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Combined with the use of renewable energy sources for its production, hydrogen represents a possible alternative gas turbine fuel for future low-emission power generation. Due to the difference in the physical properties of hydrogen compared to other fuels such as natural gas, well-established gas turbine combustion systems cannot be directly applied to dry low NOₓ (DLN) hydrogen combustion. The DLN micromix combustion of hydrogen has been under development for many years, since it has the promise to significantly reduce NOₓ emissions. This combustion principle for air-breathing engines is based on crossflow mixing of air and gaseous hydrogen. Air and hydrogen react in multiple miniaturized diffusion-type flames with an inherent safety against flashback and with low NOₓ emissions due to a very short residence time of the reactants in the flame region. The paper presents an advanced DLN micromix hydrogen application. The experimental and numerical study shows a combustor configuration with a significantly reduced number of enlarged fuel injectors with high-thermal power output at constant energy density. Larger fuel injectors reduce manufacturing costs, are more robust and less sensitive to fuel contamination and blockage in industrial environments. The experimental and numerical results confirm the successful application of high-energy injectors, while the DLN micromix characteristics of the design point, under part-load conditions, and under off-design operation are maintained. Atmospheric test rig data on NOₓ emissions, optical flame-structure, and combustor material temperatures are compared to numerical simulations and show good agreement. The impact of the applied scaling and design laws on the miniaturized micromix flamelets is particularly investigated numerically for the resulting flow field, the flame-structure, and NOₓ formation.
Combined with the use of renewable energy sources for its production, Hydrogen represents a possible alternative gas turbine fuel within future low emission power generation. Due to the large difference in the physical properties of Hydrogen compared to other fuels such as natural gas, well established gas turbine combustion systems cannot be directly applied for Dry Low NOx (DLN) Hydrogen combustion. Thus, the development of DLN combustion technologies is an essential and challenging task for the future of Hydrogen fuelled gas turbines. The DLN Micromix combustion principle for hydrogen fuel has been developed to significantly reduce NOx-emissions. This combustion principle is based on cross-flow mixing of air and gaseous hydrogen which reacts in multiple miniaturized diffusion-type flames. The major advantages of this combustion principle are the inherent safety against flash-back and the low NOx-emissions due to a very short residence time of reactants in the flame region of the micro-flames. The Micromix Combustion technology has been already proven experimentally and numerically for pure Hydrogen fuel operation at different energy density levels. The aim of the present study is to analyze the influence of different geometry parameter variations on the flame structure and the NOx emission and to identify the most relevant design parameters, aiming to provide a physical understanding of the Micromix flame sensitivity to the burner design and identify further optimization potential of this innovative combustion technology while increasing its energy density and making it mature enough for real gas turbine application. The study reveals great optimization potential of the Micromix Combustion technology with respect to the DLN characteristics and gives insight into the impact of geometry modifications on flame structure and NOx emission. This allows to further increase the energy density of the Micromix burners and to integrate this technology in industrial gas turbines.
Combined with the use of renewable energy sources for
its production, Hydrogen represents a possible alternative gas
turbine fuel for future low emission power generation. Due to
its different physical properties compared to other fuels such
as natural gas, well established gas turbine combustion
systems cannot be directly applied for Dry Low NOx (DLN)
Hydrogen combustion. This makes the development of new
combustion technologies an essential and challenging task
for the future of hydrogen fueled gas turbines.
The newly developed and successfully tested “DLN
Micromix” combustion technology offers a great potential to
burn hydrogen in gas turbines at very low NOx emissions.
Aiming to further develop an existing burner design in terms
of increased energy density, a redesign is required in order to
stabilise the flames at higher mass flows and to maintain low
emission levels.
For this purpose, a systematic design exploration has
been carried out with the support of CFD and optimisation
tools to identify the interactions of geometrical and design
parameters on the combustor performance. Aerodynamic
effects as well as flame and emission formation are observed
and understood time- and cost-efficiently. Correlations
between single geometric values, the pressure drop of the
burner and NOx production have been identified as a result.
This numeric methodology helps to reduce the effort of
manufacturing and testing to few designs for single
validation campaigns, in order to confirm the flame stability
and NOx emissions in a wider operating condition field.
The Dry-Low-NOx (DLN) Micromix combustion technology has been developed as low emission combustion principle for industrial gas turbines fueled with hydrogen or syngas. The combustion process is based on the phenomenon of jet-in-crossflow-mixing (JICF). Fuel is injected perpendicular into the air-cross-flow and burned in a multitude of miniaturized, diffusion-like flames. The miniaturization of the flames leads to a significant reduction of NOx emissions due to the very short residence time of reactants in the flame. In the Micromix research approach, computational fluid dynamics (CFD) analyses are validated toward experimental results. The combination of numerical and experimental methods allows an efficient design and optimization of DLN Micromix combustors concerning combustion stability and low NOx emissions. The paper presents a comparison of several numerical combustion models for hydrogen and hydrogen-rich syngas. They differ in the complexity of the underlying reaction mechanism and the associated computational effort. The performance of a hybrid eddy-break-up (EBU) model with a one-step global reaction is compared to a complex chemistry model and a flamelet generated manifolds (FGM) model, both using detailed reaction schemes for hydrogen or syngas combustion. Validation of numerical results is based on exhaust gas compositions available from experimental investigation on DLN Micromix combustors. The conducted evaluation confirms that the applied detailed combustion mechanisms are able to predict the general physics of the DLN-Micromix combustion process accurately. The FGM method proved to be generally suitable to reduce the computational effort while maintaining the accuracy of detailed chemistry.
The Dry-Low-NOx (DLN) Micromix combustion technology has been developed originally as a low emission alternative for industrial gas turbine combustors fueled with hydrogen. Currently the ongoing research process targets flexible fuel operation with hydrogen and syngas fuel.
The non-premixed combustion process features jet-in-crossflow-mixing of fuel and oxidizer and combustion through multiple miniaturized flames. The miniaturization of the flames leads to a significant reduction of NOx emissions due to the very short residence time of reactants in the flame.
The paper presents the results of a numerical and experimental combustor test campaign. It is conducted as part of an integration study for a dual-fuel (H2 and H2/CO 90/10 Vol.%) Micromix combustion chamber prototype for application under full scale, pressurized gas turbine conditions in the auxiliary power unit Honeywell Garrett GTCP 36-300.
In the presented experimental studies, the integration-optimized dual-fuel Micromix combustor geometry is tested at atmospheric pressure over a range of gas turbine operating conditions with hydrogen and syngas fuel. The experimental investigations are supported by numerical combustion and flow simulations. For validation, the results of experimental exhaust gas analyses are applied.
Despite the significantly differing fuel characteristics between pure hydrogen and hydrogen-rich syngas the evaluated dual-fuel Micromix prototype shows a significant low NOx performance and high combustion efficiency. The combustor features an increased energy density that benefits manufacturing complexity and costs.
Kawasaki Heavy Industries, Ltd. (KHI), Aachen University of Applied Sciences, and B&B-AGEMA GmbH have investigated the potential of low NOx micro-mix (MMX) hydrogen combustion and its application to an industrial gas turbine combustor. Engine demonstration tests of a MMX combustor for the M1A-17 gas turbine with a co-generation system were conducted in the hydrogen-fueled power generation plant in Kobe City, Japan.
This paper presents the results of the commissioning test and the combined heat and power (CHP) supply demonstration. In the commissioning test, grid interconnection, loading tests and load cut-off tests were successfully conducted. All measurement results satisfied the Japanese environmental regulation values. Dust and soot as well as SOx were not detected. The NOx emissions were below 84 ppmv at 15 % O2. The noise level at the site boundary was below 60 dB. The vibration at the site boundary was below 45 dB.
During the combined heat and power supply demonstration, heat and power were supplied to neighboring public facilities with the MMX combustion technology and 100 % hydrogen fuel. The electric power output reached 1800 kW at which the NOx emissions were 72 ppmv at 15 % O2, and 60 %RH. Combustion instabilities were not observed. The gas turbine efficiency was improved by about 1 % compared to a non-premixed type combustor with water injection as NOx reduction method. During a total equivalent operation time of 1040 hours, all combustor parts, the M1A-17 gas turbine as such, and the co-generation system were without any issues.
An overview on dry low NOx micromix combustor development for hydrogen-rich gas turbine applications
(2019)
The Dry-Low-NOₓ (DLN) Micromix combustion technology has been developed as low emission combustion principle for industrial gas turbines fueled with hydrogen or syngas. The combustion process is based on the phenomenon of jet-in-crossflow-mixing. Fuel is injected perpendicular into the air-cross-flow and burned in a multitude of miniaturized, diffusion-like flames. The miniaturization of the flames leads to a significant reduction of NOₓ emissions due to the very short residence time of reactants in the flame.
In the Micromix research approach, CFD analyses are validated towards experimental results. The combination of numerical and experimental methods allows an efficient design and optimization of DLN Micromix combustors concerning combustion stability and low NOₓ emissions.
The paper presents a comparison of several numerical combustion models for hydrogen and hydrogen-rich syngas. They differ in the complexity of the underlying reaction mechanism and the associated computational effort.
For pure hydrogen combustion a one-step global reaction is applied using a hybrid Eddy-Break-up model that incorporates finite rate kinetics. The model is evaluated and compared to a detailed hydrogen combustion mechanism derived by Li et al. including 9 species and 19 reversible elementary reactions. Based on this mechanism, reduction of the computational effort is achieved by applying the Flamelet Generated Manifolds (FGM) method while the accuracy of the detailed reaction scheme is maintained.
For hydrogen-rich syngas combustion (H₂-CO) numerical analyses based on a skeletal H₂/CO reaction mechanism derived by Hawkes et al. and a detailed reaction mechanism provided by Ranzi et al. are performed.
The comparison between combustion models and the validation of numerical results is based on exhaust gas compositions available from experimental investigation on DLN Micromix combustors.
The conducted evaluation confirms that the applied detailed combustion mechanisms are able to predict the general physics of the DLN-Micromix combustion process accurately. The Flamelet Generated Manifolds method proved to be generally suitable to reduce the computational effort while maintaining the accuracy of detailed chemistry.
Especially for reaction mechanisms with a high number of species accuracy and computational effort can be balanced using the FGM model.
The utilisation of vehicle-oriented gasoline in general aviation is very desirable for both ecological and economical reasons, as well as for general considerations of availability. As of today vehicle fuels may be used if the respective engine and cell are certified for such an operation. For older planes a supplementary technical certificate is provided for gasoline mixtures with less than 1 % v/v ethanol only, though. Larger admixtures of ethanol may lead to sudden engine malfunction and should be considered as considerable security risks. Major problems are caused by the partially ethanol non-withstanding materials, a necessarily changed stochiometric adjustment of the engine for varying ethanol shares and the tendency for phase separation in the presence of absorbed water. The concepts of the flexible fuel vehicles are only partially applicable in the view of air security.
Auch in der allgemeinen Luftfahrt wäre es wünschenswert, die bereits vorhandenen Verbrennungsmotoren mit weniger CO₂-trächtigen Kraftstoffen als dem heute weit verbreiteten Avgas 100LL betreiben zu können. Es ist anzunehmen, dass im Vergleich die unter Normalbedingungen gasförmigen Kraftstoffe CNG, LPG oder LNG deutlich weniger Emissionen produzieren. Erforderliche Antriebssystemanpassungen wurden im Rahmen eines Forschungsprojekts an der FH Aachen untersucht.
Up in the clouds and above fuels and construction materials must be very carefully selected to ensure a smooth flight and touchdown. Out of around 38,000 single and dual-engined propeller aeroplanes, roughly a third are affected by a new trend in the fuel sector that may lead to operating troubles or even emergency landings: The admixture of bio-ethanol to conventional gasoline. Experiences with these fuels may be projected to alternative mixtures containing new components.
In general aviation, too, it is desirable to be able to operate existing internal combustion engines with fuels that produce less CO₂ than Avgas 100LL being widely used today It can be assumed that, in comparison, the fuels CNG, LPG or LNG, which are gaseous under normal conditions, produce significantly lower emissions. Necessary propulsion system adaptations were investigated as part of a research project at Aachen University of Applied Sciences.
Numerical Study on Increased Energy Density for the DLN Micromix Hydrogen Combustion Principle
(2014)
The feasibility study presents results of a hydrogen combustor integration for a Medium-Range aircraft engine using the Dry-Low-NOₓ Micromix combustion principle. Based on a simplified Airbus A320-type flight mission, a thermodynamic performance model of a kerosene and a hydrogen-powered V2530-A5 engine is used to derive the thermodynamic combustor boundary conditions. A new combustor design using the Dry-Low NOx Micromix principle is investigated by slice model CFD simulations of a single Micromix injector for design and off-design operation of the engine. Combustion characteristics show typical Micromix flame shapes and good combustion efficiencies for all flight mission operating points. Nitric oxide emissions are significant below ICAO CAEP/8 limits. For comparison of the Emission Index (EI) for NOₓ emissions between kerosene and hydrogen operation, an energy (kerosene) equivalent Emission Index is used.
A full 15° sector model CFD simulation of the combustion chamber with multiple Micromix injectors including inflow homogenization and dilution and cooling air flows investigates the combustor integration effects, resulting NOₓ emission and radial temperature distributions at the combustor outlet. The results show that the integration of a Micromix hydrogen combustor in actual aircraft engines is feasible and offers, besides CO₂ free combustion, a significant reduction of NOₓ emissions compared to kerosene operation.
Biofuels potentially interesting also for aviation purposes are predominantly liquid fuels produced from biomass. The most common biofuels today are biodiesel and bioethanol. Since diesel engines are rather rare in aviation this survey is focusing on ethanol admixed to gasoline products.
The Directive 2003/30/EC of the European Parliament and the Council of May 8th 2003 on the promotion of the use of biofuels or other renewable fuels for transport encourage a growing admixture of biogenic fuel components to fossil automotive gasoline. Some aircraft models equipped with spark ignited piston engines are approved for operation with automotive gasoline, frequently called “MOGAS” (motor gasoline). The majority of those approvals is limited to MOGAS compositions that do not contain methanol or ethanol beyond negligible amounts. In the past years (bio-)MTBE or (bio-)ETBE have been widely used as blending component of automotive gasoline whilst the usage of low-molecular alcohols like methanol or ethanol has been avoided due to the handling problems especially with regard to the strong affinity for water. With rising mandatory bio-admixtures the conversion of the basic biogenic ethanol to ETBE, causing a reduction of energetic payoff, becomes more and more unattractive. Therefore the direct ethanol admixture is accordingly favoured.
Due to the national enforcements of the directive 2003/30/EC more oxygenates produced from organic materials like bioethanol have started to appear in automotive gasolines already. The current fuel specification EN 228 already allows up to 3 % volume per volume (v/v) (bio-)methanol or up to 5 % v/v (bio-)ethanol as fuel components. This is also roughly the amount of biogenic components to comply with the legal requirements to avoid monetary penalties for producers and distributors of fuels.
Since automotive fuel is cheaper than the common aviation gasoline (AVGAS), creates less problems with lead deposits in the engine, and in general produces less pollutants it is strongly favoured by pilots. But being designed for a different set of usage scenarios the use of automotive fuel with low molecular alcohols for aircraft operation may have adverse effects in aviation operation. Increasing amounts of ethanol admixtures impose various changes in the gasoline’s chemical and physical properties, some of them rather unexpected and not within the range of flight experiences even of long-term pilots.