Combustion characteristics of a lean premixed LPG–air combustor

Fuel/air mixing effects in a premixer have been examined to investigate the combustion characteristics, such as the emission of NO_x and CO, under simulated lean premixed gas turbine combustor conditions at normal and elevated pressures of up to 3.5 bar with air preheat temperature of 450 K. The results obtained have been compared with a diffusion flame type gas turbine combustor for emission characteristics. The results show that the NO_x emission is profoundly affected by the mixing between fuel and air in the combustor. NO_x emission is lowered by supplying uniform fuel/air gas mixture to the combustor and the NO_x emission reduces with decrease in residence time of the hot gases in the combustor. The NO_x emission level of the lean premixed combustor is a strong function of equivalence ratio and the dependency is smaller for a traditional diffusion flame combustor under the examined experimental conditions. Furthermore, the recirculation flow, affected by dome angle of combustor, reduces the high temperature reaction zone or hot spot in the combustor, thus reducing the NO_x emission levels.     

Impact of H2 addition on flame stability and pollutant emissions for an atmospheric kerosene/air swirled flame of laboratory scaled gas turbine

The purposes of this study are to compare the stability domains and the pollutant emissions when combustion occurs with and without addition of H₂ to a kerosene (Jet A1)/air premixed prevaporised mixture injected in a lean gas turbine combustor. Chemiluminescence of CH*, pollutant emissions (NO_x and CO) and pressure fluctuations data are simultaneously collected in order to determine the effects of H₂ addition on the stability of the combustion and on the flame structure for an inlet temperature of 473 K, atmospheric pressure and for a large range of equivalence ratio (from 0.3 to 1). Addition of hydrogen enables keeping stable combustion conditions when, for the same kerosene mass flow, the flame becomes lifted and very unstable. As for pollutant emissions, results show that the equivalence ratio is the key parameter to control NO_x emission even in the situation where the combustion power is increased due to H₂ addition. As H₂ addition strongly increases the flammability limits and the combustion stability domain, stable combustion can occur at leaner equivalence ratio and then decreases CO and NO_x emissions. This is an important fact since no substitution effect takes place in the reduction of NO_x and CO emissions. Study at constant combustion power and equivalence ratio by adjusting hydrogen and kerosene mass flow shows again a decrease in the pollutant emissions. Hydrogen injection in power generation systems using combustion seems to be a promising way in combustion research since due to the combined effects of enlarging combustion stability domain and reducing NO_x emissions by substituting kerosene to the benefit of H₂.     

Theoretical investigation of the combustion performance of ammonia/hydrogen mixtures on a marine diesel engine

Ammonia is a good hydrogen carrier and can be well combined with hydrogen for combustion. The combustion performance of the mixtures of ammonia and hydrogen in a medium-speed marine diesel engine was investigated theoretically. The HCCI combustion mode was selected for reducing thermal-NO_x production. The start fire characteristic of the NH₃–H₂ mixtures was studied under different equivalence ratio, hydrogen-doped ratio, and intake air temperature and pressure. Then, the combustion performance of the NH₃–H₂ mixtures (doping 30% hydrogen) was analyzed at a typical operation condition of engine. The addition hydrogen improved the laminar flame velocity of ammonia, and affected the NO_x emission. For the medium-speed marine engine fueled with NH₃–H₂, reducing combustion temperature, introducing EGR and combining with post-treatment technology would be a feasible scheme to reduce NO_x emission.     

Effects of rectangular rib on exergy efficiency of a hydrogen-fueled micro combustor

In order to further optimize the working performance of micro-cylindrical combustor, the combustion chamber of the micro-cylindrical combustor is inserted in a rectangular rib. Extensive numerical investigations are conducted to compare the exergy efficiency of non-ribbed and rectangular-ribbed micro combustors under various hydrogen mass flow rates and hydrogen/air equivalence ratios. Moreover, the effects of dimensionless rib positions and heights on the exergy efficiency of micro-cylindrical combustor are also widely investigated. Results suggest that the exergy efficiency of the rectangular-ribbed micro combustor is significantly higher than that of the non-ribbed micro combustor under different inlet conditions. Moreover, the exergy efficiency of the rectangular-ribbed micro combustor is significantly affected by the dimensionless positions l. The optimum dimensionless l is increased with the increase of hydrogen mass flow rate. This work offers us significant reference for optimizing the micro combustor in energy utilization.     

Swirling distributed combustion for clean energy conversion in gas turbine applications

Distributed combustion provides significant performance improvement of gas turbine combustors. Key features of distributed combustion includes uniform thermal field in the entire combustion chamber, thus avoiding hot-spot regions that promote NO_x emissions (from thermal NO_x) and significantly improved pattern factor. Rapid mixing between the injected fuel and hot oxidizer has been carefully explored for spontaneous ignition of the mixture to achieve distributed combustion reactions. Distributed reactions can be achieved in premixed, partially premixed or non-premixed modes of combustor operation with sufficient entrainment of hot and active species present in the flame and their rapid turbulent mixing with the reactants. Distributed combustion with swirl is investigated here for our quest to explore the beneficial aspects of such flows on clean combustion in simulated gas turbine combustion conditions. The goal is to develop high intensity combustor with ultra low emissions of NO and CO, and much improved pattern factor. Experimental results are reported from a cylindrical geometry combustor with different modes of fuel injection and gas exit stream location in the combustor. In all the configurations, air was injected tangentially to impart swirl to the flow inside the combustor. Ultra-low NO_x emissions were found for both the premixed and non-premixed combustion modes for the geometries investigated here. Swirling flow configuration, wherein the product gas exits axially resulted in characteristics closest to premixed combustion mode. Change in fuel injection location resulted in changing the combustion characteristics from traditional diffusion mode to distributed combustion regime. Results showed very low levels of NO (∼3 PPM) and CO (∼70 PPM) emissions even at rather high equivalence ratio of 0.7 at a high heat release intensity of 36 MW/m³-atm with non-premixed mode of combustion. Results are also reported on lean stability limit and OH^* chemiluminescence under both premixed and non-premixed conditions for determining the extent of distribution combustion conditions.     

Flame stability and emission characteristics of propane-fueled flat-flame miniature combustor for ultra-micro gas turbines

An engineering model of a propane-fueled miniature combustor was developed for ultra-micro gas turbines. The combustion chamber had a diameter of 20 mm, height of 4 mm, and volume of 1.26 cm³. The flat-flame burning method was applied for lean-premixed propane–air combustion. To create the stagnation flow field for a specific flat-flame formation, a flat plate was set over the porous plate in the combustion chamber. A burning experiment was performed to evaluate the combustion characteristics. The flame stability limit was sufficiently wide to include the design operation conditions of an equivalence ratio of 0.55 and air mass flow rate of 0.15 g/s, and the dominant factors affecting the limit were clarified as the heat loss and velocity balance between the burning velocity and the premixture flow velocity at the porous plate. CO, total hydrocarbons (THC), and NO_x emission characteristics were established based on the burned gas temperatures in the combustion chamber and the temperature distribution in the combustor. At an air mass flow rate of less than 0.10 g/s, CO and THC emissions were more than 1000 ppm due to large heat loss. As the air mass flow rate increased, the heat loss decreased, but CO emissions remained large due to the short residence time in the combustion chamber. NO_x emission depended mainly on the burned gas temperature in the combustion chamber as well as on the residence time. To reduce emissions despite the short residence time, a platinum mesh was placed after the combustion chamber, which drastically decreased the CO emissions. The combustor performance was compared with that of other miniature combustors, and the results verified that the present combustor has suitable combustion characteristics for a UMGT, although the overall combustor size and heat loss need to be reduced.     

Performance analysis of a novel eco‐friendly internal combustion engine cycle

The Miller cycle applications have been performed to diminish NO_x released from internal combustion engines (ICEs), in recent years. The Miller cycle provides decreased compression ratio and enhanced expansion ratio; hereby, maximum in‐cylinder combustion temperatures diminish, and NO_x formations slow down remarkably. Another less‐known method is Takemura cycle application, which provides heat addition into engine cylinder at constant combustion temperatures. In this study, a novel cycle including the Miller cycle and the Takemura cycle has been developed by using novel numerical models and computing methods with seven processes and a novel way to decrease NO_x emissions at higher levels compared with the single applications of known cycles. A comprehensive performance examination of the proposed cycle engine in terms of performance characteristics such as effective power (EFP), effective power density (EFPD), exergy destruction (X), exergy efficiency (ε), and ecological coefficient of performance (ECOP) has been conducted. The impacts of engine operating and design parameters on the performance characteristics have been computationally examined. Furthermore, irreversibilities depending on incomplete combustion loss (INCL), exhaust output loss (EXOL), heat transfer loss (HTRL), and friction loss (FRL) have been considered in the performance simulations. The minimum exergy destruction and maximum performance specifications have been observed with 30 of the compression ratio. Maximum effective power values have been obtained at range between 1 and 1.2 of equivalence ratio. The optimum range for exergy efficiency is between 0.8 and 1 of equivalence ratio. Increasing engine speed has provided enhancing effective power. However, an optimum range has been found for the exergy efficiency that is interval of 3000 to 4000 rpm. The results obtained can be assessed by researchers studying on modeling of the engine systems and designs.     

Flame stabilization and emission of small Swiss-roll combustors as heaters

The characteristics of small Swiss-roll combustors were investigated experimentally in detail. Three types of Swiss-roll combustors of different designs and two cases of heat transfer conditions were studied. The effects of design parameters on the performance of these combustors were examined. Each combustor consisted of a combustion region at the center (called the combustion room) and double spiral-shaped channels, the widths of which were smaller than the minimum quenching distance of a propane premixed flame at a normal state. Flames could be stabilized successfully for a wide range of equivalence ratios and mean velocities by using the recirculated heat from the burned gas, and blow-off was not observed. Temperature distributions of the combustors, variation of gas temperature, and the concentrations of the exhaust gas from the combustors were also investigated. Mean temperatures of the combustors were found to be governed by both the radiant heat loss from the combustors and the total chemical energy liberated by the combustors. Efficiencies of the combustors as heaters were evaluated. As a combustor became smaller, its thermal efficiency as a heater increased and its NO_x emission decreased, while the emission of CO increased. By adding a catalytic reactor at the exhaust port, it was found that the emission of CO could be eliminated. This study provides new experimental results for a small Swiss-roll combustor, which represents an essential step toward the development of a microcombustor.     

Effect of methane reforming before combustion on emission and calorimetric characteristics of its combustion process

In this study, combustion and emission characteristics of methane mixed with steam (CH₄/H₂O) and the products of methane reforming with steam (CO/H₂/H₂O) were compared. Four fuel compositions were analysed: CH₄+H₂O, CH₄+2H₂O, and products of complete methane reforming in these mixtures, respectively. A comparison was carried out through the numerical model created via Ansys Fluent 2019 R2. A combustion process was simulated using a non-premixed combustion model, standard k-ϵ turbulence model and P-1 radiation model. The combustor heat capacity for interrelated fuel compositions was kept constant due to air preheating before combustion. The inlet air temperature was varied to gain a better insight into the combustion behaviour at elevated temperatures. The effect of steam addition on the emission characteristics and flame temperatures was also evaluated. NO_x formation was assessed on the outlet of the combustion zone. The obtained results indicate that syngas has a higher combustion temperature than methane (in the same combustor heat capacity) and therefore emitted 27% more NO_x comparing to methane combustion. With the air inlet temperature increment, the pollutant concentration difference between the two cases decreased. Steam addition to fuel inlet resulted in lesser emissions both for methane and syngas by 57% and 28%, respectively. In summary, syngas combustion occurred at higher temperature and produced more NO_x emissions in all cases considered.     

Thermal and emission characteristics of a turbulent swirling inverse diffusion flame

The thermal and emission characteristics of a swirl-stabilized turbulent inverse diffusion flame (IDF) burning liquefied petroleum gas (LPG) were studied experimentally and the results of visible flame lengths, flame temperatures, in-flame gaseous species concentrations and global pollutant emissions were reported.The flame shape and length of the swirling IDF and a non-swirling IDF were compared. The swirling IDF is featured by a large internal recirculation zone (IRZ), which plays an important role in stabilizing and shortening the flame. Compared with the non-swirling IDF, the swirling IDF is shorter, wider and more stable. For the swirling IDF, both temperature and species distributions are uniform in the IRZ. Comparison of the radial NO_x/temperature distributions indicates that the thermal NO mechanism plays a leading role in NO_x formation, since the high-temperature IRZ favors thermal NO production. The effects of air jet Reynolds number (Re) and overall equivalence ratio (Ф) on centerline temperature and emission index were examined. The main finding is that the IRZ which is large in size and high in temperature dominates the thermal and emission characteristics of the swirling flame.Efforts were made to compare the global NO_x and CO emissions of the swirling and non-swirling IDFs. It was found that strong swirl and lean combustion are two key factors for reducing NO_x emission. However, the decreasing NO_x emission is compromised by increasing CO. Under stoichiometric and rich conditions, EINO_x of the swirling IDFs is slightly higher, but the EICO is significantly lower. Further comparison of EINO_x with other studies indicates that the swirling IDF can achieve low NO_x emission.     

The combustion tuning methodology of an industrial gas turbine using a sensitivity analysis

This paper presents the results of combustion performance testing of a 5.25 MWe industrial gas turbine which features a conical counter-flow double-swirl stabilized, premixed combustor and the Combustion Tuning methodology using a Sensitivity Analysis (abbreviated to CTSA). The combustion performance test was conducted in an atmospheric pressure, optically accessible, real engine scale combustor. The atmospheric rig and real engine correlation was verified by comparing real engine data which were gathered from high pressure tests. NOx and CO emissions, combustor temperature at the fuel nozzle, dump plane and exhaust, dynamic pressure and flame structure, using planer laser induced fluorescence, were investigated with respect to power load and ambient temperature. To enhance the NOx and CO emission performances with stable combustion, the relative sensitivities of five control parameters were analyzed, and on the basis of sensitivity analysis data, combustion tuning testing was conducted. By using the CTSA, NOx emission in exhaust gas was reduced from 18 to 2.2 ppm at base load, with high combustion efficiency (>99.9%), and very little pressure fluctuation (P_rms < 0.1 kPa).     

Effects of compression ratio on performance and emission characteristics of heavy-duty SI engine fuelled with HCNG

The wide range of hydrogen's flammable limits enables ultra-lean combustion. A lean burn reduces the combustion temperature, increases thermal efficiency, and reduces knock, which is a serious problem in a spark ignition (SI) engine. The anti-knock improvement from hydrogen addition makes it feasible to increase the compression ratio (CR) and further improve the thermal efficiency. Herein, the effects of the CR on performance and emission characteristics were investigated using an 11-L heavy-duty SI engine fuelled with HCNG30 (CNG 70 vol%, hydrogen 30 vol%) and CNG. These fuels were used to operate an engine with CRs of 10.5 and 11.5. The results showed that thermal efficiency improved with an increased CR, which significantly decreased CO₂ emission. On the other hand, the NO_x emission was largely increased. Nevertheless, for HCNG30, a CR of 11.5 improved thermal efficiency by 6.5% and decreased NO_x emission by over 75%, as compared to a conventional CNG engine.     

NOx emission and thermal efficiency of a 300 MWe utility boiler retrofitted by air staging

Full-scale experiments were performed on a 300 MWe utility boiler retrofitted with air staging. In order to improve boiler thermal efficiency and to reduce NO_x emission, the influencing factors including the overall excessive air ratio, the secondary air distribution pattern, the damper openings of CCOFA and SOFA, and pulverized coal fineness were investigated. Through comprehensive combustion adjustment, NO_x emission decreased 182 ppm (NO_x reduction efficiency was 44%), and boiler heat efficiency merely decreased 0.21%. After combustion improvement, high efficiency and low NO_x emission was achieved in the utility coal-fired boiler retrofitted with air staging, and the unburned carbon in ash can maintain at a desired level where the utilization of fly-ash as byproducts was not influenced.     

Hydrogen addition effects on methane-air colorless distributed combustion flames

In this investigation the role of hydrogen addition in a reverse flow configuration, consisting of both non-premixed and premixed combustion modes, have been examined for the CDC flames. In the non-premixed configuration the air injection port is positioned at combustor exit end while the fuel injection port is positioned on the side so that the fuel is injected in cross-flow with respect to air injection. The thermal intensity of the flames investigated is 85 MW/m³ atm to simulate high thermal intensity gas turbine combustion conditions. The results are presented on the global flame signatures, exhaust emissions, and radical emissions using experiments and flowfield using numerical simulations. Ultra low NO_x emissions are found for both the premixed and non-premixed combustion modes. Addition of hydrogen to methane fuel resulted in only a slight increase of NO emission, significant decrease of CO emission and extended the lean operational limit of the combustor.     

Numerical study of hydrogen‐enriched methane–air combustion under ultra‐lean conditions

The demand for gas turbines that accept a variety of fuels has continuously increased over the last decade. Understanding the effects of varying fuel compositions on combustion characteristics and emissions is critical to designing fuel‐flexible combustors. In this study, the combustion characteristics and emissions of methane and hydrogen‐enriched methane were both experimentally and numerically investigated under ultra‐lean conditions (Ø ≤ 0.5). This study was performed using global mechanisms with a one‐step mechanism by Westbrook and Dryer and a two‐step mechanism with an irreversible and reversible CO/CO₂ step (2sCM1 and 2sCM2). Results show that the 2sCM2 mechanism under‐predicted the temperature, major species, and NO_x by more than 100% under ultra‐lean conditions; thus, we proposed a modified‐2sCM2 mechanism to better simulate the combustion characteristics. The mechanisms of Westbrook, 2sCM1, and modified 2sCM2 predicted the temperature and the CO₂ emission with an average deviation of about 5% from the experimental values. Westbrook and 2sCM1, however, over‐predicted the NO_x emission by approximately 81% and 152%, respectively, as compared with an average under‐prediction of 11% by the modified‐2sCM2 mechanism. The numerical results using the proposed modified‐2sCM2 mechanism shows that the presence of hydrogen in the fuel mixture inhibits the oxidation of methane that led to the formation of unburned hydrocarbons in the flame. We also showed that for any given fuel compositions of H₂/CH₄, there is an optimum equivalence ratio at which the pollutant emissions (CO and NO_x) from the combustor are minimal. Zero CO and 5 ppm NO_x emissions were observed at the optimal equivalence ratio of 0.45 for a fuel mixture containing 30% H₂. The present study provides a basis for ultra‐lean combustion toward achieving zero emissions from a fuel‐flexible combustor. Copyright © 2016 John Wiley & Sons, Ltd.     

Performance characteristics of methanol and kerosene fuelled meso-scale heat-recirculating combustors

A meso-scale heat recirculating combustor has been developed for the combustion of methanol and kerosene fuels with oxygen enriched superheated steam as an oxidizer. The steam oxygen mixture is a surrogate for the decomposition products of hydrogen peroxide, and as such the combustor development is toward meso-scale bi-propellant propulsion. Both the extinction behavior and thermal performances have been examined under partially-premixed and non-premixed configurations of a unique design incorporating heat recirculation. Stable combustion with thermal efficiencies of ∼90% has been demonstrated with both methanol and kerosene. Global flame behavior is investigated through direct image photography of the flame that revealed different flame modes at various equivalence ratios (Φ), including “flameless” combustion of kerosene. Density impulse values calculated based on exhaust temperatures and simulated equilibrium gas properties and assuming 1 atm chamber pressure and expansion to vacuum show that the maximum density impulse of kerosene/steam/oxygen combustion to be within 6% of the adiabatic density impulse of hydrazine/nitrogen tetroxide.     

Effect of different turbulence models on combustion and emission characteristics of hydrogen/air flames

This paper aims to present modeling results of hydrogen/air combustion in a micro-cylindrical combustor. Modeling studies were carried out with different turbulence models to evaluate performance of these models in micro combustion simulations by using a commercially available computational fluid dynamics code. Turbulence models implemented in this study are Standard k-ε, Renormalization Group k-ε, Realizable k-ε, and Reynolds Stress Transport. A three-dimensional micro combustor model was built to investigate impact of various turbulence models on combustion and emission behavior of studied hydrogen/air flames. Performance evaluation of these models was executed by examining combustor outer wall temperature distribution; combustor centerline temperature, velocity, pressure, species and NO_x profiles. Combustion reaction scheme with 9 species and 19 steps was modeled using Eddy Dissipation Concept model. Results obtained from this study were validated with published experimental data. Numerical results showed that two equation turbulence models give consistent simulation results with published experimental data by means of trend and value. Renormalization Group k-ε model was found to give consistent simulation results with experimental data, whereas Reynolds Stress Model was failed to predict detailed features of combustion process.     

Effects of dual-inlet on premixed hydrogen/air combustion characteristics and thermal performance for micro thermophotovoltaic application

Premixed H₂/air combustion in the micro-combustor with dual-inlet is investigated. Effects of the second-inlet settings on the combustion characteristics, thermal performance and radiation efficiency are discussed and compared. The results indicate that the second-inlet can efficiently modify burning characteristics and heat transmission, improving the burner thermal performance. With the increase of the distance between second-inlet and inlet, the mean outer wall temperature T_m is first risen and then down with a fixed reactants ratio of second-inlet Q_in. It also affects the flow field and radiation temperature, and combustor C3 achieves the highest T_m 1180.9 K and radiation efficiency 28.231% at the total flow rate m_f = 3.376 × 10^?5 kg/s and Q_in = 10%. For an augment of m_f, the radiation temperature is improved while radiation efficiency is declined, and the combustor C2 obtains the highest radiation power 42.3 W at m_f = 5.626 × 10^?5 kg/s and Q_in = 20%.     

An overview on dry low NOx micromix combustor development for hydrogen-rich gas turbine applications

The paper presents a survey of the interactive optimization cycle at Aachen University of Applied Sciences, used for the development of a new low emission Micromix combustor module for application in hydrogen fueled industrial gas turbines. During the development process, experimental and numerical methods are applied to optimize a given baseline combustor with 0.3 mm nozzles with respect to combustion efficiency, combustion stability, higher thermal power output per nozzle and reduced manufacturing complexity.Within the described research cycle combustion and flow simulations are used in the context of parametric studies for generating optimized burner geometries and the phenomenological interpretation of the experimental results. Experimental tests, carried out on an atmospheric combustion chamber test stand provide the basis for validation of simulation results and proof of the predicted combustion characteristics under scaled down gas turbine conditions.In the presented studies, an integration-optimized Micromix combustor with a nozzle diameter of 0.84 mm is tested at atmospheric pressure over a range of gas turbine operating conditions with hydrogen fuel. The combustor module offers an increase in the thermal power output per nozzle by approx. 390% at a significant reduced number of injectors when compared to the baseline design. This greatly benefits manufacturing complexity and the robustness of the combustion process against fuel contamination by particles.During atmospheric testing, the optimized combustor module shows satisfactory operating behavior, combustion efficiency and pollutant emission level. Within the evaluated operating range, which correlates to gas turbine part-, full- and overload conditions, the investigated combustor module exceeds 99% combustion efficiency. The Micromix combustor achieves NO_x emissions less than 2.5 ppm corrected to 15 Vol% O₂ at the design point.Based on numerical analyses and experimental low pressure testing, a full-scale gas turbine combustion chamber is derived. High pressure testing in the auxiliary power unit Honeywell/Garrett GTCP 36–300 shows stable operation during acceleration of the engine, during IDLE and during load variations between IDLE and Main Engine Start (MES) mode. Throughout the investigated operating range, the combustion chamber generates low NO_x emissions under full-scale gas turbine conditions.