Development and characterization of a low-NOx partially premixed hydrogen burner using numerical simulation and flame diagnostics

The utilization of hydrogen as a fuel in free jet burners faces particular challenges due to its special combustion properties. The high laminar and turbulent flame velocities may lead to issues in flame stability and operational safety in premixed and partially premixed burners. Additionally, a high adiabatic combustion temperature favors the formation of thermal nitric oxides (NO). This study presents the development and optimization of a partially premixed hydrogen burner with low emissions of nitric oxides. The single-nozzle burner features a very short premixing duct and a simple geometric design. In a first development step, the design of the burner is optimized by numerical investigation (Star CCM+) of mixture formation, which is improved by geometric changes of the nozzle. The impact of geometric optimization and of humidification of the combustion air on NO_x emissions is then investigated experimentally. The hydrogen flame is detected with an infrared camera to evaluate the flame stability for different burner configurations. The improved mixture formation by geometric optimization avoids temperature peaks and leads to a noticeable reduction in NO_x emissions for equivalence ratios below 0.85. The experimental investigations also show that NO_x emissions decrease with increasing relative humidity of combustion air. This single-nozzle forms the basis for multi-nozzle burners, where the desired output power can flexibly be adjusted by the number of single nozzles.     

Combustion behavior and stability map of hydrogen-enriched oxy-methane premixed flames in a model gas turbine combustor

The article describes an experimental study and comparison of the combustion behavior and determines the stability map of turbulent premixed H₂-enriched oxy-methane flames in a model gas turbine combustor. Static stability limits, in terms of flashback and blow-out limits, are recorded over a range of hydrogen fraction (HF) at a fixed oxygen fraction (OF) of 30% and a particular inlet bulk velocity, and the results are compared with the non-enriched case (HF = 0%). The static stability limits are also recorded for different inlet bulk velocity (4.4, 5.2, and 6 m/s) and the results are compared to explore the effect of flow dynamics on operability limits of H₂-enriched flames. The stability maps are presented as a function of equivalence ratio (0.3–1.0) and HF (0%–75%) plotted on the contours of adiabatic flame temperature (AFT), power density (PD), inlet Reynolds number (Re) and reacting mixture mass flow rate ($\dot{m}$) to understand the physics behind flashback and blow-out phenomena. The results indicated that both the flashback and blow-out limits tend to move towards the leaner side with increasing HF due to the improved chemical kinetics. The stability limits are observed to follow the Reynolds number indicating its key role in controlling flame static stability limits. The results showed that H₂ enrichment is effective in the zone from HF = 20% up to HF = 50%, and O₂ enrichment is also effective in a similar zone from OF = 20% up to 50%, with wider stability boundaries for H₂ enrichment. Axial and radial temperature profiles are presented to explore the effect of HF on the progress of chemical reactions within the combustor and to serve as the basis for validation of numerical models. Flame shapes are recorded using a high-speed camera and compared for different inlet velocities to explore the effects of H₂-enrichment and equivalence ratio on flame stability. The equivalence ratio at which a transition of flame stabilization from the inner shear layer (ISL) to the outer recirculation zone (ORZ) occurs is determined for different inlet bulk velocities. The value of the transition equivalence ratio is found to decrease while increasing the inlet bulk velocity. Flame shapes near flashback limit, as well as near blow-out limit, are compared to explore the mechanisms of flame extinctions. Flame shapes are compared at fixed adiabatic flame temperature, fixed inlet velocity and fixed flow swirl to isolate their effects and investigate the effect of kinetic rates on flame stability. The results showed that the adiabatic flame temperature does not govern the flame static stability limits.     

A filtered-laminar-flame PDF sub-grid-scale closure for LES of premixed turbulent flames: II. Application to a stratified bluff-body burner

Large eddy simulation of the two stratified nonswirling configurations of the Cambridge burner studied by Sweeney et al. (2012) is presented. The sub-grid-scale combustion closure relies on a physical space filtering operation with a filter size determined locally depending on the resolved and sub-grid-scale flame properties, which is discussed in a companion paper. Similarly to the premixed configuration of the same burner, the modeling reproduces the differential diffusion effects leading to accumulation of carbon and an enhancement of mixture fraction in the recirculation zone, an effect that is less pronounced than in the fully lean premixed case, because of the modification of the topology of the reaction zone that is induced by the mixture stratification. The study of the LES combustion regimes shows that the reaction zones develop under a quite large range of flame topologies, from wrinkled flamelets up to thin reaction zones. Instantaneous and time-averaged LES data were analyzed to extract information concerning the degree of stratification and the orientation of flame and mixing vectors. A decomposition of the flame response into premixed, diffusion, and partially premixed flamelets is performed, to conclude that the premixed mode dominates close to the burner, with a partially premixed burning regime further downstream. Overall, the length scales associated with stratification were found to be much larger than that of the reaction zone and flame, resulting in a quasi-homogeneous propagation, predominantly in a back supported stratified combustion regime. Overall good agreement between simulation and measurements was obtained for either configurations.     

Experimental investigation of the morphology and stability of diffusion and edge flames in an opposed jet burner

The stability of methane/air and hydrogen/air flames in an axisymmetric counterflow burner was investigated experimentally for different burner geometries, degrees of fuel dilution, and combinations of flow velocities. Both planar diffusion flames and edge flames were observed, and the transitions between these flame types were studied. The experimental results confirmed previously published numerical predictions on diluted hydrogen/air flames: the existence of two distinct stable flame types; the possibility of switching between the two flame types by perturbing the flames, e.g., by suitably changing a flow velocity; and the strong hysteresis for the transition from one flame type to the other. Flame stability diagrams were compiled which delineate the range of fuel and air flow velocities for which the planar diffusion flame and the toroidal edge flame are stable. The lower boundary curve for the edge flame stability exhibits a characteristic minimum at a well-defined value of the fuel velocity. For fuel velocities lower than this value, the transition between the edge and the diffusion structure is reversible, and the flames exhibit bistable behavior. For higher fuel velocities, the decrease of air velocity leads to the extinction of the edge flame. An investigation of both the cold and the reactive flow field identified bistable behavior for the flow field as well. Except for very low flow rates, the stagnation plane stabilizes in two positions, close to either of the two nozzles. Detailed numerical simulations of hydrogen flames capture the essentials of this behavior. The observed flame extinction results from the interaction of the flame dynamics with the dynamics of the flow field.     

Demonstration of a burner for the investigation of partially premixed low-temperature flames

A burner, which stabilizes near-one-dimensional low-temperature flames at atmospheric pressure, was designed to access the combustion regime near 1500 K for quantitative species diagnostics. Combustion temperatures between 1300 and 1800 K in argon-diluted methane-oxygen flames were achieved by preheating the burner and adapting the inert gas flow. Mass spectrometry with electron ionization was used to determine mole fractions profiles of reactants, products, and intermediates. Combustion parameters were varied including stoichiometry, diluent mole fraction and preheat temperature. Mole fraction profiles resemble those taken in regular premixed flat flames. A number of C₁- and C₂-intermediates as well as some oxygenated species were identified. Higher-mass species (m/z > 42) were not detected in the low-temperature methane-oxygen flames which contain 90% argon in the cold gases.     

Experimental investigation of the stability and emission characteristics of premixed formic acid-methane-air flames in a swirl combustor

Formic acid (FA) is a potential hydrogen energy carrier and low-carbon fuel by reversing the decomposition products, CO₂ and H_2, back to restore FA without additional carbon release. However, FA-air mixtures feature high ignition energy and low flame speed; hence stabilizing FA-air flames in combustion devices is challenging. This study experimentally investigates the flame stability and emission of swirl flames fueled with pre-vaporized formic acid-methane blends over a wide range of formic acid fuel fractions. Results show that by using a swirl combustor, the premixed formic acid-methane-air flames could be stabilized over a wide range of FA fuel fractions, Reynolds numbers, and swirl numbers. The addition of formic acid increases the equivalence ratios at which the flashback and lean blowout occur. When Reynolds number increases, the equivalence ratio at the flashback limit increases, but that decreases at the lean blowout limit. Increasing the swirl number has a non-monotonic effect on stability limits variation because increasing the swirl number changes the axial velocity on the centerline of the burner throat non-monotonically. In addition, emission characteristics were investigated using a gas analyzer. The CO and NO concentrations were below 20 ppm for all tested conditions, which is comparable to that seen with traditional hydrocarbon fuels, which is in favor of future practical applications with formic acid.     

The effects of the design of the cap of a natural gas-fired cooktop burner on flame stability

Results of an investigation aiming to study the effects of the burner cap design factors on flame stability are presented in this paper. Flame stability is an essential part of the operation of all domestic burners, including natural gas-fired cooktops. At high thermal inputs flame lifts are encountered above certain levels of primary aeration, whereas flashback only takes place at low thermal inputs, due to natural gas' low flame speed, above certain levels of primary aeration. In this work, flame lift limits were measured at 3·3 kW thermal input and the highest primary aeration above which flame lifts started to become visible was the stability limit at this thermal input. Around 60% primary aeration was desired to minimize pollutant emissions. Turndown tests were done at 40% primary aeration. The lowest thermal input below which the flame flashed back in less than 30 s was the turndown limit. A turndown ratio of at least 5 was aimed for (i.e. 0·67 kW or less would be desirable). The cap design factors studied were: the angle under the cap, the angle under the overlap, the shape under the cap, the size of the cap overlap, the height of overlap above the burner, cap material and cap thickness. The only feature of the burner head included in the tests was the angle at the top of the burner head, the part which comes into contact with the cap. The ‘Factorial Experimental Design’ method with statistical analysis was used. This enabled detection of interactions between factors as well as the effects of each single factor. The results show that combinations of factors which gave a balance between the performance at 3·3 kW and a satisfactory turndown ratio of 5 would be preferred. Those which gave very high turndown ratios were usually operable only at very low primary aerations (well below 60%) at 3·3 kW. Overall, the preferred combination of factors would be: 15° burner head top angle and angle under the cap, indent under the cap, 2·2 mm overlap with 15° angle at zero height above the burner, and thin aluminium caps. For the burner used in the experiments, such a combination should have no problem operating at up to 61% primary aeration at 3·3 kW and having a turndown ratio of 5·3. © 1998 John Wiley & Sons, Ltd.     

An experimental study of a cylindrical multi-hole premixed burner for the development of a condensing gas boiler

This study experimentally examined a cylindrical multi-hole premixed burner for its potential use for a condensing gas boiler, which produces less NO_x emissions and performs better. In this study, the hole diameters and the arrangement of a multi-hole burner were investigated using a flat burner model. The combustion characteristics for the flame stability as well as the NO_x and CO emissions were examined using a cylindrical burner. For an optimal operating condition, the equivalence ratio for the cylindrical burner was between 0.70 and 0.75. For this condition, the turn-down ratio was 3:1 or higher, which was suitable for appropriate control of the boiler operation. The NO_x and CO emissions were less than 40 ppm and less than 30 ppm, respectively, for a 0% O₂ basis. The LPG and LNG were able to be used in this type of burner because there was no phenomenal difference in the stable combustion region between them.     

Large eddy simulation of premixed hydrogen/methane/air flame propagation in a closed duct

In this paper, large eddy simulation (LES) is performed to investigate the propagation characteristics of premixed hydrogen/methane/air flames in a closed duct. In LES, three stoichiometric hydrogen/methane/air mixtures with hydrogen fractions (volume fractions) of 0, 50% and 100% are used. The numerical results have been verified by comparison with experimental data. All stages of flame propagation that occurred in the experiment are reproduced qualitatively in LES. For fuel/air mixtures with hydrogen fractions of 0 and 50%, only four stages of “tulip” flame formation are observed, but when the hydrogen fraction is 100%, the distorted “tulip” flame appears after flame front inversion. In the acceleration stage, the LES and experimental flame speed and pressure dynamic coincide with each other, except for a hydrogen fraction of 0. After “tulip” flame formation, all LES and experimental flame propagation speeds and pressure dynamics exhibit the same trends for hydrogen fractions of 0 and 100%. However, when the hydrogen fraction is 50%, a slight periodic oscillation appears only in the experiment. In general, the different structures displayed in the flame front during flame propagation can be attributed to the interaction between the flame front, the vortex and the reverse flow formed in the unburned and burned zones.     

A numerical study of the stability of one-dimensional laminar premixed flames in inert porous media

This work presents a numerical study of the stabilization diagram of methane/air premixed flames in a finite porous media foam with a uniform ambient temperature. A set of steady computations are considered, using a 1D numerical model that takes into account solid and gas energy equations as well as chemistry and radiation models. The present results show that both stable and unstable solutions, for upper and lower flames, exist either at the surface or submerged in the porous matrix. The influence of the 1D computational domain, boundary conditions, and gas/solid interface treatment on the stability of the calculated flames is also discussed. A linearized version of the discrete-ordinates radiation model is included in the linear stability analysis to discuss the influence of radiation on the stability of the flames. The full stabilization diagram and the linear stability analysis provide information on the stability of the flames, pointing to the existence of unstable upstream surface flames as well as unstable submerged flames on the downstream part of the porous media.     

LES of a premixed jet flame DNS using a strained flamelet model

Turbulent premixed flames in the thin and broken reaction zones regimes are difficult to model with Large Eddy Simulation (LES) because turbulence strongly perturbs subfilter scale flame structures. This study addresses the difficulty by proposing a strained flamelet model for LES of high Karlovitz number flames. The proposed model extends a previously developed premixed flamelet approach to account for turbulence’s perturbation of subfilter premixed flame structures. The model describes combustion processes by solving strained premixed flamelets, tabulating the results in terms of a progress variable and a hydrogen radical, and invoking a presumed PDF framework to account for subfilter physics. The model is validated using two dimensional laminar flame studies, and is then tested by performing an LES of a premixed slot-jet direct numerical simulation (DNS). In the premixed regime diagram this slot-jet is found at the edge of the broken reaction zones regime. Comparisons of the DNS, the strained flamelet model LES, and an unstrained flamelet model LES confirm that turbulence perturbs flame structure to leading order effect, and that the use of an unstrained flamelet LES model under-predicts flame height. It is shown that the strained flamelet model captures the physics characterizing interactions of mixing and chemistry in highly turbulent regimes.     

Effects of non-equidiffusion on unsteady propagation of hydrogen-enriched methane/air premixed flames

A Large Eddy Simulation (LES) model was developed to simulate the unsteady propagation of hydrogen-enriched methane/air premixed flames around toroidal vortices. Although the LES model does not take into account the non-equidiffusive effects associated with the hydrogen presence (preferential diffusion and non-unity Lewis number), it gives good predictions of experimental data previously obtained for lean mixtures with hydrogen mole fraction in the fuel (hydrogen plus methane) varying from 0 to 0.5. In particular, for each fuel composition, size and velocity of the toroidal vortex generated ahead of the propagating flame front are well reproduced along with the evolution of the flame shape and structure resulting from the interaction with the vortex. The negligible role played by the non-equidiffusive effects has been attributed to the fact that, at the conditions investigated, the characteristic time of hydrogen diffusion is one order of magnitude higher than the characteristic time of flame roll-up around the vortex.     

Mechanism analysis on the pulverized coal combustion flame stability and NOx emission in a swirl burner with deep air staging

Low NOx burner and air staged combustion are widely applied to control NOx emission in coal-fired power plants. The gas-solid two-phase flow, pulverized coal combustion and NOx emission characteristics of a single low NOx swirl burner in an existing coal-fired boiler was numerically simulated to analyze the mechanisms of flame stability and in-flame NOx reduction. And the detailed NOx formation and reduction model under fuel rich conditions was employed to optimize NOx emissions for the low NOx burner with air staged combustion of different burner stoichiometric ratios. The results show that the specially-designed swirl burner structures including the pulverized coal concentrator, flame stabilizing ring and baffle plate create an ignition region of high gas temperature, proper oxygen concentration and high pulverized coal concentration near the annular recirculation zone at the burner outlet for flame stability. At the same time, the annular recirculation zone is generated between the primary and secondary air jets to promote the rapid ignition and combustion of pulverized coal particles to consume oxygen, and then a reducing region is formed as fuel-rich environment to contribute to in-flame NO_X reduction. Moreover, the NOx concentration at the outlet of the combustion chamber is greatly reduced when the deep air staged combustion with the burner stoichiometric ratio of 0.75 is adopted, and the CO concentration at the outlet of the combustion chamber can be maintained simultaneously at a low level through the over-fired air injection of high velocity to enhance the mixing of the fresh air with the flue gas, which can provide the optimal solution for lower NOx emission in the existing coal-fired boilers.     

DNS of a premixed turbulent V flame and LES of a ducted flame using a FSD-PDF subgrid scale closure with FPI-tabulated chemistry

Two complementary simulations of premixed turbulent flames are discussed. Low Reynolds number two-dimensional direct numerical simulation of a premixed turbulent V flame is first performed, to further analyze the behavior of various flame quantities and to study key ingredients of premixed turbulent combustion modeling. Flame surface density, subgrid-scale variance of progress variables, and unresolved turbulent fluxes are analyzed. These simulations include fully detailed chemistry from a flame-generated tabulation (FPI) and the analysis focuses on the dynamics of the thin flame front. Then, a novel subgrid scale closure for large eddy simulation of premixed turbulent combustion (FSD-PDF) is proposed. It combines the flame surface density (FSD) approach with a presumed probability density function (PDF) of the progress variable that is used in FPI chemistry tabulation. The FSD is useful for introducing in the presumed PDF the influence of the spatially filtered thin reaction zone evolving within the subgrid. This is achieved via the exact relation between the PDF and the FSD. This relation involves the conditional filtered average of the magnitude of the gradient of the progress variable. In the modeling, this conditional filtered mean is approximated from the filtered gradient of the progress variable of the FPI laminar flame. Balance equations providing mean and variance of the progress variable together with the measure of the filtered gradient are used to presume the PDF. A three-dimensional larger Reynolds number flow configuration (ORACLES experiment) is then computed with FSD-PDF and the results are compared with measurements.     

Numerical study of a high-hydrogen micromix model burner using flamelet-generated manifold

The flamelet-generated manifolds (FGM) method was adopted in this study to consider the preferential diffusion in a high-hydrogen micro-mixing model burner. That is, when solving the FGM flamelet, accurate diffusion rate was obtained from two methods: multicomponent formulation and constant detailed Lewis numbers assumption. Then a new method of filling the thermochemical state and the source term in the mixture fraction and the process variable space also was proposed, namely the linear triangular dissection interpolation method, to predict the position of the hydrogen-rich micro-mixing flame front. Compared with the Fluent approach to establish the diffusion FGM flamelet, the results showed that the two FGMs have similar flame predictions in high hydrogen content fuels, and both can accurately capture the location of the internal and external shear layer boundaries of the micro-mixing multi-jet flame in the steady state, while the Fluent approach based on the uniform Lewis number assumption predicts results that deviated significantly from the experimental results. However, for the internal shear layer, both methods have large predicted OH gradients compared to the experimental results due to the lack of effective Lewis number correction for the control variable transport equation. The results using linear triangular dissection interpolation maybe superior to the method with linear interpolation of the process variable quenching boundary toward zero, which leads to flashback due to overestimation of the process variable source term in the region below the diffusion FGM quenching boundary.     

Combustion efficiency measurements and burner characterization in a hydrogen-oxyfuel combustor

Energy generation from renewable sources in the power sector keeps constantly increasing. This raises the demand for fast and flexible large-scale storage technologies. Steam generation via stoichiometric combustion of hydrogen and oxygen within a steam cycle is a promising way to recombine both gases, which can be generated by electrolysis utilizing excess renewable energy. At the same time, this technology could provide balancing and spinning network reserves. A crucial parameter of this approach is the combustion efficiency, since residual hydrogen or oxygen can damage downstream components of the power plant steam cycle. The current paper investigates the combustion of hydrogen and oxygen under steam diluted conditions. Flow field, mixing, flame types and combustion efficiency are assessed. The combustion efficiency measurement is very challenging in this case, as the combustor products consist mostly of pure steam and cannot be dried for conventional gas analysis. This is solved by an in-situ measurement method to quantify the combustion efficiency. Initial results of this approach are also presented in the current work.     

Stabilization regimes and pollutant emissions from a dual fuel CH4/H2 and dual swirl low NOx burner

Burning hydrogen in gas turbines is a relevant technological solution to decarbonize power production and propulsion systems. However, ensuring low NOx emission and preventing flashback can be challenging with hydrogen. Stabilization regimes and pollutant emissions from partially premixed CH₄/H₂/air flames above a coaxial Dual Fuel Dual Swirl injector are investigated in a laboratory-scale combustor at atmospheric conditions for increasing hydrogen contents. The injector consists of an external annular swirler providing premixed methane/air and a central channel fed with pure hydrogen. This burner virtually removes the risk of flashback due to the late injection of hydrogen. Flame stabilization regimes, CO and NOx emissions are analyzed for different configurations of the injector and operating points. The effect of swirling the hydrogen stream is investigated together with the influence of the hydrogen injector recess, i.e. its nozzle position with respect to the backplane of the combustion chamber. It is shown that swirling the central hydrogen stream favors aerodynamically stabilized flames resulting in a low thermal stress on the injector and limited NOx emissions. The study also highlights that a small recess of the central hydrogen injector widely extends the operability range of the burner with aerodynamically stabilized flames. With a sufficient inner swirl and a small recess, flames detach from the injector rim when the hydrogen bulk velocity is large enough. In this configuration, it is found that NOx emissions remain low even for operation with pure hydrogen. Moreover, NOx emissions decrease when increasing the thermal power for a fixed equivalence ratio.     

Experimental and numerical studies on the premixed syngas swirl flames in a model combustor

Experimental and numerical investigations were performed to study the combustion characteristics of synthesis gas (syngas) under premixed swirling flame mode. Four different type of syngases, ranging from low to high H₂ content were tested and simulated. The global flame structures and post emission results were obtained from experimental work, providing the basis of validation for simulations using flamelet generated manifold (FGM) modelling approach via a commercial computational fluid dynamic software. The FGM method was shown to provide reasonable agreement with experimental result, in particular the post-exhaust emissions and global flame shapes. Subsequently, the FGM method was adopted to model the flame structure and predict the radical species in the reaction zones. Simulation result shows that H₂-enriched syngas has lower peak flame temperature with lesser NO species formed in the reaction zone.