed.     

Experimental investigation on the scale effects on diffusion H2/air flames in Y-shaped micro-combustors

In the present study, characteristics of diffusion H₂-air flame in three Y-shaped cylindrical micro-combustors with a diameter of d = 1, 2 and 3 mm were investigated experimentally. The mixture was ignited near the exit of a 200-mm long horizontal channel. First, it is found that more flame propagation modes appear in the combustor with d = 2 mm. Moreover, noise emission commences earlier in larger combustors. Two stages of noise emission are detected in the combustors with d = 2 and 3 mm, whereas only one stage appears under d = 1 mm. In addition, the mean flame propagation speed is the minimum in the combustor with d = 2 mm. Furthermore, the results show that the length of edge flame becomes longer in the combustor with a larger diameter. Interestingly, traveling isolated flame cells, which is also termed “traveling flame street”, is observed in the micro-combustors with d = 1 mm. Finally, the regime diagrams of flame propagation modes are drawn for the three micro-combustors. In conclusion, the present study not only reveals the relationship between flame characteristics and physical and geometrical parameters, but also provides useful guidance for the design of micro-combustors.     

Updated jet flame radiation modeling with buoyancy corrections

Radiative heat fluxes from small to medium-scale hydrogen jet flames (<10 m) compare favorably to theoretical predictions provided the product species thermal emittance and optical flame thickness are corrected for. However, recent heat flux measurements from two large-scale horizontally orientated hydrogen flames (17.4 and 45.9 m respectively) revealed that current methods underpredicted the flame radiant fraction by 40% or more. Newly developed weighted source flame radiation models have demonstrated substantial improvement in the heat flux predictions, particularly in the near-field, and allow for a sensible way to correct potential ground surface reflective irradiance. These updated methods are still constrained by the fact that the flame is assumed to have a linear trajectory despite buoyancy effects that can result in significant flame deformation. The current paper discusses a method to predict flame centerline trajectories via a one-dimensional flame integral model, which enables optimized placement of source emitters for weighted multi-source heat flux prediction methods. Flame shape prediction from choked releases was evaluated against flame envelope imaging and found to depend heavily on the notional nozzle model formulation used to compute the density weighted effective nozzle diameter. Nonetheless, substantial improvement in the prediction of downstream radiative heat flux values occurred when emitter placement was corrected by the flame integral model, regardless of the notional nozzle model formulation used.     

Optimal design of a sleeve-type steam methane reforming reactor for hydrogen production from natural gas

The three-dimensional computational fluid dynamics (CFD) model was used in a sleeve-type steam methane reforming (SMR) reactor for H₂ production of 2.5 Nm³/h from natural gas. The feed and combustion gases acted as a counter-current heat exchange owing to a narrow sleeve equipped between the combustor and catalyst-bed. The CFD results were validated against the experimental data of the SMR reactor with a sleeve gap size of 3 mm. The effect of the sleeve gap size and the flame shape on process performances such as H₂ production rate, thermal efficiency, and uniformity of catalyst-bed temperature was investigated using the CFD model. The sleeve gap size influenced the gas velocity inside the sleeve gap and the convective heat transfer. The SMR reactor with a sleeve gap size of 7 mm showed the highest H₂ production rate and thermal efficiency when comparing six sleeve gap sizes ranging from 2 to 10 mm. A new flame shape for the SMR reactor with the sleeve gap size of 7 mm was proposed to improve the process performances.     

A study of barrier walls for mitigation of unintended releases of hydrogen

Hydrogen jet flames resulting from ignition of unintended releases can be extensive in length and pose significant radiation and impingement hazards. Depending on the leak diameter and source pressure, the resulting consequence distances can be unacceptably large. One possible mitigation strategy to reduce exposure to jet flames is to incorporate barriers around hydrogen storage and delivery equipment. An experimental and modeling program has been performed at Sandia National Laboratories to better characterize the effectiveness of barrier walls to reduce hazards. This paper describes the experimental and modeling program and presents results obtained for various barrier configurations. The experimental measurements include flame deflection using standard and infrared video and high-speed movies (500 fps) to study initial flame propagation from the ignition source. Measurements of the ignition overpressure, wall deflection, radiative heat flux, and wall and gas temperature were also made at strategic locations. The modeling effort includes three-dimensional calculations of jet flame deflection by the barriers, computations of the thermal radiation field around barriers, predicted overpressure from ignition, and the computation of the concentration field from deflected unignited hydrogen releases. The various barrier designs are evaluated in terms of their mitigation effectiveness for the associated hazards present. The results show that barrier walls are effective at deflecting jet flames in a desired direction and can help attenuate the effects of ignition overpressure and flame radiative heat flux.     

Multimode heat transfer in cyclic flow reversal combustion in a porous medium

Experimental and numerical studies of combustion and multimode heat transfer in a porous medium, with and without a cyclic flow reversal of a mixture through a porous medium, were performed. Parametric studies were done in order to understand combustion characteristics such as maximum flame temperature and radiative heat flux using a one‐ dimensional conduction, convection, radiation and premixed flame model. The porous medium was assumed to emit and absorb radiant energy, while scattering is ignored. Non‐local thermodynamic equilibrium between the solid an d gas is taken into account by introducing separate energy equations for the gas and the solid phase. As a prelimina ry study, the combustion regime was described by a one‐step global mechanism with an internal heat source uniformly dist ributed along the reaction zone. The effects of the flame position, cyclic flow reversal, period of the cyclic flow rever sal, the optical thickness and the flow velocity on the burner performance were clarified by a rigorous radiation analysis. Th e model was validated by comparing the theoretical results with the experiments. It was shown that, for maximizing the fl ame temperature and the net radiative heat flux feedback, the flame should be stabilized near the centre of the po rous medium with a cyclic flow reversal, the period of which should be as small as possible. A high optical thickness prod uced a high flame temperature and a high net radiative feedback. Also, a high flow velocity at low period of the cyclic f low reversal of mixture yielded a high value of both the flame temperature and the net radiative feedback. Thermal structure predictions in terms of the gas‐phase and the solid‐phase temperature distributions along the axis of the combustor show good agreement with the experimental ones. Copyright © 1999 John Wiley & Sons, Ltd.     

Numerical study on premixed hydrogen/air combustion characteristics and heat transfer enhancement of micro-combustor embedded with pin fins

Aimed at improving the energy output performance of the Microthermal Photovoltaic (MTPV) system, it is necessary to optimize the structure of the micro combustor. In this paper, micro combustor with in-line pin fins arrays (MCIPF) and micro combustor with both end-line pin fins arrays (MCEPF) were presented to realize the efficient combustion and heat transfer enhancement, and the influence of inlet velocity, equivalent ratio, and materials on thermal performance was investigated. The results showed that pin fins embedding is beneficial to improving combustion, and the combustion efficiency of MCIPF and MCEPF reaches 98.5% and 98.7%, which is significantly higher than that of the conventional cylindrical combustor (MCC). However, with the increase of inlet velocity from 8 m/s to 14 m/s, MCIPF exhibits the highest external wall temperature with a range of (1302–1386 K), while MCEPF maintains the best temperature uniformity. As the inlet velocity increases to 10 m/s, the external wall temperature and temperature uniformity reach the optimum. Besides, under the conditions of different equivalence ratios, both external wall temperature and heat flux increases first and then decreases, meanwhile the temperature uniformity of MCEPF is significantly improved compared with that of MCIPF, they all exhibit the highest external wall temperature with an equivalence ratio of 1.1, and the thermal performance is greatly enhanced. By comparing the heat transfer performance of combustors with different materials based on MCEPF, it is interesting to find that the application of high thermal conductivity materials can not only increase the external wall temperature, but also improve the temperature uniformity. Therefore, materials with high thermal conductivity such as Aluminum, Red Copper and Silicon Carbide should be selected for application in micro combustors and their components. The current work provides a new design method for the enhanced heat transfer of the micro combustor.     

Flame dynamics of a meso-scale heat recirculating combustor

The dynamics of premixed propane–air flame in a meso-scale ceramic combustor has been examined here. The flame characteristics in the combustor were examined by measuring the acoustic emissions and preheat temperatures together with high-speed cinematography. For the small-scale combustor, the volume to surface area ratio is small and hence the walls have significant effect on the global flame structure, flame location and flame dynamics. In addition to the flame–wall thermal coupling there is a coupling between flame and acoustics in the case of confined flames. Flame–wall thermal interactions lead to low frequency flame fluctuations (∼100 Hz) depending upon the thermal response of the wall. However, the flame–acoustic interactions can result in a wide range of flame fluctuations ranging from few hundred Hz to few kHz. Wall temperature distribution is one of the factors that control the amount of reactant preheating which in turn effects the location of flame stabilization. Acoustic emission signals and high-speed flame imaging confirmed that for the present case flame–acoustic interactions have more significant effect on flame dynamics. Based on the acoustic emissions, five different flame regimes have been identified; whistling/harmonic mode, rich instability mode, lean instability mode, silent mode and pulsating flame mode.     

Analysis of non-adiabatic heat-recirculating combustors

A simple first-principles model of counter current heat-recirculating combustors is developed, including the effects of heat transfer from the product gas stream to the reactant stream, heat loss to ambient, and heat conduction in the streamwise direction through the dividing wall (and heat transfer surface) between the reactant and product streams. It is shown that streamwise conduction through the wall has a major effect on the operating limits of the combustor, especially at small dimensionless mass fluxes (M) or Reynolds numbers that would be characteristic of microscale devices. In particular, if this conduction is neglected, there is no small-M extinction limit because smaller M leads to larger heat recirculation and longer residence times that overcome heat loss if M is sufficiently small. In contrast, even a small effect of conduction along this surface leads to significantly higher minimum M. Comparison is made with an alternative configuration of a flame stabilized at the exit of a tube, where heat recirculation occurs via conduction through tube wall; it is found that the counter-current exchanger configuration provides superior performance under similar operating conditions. Implications for microscale combustion are discussed.     

The influences of thermophysical properties of porous media on superadiabatic combustion with reciprocating flow

The influences of thermophysical properties of porous media on superadiabatic combustion with reciprocating flow is numerically studied in order to improve the understanding of the complex heat transfer and optimum design of the combustor. The heat transfer performance of a porous media combustor strongly depends on the thermophysical properties of the porous material. In order to explore how the material properties influence reciprocating superadiabatic combustion of premixed gases in porous media (short for RSCP), a two‐dimensional mathematical model of a simplified RSCP combustor is developed based on the hypothesis of local thermal non‐equilibrium between the solid and the gas phases by solving separate energy equations for these two phases. The porous media is assumed to emit, absorb, and isotropically scatter radiation. The finite‐volume method is used for computing radiation heat transfer processes. The flow and temperature fields are calculated by solving the mass, moment, gas and solid energy, and species conservation equations with a finite difference/control volume approach. Since the mass fraction conservation equations are stiff, an operator splitting method is used to solve them. The results show that the volumetric convective heat transfer coefficient and extinction coefficient of the porous media obviously affect the temperature distributions of the combustion chamber and burning speed of the gases, but thermal conductivity does not have an obvious effect. It indicates that convective heat transfer and heat radiation are the dominating ways of heat transfer, while heat conduction is a little less important. The specific heat of the porous media also has a remarkable impact on temperature distribution of gases and heat release rate. © 2006 Wiley Periodicals, Inc. Heat Trans Asian Res, 35(5): 336–350, 2006; Published online in Wiley InterScience ( www.interscience.wiley.com ). DOI 10.1002/htj.20120     

Pool boiling heat transfer in a vertical annulus with a stepped outside tube

Effects of a stepped outside tube on nucleate pool boiling heat transfer in a vertical annulus with closed bottoms have been investigated experimentally. For the study saturated water at atmospheric pressure and a heated tube of 200 mm length and 19 mm diameter were used. The shape of an outside tube of the annulus has step geometry and the ratio between the upper and lower regions are varied from 0.23 to 4.43. The existence of the stepped outside tube changes heat transfer characteristics and its effect becomes evident as the gap ratio is smaller than 1. For the tested gap ratios heat transfer deterioration is observed as the heat flux is higher than 80 kW/m² comparing to the single unrestricted tube. The major cause for the tendency is attributed to the loss of liquid agitation intensity around the stepped regions of the annulus.     

Statistical modeling of thermal radiation transfer in buoyant turbulent diffusion flames

A statistical (Monte Carlo) method for radiative heat transfer has been incorporated in CFD modeling of buoyant turbulent diffusion flames in stagnant air and in a cross-wind. The model and the computational tool have been developed and applied to simulate both burner flames with controlled fuel supply rate and in self-sustained pool fires with burning rates coupled with flame radiation. The gas–soot mixture was treated either as gray (using the effective absorption coefficient derived from total emissivity data or the Planck mean absorption coefficient) or as non-gray (using the weighed sum of gray gases model). The comparison of predicted radiative heat fluxes indicates applicability of the gray media assumption in modeling of thermal radiation in case of high soot content. The effect of turbulence-radiation interaction is approximately taken into account in calculation of radiation emission, which is corrected to allow for temperature self-correlation and absorption-temperature correlation. In modeling buoyant propane flames in still air above 0.3 m diameter burner, extensive comparison is presented of the predictions with the measurements of gas species concentrations, temperature, velocity and their turbulent fluctuations, and radiative heat fluxes obtained in flames with different heat release rates. Similar to previously published experimental data, the predicted burning rate of flames above the acetone pools exposed to flame radiation increases with the pool diameter and approaches a constant level for large pool sizes. The magnitude of predicted burning rates is shown to be in agreement with the reported measurements. Augmentation of burning rate of the pool fire in a cross-wind because of increased net radiative heat flux received by the fuel surface and non-monotonic dependence of burning rate on cross-wind velocity, subject to the pool diameter, is predicted. The statistical treatment of thermal radiation transfer has been found to be robust and computationally efficient.     

Numerical Study of the Swirl Effect on a Coaxial Jet Combustor Flame Including Radiative Heat Transfer

A numerical study of the swirl effect on a coaxial jet combustor flame including radiative heat transfer is presented. In this work, the standard k-ε model is applied to investigate the turbulence effect, and the eddy dissipation model (EDM) is used to model combustion. The radiative heat transfer and the properties of gases and soot are considered using a coupled of the finite-volume method (FVM), and the narrow-band based weighted-sum-of-gray gases (WSGG-SNB) model. The results of this work are validated by experiment data. The results clearly show that radiation must be taken into account to obtain good accuracy for turbulent diffusion flame in combustor chamber. Flame is very influenced by the radiation of gases, soot, and combustor wall. However, swirl is an important controlling variable on the combustion characteristics and pollutant formation.     

Development of high intensity CDC combustor for gas turbine engines

Colorless distributed combustion (CDC) has been demonstrated to provide ultra-low emission of NOx and CO, improved pattern factor and reduced combustion noise in high intensity gas turbine combustors. The key feature to achieve CDC is the controlled flow distribution, reduce ignition delay, and high speed injection of air and fuel jets and their controlled mixing to promote distributed reaction zone in the entire combustion volume without any flame stabilizer. Large gas recirculation and high turbulent mixing rates are desirable to achieve distributed reactions thus avoiding hot spot zones in the flame. The high temperature air combustion (HiTAC) technology has been successfully demonstrated in industrial furnaces which inherently possess low heat release intensity. However, gas turbine combustors operate at high heat release intensity and this result in many challenges for combustor design, which include lower residence time, high flow velocity and difficulty to contain the flame within a given volume. The focus here is on colorless distributed combustion for stationary gas turbine applications. In the first part of investigation effect of fuel injection diameter and air injection diameter is investigated in detail to elucidate the effect fuel/air mixing and gas recirculation on characteristics of CDC at relatively lower heat release intensity of 5 MW/m³ atm. Based on favorable conditions at lower heat release intensity the effect of confinement size (reduction in combustor volume at same heat load) is investigated to examine heat release intensity up to 40 MW/m³ atm. Three confinement sizes with same length and different diameters resulting in heat release intensity of 20 MW/m³ atm, 30 MW/m³ atm and 40 MW/m³ atm have been investigated. Both non-premixed and premixed modes were examined for the range of heat release intensities. The heat load for the combustor was 25 kW with methane fuel. The air and fuel injection temperature was at normal 300 K. The combustor was operated at 1 atm pressure. The results were evaluated for flow field, fuel/air mixing and gas recirculation from numerical simulations and global flame images, and emissions of NO, CO from experiments. It was observed that the larger air injection diameter resulted in significantly higher levels of NO and CO whereas increase in fuel injection diameter had minimal effect on the NO and resulted in small increase of CO emissions. Increase in heat release intensity had minimal effect on NO emissions, however it resulted in significantly higher CO emissions. The premixed combustion mode resulted in ultra-low NO levels (<1 ppm) and NO emission as low as 5 ppm was obtained with the non-premixed flame mode.     

Efficiency analysis of radiative slab heating in a walking-beam-type reheating furnace

The thermal efficiency of a reheating furnace was predicted by considering radiative heat transfer to the slabs and the furnace wall. The entire furnace was divided into fourteen sub-zones, and each sub-zone was assumed to be homogeneous in temperature distribution with one medium temperature and wall temperature, which were computed on the basis of the overall heat balance for all of the sub-zones. The thermal energy inflow, thermal energy outflow, heat generation by fuel combustion, heat loss by the skid system, and heat loss by radiation through the boundary of each sub-zone were considered to give the two temperatures of each sub-zone. The radiative heat transfer was solved by the FVM radiation method, and a blocked-off procedure was applied to the treatment of the slabs. The temperature field of a slab was calculated by solving the transient heat conduction equation with the boundary condition of impinging radiation heat flux from the hot combustion gas and furnace wall. Additionally, the slab heating characteristics and thermal behavior of the furnace were analyzed for various fuel feed conditions.