Design Improvement Survey for NOx Emissions Reduction of a Heavy-Duty Gas Turbine Partially Premixed Fuel Nozzle Operating With Natural Gas: Numerical Assessment

2015 ◽  
Vol 138 (1) ◽  
Author(s):  
Alessandro Innocenti ◽  
Antonio Andreini ◽  
Bruno Facchini ◽  
Matteo Cerutti ◽  
Gianni Ceccherini ◽  
...  
Keyword(s):  
Gas Turbine ◽  
Turbulent Combustion ◽  
Operating Conditions ◽  
Combustion Model ◽  
Formation Mechanisms ◽  
Heavy Duty ◽  
Flamelet Generated Manifold ◽  
Fuel Nozzle ◽  
Partially Premixed ◽  
Heavy Duty Gas Turbine

A numerical investigation of a low NOx partially premixed fuel nozzle for heavy-duty gas turbine applications is presented in this paper. Availability of results from a recent test campaign on the same fuel nozzle architecture allowed the exhaustive comparison study presented in this work. At first, an assessment of the turbulent combustion model was carried out, with a critical investigation of the expected turbulent combustion regimes in the system and taking into account the partially premixed nature of the flame due to the presence of diffusion type pilot flames. In particular, the fluent partially premixed combustion model and a flamelet approach are used to simulate the flame. The laminar flamelet database is generated using the flamelet generated manifold (FGM) chemistry reduction technique. Species and temperature are parameterized by mixture fraction and progress variable. Comparisons with calculations with partially premixed model and the steady diffusion flamelet (SDF) database are made for the baseline configuration in order to discuss possible gains associated with the introduced dimension in the FGM database (reaction progress), which makes it possible to account for nonequilibrium effects. Numerical characterization of the baseline nozzle has been carried out in terms of NOx. Computed values for both the baseline and some alternative premixer designs have been then compared with experimental measurements on the reactive test rig at different operating conditions and different split ratios between main and pilot fuel. Numerical results allowed pointing out the fundamental NOx formation processes, both in terms of spatial distribution within the flame and in terms of different formation mechanisms. The obtained knowledge would allow further improvement of fuel nozzle design.

Design Improvement Survey for NOx Emissions Reduction of a Heavy-Duty Gas Turbine Partially Premixed Fuel Nozzle Operating With Natural Gas: Numerical Assessment

2015 ◽  
Author(s):  
Alessandro Innocenti ◽  
Antonio Andreini ◽  
Bruno Facchini ◽  
Matteo Cerutti ◽  
Gianni Ceccherini ◽  
...  
Keyword(s):  
Gas Turbine ◽  
Turbulent Combustion ◽  
Operating Conditions ◽  
Combustion Model ◽  
Formation Mechanisms ◽  
Heavy Duty ◽  
Flamelet Generated Manifold ◽  
Fuel Nozzle ◽  
Partially Premixed ◽  
Heavy Duty Gas Turbine

A numerical investigation of a low NOx partially premixed fuel nozzle for heavy-duty gas turbine applications is presented in this paper. Availability of results from a recent test campaign on the same fuel nozzle architecture allowed the exhaustive comparison study presented in this work. At first, an assessment of the turbulent combustion model was carried out, with a critical investigation of the expected turbulent combustion regimes in the system and taking into account the partially premixed nature of the flame due to the presence of diffusion type pilot flames. In particular, the Fluent partially premixed combustion model and a flamelet approach are used to simulate the flame. The laminar flamelet database is generated using the Flamelet Generated Manifold (FGM) chemistry reduction technique. Species and temperature are parameterized by mixture-fraction and progress variable. Comparisons with calculations with partially premixed model and the steady diffusion flamelet (SDF) database are made for the baseline configuration in order to discuss possible gains associated with the introduced dimension in the FGM database (reaction progress) which makes it possible to account for non-equilibrium effects. Numerical characterization of the baseline nozzle has been carried out in terms of NOx. Computed values for both the baseline and some alternative premixer designs have been then compared with experimental measurements on the reactive test rig at different operating conditions and different split ratios between main and pilot fuel. Numerical results allowed pointing out the fundamental NOx formation processes, both in terms of spatial distribution within the flame and in terms of different formation mechanisms. The obtained knowledge would allow further improvement of fuel nozzle design.

Numerical Investigations of NOx Emissions of a Partially Premixed Burner for Natural Gas Operations in Industrial Gas Turbine

2014 ◽  
Author(s):  
Alessandro Innocenti ◽  
Antonio Andreini ◽  
Andrea Giusti ◽  
Bruno Facchini ◽  
Matteo Cerutti ◽  
...  
Keyword(s):  
Gas Turbine ◽  
Turbulent Combustion ◽  
Fuel Injection ◽  
Formation Rate ◽  
Operating Conditions ◽  
Combustion Model ◽  
Nox Emissions ◽  
Air Concentration ◽  
Partially Premixed ◽  
Industrial Gas Turbine

In the present paper a numerical analysis of a low NOx partially premixed burner for industrial gas turbine applications is presented. The first part of the work is focused on the study of the premixing process inside the burner. Standard RANS CFD approach was used: k–ε turbulence model was modified and calibrated in order to find a configuration able to fit available experimental profiles of fuel/air concentration at the exit of the burner. The resulting profiles at different test points have been used to perform reactive simulations of an experimental test rig, where exhaust NOx emissions were measured. An assessment of the turbulent combustion model was carried out with a critical investigation of the expected turbulent combustion regimes in the system and taking into account the partially premixed nature of the flame due to the presence of diffusion type pilot flames. A reliable numerical setup was discovered by comparing predicted and measured NOx emissions at different operating conditions and at different split ratio between main and pilot fuel. In the investigated range, the influence of the premixer in the NOx formation rate was found to be marginal if compared with the pilot flame one. The calibrated numerical setup was then employed to explore possible modifications to fuel injection criteria and fuel split, with the aim of minimizing exhaust NOx emissions. This preliminary numerical screening of alternative fuel injection strategies allowed to define a set of advanced configurations to be investigated in future experimental tests.

Design Improvement Survey for NOx Emissions Reduction of a Heavy-Duty Gas Turbine Partially Premixed Fuel Nozzle Operating With Natural Gas: Experimental Campaign

2015 ◽  
Author(s):  
Matteo Cerutti ◽  
Roberto Modi ◽  
Danielle Kalitan ◽  
Kapil K. Singh
Keyword(s):  
Pressure Drop ◽  
Natural Gas ◽  
Gas Turbine ◽  
Pollutant Emissions ◽  
Nox Emissions ◽  
Heavy Duty ◽  
Fuel Nozzle ◽  
Partially Premixed ◽  
Heavy Duty Gas Turbine ◽  
The Impact

As government regulations become increasingly strict with regards to combustion pollutant emissions, new gas turbine combustor designs must produce lower NOx while also maintaining acceptable combustor operability. The design and implementation of an efficient fuel/air premixer is paramount to achieving low emissions. Options for improving the design of a natural gas fired heavy-duty gas turbine partially premixed fuel nozzle have been considered in the current study. In particular, the study focused on fuel injection and pilot/main interaction at high pressure and high inlet temperature. NOx emissions results have been reported and analyzed for a baseline nozzle first. Available experience is shared in this paper in the form of a NOx correlative model, giving evidence of the consistency of current results with past campaigns. Subsequently, new fuel nozzle premixer designs have been investigated and compared, mainly in terms of NOx emissions performance. The operating range of investigation has been preliminarily checked by means of a flame stability assessment. Adequate margin to lean blow out and thermo-acoustic instabilities onset has been found while also maintaining acceptable CO emissions. NOx emission data were collected over a variety of fuel/air ratios and pilot/main splits for all the fuel nozzle configurations. Results clearly indicated the most effective design option in reducing NOx. In addition, the impact of each design modification has been quantified and the baseline correlative NOx emissions model calibrated to describe the new fuel nozzles behavior. Effect of inlet air pressure has been evaluated and included in the models, allowing the extensive use of less costly reduced pressure test campaigns hereafter. Although the observed effect of combustor pressure drop on NOx is not dominant for this particular fuel nozzle, sensitivity has been performed to consolidate gathered experience and to make the model able to evaluate even small design changes affecting pressure drop.

Numerical Analysis of the Dynamic Flame Response and Thermo-Acoustic Stability of a Full-Annular Lean Partially-Premixed Combustor

2016 ◽  
Author(s):  
Alessandro Innocenti ◽  
Antonio Andreini ◽  
Bruno Facchini ◽  
Matteo Cerutti
Keyword(s):  
Dynamic Response ◽  
Gas Turbine ◽  
Operating Conditions ◽  
System Stability ◽  
Driving Mechanism ◽  
Heavy Duty ◽  
Flame Response ◽  
Partially Premixed ◽  
Heavy Duty Gas Turbine ◽  
Acoustic Stability

A thermo-acoustic stability of a full-annular lean partially-premixed heavy-duty gas turbine combustor is carried out in the present paper. A sensitivity analysis is performed, varying the flame temperature for two operating conditions. The complex interaction between the system acoustics and the turbulent flame is studied in Ansys Fluent, using Unsteady-RANS simulations with Flamelet-Generated Manifolds combustion model. Perturbations are introduced in the system imposing a broadband excitation as inlet boundary condition. The flame response is then computed exploiting system identification techniques. The identified flame transfer functions are compared each other and the results analysed in order to give more physical insight on the coupling mechanisms responsible for the flame dynamic response. The effect of fuel mass flow fluctuations is then introduced as further driving input, describing the flame as a Multi-Input Single-Output system. Further in-depth studies are carried out on pilot flames aiming at replicating the dynamic response of the real flame and understanding the driving mechanism of thermo-acoustic instability onset as well. The obtained results are implemented into a finite element model of the combustor, realized in COMSOL Multiphysics, to analyse the system stability. Numerical model affordability has been assessed through comparisons with results from full-annular combustor experimental campaign carried out by GE Oil & Gas since the early phases of the design and development of a heavy-duty gas turbine. This allowed the discussion of the model ability to describe the stability properties of the combustor and to catch the instabilities onset as detected experimentally. Valuable indications for future design optimization were also identified thanks to the obtained results.

Numerical Investigations of Pollutant Emissions From Novel Heavy-Duty Gas Turbine Burners Operated With Natural Gas

2020 ◽  
Vol 142 (3) ◽  
Author(s):  
Daniele Pampaloni ◽  
Pier Carlo Nassini ◽  
Antonio Andreini ◽  
Bruno Facchini ◽  
Matteo Cerutti
Keyword(s):  
Flow Field ◽  
Gas Turbine ◽  
Design Process ◽  
Gas Turbines ◽  
Operating Conditions ◽  
Pollutant Emissions ◽  
Formation Mechanisms ◽  
Heavy Duty ◽  
Heavy Duty Gas Turbine ◽  
Cost Efficient

Abstract A numerical investigation of pollutant emissions of a novel dry low-emissions burner for heavy-duty gas turbine applications is presented. The objective of this work is to develop and assess a robust and cost-efficient numerical setup for the prediction of NOx and CO emissions in industrial gas turbines and to investigate the pollutant formation mechanisms, thus supporting the design process of a novel low-emission burner. To this end, a comparison against experimental data, from a recent experimental campaign performed by BHGE in cooperation with University of Florence, has been exploited. In the first part of this work, a Reynolds-averaged Navier–Stokes (RANS) approach on both a simplified geometry and the complete domain is adopted to characterize the global flame behavior and validate the numerical setup. Then, unsteady simulations exploiting the scale adaptive simulation (SAS) approach have been performed to assess the prediction improvements that can be obtained with the unsteady modeling of the flame. For all simulations, the flamelet generated manifold (FGM) model has been used, allowing the reliable and cost-efficient application of detailed chemistry mechanisms in computational fluid dynamics (CFD) simulation. However, FGM typically faces issues predicting flame emissions, such as NOx and CO, due to the wide range of time scales involved, from turbulent mixing to pollutant species oxidation. Specific models are typically used to predict NOx emissions, starting from the converged flow-field and introducing additional transport equations. Also CO prediction, especially at part-load operating conditions could be an issue for flamelet-based model: in fact, as the load decreases and the extinction limit approaches, a superequilibrium CO concentration, which cannot be accurately predicted by FGM, appears in the exhaust gases. To overcome this issue, a specific CO-burn-out model, following the original idea proposed by Klarmann, has been implemented in ANSYS fluent. The model allows to decouple the effective CO oxidation term from the one computed by FGM, defining a postflame zone where the source term of CO is treated following the Arrhenius formulation. In order to support the design process, an indepth CFD investigation has been carried out, evaluating the impact of an alternative burner geometrical configuration on stability and emissions and providing detailed information about the main regions and mechanisms of pollutants production. The outcomes support the analysis of experimental results, allowing an indepth investigation of the complex flow-field and the flame-related quantities, which have not been measured during the tests.

Numerical Investigations of Pollutant Emissions From Novel Heavy Duty Gas Turbine Burners Operated With Natural Gas

2019 ◽  
Author(s):  
Daniele Pampaloni ◽  
Pier Carlo Nassini ◽  
Antonio Andreini ◽  
Bruno Facchini ◽  
Matteo Cerutti
Keyword(s):  
Flow Field ◽  
Gas Turbine ◽  
Design Process ◽  
Gas Turbines ◽  
Operating Conditions ◽  
Pollutant Emissions ◽  
Formation Mechanisms ◽  
Heavy Duty ◽  
Heavy Duty Gas Turbine ◽  
Cost Efficient

Abstract A numerical investigation of pollutant emissions of a novel dry low-emissions burner for heavy-duty gas turbine applications is presented. The objective of the work is to develop and assess a robust and cost-efficient numerical setup for the prediction of NOx and CO emissions in industrial gas turbines and to investigate the pollutant formation mechanisms, thus supporting the design process of a novel low-emission burner. To this end, a comparison against experimental data, from a recent experimental campaign performed by BHGE in cooperation with University of Florence, has been exploited. In the first part of this work, a RANS approach on both a simplified geometry and the complete domain is adopted to characterize the global flame behavior and validate the numerical setup. Then, unsteady simulations exploiting the Scale Adaptive Simulation (SAS) approach have been performed to assess the prediction improvements that can be obtained with the unsteady modelling of the flame. For all simulations, the Flamelet Generated Manifold (FGM) model has been used, allowing the reliable and cost-efficient application of detailed chemistry mechanisms in CFD simulation. However, FGM typically faces issues predicting flame emissions, such as NOx and CO, due to the wide range of time scales involved, from turbulent mixing to pollutant species oxidation. Specific models are typically used to predict NOx emissions, starting from the converged flow field and introducing additional transport equations. Also CO prediction, especially at part-load operating conditions could be an issue for flamelet-based model: in fact, as the load decreases and the extinction limit approaches, a super-equilibrium CO concentration, which cannot be accurately predicted by FGM, appears in the exhaust gases. To overcome this issue, a specific CO burn-out model, following the original idea proposed by Klarmann, has been implemented in ANSYS Fluent. The model allows to decouple the effective CO oxidation term from the one computed by FGM, defining a post-flame zone where the source term of CO is treated following the Arrhenius formulation. In order to support the design process, an in-depth CFD investigation has been carried out, evaluating the impact of an alternative burner geometrical configuration on stability and emissions and providing detailed information about the main regions and mechanisms of pollutants production. The outcomes support the analysis of experimental results, allowing an in-depth investigation of the complex flow-field and the flame-related quantities, which have not been measured during the tests.

Experience With Large Heavy-Duty Gas Turbine Rotors

1981 ◽  
Author(s):  
O. R. Schmoch ◽  
B. Deblon
Keyword(s):  
Gas Turbine ◽  
Gas Turbines ◽  
Turbine Rotor ◽  
Strength Properties ◽  
Operating Conditions ◽  
Material Strength ◽  
Heavy Duty ◽  
Turbine Rotors ◽  
Heavy Duty Gas Turbine ◽  
Response To Temperature

The peripheral speeds of the rotors of large heavy-duty gas turbines have reached levels which place extremely high demands on material strength properties. The particular requirements of gas turbine rotors, as a result of the cycle, operating conditions and the ensuing overall concepts, have led different gas turbine manufacturers to produce special structural designs to resolve these problems. In this connection, a report is given here on a gas turbine rotor consisting of separate discs which are held together by a center bolt and mutually centered by radial serrations in a manner permitting expansion and contraction in response to temperature changges. In particular, the experience gained in the manufacture, operation and servicing are discussed.

Performance and Numerical Flow Investigations of an Industrial Gas Turbine Intake System Under Different Operating Conditions

2006 ◽  
Author(s):  
Friederike C. Mund ◽  
Pericles Pilidis
Keyword(s):  
Gas Turbine ◽  
Operating Conditions ◽  
Relative Reduction ◽  
Maximum Deviation ◽  
Heavy Duty ◽  
Flow Distortion ◽  
Local Flow ◽  
Intake System ◽  
Heavy Duty Gas Turbine ◽  
Industrial Gas Turbine

An important loss in an industrial gas turbine is caused by the intake system. Even though these losses have a direct effect on the performance of the engine, the design of the intake system is dominated by local space restriction. Consequently, intake losses are site specific parameters. They correlate with the airflow velocity and therefore operating conditions of the engine affect the intake performance. But due to the high experimental effort necessary to investigate intake losses, only sparse information about this effect is available. For the present study a typical vertical industrial intake duct was investigated numerically for different operating scenarios. The performance simulation of a single shaft heavy duty gas turbine provided boundary conditions for the CFD (Computational Fluid Dynamics) study of the intake duct. For all operating conditions a large scale vortex developed in the intake plenum and entered the compressor. Bearing support struts caused local flow distortion at the compressor inlet. Even for extreme operating scenarios the relative changes of pressure recovery compared to the design point value were small (0.1%). However, the resulting power change was generally in excess of the intake loss deviation. Applied to a heavy duty gas turbine, the maximum deviation of 0.2% of power was equivalent to about 0.4 MW. In most cases lower pressure losses were predicted which benefited the overall engine performance. For the cold scenario the intake performance deteriorated and resulted in a relative reduction of power of nearly 0.5 MW.

Prediction of CO Emission Index for Aviation Gas Turbine Combustor Using Flamelet Generated Manifold Combustion Model

2021 ◽  
Author(s):  
Saurabh Patwardhan ◽  
Pravin Nakod ◽  
Stefano Orsino ◽  
Rakesh Yadav ◽  
Fang Xu ◽  
...  
Keyword(s):  
Gas Turbine ◽  
Liquid Fuel ◽  
Operating Conditions ◽  
Turbine Engines ◽  
Combustion Model ◽  
Gas Turbine Engines ◽  
Gas Turbine Combustor ◽  
Flamelet Generated Manifold ◽  
Emission Index ◽  
Co Emission

Abstract Carbon monoxide (CO) has been identified as one of the regulated pollutants and gas turbine manufacturers target to reduce the CO emission from their gas turbine engines. CO forms primarily when carbonous fuels are not burnt completely, or products of combustion are quenched before completing the combustion. Numerical simulations are effective tools that allow a better understanding of the mechanisms of CO formation in gas turbine engines and are useful in evaluating the effect of different parameters like swirl, fuel atomization, mixing etc. on the overall CO emission for different engine conditions like idle, cruise, approach and take off. In this paper, a thorough assessment of flamelet generated manifold (FGM) combustion model is carried out to predict the qualitative variation and magnitude of CO emission index with the different configurations of a Honeywell test combustor operating with liquid fuel under idle condition, which is the more critical engine condition for CO emission. The different designs of the test combustor are configured in such a way that they yield different levels of CO and hence are ideal to test the accuracy of the combustion model. Large eddy simulation (LES) method is used for capturing the turbulence accurately along with the FGM combustion model that is computationally economical compared to the detailed/reduced chemistry modeling using finite rate combustion model. Liquid fuel spray breakup is modeled using stochastic secondary droplet (SSD) model. Four different configurations of the aviation gas turbine combustor are studied in this work referring to earlier work by Xu et al. [1]. It is shown that the FGM model can predict CO trends accurately. The other global parameters like exit temperature, NOx emissions, pattern factor also show reasonable agreement with the test data. The sensitivity of the CO prediction to the liquid fuel droplet breakup model parameters is also studied in this work. Although the trend of CO variation is captured for different values of breakup parameters, the absolute magnitude of CO emission index differs significantly with the change in the values of breakup parameters suggesting that the spray has a larger impact on the quantitative prediction of CO emission. An accurate prediction of CO trends at idle conditions using FGM model extends the applicability of FGM model to predict different engine operating conditions for different performance criteria accurately.

A Fully Non-Adiabatic Flamelet Generated Manifold Model for High Fidelity Modeling of Turbulent Combustion in Gas Turbine Like Conditions

2020 ◽  
Author(s):  
Rakesh Yadav ◽  
Ishan Verma ◽  
Abhijit Modak ◽  
Shaoping Li
Keyword(s):  
Experimental Data ◽  
Gas Turbine ◽  
Turbulent Combustion ◽  
Gas Turbines ◽  
Turbulent Flame ◽  
Operating Conditions ◽  
High Fidelity ◽  
Mixture Density ◽  
Flamelet Generated Manifold ◽  
The Impact

Abstract Flamelet Generated Manifold (FGM) has proven to be an efficient approach to model turbulent combustion across different regimes of combustion. The manifolds are generally created by solving laminar premixed or opposed flow configurations. Gas turbine combustors often involve many strong non-adiabatic events such as multiple temperature boundaries, quenching from cooling and effusion holes, conjugate heat transfer, soot radiation interaction, phase change from spray and the modulation of inlet conditions. The adiabatic assumption of the underlying flamelet generation in the FGM is, therefore, prone to errors in the prediction of flame speed, liner temperatures, and pollutant formation. In this work, a novel approach to generate fully non-adiabatic manifold is proposed and validated. The FGM manifold is created using a series of non-adiabatic flamelets, each flamelet is solved in one-dimensional physical space. The non-adiabatic flamelets are generated with an optimal combination of freely propagating and burner stabilized flames. This hybrid method of the flamelet configuration allows modeling large heat gain and loss without encountering any unrealistic temperature in the flamelet solution. Such fully non-adiabatic flamelets are then convoluted to generate a five-dimensional Non-adiabatic Flamelet Generated Manifold (NFGM) Probability Density Function (PDF.). The average properties such as temperature, mixture density, species concentration, rate of reaction, etc. from PDF are then coupled with the CFD solution. The non-adiabatic flamelets and corresponding NFGM is implemented into ANSYS Fluent software version 2020R1. This approach is validated first for canonical cases, followed by gas turbine like conditions of swirl stabilized methane fueled turbulent flame, developed at DLR Stuttgart as the PRECCINSTA combustor. The experimental data for this combustor is available for multiple operating conditions. A stable operating point (φ = 0.83, P = 30 kW) is chosen. The proposed nonadiabatic NFGM is used with Stress blended eddy simulation (SBES). The current NFGM-SBES results are compared with experimental data as well as the previously published works. The impact of modeling heat release in flamelet is used to analyze the M-shape versus V-shape flame transition and the peaks of the carbon monoxide in mixing shear layers. The findings from the current work, in terms of accuracy, validity and best practices while modeling NFGM-SBES are discussed and summarized. The improved results of NFGM compared to adiabatic FGM are encouraging and provides a potential high-fidelity tool for accurate, yet efficient modeling of turbulent combustion inside gas turbines.

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