Lean Blowout Limit Prediction in a Combustor with the Pilot Flame

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4th International Conference on Power and Energy Systems Engineering, CPESE 2017, 25-29 2017, Berlin, Germany 4th International Conference September on Power and Energy Systems Engineering, CPESE 2017, 25-29 September 2017, Berlin, Germany

Lean Blowout Limit Prediction in a Combustor with Pilot Flame The 15th International Symposium on District Heating andthe Cooling Lean Blowout Limit Prediction in a Combustor with the Pilot Flame Ivan the A. Zubrilin*, Nikita Gurakov, Matveev Assessing feasibility ofI. using theSergey heatG.demand-outdoor Ivan A. Zubrilin*, Nikita I. Gurakov, Sergey G. Matveev National Research 34, Moskovskoye shosse, Samara, 443086,demand Russia temperatureSamara function forUniversity, a long-term district heat forecast Samara National Research University, 34, Moskovskoye shosse, Samara, 443086, Russia

I. Andrića,b,c*, A. Pinaa, P. Ferrãoa, J. Fournierb., B. Lacarrièrec, O. Le Correc

Abstract a IN+ Center for Innovation, Technology and Policy Research - Instituto Superior Técnico, Av. Rovisco Pais 1, 1049-001 Lisbon, Portugal Abstract b Veolia chambers Recherche & Innovation, 291 Daniel, 78520 Limay, France One of the important combustion characteristic is Avenue the leanDreyfous blowout (LBO) limits. There are several ways to expand c Département Systèmes Énergétiques et Environnement IMT Atlantique, 4 rue Alfred Kastler, 44300 combustor Nantes, France LBOof limits. One of them is using pilot flame.characteristic The present research relates to LBO modeling withtothe pilot One the important combustion chambers is the lean blowout (LBO) limits. inside There the are several ways expand flame. The simplified version of apilot power plantThe combustion chamberrelates was used. Themodeling experimental was used towith validate the LBO limits. One of them is using flame. present research to LBO insidedata the combustor the pilot model. The Experiments conducted at theplant inlet combustion air temperatures ranging 575 K, and changing relative flow rate flame. simplifiedwere version of a power chamber wasfrom used.373 Thetoexperimental data wasthe used to validate the be achieved of the pilot fuel fromwere 0 to 1. Methane at was thetemperatures fuel. It was found that the 373 minimum of changing the φLBO can model. Experiments conducted theused inletasair ranging from to 575value K, and the relative floweven rate Abstract be when portion the0fuel the pilot zone,asand when the that fuelthe is fully supplied to of thethe pilot circuit. φLBO can can beSoachieved even of the apilot fuel of from to 1.enters Methane was used the not fuel.only It was found minimum value φLBO reduced up to 4 times compared to supplying fuel only to main circuit. It is also shown that there is a correlation between φ can when a portion of the fuel enters the pilot zone, and not only when the fuel is fully supplied to the pilot circuit. So φ LBO LBO District heating networks are commonly addressed in the literature as one of the most effective solutions for decreasing be the be obtained as a result of the RANS and fuel/air equivalence ratio averaged over the surface ofmain the recirculation zone φRF, that reduced up to 4 times compared to fuel only to circuit. It is high also investments shown thatcan there isare a correlation between φLBO greenhouse gas emissions from thesupplying building sector. These systems require which returned through heat for fuel was simulations combustion. To generalize collected the φRF value, , thatdemand canan bearbitrary obtained as adistribution, result RANS and fuel/air equivalence ratio climate averaged over the the surface of thedata recirculation zone obtained φRFheat sales. Due without to the changed conditions and building renovation policies, in the future couldofdecrease, scaled to φ , obtained for supplying the fuel only in the main circuit. In this case φ value was calculated using LES value, obtained for an arbitrary fuel distribution, was simulations without combustion. To generalize the collected data the φ LBO LBO RF prolonging the investment return period. approach for each air flow rate, pressure and initial temperature. As the result of the work, the methodology that allows to scaled to φ , obtained for supplying the fuel only in the main circuit. In this case φ value was calculated using LES LBO LBO The main scope of this paper is to assess the feasibility of using the heat demand – outdoor temperature function for heat demand determine LBO limits of combustion chambers with the pilot flame was developed. The presented method is based on a series of approach for each air flow rate, pressure and initial temperature. As the result of the work, the methodology that allows to forecast. The district of Alvalade, located in Lisbon (Portugal), was used as a case study. The district is consisted of 665 steady andLBO transient 3D determine limits combustion chambers with pilot flame wasweather developed. The presented method high) is based a series of buildings that vary inofsimulations. both construction period andthetypology. Three scenarios (low, medium, andonthree district ©renovation 2017and Thetransient Authors. Published by Elsevier Ltd. steady 3D simulations. scenarios were developed (shallow, deep). To estimate the error, obtained heat demand values were © 2017 The Authors. Published by Elsevier Ltd. intermediate, Peer-review under responsibility of the organizing committee of CPESE developed 2017. © 2017 The Authors. Published by Elsevier Ltd. compared with results from a dynamic heat demand model,of previously validatedon byPower the authors. Peer-review under responsibility of the scientific committee the 4th Internationaland Conference and Energy Peer-review under responsibility of the organizing committee of CPESE 2017. The results showed that when only weather change is considered, the margin of error could be acceptable for some applications Systems Engineering. Keywords: large eddy simulation; lean flame blowout; pilot flame, power plant, combustion chamber

(the error in annual demand was lower than 20% for all weather scenarios considered). However, after introducing renovation scenarios, the error value increased up to 59.5% (depending on the weather and renovation scenarios combination considered). The value of slope coefficient increased on average within the range of 3.8% up to 8% per decade, that corresponds to the decrease in the number of heating hours of 22-139h during the heating season (depending on the combination of weather and renovation scenarios considered). On the other hand, function intercept increased for 7.8-12.7% per decade (depending on the coupled scenarios). The values suggested could be used to modify the function parameters for the scenarios considered, and improve the accuracy of heat demand estimations.

Keywords: large eddy simulation; lean flame blowout; pilot flame, power plant, combustion chamber

© 2017 The Authors. Published by Elsevier Ltd. * Corresponding author. Tel.: 79198065321. Peer-review under responsibility of the Scientific Committee of The 15th International Symposium on District Heating and E-mail address: [email protected] * Corresponding author. Tel.: 79198065321. Cooling.

 E-mail address: [email protected]  Keywords: Heat demand; Forecast; Climate change 1876-6102 © 2017 The Authors. Published by Elsevier Ltd. Peer-review©under the organizing committee 1876-6102 2017responsibility The Authors. of Published by Elsevier Ltd. of CPESE 2017. Peer-review under responsibility of the organizing committee of CPESE 2017.

1876-6102 © 2017 The Authors. Published by Elsevier Ltd. Peer-review under responsibility of the Scientific Committee of The 15th International Symposium on District Heating and Cooling. 1876-6102 © 2017 The Authors. Published by Elsevier Ltd. Peer-review under responsibility of the scientific committee of the 4th International Conference on Power and Energy Systems Engineering. 10.1016/j.egypro.2017.11.105

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Nomenclature – equivalence ratio at the combustion chamber outlet, during the LBO; –equivalence ratio during the flame LBO when all the fuel is fed into the main circuit; –equivalence ratio at the combustion chamber outlet, during the LBO obtained experimentally; – equivalence ratio average over the surface of recirculation zone; equivalence ratio averaged over the surface of recirculation zone when all fuel is fed into the main circuit; –equivalence ratio average over the surface of recirculation zone obtained by LES; –equivalence ratio average over the surface of recirculation zone obtained by RANS; – fuel-air equivalence ratio at combustion chamber outlet; – relative pilot fuel mass flow rate, ; – combustion chamber pressure drop; RANS – Reynolds averaged Navier-Stokes; CFD – Computational Fluid Dynamics; LES – Large Eddy Simulation. 1.

Introduction

In order to provide required nitrous oxides (NOx) emission for gas turbine power plants, the combustion of lean premixed mixtures became the most prevalent. However, in this case, during the transient engine behaviour and at idle, the risk of flame blowout increases. The extension of the combustion chamber stable operation limits can be achieved by burning of partially premixed fuel-air mixtures, when the main part of the fuel mixes with the air before the combustion zone, and the rest fuel is used to create the pilot flame. The following models are quite frequently used for LBO limits prediction during combustion chamber designing and development stages: semi-empirical models, modeling in a transient three-dimensional case and hybrid simulation. Semi-empirical models are approximate expressions, build on the generalization of experimental data on the basis of some theoretical assumptions. One of the first studies devoted to the generalization of flame blowout data was carried out by E. DeZubay [1]. A. Lefebvre made a significant contribution to semi-empirical models in his researches [2]. The authors of several works [3, 4] for a wider range of fuels, obtained the expression which considers its characteristics, for instance, H/C relation. All the studies presented above are related to the flameholders with two-dimensional flow downstream. Meanwhile, the swirled flow, which is the most common way to stabilize the flame in combustion chambers, has strong three-dimensional flow structure. The expressions to predict LBO limit in swirled flow are presented in papers [5, 6]. The presented expressions allow to quickly estimate LBO limits during the burning of premixed mixtures after the flameholders in the form of bluff bodies or vane swirlers, and also during the diffusion and homogeneous combustion in main combustion chambers. However, its applicability is limited by empirical coefficients, which were obtained in specific conditions. In recent decades the use of methods of Computational Fluid Dynamics (CFD), at the combustor designing stage, had been widely adopted. For instance, the method of Large Eddy Simulation (LES) allows obtaining LBO limits directly from calculation results [7-11]. The existing semi-empirical methods were developed basically for diffusion and premixed combustion. The direct numerical simulation of the flame blowout in combustion chamber requires significant resources and is inappropriate in engineering practice. The combined method of LBO calculation, based on steady state threedimensional simulations, might be the solution of the task. The similar combined methods are presented in the studies, where the results of 3D calculations in a steady case were used to create reactor chains [12], in specific criteria equations [13, 14] or in modified already existing equations [15]. For instance, the modified semi-empirical Lefebvre’s formula for combustion chamber LBO calculation [16] was presented in the study [17]. The shortcoming of most of the works devoted to the generalization of combustion chamber LBOs is its applicability only in cases of premixed mixtures or diffusion combustion. It is well known that the use of the pilot



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flame is one of the most effective methods to stabilize the flame [18-22]. In this regard, the development of the method, which determines the LBO limit, taking into account the burning of partially premixed mixtures, is the actual task. The goal of the article is to develop the method, which will allow to calculate LBO limits of partially premixed mixtures in gaseous-fueled combustion chambers. This work presents the detailed description of the simulated combustion chamber, the results of experimental (at various temperatures) and simulation researches and the algorithm of the developed method. 2.

The description of the combustion chamber

The individual simulated combustion chamber with the burner was developed for the computational and experimental research of partially premixed mixtures combustion. This burner was created similar to the burner, installed into the combustion chamber of one of the industrial gas turbine power plants. The burner consists of the mixing chamber converging circular duct, in which the air and the fuel of the main circuit are mixed. The pilot fuel is entered along the axis of the central body, through the nozzle. Air cooling nozzles were used to prevent the central body from overheating. The main fuel feed is realized through the fuel pipes to swirler inlet. The location and the size of the holes were selected in such a way, that the fuel distribution profile in the outlet of the burner was similar to fuel distribution profile in the prototype burner [23]. The design feature of this burner allows to research the influence of different parameters of the burner on combustion processes. There are following variants of design modifications: change of profile and angle of the swirler vanes; change of cylindrical nozzle size; change of number of holes, its diameter and also the jet nozzle angle; the substitution of disposable element of the main fuel circuit manifold for the element with the other number of fuel pipes with altered holes diameters and location, and the other direction of fuel feed. The design and characteristic dimensions of the simulated individual combustion chamber are presented in the Fig.1. The flame tube of individual combustion chamber has two rows of cooling system holes and one row of mixture holes on its cylindrical segment. On the cone segment, there is one row of cooling system holes. The characteristic residence time and the layout of air feed into the flame tube of the investigated combustion chamber corresponds to similar parameters of the prototype combustion chamber flame tube. 3.

Experimental investigation of LBO limits

The experimental setup for flame blowout study contains Leister air heater (Switzerland) with the executive and regulating equipment. The total fuel consumption was determined by a Coriolis mass meter «Yokogawa» (measurement error within 0,15-15 g/s is ± 1,5%). Fuel consumption in the pilot circuit is maintained via thermal mass flowmeter regulator «Bronkhorst High-Tech» Series EL-FLOW (measurement error within 0.02 - 1 g / s, is ± 1%). Static pressure in the fuel circuit was determined by piezometric method (with the error of measurement ± 0,7%). Air mass flowrate was determined by flowmeter «SMC» with measurement error of 2% in the range up to 60 g/s. Inlet air temperature was determined with the thermocouple type K (chromel-alumel). Temperature measurement error is ± 0,99% for measurements up to 600K.

Fig. 1. The scheme of investigated individual combustion chamber: 1 mixture holes; 2 the third row of cooling holes

The algorithm of the LBO determination in the simulated combustion chamber with air fuel premixed dual circuit burner is the following: at the beginning, the air, with previously set temperature and the flow rate, less than required, is being fed. Then, the fuel gas is injected into the pilot circuit and the fuel ignition occurs. After the

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ignition, the required air flow rate and fuel gas consumption in the main circuit are being set. Then the pilot fuel feed is smoothly reduced until the LBO takes place. Experiments were repeated for the different main circuit fuel consumption. , where – the air to The obtained data is presented in the Fig. 2 as the dependence can be fuel ratio at the combustion chamber outlet, during the LBO. It was found that the minimum value of reached at a specific consumption ratio between main and pilot fuel circuits, and not with the all fuel feed into the by multiple times, comparing to the variant pilot circuit, as it was supposed. This has resulted in a decrease of of fuel feed into the main circuit only. 4.

Three dimensional simulation

In order to generalize the obtained data, the stabilization contact theory were used. According to the theory, the blowout depends on the relation of the amount of heat required for fresh mixture ignition and the amount of heat transmitted from the recirculation zone combustion products. As a result, the equivalence ratio on the recirculation is one of the main parameters that determines the flame stabilization since it determines zone surface of temperature between fresh mixture and combustion products. The use of RANS is reasonable to decrease the total , whereas the flame blowout was determined using LES time of simulations, during the determination of approach. The commercial CFD software ANSYS Fluent 16.0 was employed to carry out the simulation. [24]. All RANS simulations were conducted using the compressible pressure-based solver. The governing equations of flow were discretized with the finite volume method. The Reynolds stress terms in the conservation equations were closed by the Reynolds Stress Transport model [25] with standard constants. Details of the models and the solver can be found in the user’s guide of ANSYS Fluent.

a) Fig. 2. The results of experimental prediction of LBO: а)

b) , b)

%

Unsteady LBO simulation was performed using LES with Smagorinsky-Lilly subgrid model. Combustion was described by Flamelet Generated Manifold model [26-30] with Finite Rate Chemistry as a subgrid model. Finite Rate Chemistry approach assumes that flame propagation is determined by laminar burning velocity only. Laminar burning velocity was set as a function of φ for appropriate inlet air temperature [31]. According to [32] Finite Rate Chemistry approach as turbulence-chemistry interaction model with sufficient grid resolution gives reasonable results of lean flame blowout simulation. The methane laminar flame speeds were determined by chemical kinetics simulation results. The simulations were carried out with CHEMKIN software. As a kinetic mechanism of chemical reactions GRI 3.0 was used. The Discrete Ordinates radiation model [33] was used to calculate radiation fluxes. The heat flow through the walls was ignored and the adiabatic wall was accepted. Vortex method [34] with 5% turbulence intensity was used to simulate inlet velocity fluctuations. More details concerning the applied LBO simulation algorithm and results of its validation could be found in the paper [32]. For simulation the hybrid mesh was used: structured hex mesh for the flame tube internal domain and unstructured mesh for complex elements such as flame tube cooling holes. The total number of cells is 5.04 million. Examination of mesh resolution for LES includes three criteria which were checked for stable combustion with



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

and : the ratio of subgrid to molecular viscosity [35]:

277

≤ 20 (Fig 3);

 the presence of Kolmogorov – Obukhov law (Law "5/3") in resulting spectrum of energy density for velocity fluctuations (Fig 4) [36, 37]; ≥0.8 [38-40] (Fig.5).  the ratio of the resolved and the total turbulence kinetic energy IQη As we can see from figures all criteria show that the mesh resolution is sufficient for using LES. 5.

The generalization of computational and experimental data of the flame LBO

Fig. 6 shows the correlation between , obtained as a result of RANS simulation without combustion and as the result of LES calculation without combustion. As it can be seen, the calculation without burning in determination instead of LES simulation. steady three dimensional case can be further used for

Power Spectral Density

10.000 1.000

0.100 0.010 0.001

Fig. 3 – Spatial distribution of

Fig. 5 – Spatial distribution of IQη

10

100

1 000

10 000

Frequency, Hz

100 000

Fig. 4 – Velocity power spectral density

Fig.6 – The results correlation of steady and transient simulations

Fig. 7 shows the fuel-air equivalence ratio distribution on the surface of recirculation mixing zone during three different variants of fuel distribution between circuits. According to Fig. 7, the fuel distribution effects mainly on the root part of the recirculation zone. In this area air-fuel mixture from the swirler mixes with recirculation zone can be explained by specific ways of air and fuel mixing mixture. Thus, the extremum of function processes. and obtained as a result of RANS simulation of fuel The Fig. 8 shows the correlation between % and . As we can and air mixing without combustion. Results were obtained for see from the Fig. 8, there are several groups of data that can be classified by the combustion chamber pressure drop. (and respectively for low flow velocity) may be less than it is for high to provide As expected, for low the same value due to lower contact time between fresh air-fuel mixture and hot combustion products of by (obtained recirculation zone. In order to summarize data for different flow velocities we divided

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during experiments) and by (obtained during simulations). The Fig. 9 shows generalization of all investigated data by inlet air temperature. In general terms, the obtained data can be generalized using the following dependence: , where = 137; –determined by LES for each pressure drop; , –determined by RANS in nonreacting conditions. In accordance with the obtained results, the method of flame LBO determination is the following: 1. The three-dimensional geometrical combustion chamber is created on the base of preliminary design calculations. , is 2. On the basis of RANS calculation results without combustion, the dependence determined and the dependence is formed.

3. Using the LES approach the dependence is determined, where - air consumption at a fixed temperature. 4. The prediction of flame LBO limit for a random fuel distribution realizes according to the dependence: .

a)

b)

Fig.7 – Distribution of fuel-air equivalence ratio on recirculation zones during the change of fuel distribution, , b) , c) a)

c) , Tk=500K:

Fig. 10 shows the results correlation between the proposed method and experimental data for the investigated combustion chamber. The obtained results show that the developed method allows to describe the location of blowout characteristics extremum, which was determined during experimental investigations. That is why this method can be used for determination of flame blowout characteristics during the burning of partially mixed mixtures.



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Fig. 8 – The correlation between simulation and experimental data

Fig. 10 The correlation between the proposed method

6.

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Fig. 9 – The generalization of flame LBO data

and experimental data

,

, Tk=500K

Conclusion

The developed simulated combustion chamber is similar to gas turbine power plant combustion chamber according to air distribution layout along the flame tube and burning process in the primary zone. The lean flame blowout characteristics of simulated combustion chamber during the burning of the partially premixed mixture were , that was reached by specific consumption obtained experimentally. It was shown, that the minimum value of ,when all ratio between main and pilot fuel circuits of the burner, can be several times lower, than the value of fuel is fed into the main circuit. As the calculations in three dimensional case showed, it is connected with the equals to minimum specific ways of air and fuel mixing processes in the primary zone: the minimum value of . It was also proved that can be calculated using RANS approach. The results of the computational value of and experimental research of flame LBO in a combustion chamber during the burning of a partially premixed mixture enabled the development of a method to calculate lean flame blowout limit included stationary and transient computational simulations in three dimensional case. Acknowledgement This work was supported by the Ministry of Education and Science of the Russian Federation in the framework of the implementation of the Program “Research and development on priority directions of scientific-technological complex of Russia for 2014-2020” (RFMEFI58716X0033). Equipment of CAM technology common use center (RFMEFI59314X0003) was used in these studies.

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