"Low NOx Flameless Combustion for Jet Engines and Gas turbines"

10090807060504020252015present3020100Noise (dB)Nox, CO, UHC(%)FuelConsumption(%)MaintananceCost (%)2025present• NOx, CO & UHC emissions are to be reduced by 70% by year2015 and 80% by year 2025• Fuel Consumption & CO 2 emission to be cut by 15% by year 2015and 25% by year 202520159 th Israeli Symposium on JetEngines and Gas Turbines,October 7 2010,Technion, IstarelAnticipated Future Projections ofEngine performance2Turbo and JetEngine LaboratoryTechnion – Israelwww. jet-engine-lab.technion.ac.il

ppm NOx200 ..........…100..............0 ................9 th Israeli Symposium on JetEngines and Gas Turbines,October 7 2010,Technion, IstarelFLOXCOM RELATIVEPERFORMANCE5Turbo and JetEngine LaboratoryTechnion – Israelwww. jet-engine-lab.technion.ac.il

2200° CTconventional1500° C400° Cflameless1300° CXNo NOxproduction9 th Israeli Symposium on JetEngines and Gas Turbines,October 7 2010,Technion, IstarelTHE CONCEPT OF FLAMELESS GAS TURBINECOMBUSTOR6Turbo and JetEngine LaboratoryTechnion – Israelwww. jet-engine-lab.technion.ac.il

FLAMELESS OXIDATION METHOD FOR NOx REDUCTION9 th Israeli Symposium on JetEngines and Gas Turbines,October 7 2010,Technion, IstarelFlameless Combustion9Turbo and JetEngine LaboratoryTechnion – Israelwww. jet-engine-lab.technion.ac.il

FLAMELESS OXIDATION IN FURNACESIndustrial FurnaceInletMain combustion(flamelessoxidation)Heat extractionExhaust0-5% O2Gas TurbineInletMaincombustionExhaust14-18% O2?9 th Israeli Symposium on JetEngines and Gas Turbines,October 7 2010,Technion, IstarelFLAMELESS OXIDATION IN FURNACES ANDGAS TURBINE.11Turbo and JetEngine LaboratoryTechnion – Israelwww. jet-engine-lab.technion.ac.il

NormalCombustionTemp. of Reactants (K)1614121086420IndustrialfurnacesGasturbinesII I0 5 10 15 20 251800Oxygen mole fraction, %I – BEFORE COMBUSTION(STIRRING AIR),II – AFTER COMBUSTION,CO 2,H 2O.15001200900IF GASES WITH LARGEOXYGEN CONCENTRATIONARE RECIRCULATED,HIGH ADIABATICTEMPERATURES ( ANDNOx) ARE OBTAINEDRecirculation Ratio16 8 42 1 0.502100FlamelessCombustionAuto Ignition TempLifted flamesHot FlamesIgnition BoundaryOxy-rich Flames600Non Combustiblezone3000 3 6 9 12 15 18 21 24 27 30%O 2 in reactants100 97 94 91 88 85 82 79 76 73 70% Dilutants (N 2 +CO 2 +H 2 O)9 th Israeli Symposium on JetEngines and Gas Turbines,October 7 2010,Technion, IstarelO 2, CO 2, H 2O MOLE FRACTION AT THERECIRCULATION ZONE12Turbo and JetEngine LaboratoryTechnion – Israelwww. jet-engine-lab.technion.ac.il

CONVENTIONAL GAS TURBINEGAS TURBINE WITH THE FLOXCOM COMBUSTOR●4●1●2●3’●3●5●69 th Israeli Symposium on JetEngines and Gas Turbines,October 7 2010,Technion, IstarelIMPLEMENTATION OF FLOXCOM METHODIN GAS TURBINES13Turbo and JetEngine LaboratoryTechnion – Israelwww. jet-engine-lab.technion.ac.il

INDICATIONS OF INCOMPLETE COMBUSTION9 th Israeli Symposium on JetEngines and Gas Turbines,October 7 2010,Technion, IstarelCFD SIMULATIONS(Farid C. Christo, The University of South Australia)14Turbo and JetEngine LaboratoryTechnion – Israelwww. jet-engine-lab.technion.ac.il

OPTIONAL AIR INLETS MODIFICATIONSDiluting airStirring air9 th Israeli Symposium on JetEngines and Gas Turbines,October 7 2010,Technion, IstarelA 60 0 MODEL OF THE COMBUSTOR SHOWINGSTIRRING AND DILUTING AIR INLET HOLES15Turbo and JetEngine LaboratoryTechnion – Israelwww. jet-engine-lab.technion.ac.il

9 th Israeli Symposium on JetEngines and Gas Turbines,October 7 2010,Technion, IstarelSECTOR COMBUSTOR - FULLYASSSEMBELED16Turbo and JetEngine LaboratoryTechnion – Israelwww. jet-engine-lab.technion.ac.il

9 th Israeli Symposium on JetEngines and Gas Turbines,October 7 2010,Technion, IstarelOPERATING TEST RIG AT IST, PORTUGALPHASE I17Turbo and JetEngine LaboratoryTechnion – Israelwww. jet-engine-lab.technion.ac.il

9 th Israeli Symposium on JetEngines and Gas Turbines,October 7 2010,Technion, IstarelCOMBUSTION TESTS18Turbo and JetEngine LaboratoryTechnion – Israelwww. jet-engine-lab.technion.ac.il

MEASUREMENTSPERFORMED ATTHE SYMMETRYPLANE(IST PORTUGAL)9 th Israeli Symposium on JetEngines and Gas Turbines,October 7 2010,Technion, IstarelCONTOURS OF TEMPERATURE AND O2,CO, NOX, HC, AND CO2 CONCENTRATIONS20Turbo and JetEngine LaboratoryTechnion – Israelwww. jet-engine-lab.technion.ac.il

9 th Israeli Symposium on JetEngines and Gas Turbines,October 7 2010,Technion, IstarelHIGH PRESSURE FLOXCOM TEST RIG ATANSALDO BARI21Turbo and JetEngine LaboratoryTechnion – Israelwww. jet-engine-lab.technion.ac.il

ppm2018161412108642NOxNOCOppm200018001600140012001000800600400200002.5 2.7 2.9 3.1 3.3l3.5 3.7 3.9 4.19 th Israeli Symposium on JetEngines and Gas Turbines,October 7 2010,Technion, IstarelEMISSION TEST DIAGRAM AT 2.5 BARS (abs.),NO AND NO 2 Vs. THE EXCESS AIR PARAMETER22Turbo and JetEngine LaboratoryTechnion – Israelwww. jet-engine-lab.technion.ac.il

PRELIMINARY DESIGN MODIFICATIONSCOMBUSTION EFFICIENCYNOxa)Air inlet (total = 14 holes × 2 sections)Config.Left inletRight inletA oooooooooooooo ooooooooooooooB o●o●o●o●o●o●o● o●o●o●o●o●o●o●C oooooooooooooo ●●●●●●●●●●●●●●b)P=1 bar (abs)Q= 4KW(24 KW complete section)D o●o●o●o●o●o●o● ●●●●●●●●●●●●●●9 th Israeli Symposium on JetEngines and Gas Turbines,October 7 2010,Technion, IstarelEFFECT OF GEOMETRICALVARIATIONSc)23Turbo and JetEngine LaboratoryTechnion – Israelwww. jet-engine-lab.technion.ac.il

ppmNOxηa)P=1 bar (abs)Q= 8KW(48 KW completesection)b)Fuel mixture12349c)CH4 %1009181.97639.2H2 %0918.12443.3CO2 %000017.5LHV(MJ/Nm3)35.8033.5531.2729.7918.70Tad (ºC)195219561961196519239 th Israeli Symposium on JetEngines and Gas Turbines,October 7 2010,Technion, IstarelEFFECT OF FUEL COMPOSITION(COMBUSTION OF SYNGAS)24Turbo and JetEngine LaboratoryTechnion – Israelwww. jet-engine-lab.technion.ac.il

• FLOXCOM COMBUSTOR HAS LARGE STABLE OPERATIONALRANGE.• NOx EMISSION IS LOW AS EXPECTED.• CO AND UHC ARE MODERATE, DESIGN MODIFICATION IS AREREQUIRED• BASIC STUDY IS NEEDED TO FILL GAPS2nd PHASE OF THE STUDY:• A BETTER AERO-THERMO DESIGN• A MODIFIED CONCEPT• CONTINUATION WITH BASIC STUDY9 th Israeli Symposium on JetEngines and Gas Turbines,October 7 2010,Technion, IstarelINTERMEDIATE CONCLUSION25Turbo and JetEngine LaboratoryTechnion – Israelwww. jet-engine-lab.technion.ac.il

MODIFIED FLOXCOM DESIGNAIR FUELAIR FUEL9 th Israeli Symposium on JetEngines and Gas Turbines,October 7 2010,Technion, Istarel26Turbo and JetEngine LaboratoryTechnion – Israelwww. jet-engine-lab.technion.ac.il

Mesh of simulated regionVelocity field;centreline cross-sectionStatic temperaturemap, general view.9 th Israeli Symposium on JetEngines and Gas Turbines,October 7 2010,Technion, Istarel27Turbo and JetEngine LaboratoryTechnion – Israelwww. jet-engine-lab.technion.ac.il

3-5 ppmNOx concentrations9 th Israeli Symposium on JetEngines and Gas Turbines,October 7 2010,Technion, Istarel28Turbo and JetEngine LaboratoryTechnion – Israelwww. jet-engine-lab.technion.ac.il

MODIFIED CONCEPTConventional Flameless for GasTurbineInletMaincombustionExhaust14-18% O2New design forAero-engineHeat extraction21 % O2InletMaincombustionExhaustADVANTEGEOUS:•COOLER FLAME•NEED FOR LOWERRECIRCULATION RATIO5-8 % O29 th Israeli Symposium on JetEngines and Gas Turbines,October 7 2010,Technion, IstarelMODIFIED FLAMELESS COMBUSTOR WITHINTERNAL HEAT EXCHANGER.29Turbo and JetEngine LaboratoryTechnion – Israelwww. jet-engine-lab.technion.ac.il

x JunctionPrimary AirMain Combustion2 3Inlet1Pre - combustionRecirculation ZoneFuel45ExitSecondary AirHeat exchanger9 th Israeli Symposium on JetEngines and Gas Turbines,October 7 2010,Technion, IstarelHEAT AND FLOW DIAGRAM -MODIFIED FLAMELESS COMBUSTOR.30Turbo and JetEngine LaboratoryTechnion – Israelwww. jet-engine-lab.technion.ac.il

פתח הזרמתאוויראזור האווירהעוקףפתחי הזרמתדלקצלעות מחליףהחום באזורהבעירהדופן תא ‏(אזור)‏הבעירהUSING OPTIMAL CONFIGURATION,COMBUSTION TEMPERATURE MAY BEREDUCED BY AS MUCH AS 170 °C !9 th Israeli Symposium on JetEngines and Gas Turbines,October 7 2010,Technion, IstarelTHE HEAT TARNSFER MECHANISM31Turbo and JetEngine LaboratoryTechnion – Israelwww. jet-engine-lab.technion.ac.il

BASIC STUDY : HIGH MEMENTUM SINGLE JET FLAMELESS COMBUSTOR9 th Israeli Symposium on JetEngines and Gas Turbines,October 7 2010,Technion, IstarelSINGLE JET STUDY32Turbo and JetEngine LaboratoryTechnion – Israelwww. jet-engine-lab.technion.ac.il

DIFFUSIONFLAMELESS9 th Israeli Symposium on JetEngines and Gas Turbines,October 7 2010,Technion, Istarel33Turbo and JetEngine LaboratoryTechnion – Israelwww. jet-engine-lab.technion.ac.il

GASEOUSEFUEL INLETSAIR INLETCH 4AirMESH FOR 1/16SECTOR9 th Israeli Symposium on JetEngines and Gas Turbines,October 7 2010,Technion, IstarelCFD SIMULATIONS - TECHNIONCOMBUSTION CHAMBER WITH 16 FUEL INLET34Turbo and JetEngine LaboratoryTechnion – Israelwww. jet-engine-lab.technion.ac.il

To outletCH 4inletAir inlet| | | | | | | |0 25 50 75mm9 th Israeli Symposium on JetEngines and Gas Turbines,October 7 2010,Technion, IstarelVELOCITY FIELD AT THE CENTER LINECROSS-SECTION35Turbo and JetEngine LaboratoryTechnion – Israelwww. jet-engine-lab.technion.ac.il

TEMPERATUREDISTRIBUTION~1800K9 th Israeli Symposium on JetEngines and Gas Turbines,October 7 2010,Technion, IstarelTEMPERATURE DISTRIBUTION36Turbo and JetEngine LaboratoryTechnion – Israelwww. jet-engine-lab.technion.ac.il

RECIRCULATION REGIONTo outlet9 th Israeli Symposium on JetEngines and Gas Turbines,October 7 2010,Technion, IstarelV z- VELOCITY COMPONENT'S DISTRIBUTION37Turbo and JetEngine LaboratoryTechnion – Israelwww. jet-engine-lab.technion.ac.il

DIFFUSION REGIONFUEL ENTRAINMENTPreliminary NO predictions| | | | || |0 3 6 9 12 mmTemperature distributionNO level5 ppm0NO mass-fraction distribution9 th Israeli Symposium on JetEngines and Gas Turbines,October 7 2010,Technion, IstarelTEMPERATURE DISTRIBUTION –(NEAR NOZZLE REGION)38Turbo and JetEngine LaboratoryTechnion – Israelwww. jet-engine-lab.technion.ac.il

T KexperimentsimulationTHERE IS STILLROOM FORIMPROVEMENTSIN THEMODELING …9 th Israeli Symposium on JetEngines and Gas Turbines,October 7 2010,Technion, IstarelCOMPARISON – CFD SIMULATIONS -EXPERIMENT39Turbo and JetEngine LaboratoryTechnion – Israelwww. jet-engine-lab.technion.ac.il

RegimeT max, KT exit, KCO exitNO exitK recirc.Adiabatic246019008.6x10 -12 ≃ 046x10 -61.6Flux = -15kW/m 2229017603.3x10 -12 ≃ 04.4x10 -61.6Flux = -25kW/m 2219016802.5x10 -12 ≃ 00.76x10 -61.6Exp. data-1630010x10 -6-INCORPORATION OFHEAT LOSS IN THEMODELING IMPROVEDRESULTS9 th Israeli Symposium on JetEngines and Gas Turbines,October 7 2010,Technion, IstarelCOMPARISON OF SIMULATION ANDTEST RESULTS40Turbo and JetEngine LaboratoryTechnion – Israelwww. jet-engine-lab.technion.ac.il

LNG/ LH2 Main Combustor Kerosene/ Biofuel Secondary Flameless Combustor Bleed cooling by LH2 Counter rotating shrouded fans Higher Specific Thrust Low Installation Penalty9 th Israeli Symposium on JetEngines and Gas Turbines,October 7 2010,Technion, Istarel41Turbo and JetEngine LaboratoryTechnion – Israelwww. jet-engine-lab.technion.ac.il

summary• Basic modeling of the FLOXCOM combustion methodwas complete.• Detailed investigation into better internal mixing andenhanced wall heat transfer is currently beingperformed.• CFD modeling of Jet Flame configuration coupled withexperimental result seems to present an efficient tool toimprove modeling.• Final integration stage is still needed for an engineeringflameless combustion design9 th Israeli Symposium on JetEngines and Gas Turbines,October 7 2010,Technion, Istarel42Turbo and JetEngine LaboratoryTechnion – Israelwww. jet-engine-lab.technion.ac.il

GE-90U 2 C T 1 c 1 P c9'9' n ' pc 07' P 07'9 th Israeli Symposium on JetEngines and Gas Turbines,October 7 2010,Technion, IstarelINCORPORATION OF MODIFIED COMBUSTORIN A TURBO-FAN ENGINE.43Turbo and JetEngine LaboratoryTechnion – Israelwww. jet-engine-lab.technion.ac.il

Recirculation ZoneInletPrimaryairMixing ZoneExitRecirculation ZoneFuel InletMixing holesSecondary AirExitCompositeMetallic FinsFuelInlet9 th Israeli Symposium on JetEngines and Gas Turbines,October 7 2010,Technion, IstarelSCHEMATIC REPRESENTATION OF THE FLUIDFLOW WITHIN THE “MODIFIED” COMBUSTORS44Turbo and JetEngine LaboratoryTechnion – Israelwww. jet-engine-lab.technion.ac.il

T2 T3[ x3] [ x3]T1[ x3]Air InExhaust gasesP1[ x3]T1...T3 - Temperature SensoresP1 - Pressure sensores9 th Israeli Symposium on JetEngines and Gas Turbines,October 7 2010,Technion, IstarelCROSS SECTION OF THE 360 DEGREESMODEL OF THE FLOXCOM COMBUSTOR.45Turbo and JetEngine LaboratoryTechnion – Israelwww. jet-engine-lab.technion.ac.il

ppm NOx200 ..........…100..............0 ................9 th Israeli Symposium on JetEngines and Gas Turbines,October 7 2010,Technion, IstarelFLOXCOM RELATIVEPERFORMANCE46Turbo and JetEngine LaboratoryTechnion – Israelwww. jet-engine-lab.technion.ac.il