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Numerical Study on Increased Energy Density for the DLN Micromix Hydrogen Combustion Principle
(2014)
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.
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.
The paper presents an overview of the past and present of low-emission combustor research with hydrogen-rich fuels at Aachen University of Applied Sciences. In 1990, AcUAS started developing the Dry-Low-NOx Micromix combustion technology. Micromix reduces NOx emissions using jet-in-crossflow mixing of multiple miniaturized fuel jets and combustor air with an inherent safety against flashback. At first, pure hydrogen as fuel was investigated with lab-scale applications. Later, Micromix prototypes were developed for the use in an industrial gas turbine Honeywell/Garrett GTCP-36-300, proving low NOx characteristics during real gas turbine operation, accompanied by the successful definition of safety laws and control system modifications. Further, the Micromix was optimized for the use in annular and can combustors as well as for fuel-flexibility with hydrogen-methane-mixtures and hydrogen-rich syngas qualities by means of extensive experimental and numerical simulations. In 2020, the latest Micromix application will be demonstrated in a commercial 2 MW-class gas turbine can-combustor with full-scale engine operation. The paper discusses the advances in Micromix research over the last three decades.
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.