An experimental study of mild flameless combustion of methane/hydrogen mixtures

This paper presents an experimental study of mild flameless combustion regime applied to methane/hydrogen mixtures in a laboratory-scale pilot furnace with or without air preheating. Results show that mild flameless combustion regime is achieved from pure methane to pure hydrogen whatever the CH₄/H₂ proportion. The main reaction zone remains lifted from the burner exit, in the mixing layer of fuel and air jets ensuring a large dilution correlated to low NOx emissions whereas CO₂ concentrations obviously decrease with hydrogen proportion. A decrease of NOx emissions is measured for larger quantity of hydrogen due mainly to the decrease of prompt NO formation. Without air preheating, a slight increase of the excess air ratio is required to control CO emissions. For pure hydrogen fuel without air preheating, mild flameless combustion regime leads to operating conditions close to a "zero emission furnace", with ultra-low NOx emissions and without any carbonated species emissions.     

The study of methods of NOx inhibition during fuel combustion at power plants with allowance for the use of hydrogen additions

The paper considers methods of NO_x inhibition by affecting the process of NO_x formation. The dependences for the degree of NO_x concentration reduction while intensifying the flame cooling, during water spray to the furnace, and while using flue gases recirculation as well as during fuel emulsification or nonstoichiometric fuel combustion have been obtained. The obtained formulas include a set of parameters which could affect the final value of NO_x concentration. The effect of a given factor could be evaluated on the basis of these dependencies. The calculated degrees of NO_x inhibition display good agreement with full-scale experimental data. The authors study the effect of NO_x concentration on ignition of the alternative hydrogen fuel during co-combustion in the furnace volume. The analysis of experimental data on hydrogen ignition delay in the presence of nitrogen oxides has been carried out. It is shown that depending on NO_x concentration, minimum ignition delay could occur, i.e. minimum effect of additives on the quality of alternative hydrogen fuel combustion may be allowable.The results of the study could be used for design engineering of power plants with the reduced NO_x environmental effect.     

Study on using hydrogen and ammonia as fuels: Combustion characteristics and NOx formation

This paper evaluates the potential of hydrogen (H₂) and ammonia (NH₃) as carbon‐free fuels. The combustion characteristics and NO_x formation in the combustion of H₂ and NH₃ at different air‐fuel equivalence ratios and initial H₂ concentrations in the fuel gas were experimentally studied. NH₃ burning velocity improved because of increased amounts of H₂ atom in flame with the addition of H₂. NH₃ burning velocity could be moderately improved and could be applied to the commercial gas engine together with H₂ as fuels. H₂ has an accelerant role in H₂–NH₃–air combustion, whereas NH₃ has a major effect on the maximum burning velocity of H₂–NH₃–air. In addition, fuel‐NO_x has a dominant role and thermal‐NO_x has a negligible role in H₂–NH₃–air combustion. Thermal‐NO_x decreases in H₂–NH₃–air combustion compared with pure H₂–air combustion. NO_x concentration reaches its maximum at stoichiometric combustion. Furthermore, H₂ is detected at an air‐fuel equivalence ratio of 1.00 for the decomposition of NH₃ in flame. Hence, the stoichiometric combustion of H₂ and NH₃ should be carefully considered in the practical utilization of H₂ and NH₃ as fuels. H₂ as fuel for improving burning performance with moderate burning velocity and NO_x emission enables the utilization of H₂ and NH₃ as promising fuels. Copyright © 2014 John Wiley & Sons, Ltd.     

Design and numerical analysis of a 3 kWe flameless microturbine combustor for hydrogen fuel

In this work, a new 3 kWe flameless combustor for hydrogen fuel is designed and analyzed using CFD simulation. The strategy of the design is to provide a large volumetric combustion for hydrogen fuel without significant rise of the temperature. The combustor initial dimensions and specification were obtained from practical design procedures, and then optimized using CFD simulations. A three-dimensional model for the designed combustor is constructed to further analysis of flameless hydrogen combustion and consideration that leads to disappearance of flame-front and flameless combustion. The key design parameters including aerodynamic, temperature at walls and flame, NO_X, pressure drop, combustion efficiency for the hydrogen flame is analyzed in the designed combustor. To well demonstrate the combustor, the NO_X and entropy destruction and finally energy conversion efficiency, and overall operability in the microturbine cycle of hydrogen flameless combustor is compared with a 3 kWe design counterpart for natural gas. The findings demonstrate that hydrogen flameless combustion is superior to derive the microturbines with significantly lower NO_X, and improvements in energy efficiency, and cycle overall efficiency with low wall temperatures guaranteeing the long-term operation of combustor and microturbine parts.     

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.     

Flameless combustion role in the mitigation of NOX emission: a review

Nitrogen oxide formation is one source of pollution emission in fossil fuel combustion. Numerous technologies, such as flameless combustion, have been introduced to prevent such formation. This paper presents a panorama of flameless combustion and its principles. The influence of this technology on air preheats and gas diluents is discussed, as well as the effect of the firing mode on thermal NO_X. The benefits of flameless combustion, including its energy conservation capability and capability to reduce pollutant emissions such as NO_X emission to overcome environmental dilemmas in combustion, are discussed in this paper. Copyright © 2014 John Wiley & Sons, Ltd.     

Experimental study on combustion of torrefied palm kernel shell (PKS) in oxy‐fuel environment

Oxy‐combustion of biomass can be a major candidate to achieve negative emission of CO₂ from a pulverized fuel (pf)‐firing power generation plants. Understanding combustion behavior of biomass fuels in oxy‐firing conditions is a key for design of oxy‐combustion retrofit of pulverized fuel power plant. This study aims to investigate a lab‐scale combustion behavior of torrefied palm kernel shell (PKS) in oxy‐combustion environments in comparison with the reference bituminous coal. A 20 kW_th‐scale, down‐firing furnace was used to conduct the experiments using both air (conventional) and O₂/CO₂ (30 vol% for O₂) as an oxidant. A bituminous coal (Sebuku coal) was also combusted in both air‐ and oxy‐firing condition with the same conditions of oxidizers and thermal heat inputs. Distributions of gas temperature, unburned carbon, and NO_x concentration were measured through sampling of gases and particles along axial directions. Moreover, the concentrations of SO_x and HCl were measured at the exit of the furnace. Experimental results showed that burnout rate was enhanced during oxy‐fuel combustion. The unburnt carbon in the flue gas was reduced considerably (~75%) during combustion of torrefied PKS in oxy‐fuel environment as compared with air‐firing condition. In addition, NO emission was reduced by 16.5% during combustion of PKS in oxy‐fuel environment as compared with air‐firing condition.     

Assessment of natural gas/hydrogen blends as an alternative fuel for industrial heat treatment furnaces

The present study investigates the application of natural gas/hydrogen blends as an alternative fuel for industrial heat treatment furnaces and their economic potential for decreasing carbon dioxide emissions in this field of application. Doing so, a detailed technological analysis of several influencing parameters on the heating system was performed as well as a consideration of furnace heating technology challenges. Starting with an evaluation of the main thermophysical properties of the blends and their corresponding flue gases, requirements for the heating systems were identified. Potential ways of decreasing flue gas losses and increasing the heat transfer are shown. In the radiant tube application, an increased overall combustion efficiency of about 1.2% was measured at 40 vol% hydrogen in the fuel gas. Influences on the air to gas ratio control system of the furnace is a further important point, which was considered in this study. Two commonly used control systems were evaluated concerning their capabilities to regulate the gas flow rates of blends with varying hydrogen contents and combustion properties, such as Wobbe Index. This is important, since it shows the capability to retrofit existing furnaces. Two types of burners were tested with different natural gas/hydrogen blends. This includes an open jet burner with air-staged and flameless combustion operation modes. A recuperative burner for radiant tube application was considered as well in these tests. Doing so, the nitrogen oxide formation of both systems under different operating conditions and different fuel blends were evaluated. An increase by about 10% at air-staged combustion and about 100% at flameless combustion was measured by a hydrogen content of 40 vol% in comparison to pure natural gas firing. Finally, the additional fuel costs of natural gas hydrogen blends and different cases are presented in an economic analysis. The driving force for the use of hydrogen as a fuel is the price of the CO2 certificates, which are considered in the analysis at a current price of 25.2 €/t CO2.     

Reactive structures and NOx emissions of methane/hydrogen mixtures in flameless combustion

Methane/hydrogen combustion represents a concrete solution for the energy scenario to come. Indeed, the addition of hydrogen into the natural gas pipeline is one of the solutions foreseen to reduce CO₂ emissions. Nevertheless, the replacement of methane by hydrogen will enhance the reactivity of the system, increasing NOx emissions. To overcome this issue, non-conventional combustion technologies, such as flameless combustion represent an attractive solution. This study aims to improve our understanding of the behaviour of methane/hydrogen blends under flameless conditions by means of experiments and simulations. Several experimental campaigns were conducted to test fuel flexibility for different methane/hydrogen blends, varying the injector geometries, equivalence ratio and dilution degree. It was found that a progressive addition of hydrogen in methane enhanced the combustion features, reducing the ignition delay time and loosing progressively the flameless behaviour of the furnace. Reducing the air injector diameter or increasing the fuel lance length were found to be efficient techniques to reduce the maximum temperature of the system and NOx emissions in the exhausts, reaching values below 30 ppm for pure hydrogen. MILD conditions were achieved up to 75%H₂ in molar fraction, with no visible flame structures. Additionally, RANS-based simulations were also conducted to shed further light on the effect of adding hydrogen into the fuel blend. A sensitivity study was conducted for three different fuel blends: pure methane, an equimolar blend and pure hydrogen. The effect of chemistry detail, mixing models, radiation modeling and turbulence models on in-flame temperatures and NOx emissions was also studied. In particular, it was found that the usage of detailed chemistry for NOx, coupled with an adjustment of the PaSR model, filled the gap between experiments and predictions. Finally, a brute-force sensitivity revealed that NNH is the most important route for NOx production.     

A computational study on the combustion of hydrogen/methane blended fuels for a micro gas turbines

To understand the combustion performance of using hydrogen/methane blended fuels for a micro gas turbine that was originally designed as a natural gas fueled engine, the combustion characteristics of a can combustor has been modeled and the effects of hydrogen addition were investigated. The simulations were performed with three-dimensional compressible k-ε turbulent flow model and presumed probability density function for chemical reaction. The combustion and emission characteristics with a variable volumetric fraction of hydrogen from 0% to 90% were studied. As hydrogen is substituted for methane at a fixed fuel injection velocity, the flame temperatures become higher, but lower fuel flow rate and heat input at higher hydrogen substitution percentages cause a power shortage. To apply the blended fuels at a constant fuel flow rate, the flame temperatures are increased with increasing hydrogen percentages. This will benefit the performance of gas turbine, but the cooling and the NO_x emissions are the primary concerns. While fixing a certain heat input to the engine with blended fuels, wider but shorter flames at higher hydrogen percentages are found, but the substantial increase of CO emission indicates a decrease in combustion efficiency. Further modifications including fuel injection and cooling strategies are needed for the micro gas turbine engine with hydrogen/methane blended fuel as an alternative.     

Impact of injection conditions on flame characteristics from a parallel multi-jet burner

This numerical study systematically investigates the influence of initial injection conditions of reactants on flame characteristics from a parallel multi-jet burner in a laboratory-scale furnace. In particular, varying characteristics from visible flame to invisible Moderate or Intense Low-oxygen Dilution (MILD) combustion is explored. Different parameters examined include the initial separation of fuel and air streams (S), air nozzle diameter (D_a), fuel nozzle diameter (D_f), and air preheat temperature (T_a). The present simulations agree qualitatively well with previous measurements reported elsewhere for two reference cases investigated by experiment. A number of new and significant findings are then deduced from the simulations. For instance, all S, D_a and D_f are found to play significant roles in achieving a proper confluence location of air and fuel jets for establishing the MILD combustion. Particularly, varying D_a is most effective for controlling the combustion characteristics. It is also found that the stability limits of the non-premixed MILD combustion varies with different combustor systems and inlet reactant properties. Moreover, for the first time, several analytical approximations are obtained that relate the flue-gas recirculation rate and the fuel-jet penetration to D_a, D_f, S and also reactant properties.     

Flameless combustion for hydrogen containing fuels

In this paper, flameless combustion was promoted to suppress thermal-NO_x formation in the hydrogen-high-containing fuel combustion. The PSRN model was used to model the flameless combustion in the air for four fuels: H₂/CH₄ 60/40% (by volume), H₂/CH₄ 40/60%, H₂/CH₄ 20/80% and pure hydrogen. The results show that the NO_x emissions below 30 ppmv while CO emissions are under 50 ppmv, which are coincident with the experimental data in the “clean flameless combustion” regime for all the four fuels. The simulation also reveals that CO decreases from 48 ppmv to nearly zero when the hydrogen composition varies from 40% to 100%, but the NO_x emission is not sensitive to the hydrogen composition. In the highly diluted case, the NO_x and CO emissions do not depend on the entrainment ratio.     

The effect of hydrogen injection parameters on the quality of hydrogen–air mixture formation for a PFI hydrogen internal combustion engine

To research the quality of the hydrogen–air mixture formation and the combustion characteristics of the hydrogen fueled engine under different hydrogen injection timings, nozzle hole positions and nozzle hole diameter, a three-dimensional simulation model for a PFI hydrogen internal combustion engine with the inlet, outlet, valves and cylinder was established using AVL Fire software. In the maximum torque condition, research focused on the variation law of the total hydrogen mass in the cylinder and inlet and the space distribution characteristics and variation law of velocity field, concentration field and turbulent kinetic energy under different hydrogen injection parameters (injection timings, nozzle hole positions and nozzle hole area) in order to reveal the influence of these parameters on hydrogen–air mixture formation process. Then the formation quality of hydrogen–air mixture was comprehensively evaluated according to the mixture uniformity coefficient, the remnant hydrogen percentage in the inlet and restraining abnormal combustion (such as preignition and backfire). The results showed that the three hydrogen injection parameters have important influence on the forming quality of hydrogen–air mixture and combustion state. The reasonable choice of the nozzle hole position of hydrogen, nozzle hole diameter and the hydrogen injection time can improve the uniformity of the hydrogen–air mixing in the cylinder of the hydrogen internal combustion engine, and the combustion heat release reaction is more reasonable. At the end of the compression stroke, the equivalence ratio uniform coefficient increased at first and then decreased with the beginning of the hydrogen injection. When hydrogen injection starting point was with 410–430°CA, equivalence ratio uniform coefficient was larger, and ignition delay period was shorter so that the combustion performance index was also good. And remnant hydrogen percentage in the inlet was less, high concentration of mixed gas in the vicinity of the inlet valve also gathered less, thus suppressing the preignition and backfire. With the increase of the distance between the nozzle and the inlet valve, the selection of the hydrogen injection period is narrowed, and the optimum hydrogen injection time was also ahead of time. The results also showed that it was favorable for the formation of uniform mixing gas when the nozzle hole diameter was 4 mm.     

Modeling of combustion characteristics and NOx emission in highly preheated and diluted air combustion

The gas diffusion combustion in a regenerative furnace with highly preheated and diluted air has been numerically investigated in this paper. The highly preheated air combustion possesses high combustion intensity and high level temperature, but the NO_x emission also has an unwanted high level. Decreasing the oxygen concentration in the highly preheated air could decrease the NO_x emission and improve the uniformity of temperature distribution in the furnace. The combustion characteristics of highly preheated and diluted air combustion have been studied, including temperature distribution, soot formation, OH radical distribution, as well as NO_x emission. The influence of the preheated air temperature, the oxygen concentration, and the air diluent has also been investigated. The optimal combinations of the preheated air temperature and the oxygen concentration have been predicted in the case of flue gas recirculation, which could provide the highest possible temperature in the furnace while keeping the NO_x emission lower than the permitted value. © 1998 by John Wiley & Sons, Ltd.     

新型常温空气无焰燃烧实现技术及特性分析

在介绍了无焰燃烧思想及其常规蓄热式高温空气实现技术的基础上,重点介绍了本课题组发展的常温空气无焰燃烧技术,并对其进行了效率、环保、经济性、安全性和应用范围等特性分析,该技术不但完全保留了高温空气无焰燃烧技术相对于传统燃烧的优点,并且不需要复杂的预热系统和换向机构,避免了燃烧过程的脉动,适用于低排烟温度或含灰量较大排烟的燃料的直接燃烧,具有一定的技术优势和更广泛的应用范围。     

Frontiers in combustion techniques and burner designs for emissions control and CO2 capture: A review

The use of fossil fuel is expected to increase significantly by midcentury because of the large rise in the world energy demand despite the effective integration of renewable energies in the energy production sector. This increase, alongside with the development of stricter emission regulations, forced the manufacturers of combustion systems, especially gas turbines, to develop novel combustion techniques for the control of NO_x and CO₂ emissions, the latter being a greenhouse gas responsible for more than 60% to the global warming problem. The present review addresses different burner designs and combustion techniques for clean power production in gas turbines. Combustion and emission characteristics, flame instabilities, and solution techniques are presented, such as lean premixed air‐fuel (LPM) and premixed oxy‐fuel combustion techniques, and the combustor performance is compared for both cases. The fuel flexibility approach is also reviewed, as one of the combustion techniques for controlling emissions and reducing flame instabilities, focusing on the hydrogen‐enrichment and the integrated fuel‐flexible premixed oxy‐combustion approaches. State‐of‐the‐art burner designs for gas turbine combustion applications are reviewed in this study, including stagnation point reverse flow (SPRF) burner, dry low NO_x (DLN) and dry low‐emission (DLE) burners, EnVironmental burners (including EV, AEV, and SEV burners), perforated plate (PP) burner, and micromixer (MM) burner. Special emphasis is made on the MM combustor technology, as one of the most recent advances in gas turbines for stable premixed flame operation with wide turndown and effective control of NO_x emissions. Since the generation of pure oxygen is prerequisite to oxy‐combustion, oxygen‐separation membranes became of immense importance either for air separation for clean oxy‐combustion applications or for conversion/splitting of the effluent CO₂ into useful chemical and energy products. The different carbon‐capture technologies, along with the most recent carbon‐utilization approaches towards CO₂ emissions control, are also reviewed.     

Low-NOx combustors for hydrogen fueled aero engine

Against the background of increasing environmental concerns, analytical modelling and experimental tests on low-NO_x hydrogen combustors for aero engines have been conducted within the Euro-Québec Hydro-Hydrogen Pilot Project (EQHHPP). This project is jointly supported by the European Union and the Government of Québec. This is a four year program started in 1992; the objectives are to establish the NO_x reduction potential and to provide design guidelines for later development of real aero engine combustors. The paper discusses the findings from phase III.0–2 (demonstration phase) of this program (DASA Airbus, PWC, DASA, DASA MTU, DLR Final Report on the NO_x Reduction Concept EQHHPP Phase III.0–2 “Potential Use of Hydrogen in Air Propulsion”, December 1996).Various candidate fuel preparation concepts for lean hydrogen combustion with and without fuel/air premixing have been evaluated in a generic can type combustor at Pratt and Whitney Canada (PWC). Significant reduction in NO_x emissions at simulated representative engine conditions has been achieved. Two concepts were then selected for further investigation in a research type combustion chamber which represents a typical 60 ° sector of a modern annular combustor. A test rig has been built by MTU especially for these tests. Steady state testing is being performed at Daimler-Benz Aerospace. Further tests to study the transient behaviour have been conducted by United Technologies Research Centre (UTRC).In addition, kinetic modelling was performed at Deutsche Forschungsanstalt für Luft- und Raumfahrt (DLR) and PWC to provide a useful design tool for low-NO_x hydrogen combustors.     

Simulation of producer gas flameless combustion with fresh reactant diluted by hot flue gas

Flameless combustion is considered as a flexible and efficient combustion process for low heating value gas fuel. This paper presents numerical simulations of premixed flameless combustion using producer gas as a fuel. Different initial conditions of the premixed fresh reactant (air/fuel mixture) and dilution levels are taken into account for the investigation. The numerical simulations were investigated using a network of chemical reactor models with the detailed reaction mechanism of GRI‐Mech 3.0. A threshold dilution level for flameless combustion fuelled by producer gas was determined. The numerical results show that dilution of the fresh reactant with hot combustion products and initial fresh reactant temperature play important roles in flameless combustion formation and its auto‐ignition behaviour, rather than equivalence ratio of the fresh reactant. In the flameless combustion regime, temperature and chemical concentrations were reduced while chemical kinetics process was decelerated, resulting in delay of the auto‐ignition process.     

Numerical investigation into the structural characteristics of a hydrogen dual-swirl combustor with slight temperature rise combustion

For decades, hydrogen has been identified as the most promising potential fuel to replace fossil fuels. In order to fully implement it and to promote the rationality of the design of hydrogen combustion chamber structure, it is very essential to understand the hydrogen/air combustion mechanism based on structural variations. The structural characteristics of a novel dual-swirl burner for hydrogen-air non-premixed combustion was studied numerically in this study. The influences of air distributions, swirling directions and nozzle configurations of the dual-swirl burner were studied, and the combustion performance was evaluated from various aspects. The numerical results showed that there was a trade-off between lower total pressure loss and the risk of fusing when considering air distribution strategies. The co-rotating swirl burner exhibited better uniformity of temperature distribution at the downstream of the combustor. The multi jet orifices showed superior penetration depth than the circular seam. Efficient and stable combustion could be achieved, which was beneficial to improve gas turbine efficiency and stable operation.     

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.