Experimental investigations of aerodynamics, dynamics and emissions

UNIVERSITY OF CINCINNATI Date: 14-Jan-2010 I, Bassam Abd El-Nabi , hereby submit this original work as part of the requirements for the degree of: Doctor of Philosophy in Aerospace Engineering It is entitled: Single Annular Combustor: Experimental investigations of Aerodynamics, Dynamics and Emissions Student Signature: Bassam Abd El-Nabi This work and its defense approved by: Committee Chair: San-Mou Jeng, PhD San-Mou Jeng, PhD Milind Jog, PhD Milind Jog, PhD Mustafa Furhan Andac, PhD Mustafa Furhan Andac, PhD Shaaban Abdallah, PhD Shaaban Abdallah, PhD 3/8/2010 447 Single Annular Combustor: Experimental investigations of Aerodynamics, Dynamics and Emissions A thesis submitted to the Division of Graduate Studies and Research of the University of Cincinnati in partial fulfillment of the requirements for the degree of DOCTORATE OF PHILOSOPHY (Ph.D.) in the Department of Aerospace Engineering and Engineering Mechanics of the College of Engineering March 2010 by Bassam Sabry Mohammad B.S., Mechanical Engineering, Cairo University, Egypt M.S., Mechanical Engineering, Cairo University, Egypt M.S., Nuclear Engineering, Missouri University of Science and Technology, USA Committee Chair: Dr San-Mou Jeng i Abstract The present work investigates the aerodynamics, dynamics and emissions of a Single Cup Combustor Sector The Combustor resembles a real Gas Turbine Combustor with primary, secondary and dilution zones (also known as fuel rich dome combustor) The research is initiated by studying the effect of the combustor front end geometry on the flow field Two different exit configurations (one causes a sudden expansion to the swirling flow while the other causes a gradual expansion), installed in a dump combustor, are tested using LDV The results reveal that the expanding surface reduces the turbulence activities, eliminates the corner recirculation zone and increases the length of the CRZ appreciably An asymmetry in the flow field is observed due to the asymmetry of the expanding surface To study the effect of chamber geometry on the flow field, the dome configuration is tested in the combustor sector with the primary dilution jets blocked The size of the CRZ is reduced significantly (40 % reduction in the height) With active primary jets, the CRZ is reconstructed in 3D by conducting several PIV measurements off-center The confinement appears to significantly influence the shape of the CRZ such that the area ratio is similar for both the confinement and the CRZ (approximately 85%) The primary jets considerably contribute to the heat release process at high power conditions Also, the primary jets drastically impact the flow field structure Therefore, the parameters influencing the primary jets are studied using PIV (pressure drop, jets size, offcentering, interaction with convective cooling air, jet blockage and fuel injection) This study is referred to as a jet sensitivity study The results indicate that the primary jets can be used effectively in controlling the flow field structure A pressure drop of 4.3% and 7.6% result in ii similar flows with no noticeable effect on the size of the CRZ and the four jets wake regions On the other hand, the results show that the primary jets are very sensitive to perturbations The cooling air interacts with the primary jet and influences the flow field although the momentum ratio has an order of magnitude of 100:1 The results also show that the big primary jets dictate the flow field in the primary zone as well as the secondary zone However, relatively smaller jets mainly impact the primary zone Also, the results point to the presence of a critical jet diameter beyond which the dilution jets have minimum impact on the secondary region The jet off-centering shows significant effect on the flow field though it is on the order of 1.0 mm The jet sensitivity study provides the combustion engineers with useful methods to control the flow field structure, an explanation for observed flow structure under different conditions and predictable flow field behavior with engine aging All results obtained from the jet sensitivity study could be explained in terms of jet opposition Hence, similar results are expected under reacting conditions even though the results presented here are obtained under isothermal conditions The fuel injection is also shown to influence the flow field High fuel flow rate is shown to have very strong impact on the flow field and thus results in a strong distortion of both the primary and secondary zones The jets wake regions are shown to change in size with fuel injection The left jet wake region continuously reduces in size with fuel injection while the right jet wake region does not This offers a possible explanation for the observed combustion instabilities in the left primary jet region The combustion instabilities are studied using a microphone, high speed camera and regular cameras The frequency spectrum for the sector is established at different pressure drops (2, and 6%) as well as different pre-heat temperatures (200, 400 and 600F) The iii acoustic spectrum suggests that there are three frequencies of concern (280, 400 and 600 HZ) The high frequency appears to be related to the combustor ¼ longitudinal wave The 280 Hz is due to a rotating instability while the 400 Hz is related to the primary jets The emissions emanating from the combustor are studied using FTIR at pressure drop of 4% and different power conditions The sector emissions characteristics are determined Water injection is also used to control the pollutant emissions Water fuel ratio of 100% and 50% results in a corresponding reduction in the NOx concentration with 50% and 22% (at high power conditions) No noticeable effects are observed on the NOx and CO at low power conditions A high degree of homogeneity in the emissions contours is observed at the combustor exit at low power conditions (equivalence ratio of 0.3) However, this homogeneity is noticeably reduced at high power conditions (equivalence ratio of 0.6) iv v Acknowledgment All thanks are due to ALLAH (God) and may His peace and blessings be upon all His messengers and prophets including Moses, Jesus and Mohammad It was only through ALLAH's help and support that this work was accomplished I can never thank Him enough for all the blessing He bestowed upon me throughout my life and I seek His forgiveness for all my shortcomings I would like to especially recognize and express my gratitude to my advisor, Dr S M Jeng It is certainly through his support, guidance and encouragement that this work is complete He trusted me and gave me a room to make my own decisions Dr Jeng was always ready to give advice anytime Dr Jeng is one of the best things that happened in my life Dr Jeng taught me the basics of research, how to interact with people, how to think differently and how to solve problems Also, my deepest appreciation to Dr Abdallah Shabaan, Dr Millind Jog and Dr Gurhan Andac for their time and effort as my committee members I am also very thankful to the people at GE aviation This work was not possible without their help and support Special thanks to all my colleagues at the Combustion Research Lab Dr Jun Cai taught me how to use and setup the PIV, LDV and FTIR systems Mr Curt Fox offered a great deal of help He is the kind of person who would help you anything, anytime in a timely manner! Also, I am very thankful to Samir, Fumi, and Kao They helped me in experimental setup as well as running the experiments I would especially like to thank my Mom and Dad I achieved this work because of their prayers My father supported me financially since I arrived to the United States He paid a vii huge amount of money to help me earn my degree May ALLAH reward them for what they have done Finally, there is a single person who has had a greater effect on this work than anyone else, and that is my wife She has been patient and she supported and encouraged me She was taking care of the family duties to provide me with the environment and the time necessary to complete this effort We have four kids and there was no chance for me to earn my degree if she didn’t sacrifice her time and effort viii “Read: In the name of thy Lord Who createth, Createth man from a clot, Read: And thy Lord is the Most Bounteous, Who teacheth by the pen, Teacheth man that which he knew not.” -Quran (20:114) “My Lord! Advance me in knowledge.” -Quran (96:1-5) vi Table of Contents   Acknowledgment vii  Table of Contents ix  List of Figures xi  Nomenclature xvi  Introduction 1  Chapter 1.  (Literature Review) 5  1.1  Aerodynamics 5  1.1.1  Flame stabilization and Generation of CRZ 6  1.1.2  Swirl Cup 8  1.1.3  Swirl Characterization 10  1.1.4  Factors influencing the CRZ Size and strength 12  1.1.4.1  Swirl Number Effects 12  1.1.4.2  Confinement Effects 12  1.1.4.3  Reynolds Number Effects 13  1.1.4.4  Nozzle Insertion Effects 14  1.1.4.5  Combustion Effects 14  1.1.5  Realistic combustion chambers and effect of dilution jets 15  1.2  Emissions 18  1.2.1  Nitric Oxides (NOx) 21  1.2.1.1  NOx categories 23  1.2.1.2  Effect of pressure on NOx generation 28  1.2.1.3  NOx reduction techniques 29  1.2.2  Carbon Monoxide (CO) 34  1.3  Dynamics and generation of Combustion Instabilities 35  Chapter 2.  (Dump Combustor Aerodynamic) 38  2.1  Experimental setup, procedure and test conditions 38  2.1.1  Swirl Cup and test section 38  2.1.2  Experimental facility 40  2.1.3  Diagnostics 40  2.1.4  Test conditions, data acquisition and measurement Grid 41  2.2  Results and Discussions 44  2.2.1  Horizontal plane (X-Y) measurements for both configurations 44  2.2.2  Vertical plane (X-Z) measurements for both configurations 48  2.2.2.1  Axial velocity and turbulent fluctuating component 48  2.2.2.2  Radial velocity and turbulent fluctuating component 50  2.2.3  Vertical plane (Y-Z) measurements for both configurations 52  2.2.3.1  Axial velocity and turbulent fluctuating component 52  2.2.3.2  Tangential velocity and turbulent fluctuating component 53  2.2.4  Confinement effect on the flow field 54  Chapter 3.  (SAC Aerodynamics) 70  3.1  Experimental setup, procedure and test conditions 70  ix  Higher pressure drop shows minimum impact on the frequencies of concern This suggests that the instabilities generated in the SAC sector under investigation are not strongly dependent on pressure drop  The SAC sector is successfully modified to allow for a larger side window which enables capturing details of the reacting flow in the primary zone, secondary zone and the dilution zone The high speed camera is proven to be a very useful tool in the diagnostic of the instabilities  Thermal NOx is the dominant source of NOx in the SAC sector running with gaseous fuel  CO increases toward the LBO limit because of the low energy that disables the oxidation of CO to CO2 However, at high power the CO increases because of the dissociation of CO2 to CO  Water injection appreciably reduces the NOx emissions by reducing the flame temperature However, this only occurs at high power At low power the water injection has minimum influence on the combustion emissions  A reduction of the NOx emissions of up to 50% is achieved with a water fuel ratio of 100 %  NOx reduction rate is not linearly related to the water injection flow rate As the water injection flow rate doubles the rate of NOx reduction increases more than twice  Propane and methane emission are similar However, propane shows slightly less concentration of NOx and CO, but higher CO2 concentration 159  The SAC exit cross section shows emissions with high degree of non uniformity at high power conditions (global equivalence ratio of 0.6) NOx concentration is maximum near the combustor walls and reaches a minimum at the SAC exit geometrical center Local equivalence ratio shows that the equivalence ratio is high at such locations and consequently a higher flame temperature results in high generation of NOx  Water injection at high power conditions reduces the concentration of NOx at the SAC exit significantly and also increases the degree of uniformity of the concentration of different species  The contours of concentration of different species show higher degree of uniformity at low power conditions (local equivalence ratio of 0.3) However, the NOx still shows variations of around 35% This puts emphasis on the importance of measuring the species concentration at different spots to provide a better averaging and a better estimate of the emissions generated from the combustion chamber 160 Chapter (Proposed future work) The current study has answered several questions However, several others questions needs to be addressed These questions could be summarized as follows:  A probe should be used to measure the species formation inside the SAC sector PLIF measurements will also be useful The aim will be to study the zones that act as sources of NOx and CO This study should be coupled with a repeat of the jet sensitivity study The question to be answered is: if factors like partial jet blocking significantly affects the flow field structure then how does the emissions characteristics of the SAC change?  The cooling jets underneath the primary jets are to be increased in diameter The holes meant by here are the only the two or three holes right underneath the primary jet (not the whole strip) The effect on dynamics and emissions should be investigated  With the jets diameter reduced to 0.41 and 0.3 inch, the corresponding acoustic spectrum is to be established This will provide very useful insight on the effect of diameter on dynamics generation The study must be coupled with measurements of the emissions at the combustor exit It has to be verified that there is minimum impact on the CO and NOx  Cold flow PIV and LDV are to be repeated with the primary jets moved to the next cooling strip The resulting flow field is to be compared with the resulting from the placement of the primary jets at the old location The sensitivity study is also to be repeated The aim will be to quantify the reduction of the flow sensitivity with the new jets locations 161  A portion of the exhaust could be injected back in the passage before the primary jets admission points Drastic impact on the dynamics and emissions is expected The author expects a new concept to be developed based on this study Also, water injection in the passage could provide similar results  A new fuel nozzle is to be tested The fuel nozzle has to produce a stream with an angle less that the current fuel nozzle Then, the acoustic spectrum is to be established one more time The author expects improvement in the stability with the reduced angle, but emissions measurements are to be conducted simultaneously to ensure that the emissions characteristics don’t deteriorate  LDV should be used to measure the flow velocity for the reacting flow case at few points This will provide an estimation of the velocity magnitude at different regions (primary, secondary and dilution) 162 References [1] Hawthorne, W R., 1989, "The Early History of the Aircraft Gas Turbine in Britain," Munich [2] Beer, J M., and Chigier, N., 1972, Combustion Aerodynamics, Applied Science Publishers LTD, London [3] Gupta, A K., Lilley, D G., and Syred, N., 1984, Swirl Flows, Abacus Press [4] Syred, N., and Beér, J M., 1974, "Combustion in Swirling Flows: A Review," Combustion and Flame, 23(1), pp 143-201 [5] Vu, B T., and Gouldin, F C., 1982, "Flow Measurements in a Model Swirl Combustor," AIAA, 20(5), pp 642-651 [6] Roquemore, W M., and Tankin, R S., 1986, "A Study of a Bluff-Body Combustor Using Laser Sheet Lighting," Experiments in Fluids, 4(4), pp 205-213 [7] Froud, D., O'doherty, T., and Syred, N., 1995, "Phase Averaging of the Precessing Vortex Core in a Swirl Burner under Piloted and Premixed Combustion Conditions," Combustion and Flame, 100(3), pp 407-412 [8] Ji, J., and Gore, J P., 2002, "Flow Structure in Lean Premixed Swirling Combustion," Twenty-Nineth Symposium on Combustion, 29(1), pp 861-867 [9] Johnson, M R., Littlejohn, D., Nazeer, W A., Smith, K O., and Cheng, R K., 2005, "A Comparison of the Flowfields and Emissions of High-Swirl Injectors and Low-Swirl Injectors for Lean Premixed Gas Turbines," Proceedings of the Combustion Institute, 30(2), pp 2867-2874 [10] Wicksall, D M., and Agrawal, A K., 2005, "Influence of Hydrogen Addition on Flow Structure in Confined Swirling Methane Flame," Journal of Propulsion and Power, 21(1), pp 16-24 [11] Wicksall, D M., Agrawal, A K., Schefer, R W., and Keller, J O., 2005, "The Interaction of Flame and Flow Field in a Lean Premixed Swirl-Stabilized Combustor Operated on H2/Ch4/Air," Proceedings of the Combustion Institute, 30(2), pp 2875-2883 [12] Elkady, A M., 2005, "Experimental Investigation of Aerodynamics, Combustion, and Emissions Characteristics within the Primary Zone of a Gas Turbine Combustor," Ph.D University of Cincinnati, Cincinnati 163 [13] Sadanandan, R., and Stöhr, M M., W., 2008, "Simultaneous Oh-Plif and Piv Measurements in a Gas Turbine Model Combustor," Applied Physics B, 90(3-4), pp 609618 [14] Stopper, U., Aigner, M., Axa, H., Meier, W., Sadanandan, R., Stöhr, M., and Bonaldo, A., 2009, "Piv, 2d-Lif and 1d-Raman Measurements of Flow Field, Composition and Temperature in Premixed Gas Turbine Flames," Experimental Thermal and Fluid Science, 34(3), pp 396-403 [15] Mehta, J M., Shin, H.-W., and Wisler, D C., 1989, "Mean Velocity and Turbulent Flow-Field Characteristics inside an Advanced Combustor Swirl Cup," AIAA, Reno, NV [16] Mongia, H C., Al-Roub, M., Danis, A E.-L., D., Johnson, A., Vise, S., Jeng, S M., Mcdonell, V., and Samuelsen, G S., 2001, "Swirl Cup Modeling Part 1," Salt Lake City, UT [17] Hsiao, G., Mongia, H C., and Atul, V., 2003, "Swirl Cup Modeling Part Ii: Inlet Boundary Conditions," AIAA, Reno, Nevada [18] Hsiao, G., and Mongia, H C., 2003, "Swirl Cup Modeling Part 3: Grid Independent Solution with Different Turbulence Models," Reno, Nevada [19] Cai, J., Fu, Y., Elkadi, A., Jeng, S., and Mongia, H., 2003, "Swirl Cup Modeling Part 6: Effect of Confinement on Flow Characteristics,." 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Annular Combustor: Experimental investigations of Aerodynamics, Dynamics and Emissions A thesis submitted to the Division of Graduate Studies and Research of the University of Cincinnati in partial... review on aerodynamics, dynamics, and emissions is presented In Chapter 2, the effect of the method of admission of the swirling flow to the combustion chamber on the turbulence activities and the... Engineering, Missouri University of Science and Technology, USA Committee Chair: Dr San-Mou Jeng i Abstract The present work investigates the aerodynamics, dynamics and emissions of a Single Cup Combustor