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TRANSCRIPT
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Outline
Challenges faced by todays combustor designers Alternative strategies available to address the
challenges
Announcing Energico Summary
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RD software enables virtual experimentation RDs software allows designers to visualize the effects of
chemistry on their engine designs Chemistry simulation can help determine key parameters that
can affect efficiency and emissions Exclusive developer and licensor of CHEMKIN
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The Combustor Designers Dilemma
Cost of Experiments Mechanism Size CFD Complexity Cost of Design Mistakes Design Complexity Fuel Options
Emissions Regulations Fuel Consumption Design Cycle Time Design Resources
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Global Issues Driving Change
Low Emissions Regulations ICAO limits on nitrogen oxide (NOx), carbon monoxide (CO)
and Unburned Hydrocarbons New Soot/Particulate emissions regulations for commercial
aircraft in airports Fuel Flexibility
Alternative Fuels Opportunity Fuels Biofuels for carbon
dioxide (CO2) reduction
International Civil Aviation Organization NOx Limits
2012 (Proposed)
2009
2006 2003
Certification Test Data
(Engine Size)
Source: ICAO Colloquium on Aviation Emissions, May, 2007
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While Testing Costs Keep Going Up
Example: 250 MW Turbine
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Syngas from Integrated Gasification Combined Cycle (IGCC)
Opportunity Fuels Blast Furnace Gas Landfill Gas
Coal-derived, F-T fuels Bio-fuels
High in methyl esters Sources differ regionally and
are changing Oil-sand derived fuels
High in aromatics
Diverse Fuel Sources Add Risk to Design
Syngas and Fischer-Tropsch
Bio-Diesel
Biomass and Waste Fuels
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Design Changes Introduce Risk to Combustor Stability Lean-premixed combustion with low
flame temperature slows burn rates Lean Blow Off (LBO) when mixing
overpowers burning Flashback in premixed systems when
flow velocity is less than flame velocity Ignition more difficult with lean mixtures
Opportunity fuels can have inconsistent composition and flow rate Fuel composition impacts stability Combustor experiences transient conditions
with rapid load changes
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Today, Designers Use CFD and Extensive Physical Testing
Computational Fluid Dynamics Geometry resolution 3-D flow field representation Accurate prediction of mass flows Accurate heat transfer Simplified chemistry
Performance and emission requirements drive combustor testing 10-20 tests per typical combustor design $50k-200k per test in a physical prototype
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Detailed Chemistry Drives Accurate Simulation Traditional CFD and empirical approaches do not
accurately predict emissions and stability
NOx Under Predicted by CFD CO Over Predicted by CFD
Measured
Measured
NOx NOx
NOx NOx NOx NOx NOx NOx
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Designers Say They Need:
Fewer, better directed experiments
The ability to simulate conditions that cannot be experimentally tested
A way to complete rapid evaluations of fuel and operating condition effects
An accurate applications engineering tool for combustion stability assessment
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Equivalent Reactor Networks (ERNs) are Being Used to Abstract the Chemistry
Air Pre-mixed Fuel + Air
Mixing
Flame
Recirculation Post-flame
Equivalent Reactor Network
Air
Benefits of ERNs ERNs use detailed chemistry to accurately simulate pollutant emissions ERNs can identify regions where emissions are formed
Drawbacks of ERNs Can takes expert >1 month to create by hand Difficult to map results back onto combustor geometry
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Energico Adds Chemistry to the Design Flow
3-D CFD Solution
Automatically create ERN
Map chemistry results onto geometry view
Map chemistry results onto geometry view
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Combustor Flow Field Automatically Divided Into Zones
Zone creation algorithm eliminates manual analysis and errors
Designer can easily adjust and refine the algorithm to capture flow/flame structures
Energico accurately tracks all flows to stitch together the zones into an ERN
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Instant Equivalent Reactor Networks
Automation supports commercial design timelines Creates ERNs in minutes rather than months Enables widespread use by combustor designers
Accurately follows specific set of rules Correct-by-Construction
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Viewing ERN Results on Combustor Geometry Facilitates Design Modifications
NOx Production
CO Concentrations
Identify where NOx emissions are formed
Identify where CO emissions are quenched
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Assess Lean Blow Off (LBO)
Capture the flame Conduct detailed
chemistry analysis locally in flame Chemistry rate from
reaction mechanism Mixing rate from CFD
Determine how close flame is to LBO
Visualize flame within geometry to guide design modifications
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Energico has Completed a Rigorous Validation Program on Real Turbine Designs RD conducted extensive internal benchmarking with
designs supplied from industry prior to release Three major gas turbine manufacturers involved in
Program Mitsubishi Heavy Industries Kawasaki Heavy Industries Large United States manufacturer
Over 60% of power generation gas turbine market represented by validators
Program included validation of Energico on well understood designs Emissions predictions Lean Blow Off assessments
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Mitsubishi Heavy Industries
MHI is the largest gas turbine manufacturer in Japan
Energico Validation Summary: Energico predicted emissions well
within a 5% margin on natural gas Test cases on 25ppm NOx and less than 10ppm NOx cases Focused LBO testing on both fundamental experiments and
large scale combustor tests MHI Turbine Business Division Manager:
Energico can help MHI reduce costly and time consuming experimental testing
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Kawasaki Heavy Industries
Mid-size engine range up to 25MW Energico Validation Summary:
Test cases focused on a parametric variation of fuel/air ratio in production combustor
Emissions of NOx and CO predicted within 5% of experimental data
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US-based Gas Turbine Manufacturer
50MW to 400MW turbine systems Energico Validation Results:
Compared emissions results from experiments to Energico
Emissions for NOx and CO within 1ppm of experimental data
Fuel impacts on emissions predicted (syngas from IGCC)
LBO tool provides new data for effective simulation Team Leader, Combustor Simulation:
Energico is clearly superior to CFD for accurate emissions results
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Sample Energico Validation Results
Class of Combustor (all CO less than 10ppm) Fuel Type
NO Variance
CO Variance
10MW Less than 10ppm NOx Natural Gas 1ppm 2ppm
25MW 25ppm NOx Natural Gas 2ppm 2ppm
250MW Less than 10ppm NOx Natural Gas 1ppm 2ppm
250MW 25ppm NOx Natural Gas 2ppm 2ppm
250MW 25ppm NOx Syngas 2ppm 2ppm
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ENERGICO: Revolutionary Simulation Package
Mechanisms become more
detailed to capture required effects
Combustor designs are becoming
more complex
Sustainable fuels
introduce combustion uncertainty
Mechanisms become more
detailed to capture required effects
Mechanisms become more
Combustor designs are becoming
more complexmore complex
Mechanisms become more
Sustainable fuels
introduce combustion combustion uncertaintyuncertaintyuncertaintyuncertainty
Current Industry Concerns
Reduced Need for Physical Engine Testing Ability to take Advantage of Opportunity Fuels Increased Speed-to-Market for New Designs Reduced Field Failures with Capability to Accurately Simulate Emissions and LBO
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