7. low nox flameless combustion for jet engines and gas turbines, technion, israel

7/28/2019 7. Low NOx Flameless Combustion for Jet Engines and Gas Turbines, Technion, Israel

1/42

Turbo and Jet

Engine Laboratory

Technion Israel

9th Israeli Symposium on Jet

Engines and Gas Turbines,

October 7 2010,

Technion, Istarel

www. jet-engine-lab.technion.ac.il1

"Low NOx Flameless Combustion

for Jet Engines and Gas turbines"Yeshayahou Levy

Technion - ISRAEL

http://jet-engine-lab.technion.ac.il

9th

Israeli Symposium on Jet Engines and Gas Turbines

October 7 2010, Technion, Istarel

Dr. Valery Sherbaum, Technion

Dr. Vitali Ovcherenko, Technion

Dr. Vladimir Erenburg, TechnionDr. Igor Geisinski, Technion

Mr. Josef Shemenson

, Technion

Dr. Arvind

Rao, Delft, The Netherlands

Prof. Mario Costa, IST, PortugalProf. Farid

C. Christo, The University of South, Australia

MY THANKS TO ALL CONTRIBUTORS:


2/42

Turbo and Jet

Engine Laboratory

Technion Israel



October 7 2010,

Technion, Istarel


Noise (dB)Nox, CO, UHC

(%)Fuel

Consumption

(%)

Maintanance

Cost (%)

2025

2015present

0

10

20

30

40

50

60

70

80

90

100

2025

2015

present

NOx, CO & UHC emissions are to be reduced by 70% by year2015 and 80% by year 2025

Fuel Consumption & CO2

emission to be cut by 15% by year 2015

and 25% by year 2025

Anticipated Future Projections of

Engine performance


3/42

Turbo and Jet

Engine Laboratory

Technion Israel



October 7 2010,

Technion, Istarel


NOx Formation in Combustor

Conventional combustion process

Primary zone (2500K)

Dilution zone (TET=1600K)

Formation (simplified) pathways:

Thermal (>1800K)

O2 2ON2 + O NO + N

N + O2 NO + O

Prompt (CH, HCN,..)

Fuel-nitrogen (bound N)

CONVENTIONAL COMBUSTOR

NOx FORMATION REGION


4/42

Turbo and Jet

Engine Laboratory

Technion Israel



October 7 2010,

Technion, Istarel


T

X

400

C

2200

C

1300

C

1500

C

No NOxproduction

flameless

conventional

THE CONCEPT OF FLAMELESS GAS TURBINE

COMBUSTOR


5/42

Turbo and Jet

Engine Laboratory

Technion Israel



October 7 2010,

Technion, Istarel


Flameless Combustion

Different Combustion Regimes (Milani

& Saponaro, Diluted

Combustion Technologies,IFRF Combustion Journal, 2001)

CHARACTERISTICS

Recirculation of combustion productsat high temperature (> 1000C)

Reduced oxygen concentration at the

reactance

Highly transparent flame with low

acoustic oscillation

Distributed combustion zone

Uniform temperature distribution

Reduced temperature peaks

Low adiabatic flame temperature

High concentration of CO2

& H2

O

Lower Damkhler number

Low NOx and CO emission

LARGE VOLUME

% O2

% (N2

+CO2+H2O)

Observed

Experimental

Temperature

Distribution

Plessing

et al., 1998

REGULAR FLAMELESS

FLAMELESS OXIDATION METHOD FOR NOx

REDUCTION


6/42

Turbo and Jet

Engine Laboratory

Technion Israel



October 7 2010,

Technion, Istarel


FLAMELESS COMBUSTION PRINCIPLE

Conventional Combustor

High Peak Temperature

Thin reaction zone

High TemperatureGradients

High NOx production

Gas

Air

Low NOx Combustor

Low temperature peak Distributed flame

Temperature

Uniformity

Low NOx production

Gas

Air

Texit

Texit


7/42

Turbo and Jet

Engine Laboratory

Technion Israel



October 7 2010,

Technion, Istarel


FLAMELESS OXIDATION IN FURNACES AND

GAS TURBINE.

Heat extraction

Main combustion(flameless

oxidation)

Inlet Exhaust

0-5% O2

Industrial Furnace

Main

combustion

Inlet

Exhaust

14-18% O2

Gas Turbine

FLAMELESS OXIDATION IN FURNACES

?


8/42

Turbo and Jet

Engine Laboratory

Technion Israel



October 7 2010,

Technion, Istarel


IMPLEMENTATION OF FLOXCOM METHOD

IN GAS TURBINES

CONVENTIONAL GAS TURBINE

GAS TURBINE WITH THE FLOXCOM COMBUSTOR

5

3

2

1

6

4

3


9/42

Turbo and Jet

Engine Laboratory

Technion Israel



October 7 2010,

Technion, Istarel


INDICATIONS OF INCOMPLETE COMBUSTION

CFD SIMULATIONS

(Farid C. Christo, The University of South Australia)


10/42

Turbo and Jet

Engine Laboratory

Technion Israel



October 7 2010,

Technion, Istarel


Diluting air Stirring air

A 600

MODEL OF THE COMBUSTOR SHOWING

STIRRING AND DILUTING AIR INLET HOLES

OPTIONAL AIR INLETS MODIFICATIONS


11/42

Turbo and Jet

Engine Laboratory

Technion Israel



October 7 2010,

Technion, Istarel


SECTOR COMBUSTOR -

FULLY

ASSSEMBELED


12/42

Turbo and Jet

Engine Laboratory

Technion Israel



October 7 2010,

Technion, Istarel


OPERATING TEST RIG AT IST, PORTUGAL

PHASE I


13/42

Turbo and Jet

Engine Laboratory

Technion Israel



October 7 2010,

Technion, Istarel


COMBUSTION TESTS


14/42

Turbo and Jet

Engine Laboratory

Technion Israel



October 7 2010,

Technion, Istarel


72

66

60

54

48

42

36

30

24

18

12

6

0

10 m/s

k (m2s

-2)

A22SHI

A23SHI

A24SHI

A21SHI

4

4

MEAN VELOCITY VECTORS AND TURBULENT

KINETIC ENERGY FIELDS AT THE

MEASUREMENTS AT SYMMETRY PLANE INSIDE THE COMBUSTION CHAMBER

PRIMARY ZONE


15/42

Turbo and Jet

Engine Laboratory

Technion Israel



October 7 2010,

Technion, Istarel


CONTOURS OF

TEMPERATURE AND O2,

CO, NOX, HC, AND CO2 CONCENTRATIONS

MEASUREMENTS

PERFORMED ATTHE SYMMETRY

PLANE

(IST PORTUGAL)


16/42

Turbo and Jet

Engine Laboratory

Technion Israel



October 7 2010,

Technion, Istarel


HIGH PRESSURE FLOXCOM TEST RIG AT

ANSALDO BARI


17/42

Turbo and Jet

Engine Laboratory

Technion Israel



October 7 2010,

Technion, Istarel


EMISSION TEST DIAGRAM AT 2.5 BARS (abs.),

NO AND NO2 Vs. THE EXCESS AIR PARAMETER

0

2

4

6

8

10

12

14

16

18

20

2.5 2.7 2.9 3.1 3.3 3.5 3.7 3.9 4.1

ppm

0

200

400

600

800

1000

1200

1400

1600

1800

2000

ppm

NOx

NO

CO


18/42

Turbo and Jet

Engine Laboratory

Technion Israel



October 7 2010,

Technion, Istarel


EFFECT OF GEOMETRICAL

VARIATIONS

Config.

Air inlet (total = 14 holes

2 sections)

Left inlet Right inlet

A oooooooooooo oo oooooooooooooo

B ooooooo ooooooo

C oooooooooooooo

D ooooooo

P=1 bar (abs)

Q= 4KW(24 KW complete section)

PRELIMINARY DESIGN MODIFICATIONS

Config. A: ;

;

;

NOxNOxNOxNOx

Config. B:

Config. C:

;Config. D:

0.0

2.5

5.0

7.5

10.0

12.5

15.0

17.5

0.2 0.25 0.3 0.35 0.4 0.45 0.5 0.55 0.6 0.65

20.0

92

93

94

95

96

97

98

99

100

Combustio

nefficiency(%)

NOx

(dryvolu

meppm@1

5%O2)

g

NOx

COMBUSTION EFFICIENCY


19/42

Turbo and Jet

Engine Laboratory

Technion Israel



October 7 2010,

Technion, Istarel


EFFECT OF FUEL COMPOSITION

(COMBUSTION OF SYNGAS)

P=1 bar (abs)

Q= 8KW

(48 KW complete section)

94321Fuel mixture

39.27681.991100CH4

43.32418.190H2

17.50000CO2

18.7029.7931.2733.5535.80LHV (MJ/Nm3)

19231965196119561952Tad (C)


20/42

Turbo and Jet

Engine Laboratory

Technion Israel



October 7 2010,

Technion, Istarel


FLOXCOM COMBUSTOR HAS LARGE STABLE OPERATIONAL

RANGE.

NOx EMISSION IS LOW AS EXPECTED.

COAND UHCARE MODERATE, DESIGN MODIFICATION IS ARE

REQUIRED

BASIC STUDY IS NEEDED TO FILL GAPS

INTERMEDIATE CONCLUSION

2nd PHASE OF THE STUDY:


21/42

Turbo and Jet

Engine Laboratory

Technion Israel



October 7 2010,

Technion, Istarel


New design for

Aero-engine

Heat extraction

Main

combustionInlet

Exhaust

5-8 % O2

MODIFIED FLAMELESS COMBUSTOR WITH

INTERNAL HEAT EXCHANGER.

ADVANTEGEOUS:

COOLER FLAME

NEED FOR LOWER

RECIRCULATION RATIO

21 %

O2

Main

combustionInlet Exhaust

14-18% O2

Conventional Flameless for Gas

Turbine


22/42

Turbo and Jet

Engine Laboratory

Technion Israel



October 7 2010,

Technion, Istarel


HEAT AND FLOW DIAGRAM -

MODIFIED FLAMELESS COMBUSTOR.

2 3

1

Heat exchanger

5

4

x Junction

Primary Air

Secondary Air

Inlet ExitRecirculation Zone

Main Combustion

Pre-combustion

2 3

1

Heat exchanger

5

4

x Junction

Primary Air

Inlet Exit

Main Combustion

Pre-combustion

Fuel


23/42

Turbo and Jet

Engine Laboratory

Technion Israel



October 7 2010,

Technion, Istarel


THE HEAT TARNSFER MECHANISM

)(

USING OPTIMAL CONFIGURATION,

COMBUSTION TEMPERATURE MAY BE

REDUCED BY AS MUCH AS 170 C !


24/42

Turbo and Jet

Engine Laboratory

Technion Israel



October 7 2010,

Technion, Istarel

www. jet-engine-lab.technion.ac.il24SINGLE JET STUDY

SINGLE JET FLAMELESS COMBUSTOR


25/42

Turbo and Jet

Engine Laboratory

Technion Israel



October 7 2010,

Technion, Istarel


DIFFUSION

FLAMELESS


26/42

Turbo and Jet

Engine Laboratory

Technion Israel



October 7 2010,

Technion, Istarel


CFD SIMULATIONS -

TECHNION

COMBUSTION CHAMBER WITH 16 FUEL INLET

AIR

INLET

CH4

Air

Cyclic

Surfac

e

MESH FOR 1/16

SECTOR

GASEOUSEFUEL INLETS


27/42

Turbo and Jet

Engine Laboratory

Technion Israel



October 7 2010,

Technion, Istarel


TEMPERATURE DISTRIBUTION

TEMPERATURE

DISTRIBUTION

~1800K


28/42

Turbo and Jet

Engine Laboratory

Technion Israel



October 7 2010,

Technion, Istarel


VELOCITY FIELD AT THE CENTER LINE

CROSS-SECTION

| | | | | | | |

0 25 50

75

mm

To outlet

CH4

inlet

Air inlet


29/42

Turbo and Jet

Engine Laboratory

Technion Israel



October 7 2010,

Technion, Istarel


To outlet

Vz - VELOCITY COMPONENT'S DISTRIBUTION

RECIRCULATION REGION


30/42

Turbo and Jet

Engine Laboratory

Technion Israel



October 7 2010,

Technion, Istarel


TEMPERATURE DISTRIBUTION

(NEAR NOZZLE REGION)

| | | | |

| |

0 3 6 9 12 mm

DIFFUSION REGION

FUEL ENTRAINMENT

NO mass-fraction distribution

Temperature distribution

Preliminary NO predictions

NO level

5 ppm

0


31/42

Turbo and Jet

Engine Laboratory

Technion Israel



October 7 2010,

Technion, Istarel


experiment

T K

simulation

COMPARISON

CFD SIMULATIONS -

EXPERIMENT

THERE IS STILL

ROOM FOR

IMPROVEMENTS

IN THE

MODELING


32/42

Turbo and Jet

Engine Laboratory

Technion Israel



October 7 2010,

Technion, Istarel


-10x10-601630-Exp. data

1.60.76x10-62.5x10-12 016802190Flux = -25kW/m21.64.4x10

-6

3.3x10-12

017602290Flux = -15kW/m2

1.646x10-68.6x10-12 019002460Adiabatic

Krecirc.NOexitCOexitTexit

, KTmax

, KRegime

COMPARISON OF SIMULATION AND

TEST RESULTS

INCORPORATION OFHEAT LOSS IN THE

MODELING IMPROVED

RESULTS


33/42

Turbo and Jet

Engine Laboratory

Technion Israel



October 7 2010,

Technion, Istarel


summary

Basic modeling of the FLOXCOM combustion methodwas complete. Detailed investigation into internal mixing and enhancedwall heat transfer is currently being performed.

CFD modeling of Jet Flame configuration coupled with

experimental result seems to present an efficient tool togain practical knowledge.

Final integration stage is still needed for an engineeringflameless combustion design


34/42

Turbo and Jet

Engine Laboratory

Technion Israel



October 7 2010,

Technion, Istarel


INCORPORATION OF MODIFIED COMBUSTOR

IN A TURBO-FAN ENGINE.

c

c

1

9'9' n ' pc 07'

07'

PU 2 C T 1

P

GE-90

35


35/42

Turbo and Jet

Engine Laboratory

Technion Israel



October 7 2010,

Technion, Istarel


Pollutant Reduction Problem

Compromises involved withconventional combustors:

Emitted species

Flame stability

Cycle efficiency

Need for alternativecombustion conceptsLOW-EMISSION WINDOW

Wulff and Hourmouziadis, 1997

35

LOWER STABILITY LIMIT


36/42

Turbo and Jet

Engine Laboratory

Technion Israel



October 7 2010,

Technion, Istarel


COMBUSTION IN HOT VITIATED AIR

Stability limits -SchematicAfter

Wunning

and Wunning, 1997

Observed Experimental

Temperature DistributionPlessing et al., 1998

Flame

Stable and safe

combustion

Uniformly

distributed

temperature

Low-NOx emission


37/42

Turbo and Jet

Engine Laboratory

Technion Israel



October 7 2010,

Technion, Istarel


O2, CO2, H2O MOLE FRACTION AT THE

RECIRCULATION ZONE

0

24

68

1012

14

16

0 5 10 15 20 25

Oxygen mole fraction,%

Industrialfurnaces

Gas

turbinesII I

I

BEFORE COMBUSTION

(STIRRING AIR),

II

AFTER COMBUSTION,

CO2

,

H2

O.

IF GASES WITH LARGE

OXYGEN CONCENTRATION

ARE RECIRCULATED,HIGH ADIABATIC

TEMPERATURES ( AND

NOx) ARE OBTAINED


38/42

Turbo and Jet

Engine Laboratory

Technion Israel



October 7 2010,

Technion, Istarel


Recirculation Zone

InletExit

Recirculation Zone

Primary

air

Second

arya

ir

Se

condaryair

Mixing Zone

SCHEMATIC REPRESENTATION OF THE FLUID

FLOW WITHIN THE MODIFIED COMBUSTORS

Fuel Inlet

Fuel

Inlet

Exi

t

Composite

Metallic Fins

Secondary Air

Mixing holes


39/42

Turbo and Jet

Engine Laboratory

Technion Israel



October 7 2010,

Technion, Istarel


Known parameters and assumptions:Inlet air temperature T

a

Inlet mass flow rate ma

,

exit temperatures Te

100% combustion and mixing efficiency

calculated Values:

Air flow distribution: stirring air, mas,dilution air, madstirring gas, mas+mr

Temperature :

stirring gas, Tscombustion, Tc

Recirculation rate:

k

oxygen percentage in every stage of the cycle.

GLOBAL EVALUATION OF THE FLOXCOM COMBUSTORGLOBAL EVALUATION OF THE FLOXCOM COMBUSTOR


40/42

Turbo and Jet

Engine Laboratory

Technion Israel



October 7 2010,

Technion, Istarel


HIGH PRESSURE FLOXCOM TEST RIG

AT ANSALDO BARI


41/42

Turbo and Jet

Engine Laboratory

Technion Israel



October 7 2010,

Technion, Istarel


CROSS SECTION OF THE 360 DEGREES

MODEL OF THE FLOXCOM COMBUSTOR.

T1[ x3]

T2[ x3] [ x3]

T3

P1[ x3]

P1 - Pressure sensoresT1...T3 - Temperature Sensores

Air In Exhaust gases


42/42

Turbo and Jet

Engine Laboratory

Technion Israel



October 7 2010,

FLOXCOM RELATIVE

PERFORMANCE

ppm NOx

..........200

100..............

0

................

7. low nox flameless combustion for jet engines and gas turbines, technion, israel

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