Low NOx Flameless Combustion For Jet Engines and Gas Turbines, Technion, Israel

Turbo and Jet
Engine Laboratory
Technion Israel
9
th
Israeli Symposium on Jet
Engines and Gas Turbines,
October 7 2010,
Technion, Istarel
www. jet-engine-lab.technion.ac.il
1
"Low NOx Flameless Combustion
for Jet Engines and Gas turbines"
Yeshayahou Levy
Technion - ISRAEL
http://jet-engine-lab.technion.ac.il
9
th

Israeli Symposium on Jet Engines and Gas Turbines
October 7 2010, Technion, Istarel
Dr. Valery Sherbaum, Technion
Dr. Vitali Ovcherenko, Technion
Dr. Vladimir Erenburg, Technion
Dr. Igor Geisinski, Technion
Mr. Josef Shemenson

, Technion
Dr. Arvind

Rao, Delft, The Netherlands
Prof. Mario Costa, IST, Portugal
Prof. Farid

C. Christo, The University of South, Australia
MY THANKS TO ALL CONTRIBUTORS:
Turbo and Jet
Engine Laboratory
Technion Israel
9
th
October 7 2010,
Technion, Istarel
2
Noise (dB)
Nox, CO, UHC
(%)
Fuel
Consumption
(%)
Maintanance
Cost (%)
2025
2015
present
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 year
2015 and 80% by year 2025

Fuel Consumption & CO
2

emission to be cut by 15% by year 2015
and 25% by year 2025
Anticipated Future Projections of
Engine performance
Turbo and Jet
Engine Laboratory
Technion Israel
9
th
October 7 2010,
Technion, Istarel
3
NOx Formation in Combustor

Conventional combustion process

Primary zone (2500K)

Dilution zone (TET=1600K)

Formation (simplified) pathways:

Thermal (>1800K)
O2 <=> 2O
N2 + O <=-> NO + N
N + O2 <=> NO + O

Prompt (CH, HCN,..)

Fuel-nitrogen (bound N)
CONVENTIONAL COMBUSTOR
NOx FORMATION REGION
Turbo and Jet
Engine Laboratory
Technion Israel
9
th
October 7 2010,
Technion, Istarel
4
T
X
400

C
2200

C
1300

C
1500

C
No NOx
production
flameless
conventional
THE CONCEPT OF FLAMELESS GAS TURBINE
COMBUSTOR
Turbo and Jet
Engine Laboratory
Technion Israel
9
th
October 7 2010,
Technion, Istarel
5
Flameless Combustion
Different Combustion Regimes (Milani

& Saponaro, Diluted
Combustion Technologies, IFRF Combustion Journal, 2001)
CHARACTERISTICS

Recirculation of combustion products
at 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 CO
2

& H
2

O

Lower Damkhler number

Low NOx and CO emission

LARGE VOLUME
% O
2
% (N
2

+CO
2

+H
2

O)
Observed
Experimental
Temperature
Distribution
Plessing

et al., 1998
REGULAR FLAMELESS
FLAMELESS OXIDATION METHOD FOR NOx

REDUCTION
Turbo and Jet
Engine Laboratory
Technion Israel
9
th
October 7 2010,
Technion, Istarel
6
FLAMELESS COMBUSTION PRINCIPLE
Conventional Combustor

High Peak Temperature

Thin reaction zone

High Temperature
Gradients

High NOx production
Gas
Air
Low NOx Combustor

Low temperature peak

Distributed flame

Temperature
Uniformity

Low NOx production
Gas
Air
T
exit
T
exit
Turbo and Jet
Engine Laboratory
Technion Israel
9
th
October 7 2010,
Technion, Istarel
7
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
?
Turbo and Jet
Engine Laboratory
Technion Israel
9
th
October 7 2010,
Technion, Istarel
8
IMPLEMENTATION OF FLOXCOM METHOD
IN GAS TURBINES
CONVENTIONAL GAS TURBINE
GAS TURBINE WITH THE FLOXCOM COMBUSTOR
5
3
2
1
6
4
3
Turbo and Jet
Engine Laboratory
Technion Israel
9
th
October 7 2010,
Technion, Istarel
9
INDICATIONS OF INCOMPLETE COMBUSTION
CFD SIMULATIONS
(Farid C. Christo, The University of South Australia)
Turbo and Jet
Engine Laboratory
Technion Israel
9
th
October 7 2010,
Technion, Istarel
10
Diluting air
Stirring air
A 60
0

MODEL OF THE COMBUSTOR SHOWING
STIRRING AND DILUTING AIR INLET HOLES
OPTIONAL AIR INLETS MODIFICATIONS
Turbo and Jet
Engine Laboratory
Technion Israel
9
th
October 7 2010,
Technion, Istarel
11
SECTOR COMBUSTOR -

FULLY

ASSSEMBELED
Turbo and Jet
Engine Laboratory
Technion Israel
9
th
October 7 2010,
Technion, Istarel
12
OPERATING TEST RIG AT IST, PORTUGAL
PHASE I
Turbo and Jet
Engine Laboratory
Technion Israel
9
th
October 7 2010,
Technion, Istarel
13
COMBUSTION TESTS
Turbo and Jet
Engine Laboratory
Technion Israel
9
th
October 7 2010,
Technion, Istarel
14
72
66
60
54
48
42
36
30
24
18
12
6
0
10 m/s
k (m
2
s
-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
Turbo and Jet
Engine Laboratory
Technion Israel
9
th
October 7 2010,
Technion, Istarel
15
CONTOURS OF

TEMPERATURE AND O2,
CO, NOX, HC, AND CO2 CONCENTRATIONS
MEASUREMENTS
PERFORMED AT
THE SYMMETRY
PLANE
(IST PORTUGAL)
Turbo and Jet
Engine Laboratory
Technion Israel
9
th
October 7 2010,
Technion, Istarel
16
HIGH PRESSURE FLOXCOM TEST RIG AT
ANSALDO BARI
Turbo and Jet
Engine Laboratory
Technion Israel
9
th
October 7 2010,
Technion, Istarel
17
EMISSION TEST DIAGRAM AT 2.5 BARS (abs.),
NO AND NO
2
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
Turbo and Jet
Engine Laboratory
Technion Israel
9
th
October 7 2010,
Technion, Istarel
18
EFFECT OF GEOMETRICAL
VARIATIONS
Config.
Air inlet (total = 14 holes

2 sections)
Left inlet Right inlet
A oooooooooooooo oooooooooooooo
B ooooooo ooooooo
C oooooooooooooo
D ooooooo
P=1 bar (abs)
Q= 4KW
(24 KW complete section)
PRELIMINARY DESIGN MODIFICATIONS
Config. A:
;
;
;
NO
x
NO
x
NO
x
NO
x
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
C
o
m
b
u
s
t
i
o
n

e
f
f
i
c
i
e
n
c
y
(
%
)
N
O
x

(
d
r
y

v
o
l
u
m
e

p
p
m

@

1
5
%

O
2
)
g
NOx
COMBUSTION EFFICIENCY
Turbo and Jet
Engine Laboratory
Technion Israel
9
th
October 7 2010,
Technion, Istarel
19
EFFECT OF FUEL COMPOSITION

(COMBUSTION OF SYNGAS)
P=1 bar (abs)
Q= 8KW
(48 KW complete section)
9 4 3 2 1 Fuel mixture
39.2 76 81.9 91 100 CH4
43.3 24 18.1 9 0 H2
17.5 0 0 0 0 CO2
18.70 29.79 31.27 33.55 35.80 LHV (MJ/Nm3)
1923 1965 1961 1956 1952 Tad (C)
Turbo and Jet
Engine Laboratory
Technion Israel
9
th
October 7 2010,
Technion, Istarel
20

FLOXCOM COMBUSTOR HAS LARGE STABLE OPERATIONAL
RANGE.

NOx EMISSION IS LOW AS EXPECTED.

CO AND UHC ARE MODERATE, DESIGN MODIFICATION IS ARE
REQUIRED

BASIC STUDY IS NEEDED TO FILL GAPS
INTERMEDIATE CONCLUSION
2nd PHASE OF THE STUDY:
Turbo and Jet
Engine Laboratory
Technion Israel
9
th
October 7 2010,
Technion, Istarel
21
New design for
Aero-engine
Heat extraction
Main
combustion
Inlet
Exhaust
5-8 % O2
MODIFIED FLAMELESS COMBUSTOR WITH
INTERNAL HEAT EXCHANGER.
ADVANTEGEOUS:
COOLER FLAME
NEED FOR LOWER
RECIRCULATION RATIO
21 %

O2
Main
combustion
Inlet
Exhaust
14-18% O2
Conventional Flameless for Gas
Turbine
Turbo and Jet
Engine Laboratory
Technion Israel
9
th
October 7 2010,
Technion, Istarel
22
HEAT AND FLOW DIAGRAM -
MODIFIED FLAMELESS COMBUSTOR.
2
3
1
Heat exchanger
5
4
x
Junction
Primary Air
Secondary Air
Inlet
Exit
Recirculation Zone
Main Combustion
P
r
e
-
c
o
m
b
u
s
t
i
o
n
2
3
1
Heat exchanger
5
4
x
Junction
Primary Air
Inlet
Exit
Main Combustion
P
r
e
-
c
o
m
b
u
s
t
i
o
n
Fuel
Turbo and Jet
Engine Laboratory
Technion Israel
9
th
October 7 2010,
Technion, Istarel
23
THE HEAT TARNSFER MECHANISM

) (

USING OPTIMAL CONFIGURATION,
COMBUSTION TEMPERATURE MAY BE
REDUCED BY AS MUCH AS 170 C !
Turbo and Jet
Engine Laboratory
Technion Israel
9
th
October 7 2010,
Technion, Istarel
24
SINGLE JET STUDY
SINGLE JET FLAMELESS COMBUSTOR
Turbo and Jet
Engine Laboratory
Technion Israel
9
th
October 7 2010,
Technion, Istarel
25
DIFFUSION
FLAMELESS
Turbo and Jet
Engine Laboratory
Technion Israel
9
th
October 7 2010,
Technion, Istarel
26
CFD SIMULATIONS -

TECHNION
COMBUSTION CHAMBER WITH 16 FUEL INLET
AIR

INLET
CH
4
Air
C
y
c
l
i
c

S
u
r
f
a
c
e
MESH FOR 1/16
SECTOR
GASEOUSE
FUEL INLETS
Turbo and Jet
Engine Laboratory
Technion Israel
9
th
October 7 2010,
Technion, Istarel
27
TEMPERATURE DISTRIBUTION
TEMPERATURE
DISTRIBUTION
~1800K
Turbo and Jet
Engine Laboratory
Technion Israel
9
th
October 7 2010,
Technion, Istarel
28
VELOCITY FIELD AT THE CENTER LINE
CROSS-SECTION
| | | | | | | |
0 25 50

75
mm
To outlet
CH
4

inlet
Air inlet
Turbo and Jet
Engine Laboratory
Technion Israel
9
th
October 7 2010,
Technion, Istarel
29
To outlet
V
z

-

VELOCITY COMPONENT'S DISTRIBUTION
RECIRCULATION REGION
Turbo and Jet
Engine Laboratory
Technion Israel
9
th
October 7 2010,
Technion, Istarel
30
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
Turbo and Jet
Engine Laboratory
Technion Israel
9
th
October 7 2010,
Technion, Istarel
31
experiment
T K
simulation
COMPARISON

CFD SIMULATIONS -

EXPERIMENT
THERE IS STILL
ROOM FOR
IMPROVEMENTS
IN THE
MODELING
Turbo and Jet
Engine Laboratory
Technion Israel
9
th
October 7 2010,
Technion, Istarel
32
- 10x10
-6
0 1630 - Exp. data
1.6 0.76x10
-6
2.5x10
-12
0 1680 2190 Flux = -25kW/m
2
1.6 4.4x10
-6
3.3x10
-12
0 1760 2290 Flux = -15kW/m
2
1.6 46x10
-6
8.6x10
-12
0 1900 2460 Adiabatic
K
recirc.
NO
exit
CO
exit
T
exit

, K T
max

, K Regime
COMPARISON OF SIMULATION AND
TEST RESULTS
INCORPORATION OF
HEAT LOSS IN THE
MODELING IMPROVED
RESULTS
Turbo and Jet
Engine Laboratory
Technion Israel
9
th
October 7 2010,
Technion, Istarel
33
summary

Basic modeling of the FLOXCOM combustion method
was complete.

Detailed investigation into internal mixing and enhanced
wall heat transfer is currently being performed.

CFD modeling of Jet Flame configuration coupled with
experimental result seems to present an efficient tool to
gain practical knowledge.

Final integration stage is still needed for an engineering
flameless combustion design
Turbo and Jet
Engine Laboratory
Technion Israel
9
th
October 7 2010,
Technion, Istarel
34
INCORPORATION OF MODIFIED COMBUSTOR
IN A TURBO-FAN ENGINE.
c
c
1
9'
9' n' pc 07'
07'
P
U 2 C T 1
P

(
| |
(
= q
|
(
\ .
(

GE-90
Turbo and Jet
Engine Laboratory
Technion Israel
9
th
October 7 2010,
Technion, Istarel
35
Pollutant Reduction Problem

Compromises involved with
conventional combustors:

Emitted species

Flame stability

Cycle efficiency

Need for alternative
combustion concepts
LOW-EMISSION WINDOW
Wulff and Hourmouziadis, 1997
35
LOWER STABILITY LIMIT
Turbo and Jet
Engine Laboratory
Technion Israel
9
th
October 7 2010,
Technion, Istarel
36
COMBUSTION IN HOT VITIATED AIR
Stability limits -SchematicAfter

Wunning

and Wunning, 1997
Observed Experimental
Temperature Distribution
Plessing et al., 1998
Flame

Stable and safe
combustion

Uniformly
distributed
temperature

Low-NOx emission
Turbo and Jet
Engine Laboratory
Technion Israel
9
th
October 7 2010,
Technion, Istarel
37
O
2
, CO
2
, H
2
O MOLE FRACTION AT THE
RECIRCULATION ZONE
0
2
4
6
8
10
12
14
16
0 5 10 15 20 25
Oxygen mole fraction,
%
Industrial
furnaces
Gas
turbines
II I
I

BEFORE COMBUSTION
(STIRRING AIR),
II

AFTER COMBUSTION,
CO
2

,
H
2

O.
IF GASES WITH LARGE
OXYGEN CONCENTRATION
ARE RECIRCULATED,
HIGH ADIABATIC
TEMPERATURES ( AND
NOx) ARE OBTAINED
Turbo and Jet
Engine Laboratory
Technion Israel
9
th
October 7 2010,
Technion, Istarel
38
Recirculation Zone
Inlet
Exit
Recirculation Zone
Primary
air
S
e
c
o
n
d
a
r
y

a
i
r
S
e
c
o
n
d
a
r
y

a
i
r
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
Turbo and Jet
Engine Laboratory
Technion Israel
9
th
October 7 2010,
Technion, Istarel
39
Known parameters and assumptions:
Inlet air temperature T
a
Inlet mass flow rate m
a
,
exit temperatures T
e
100% combustion and mixing efficiency
calculated Values:
Air flow distribution: stirring air, m
as,
dilution air, m
ad
stirring gas, m
as
+m
r
Temperature :

stirring gas, T
s
combustion, Tc
Recirculation rate:

k
oxygen percentage in every stage of the cycle.
GLOBAL EVALUATION OF THE FLOXCOM COMBUSTOR
GLOBAL EVALUATION OF THE FLOXCOM COMBUSTOR
Turbo and Jet
Engine Laboratory
Technion Israel
9
th
October 7 2010,
Technion, Istarel
40
HIGH PRESSURE FLOXCOM TEST RIG
AT ANSALDO BARI
Turbo and Jet
Engine Laboratory
Technion Israel
9
th
October 7 2010,
Technion, Istarel
41
CROSS SECTION OF THE 360 DEGREES
MODEL OF THE FLOXCOM COMBUSTOR.
T1
[ x3]
T2
[ x3] [ x3]
T3
P1
[ x3]
P1 - Pressure sensores
T1...T3 - Temperature Sensores
Air In
Exhaust gases
Turbo and Jet
Engine Laboratory
Technion Israel
9
th
October 7 2010,
Technion, Istarel
42
FLOXCOM RELATIVE
PERFORMANCE
ppm NOx
.......... 200
100..............
0

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

Low NOx Flameless Combustion For Jet Engines and Gas Turbines, Technion, Israel

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