Experiments and Simulations of Combustion Process

The present paper is the result of a cooperation between Politecnico di Torino and AVL List Gmbh within a recent collaborative research project funded by the EC. The research work was focused on the experimental and numerical characterization of mixture formation, combustion, and emissions in direct-injection NG engines, to draw useful indication for the design of innovative, high-performance engine concepts. As a matter of fact, direct-injection IC engines running on NG are believed to be a competitive transition solution towards a sustainable mobility scenario, given their maturity, technological readiness, and flexibility with respect to the fuel quality. Moreover, gaseous-fuel engines can further decrease their carbon footprint if blending of natural gas with hydrogen is considered. Provided that mixture formation represents a key aspect for the design of direct-injection engines, the activity presented in this paper is focused on the characterization of NG injection and on the mixing process, as well as the impact these latter hold on the combustion process as well as on engine-out emissions. The mixture formation process was analyzed by means of combined CFD and optical investigations. Furthermore, a full version of the engine was tested on a dynamic test rig, providing quantitative information on the engine performance and emission characteristics. The CFD results highlighted the correlation between the mixture homogeneity and the combustion stability and hinted at a relevant impact of the jet characteristics on the air charge tumble and turbulence characteristics. Full article

Green hydrogen, produced using renewable energy, is nowadays one of the most promising alternatives to fossil fuels for reducing pollutant emissions and in turn global warming. In particular, the use of hydrogen as fuel for internal combustion engines has been widely analyzed over the past few years. In this paper, the authors show the results of some experimental tests performed on a hydrogen-fueled CFR (Cooperative Fuel Research) engine, with particular reference to the combustion. Both the air/fuel (A/F) ratio and the engine compression ratio (CR) were varied in order to evaluate the influence of the two parameters on the combustion process. The combustion duration was divided in two parts: the flame front development (characterized by laminar flame speed) and the rapid combustion phase (characterized by turbulent flame speed). The results of the hydrogen-fueled engine have been compared with results obtained with gasoline in a reference operating condition. The increase in engine CR reduces the combustion duration whereas the opposite effect is observed with an increase in the A/F ratio. It is interesting to observe how the two parameters, CR and A/F ratio, have a different influence on the laminar and turbulent combustion phases. The influence of both A/F ratio and engine CR on heat transfer to the combustion chamber wall was also evaluated and compared with the gasoline operation. The heat transfer resulting from hydrogen combustion was found to be higher than the heat transfer resulting from gasoline combustion, and this is probably due to the different quenching distance of the two fuels. Full article

The paper deals with the self-ignition and combustion of hydrogen jets in a high-speed transverse flow of hot vitiated air in a duct. The Improved Delayed Detached Eddy Simulation (IDDES) approach based on the Shear Stress Transport (SST) model is used, which in this paper is applied to a turbulent reacting flow with finite rate chemical reactions. An original Adaptive Implicit Scheme for unsteady simulations of turbulent flows with combustion, which was successfully used in IDDES simulation, is described. The simulation results are compared with the experimental database obtained at the LAERTE experimental workbench of the ONERA—The French Aerospace Laboratory. Comparison of IDDES with experimental results shows a strong sensitivity of the simulation results to the surface roughness and temperature of the duct walls. The results of IDDES modeling are in good agreement with experimental pressure distributions along the wall and with the results of videoregistration of the excited radical chemiluminescence. Full article

The development of modern vehicle drives is aimed at reducing fuel consumption (i.e., crude oil) and minimizing the exhaust emission of toxic components. One such development is the implementation of a two-stage combustion system. Such a system initiates ignition in the prechamber, and then the burning mixture flows into the main chamber, where it ignites the lean mixture. The system allows the efficient combustion of lean mixtures, both liquid and gaseous fuels, in the cylinder. This article proposes a solution for internal combustion engines with a cylinder capacity of approx. 500 cm³. The tests were carried out on a single-cylinder engine powered by pure methane supplied through a double, parallel injection system. A wide range of charge ignitability requires the use of an active chamber containing an injector and a spark plug. The tests were carried out at n = 1500 rpm with three load values (indicated mean effective pressure, IMEP): 2, 4 and 6 bar. All of these tests were carried out at a constant value of the center of combustion (CoC), 8 deg CA. This approach resulted in the ignition timing being the control signal for the CoC. As a result of the conducted research, it was found that an increase in the load, which improved the inter-chamber flow, allowed for the combustion of leaner mixtures without increasing the coefficient of variation, CoV(IMEP). The tests achieved a lean mixture combustion with a value of λ = 1.7 and an acceptable level of non-uniformity of the engine operation, CoV(IMEP) < 8%. The engine’s indicated efficiency when using a two-stage system reached a value of about 42% at λ = 1.5 (which is about 8 percentage points more than with a conventional combustion system at λ = 1.0). Full article

In this paper, a large-eddy simulation (LES) of turbulent non-premixed LO₂/CH₄ combustion under transcritical conditions is performed based on the Mascotte test rig from the Office National d’Etudes et de Recherches A$\acute{\mathrm{e}}$rospatiales (ONERA), and the aim is to understand the effects of differential diffusion on the flame behaviors. In the LES, oxygen was injected into the environment above the critical pressure while the temperature was below the critical temperature. The flamelet/progress variable (FPV) approach was used as the combustion model. Two LES cases with different species diffusion coefficient schemes—i.e., non-unity and unity Lewis numbers—for generating the flamelet tables were carried out to explore the effects of differential diffusion on the flame and flow structures. The results of the LES case with non-unity Lewis numbers were in good agreement with the experimental data. It was shown that differential diffusion had evident impacts on the flame structure and flow dynamics. In particular, when unity Lewis numbers were used to evaluate the species diffusion coefficient, the flame length was underestimated and the flame expansion was more significant. Compared to laminar counterflow flames, turbulence in jet flames allows chemical reactions to take place in a wider range of mixture fractions. The density distributions of the two LES cases in the mixture fraction space were very similar, indicating that differential diffusion had no significant effects on the phase transition under transcritical conditions. Full article

The article discusses the results of experimental studies on the course of pyrolysis oil injection through the high-pressure injector of a direct-injection engine. The pyrolysis oil used for the tests was derived from waste plastics (mainly high-density polyethylene—HDPE). This oil was then distilled. The article also describes the production technology of this pyrolysis oil on a laboratory scale. It presents the results of the chemical composition of the raw pyrolysis oil and the oil after the distillation process using GC-MS analysis. Fuel injection tests were carried out for the distilled pyrolysis oil and a 91 RON gasoline in order to perform a comparative analysis with the tested pyrolysis oil. In this case, the research was focused on the injected spray cloud analysis. The essential tested parameter was the Sauter Mean Diameter (SMD) of fuel droplets measured at the injection pressure of 400 bar. The analysis showed that the oil after distillation contained a significant proportion of light hydrocarbons similar to gasoline, and that the SMDs for distilled pyrolysis oil and gasoline were similar in the 7–9 µm range. In conclusion, it can be considered that distilled pyrolysis oil from HDPE can be used both as an additive for blending with gasoline in a spark-ignition engine or as a single fuel for a gasoline compression-ignition direct injection engine. Full article

No alternatives are currently available to operate industrial furnaces, except for hydrocarbon fuels. Plant managers, therefore, face at least two challenges. First, environmental legislation demands emission reduction. Second, changes in the origin of the fuel might cause unforeseen changes in the heat release. This paper develops the hypothesis for the detailed control of the combustion process using computational fluid dynamic models. A full-scale mock-up of a rotary cement kiln is selected as a case study. The kiln is fired by the non-premixed combustion of Dutch natural gas. The gas is injected at Mach $0.6$ via a multi-nozzle burner located at the outlet of an axially mounted fuel pipe. The preheated combustion air is fed in (co-flow) through a rectangular inlet situated above the attachment of the fuel pipe. The multi-jet nozzle burner enhances the entrainment of the air in the fuel jet. A diffusion flame is formed by thin reaction zones where the fuel and oxidizer meet. The heat formed is transported through the freeboard, mainly via radiation in a participating medium. This turbulent combustion process is modeled using unsteady Favre-averaged compressible Navier–Stokes equations. The standard k-$ϵ$ equations and standard wall functions close the turbulent flow description. The eddy dissipation concept model is used to describe the combustion process. Here, only the presence of methane in the composition of the fuel is accounted for. Furthermore, the single-step reaction mechanism is chosen. The heat released radiates throughout the freeboard space. This process is described using a P1-radiation model with a constant thermal absorption coefficient. The flow, combustion, and radiative heat transfer are solved numerically using the OpenFoam simulation software. The equations for flow, combustion, and radiant heat transfer are discretized on a mesh locally refined near the burner outlet and solved numerically using the OpenFoam simulation software. The main results are as follows. The meticulously crafted mesh combined with the outlet condition that avoids pressure reflections cause the solver to converge in a stable manner. Predictions for velocity, pressure, temperature, and species distribution are now closer to manufacturing conditions. Computed temperate and species values are key to deducing the flame length and shape. The radiative heat flux to the wall peaks at the tip of the flame. This should allow us to measure the flame length indirectly from exterior wall temperature values. The amount of thermal nitric oxide formed in the flame is quantified. The main implication of this study is that the numerical model developed in this paper reveals valuable information on the combustion process in the kiln that otherwise would not be available. This information can be used to increase fuel efficiency, reduce spurious peak temperatures, and reduce pollutant emissions. The impact of the unsteady nature of the flow on the chemical species concentration and temperature distribution is illustrated in an accompanying video. Full article

In this paper, a deep neural network (DNN)-based nonlinear model predictive controller (NMPC) is demonstrated using real-time experimental implementation. First, the emissions and performance of a 4.5-liter 4-cylinder Cummins diesel engine are modeled using a DNN model with seven hidden layers and 24,148 learnable parameters created by stacking six Fully Connected layers with one long-short term memory (LSTM) layer. This model is then implemented as the plant model in an NMPC. For real-time implementation of the LSTM-NMPC, an open-source package acados with the quadratic programming solver HPIPM (High-Performance Interior-Point Method) is employed. This helps LSTM-NMPC run in real time with an average turnaround time of 62.3 milliseconds. For real-time controller prototyping, a dSPACE MicroAutoBox II rapid prototyping system is used. A Field-Programmable Gate Array is employed to calculate the in-cylinder pressure-based combustion metrics online in real time. The developed controller was tested for both step and smooth load reference changes, which showed accurate tracking performance while enforcing all input and output constraints. To assess the robustness of the controller to data outside the training region, the engine speed is varied from 1200 rpm to 1800 rpm. The experimental results illustrate accurate tracking and disturbance rejection for the out-of-training data region. At 5 bar indicated mean effective pressure and a speed of 1200 rpm, the comparison between the Cummins production controller and the proposed LSTM-NMPC showed a 7.9% fuel consumption reduction, while also decreasing both nitrogen oxides (${\mathrm{NO}}_{\mathrm{x}}$) and Particle Matter (PM) by up to 18.9% and 40.8%. Full article

The evaporation, autoignition and micro-explosion characteristics of RP-3 kerosene droplets under sub-atmospheric pressure (0.2–1.0 bar) and elevated temperature (473–1023 K) were experimentally investigated using high-speed camera technology. The results showed that the droplet evaporation rate increased monotonically with increasing temperature and pressure under 573–873 K and 0.2–1.0 bar. The decrease of temperature and pressure was obviously detrimental to the successful autoignition of droplets and increased the ignition delay time. Autoignitions at 0.2 bar were very difficult and required an ambient temperature of at least 973 K, which was about 150 K higher than the minimum ignition temperature at 1.0 bar. Sub-atmospheric pressure environment significantly inhibits the formation of soot particle clusters during the autoignition of droplet. Reducing pressure was also discovered to reduce the likelihood of micro-explosions at 673, 773 and 823 K but increase the bubble growth rate and droplet breakage intensity. Strong micro-explosions with droplet breakage time close to 1 ms were observed at 0.6 bar and 773/823 K, showing the characteristic of bubble inertia control growth. Full article

Critical velocity is very important for smoke control in longitudinally ventilated subway tunnel fires. Numerical investigations are conducted in this paper to study the impacts of metro train blockages on critical velocity in sloping subway tunnel fires by using fire dynamics simulator (FDS) tunnel models validated with the field-experiment data. Moreover, a global model of critical velocity is presented for the blocked zone of a metro train in subway tunnel fires including influencing factors of the blockage ratio and tunnel slope. The results show that the reduction ratio of critical velocity in the blocked zone is less than the metro-train blockage ratio. The correction factor between the critical velocity reduction ratio and metro-train blockage ratio is 0.545. The aerodynamic shadow zone downstream of a subway train blockage has important impacts on the critical velocity. The critical velocity in the unblocked zone of a metro train is higher than that in the blocked zone of a metro train blockage. The reason is that smoke flow is hindered by the metro train blockage in subway tunnel fires. With an increase in the blockage–fire source distance, the critical velocity first decreases and then tends to be constant. The global model presented can accurately predict the critical velocity in a sloping subway tunnel with a train blockage. The results may provide beneficial suggestions for designing ventilation systems for subway tunnels. Full article

The present work aims to evaluate the performance of the constant-volume method by several sets of experiments carried out in three different closed vessels (a sphere and two cylinders) analyzing the obtained results in order to obtain accurate laminar burning velocities. Accurate laminar burning velocities can be used in the development of computational fluid dynamics models in order to design new internal combustion engines with a higher efficiency and lower fuel consumption leading to a lower degree of environmental pollution. The pressure-time histories obtained at various initial pressures from 0.4 to 1.4 bar and ambient initial temperature were analyzed and processed using two different correlations (one implying the cubic low coefficient and the other implying the burnt mass fraction). The laminar burning velocities obtained at various initial pressures are necessary for the realization of a complete kinetic study regarding the combustion reaction and testing the actual reaction mechanisms. Data obtained from measurements were completed and compared with data obtained from runs using two different detailed chemical kinetic mechanisms (GRI 3.0 and Warnatz) and with laminar burning velocities from literature. Our experimental burning velocities ranging from 35.3 cm/s (data from spherical vessel S obtained using the burnt mass fraction) to 37.5 cm/s (data from cylindrical vessel C1 obtained using the cubic law) are inside the interval of confidence as reported by other researchers. From the dependence of the laminar burning velocity on the initial pressure, the baric coefficients were obtained. These coefficients were further used to obtain the overall reaction orders. The baric coefficients (ranging between −0.349 and −0.212) and the overall reaction orders (ranging between 1.42 and 1.50) obtained in this study fall within the reference range of data specific to methane–air mixtures examined at ambient initial temperature. Full article

With the rapid development of agriculture in China today, the demand for agricultural machinery is rapidly increasing. A large amount of exhaust gas emissions poses a severe threat to the environment. To better promote engine fuel and air mixing, enhance engine performance, and achieve low emissions, we conducted a numerical study of the pre-chamber and nozzle design in a gasoline engine for an agricultural tractor by using the G-equation method in Converge CFD software. The relevant optimization of the three model parameters in the G-equation was performed using the improved particle swarm algorithm (PSO). The model parameters after optimization by the PSO algorithm were: $a_1=0.77$, $b_1=2.0$, $b_3=1.0$. It was confirmed that the predicted engine performance was enhanced greatly with the pre-chamber system. More importantly, the results reveal that the volume and area ratios of the pre-chamber played a crucial role in the performance of the pre-chamber. Through a series of parametric studies on the pre-chamber and main chamber characteristics, we can identify the best sets of volume and area ratios based on the combustion reaction progress, the turbulent mixing profiles, and the exhaust gas emission. The turbulent maximum strength and the exhaust gas concentration of nitrogen oxides can differ by 13 and 18 times, respectively. In practical design, we recommend the optimization of the concerned metrics with the findings in the paper. Full article

The present paper reports on the numerical simulation of flow dynamics in a model gas-turbine combustor by large eddy simulation in order to evaluate the effect of coherent flow structures on the local fluctuations of gas temperature and local concentrations of NO and CO. The simulations were performed for a generic swirler, based on the design by Turbomeca, for a Reynolds number of 15,000 at normal and elevated inlet temperature and pressure (up to 500 K and 3.4 atm). The simulation data were validated based on the velocity measurements by stereoscopic particle image velocimetry. In order to reveal coherent flow structures, the velocity snapshots were processed by the proper orthogonal method. The temporal coefficients of the decomposition were used to evaluate the conditional sampled spatial distributions of the temperature and species concentration. It is shown that the coherent fluctuations of temperature can locally reach up to 200 K with the fluctuations of NO up to 20%. Thus, the results demonstrate that coherent flow structures in a lean swirl combustor can sufficiently contribute to NOx emission. Full article

Due to its enhancement in the flame speed, ozone added in lean premixed syngas turbulent jet flame was investigated by the three-dimensional direct numerical simulation method in the near field of the flame. In the present study, numerical simulations were conducted in the lean premixed syngas turbulent jet flame configuration to explore the effects of ozone addition on freely-propagating turbulent flames. It was seen that turbulence began to significantly affect the flame surface to produce wrinkles in lean premixed gas flame with ozone added after 4D; ozone started to affect the composition field and temperature field after 8D; it accelerated the generation of intermediate products, OH and O radicals; and it will promote the production of CO₂ in the near field range. Ozone will increase the flame surface area of the lean premixed syngas flame during the ignition period and can promote the ignition process and make the combustion occur earlier. The flame surface of the case with ozone added is more easily stretched by turbulence, and ozone can improve the stability of combustion. Ozone does not affect the effective radius of the flame curvature but will broaden the distribution of the curvature term because of the enhancement effect on the displacement speed of the flame surface. Full article

In this work, an experimental study and kinetic characterization of the combustion process and a morphologic study of hydrogen/methane–air mixtures are presented. The experimental study was performed in an optical access cylindrical constant-volume combustion bomb. This bomb is equipped to register the instantaneous pressure during combustion and records the combustion images using the high-speed Schlieren optical technique. This provides straightforward information to compute the flame propagation speed and direct evidence of the apparition of cellularity on the flame front. Through the images of the combustion process, it is possible to conduct a morphological study of the process using a flame monitoring model. Simultaneously, by means of a two-zone thermodynamical model, with the temporal evolution of pressure as the main intake, significant parameters are determined during the combustion process of different fuels under premixed conditions: burning velocity, rate of combustion, burned and unburned temperature, burned mass fraction, and rate of heat release, among others. Experimental results are compared with kinetic modeling results obtained with the Cantera package using the Gri-Mech 3.0 kinetic mechanism. Results show that a greater percentage of hydrogen in the fuel mixture increases the burning velocity and the cellularity of the flame front surface. At the same time, leaner mixtures and higher equivalence ratios enhance the apparition of the cellularity onset in the flames. Burning velocity increases with the increase in the initial temperature and the fuel/air mixture equivalence ratio. All the results obtained were validated with other data from the literature. Full article

The present review describes the current achievements in the applications of a planar laser-induced fluorescence (PLIF) method for the diagnostics of liquid films, bubbles, individual droplets, and sprays. Such flows are related with strongly curved interphases, which often results in additional high errors during the PLIF data quantification because of laser light reflection, refraction, and absorption. The present review demonstrates that a two-color PLIF approach and a PLIF modification for regularly structured illumination resolves the reflection- and refraction-caused errors. The latter modification ensures proper phase separation in the measurement cross-section and visualization of the interface dynamics. The former approach provides the accurate evaluation of the local temperature and concentration both in liquid and gaseous phases even in the case of strong variations of the laser sheet intensity. With intensified cameras, the PLIF method is used for multi-parameter diagnostics of the two-phase combustion of sprays in combustion chambers with optical access. It visualizes and quantifies the liquid fuel evaporation and mixing, to measure temperature in the gas and liquid phases and to reveal the regions of pollutant formation. The PLIF technique can also be easily combined with a particle image (or tracking) velocimetry method, to evaluate local heat and mass transfer. Full article

The study here presents data from the literature regarding the characteristic parameters of explosion propagation in gaseous ethane–air mixtures. The maximum explosion pressures, maximum explosion times, maximum rates of pressure increase, and deflagration indices from experimental measurements are discussed and analyzed against the initial pressure, initial temperature, and equivalence ratio, as well as the explosion vessel characteristics. Ethane is used for ethylene production, as a refrigerant in cryogenic systems, as an alternative clean fuel in the power generation industry and automotive propulsion, and for many other applications. Therefore, the explosion characteristics of its mixtures with air are of great interest for explosions occurring after accidentally forming flammable mixtures, as well as for the prediction of combustors’ performances and/or engines that work in different conditions. Full article