Search Results (125)

This study numerically investigates the effect of catalytic activity on the cold-start ignition and combustion characteristics of a propane-fueled U-bend catalytic micro-reactor. A reactive-wall approach is employed to model the catalyst coating, wherein catalytic activity is represented by the surface area factor. The results show that surface area factors between 0.425 and 3.4 exert a significant impact on ignition and combustion behavior, reducing the ignition temperature from 682 K to 521 K and decreasing the ignition delay time from 147 s to 52 s while increasing the HTR (heterogeneous reaction) contribution from 26.1% to 65.5%. Beyond a surface area factor of 3.4, performance improvements become marginal. The temporal analysis reveals that the catalytic reaction pathway dominates during the preheating stage, whereas the gas-phase reaction pathway gains prominence following ignition, eventually reaching a stable balance between the two pathways after approximately 10 s. These findings identify low catalytic activity as a sensitive operating regime and underscore the critical role of catalytic activity in optimizing ignition performance of catalytic micro-reactors. Full article

The Zhundong coalfield in Xinjiang contains vast reserves and is a crucial source of thermal coal. However, the Zhundong coal has a high content of alkali and alkaline earth metals, which makes it prone to ash deposition and slagging in boilers, thereby limiting its large-scale utilization. Fluidized-bed preheating is an emerging clean combustion technology that can reduce the slagging and fouling risks associated with high-alkali coal by modifying its fuel properties. This study employs circulating fluidized-bed preheating technology to treat high-alkali coal, with a focus on investigating the effect of the preheated air equivalence ratio on fuel preheating modification. Through microscopic characterization of both the raw coal and preheated char, the release and transformation behaviors of elements and substances during the preheating process are revealed. The results demonstrate that fluidized preheating promotes alkali metal precipitation, and increasing the preheated air equivalence ratio (λ_Pr) enhances gas production and elemental release, with a volatile fraction mass conversion of up to 84.57%. As the λ_Pr value increased from 0.28 to 0.40, the average temperature in the preheater riser increased from 904 °C to 968 °C. Compared to the raw coal, the specific surface area of the preheated char was enhanced by a factor of 3.6 to 9.1 times, with a more developed pore structure and less graphitization, thus enhancing the surface reactivity of the preheated char. The increase in λ_Pr also facilitated the conversion from pyrrolic nitrogen to pyridinic nitrogen, thus improving combustion performance and facilitating subsequent nitrogen removal. These findings provide essential data support for advancing the understanding of preheating characteristics in high-alkali coal and for promoting the development of efficient and clean combustion technologies tailored for high-alkali coal. Full article

Decarbonization of compression-ignition engines requires evaluation of carbon-free and low-carbon fuel alternatives. Ammonia (${NH}_3$) offers zero direct carbon emissions but faces combustion challenges including low flame speed (7 $\mathrm{c}\mathrm{m}/\mathrm{s}$) and high auto-ignition temperature (657 °$\mathrm{C}$). Methanol provides improved reactivity and bound oxygen content that can enhance ignition characteristics. This computational study investigates diesel–ammonia–methanol ternary fuel blends using validated three-dimensional CFD simulations (ANSYS Forte 2023 R2; ANSYS, Inc., Canonsburg, PA, USA) with merged chemical kinetic mechanisms (247 species, 2431 reactions). The model was validated against experimental in-cylinder pressure data with deviations below 5% on a single-cylinder diesel engine (510 cm³, 17.5:1 compression ratio, 1500 rpm). Ammonia energy ratios were systematically varied (10–50%) with methanol substitution levels (0–90%). Fuel preheating at 530 K was employed for high-alcohol compositions exhibiting ignition failure at standard temperature. Results demonstrate that peak cylinder pressures of 130–145 bar are achievable at 10–30% ammonia with M30K–M60K configurations, comparable to baseline diesel (140 bar). Indicated thermal efficiency reaches 38–42% at 30% ammonia-representing 5–8 percentage point improvements over diesel baseline (31%)-but declines to 30–32% at 50% ammonia due to fundamental combustion limitations. ${CO}_2$ reductions scale approximately linearly with ammonia content: 35–55% at 30% ammonia and 75–78% at 50% ammonia. ${NO}_X$ emissions demonstrate 30–60% reductions at efficiency-optimal configurations. Multi-objective optimization analysis identifies the A30M60K configuration (30% ammonia, 60% methanol, 530 K preheating) as optimal, achieving 42% thermal efficiency, 58% ${CO}_2$ reduction, 51% ${NO}_X$ reduction, and 11% power enhancement versus diesel. This configuration occupies the Pareto frontier “knee point” with cross-scenario robustness. Full article

The present work adopts a cooled cooling air (CCA) technology based on the integrated aircraft/engine thermal management concept, by coupling an air-kerosene heat exchanger with a high-temperature combustor. Using the heat exchanger, kerosene is preheated to near-critical and supercritical conditions, and the combustion characteristics of kerosene at ambient, near-critical, and supercritical states were investigated. The combustion performance tests were carried out in a model combustor under varying fuel-to-air ratios (FARs) and different kerosene injection conditions. The experimental results show that when the combustor’s FAR is increased to 0.055, the supercritical kerosene exhibits significant advantages over kerosene of the ambient state. The comparison of the combustion performance parameters shows that the combustor outlet temperature distribution factor (OTDF) and radial temperature distribution factor (RTDF) decrease by 52.26% and 51.07%, respectively; in terms of the pollutant emissions, the CO emission index (EI_CO) and unburned hydrocarbon emission index (EI_UHC) are reduced by 66.63% and 68.33%, respectively, while the NOx emission index (EI_NOx) increases by 76.26%, and the combustion efficiency improves by 2.0%. It is noteworthy that once the kerosene reaches the supercritical state, the threshold for the optimal FAR in the combustor rises to 0.055, which carries the significant engineering value for enhancing an aero-engine combustor’s operability across variable conditions and its low-emission combustion performance. Full article

With the rapid development of renewable energy sources in power generation, utility boilers need to perform load regulation over a wide range to maintain the stability of the power supply system. Preheating combustion technology is a potential approach to achieve wide load range operation, improve combustion stability, and lower NO_x emissions from utility boilers. Preheating combustion devices (PCDs) were designed and installed in the reduction zone of a boiler. These devices preheated the coal at an excess air ratio ranging from 0.35 to 0.7 to generate high-temperature gas and char, which effectively reduced NO_x formation in the furnace. Numerical studies were conducted to evaluate the combustion performance and nitrogen oxides emissions of a 330 MW utility boiler retrofitted with PCDs at different loads. The simulations were conducted over a load range of 20% to 100% of the rated load, corresponding to an electrical power of 66 MW to 330 MW. The preheated combustion device’s previous experimental data served as the boundary conditions of the preheated product nozzles. The simulation results demonstrated that the retrofitted boiler could operate stably from 20% to 100% of the rated load, maintaining acceptable combustion efficiency and lower NO_x emissions. The combustion efficiency gradually dropped with decreasing boiler load, reaching a minimum value of 95.6%. As the load declined, the size of the imaginary tangent circle of the boiler shrank, while the ignition distance increased. Additionally, the variation in NO_x concentration with load was complex. The NO_x concentration at the furnace outlet was between 102.7 and 220.3 mg/m³, and the preheated products effectively reduced the nitrogen oxides produced by combustion in the furnace at all loads. Full article

The use of conventional fuels for heat, energy, or motion production is largely determined by the concentration of water in the fuel. Therefore, the knowledge of the moisture content is of particular importance for combustion efficiency. Specifically, the presence of water in fuels can cause corrosion, and during preheating the water vapor can cause extinguishing of the flame, while at low temperatures it can cause blockage of the network by ice that can be formed. In general, the presence of water can contribute to the development of organic and inorganic substrates that may contribute to fuel turbidity, a fact that is addressed by the addition of chemical additives. In the present work, the possibility of removing moisture from heating diesel fuel through the properties of ionic and non-ionic organic polymers, namely polyvinyl alcohol (PVA) and polyethylene oxide (PEO), was studied. The experimental data obtained by the addition of the polymers to the diesel showed that the fuel’s physicochemical properties were within the suitability limits, while the moisture content was decreased from 62 mg/kg to 50 mg/kg and 53 mg/kg, respectively, for PVA and PEO polymers. A mathematical expression of adsorption was used to simulate the experimental findings. In addition, the sulfur content was decreased from 941 mg/kg to 937 mg/kg when PVA was used. The methodology proposed for improving the physicochemical properties of heating diesel through organic polymers can optimize its combustion behavior to be more environmentally friendly. Full article

Combined Cycle Power Plants (CCPP) suffer from drops in power and efficiency due to summer time ambient conditions. This power reduction is especially important in regions with extreme summer ambient conditions. Given the substantial investment and labor involved in the establishment and operation of these power plants, mitigating power loss using various methods emerges as a promising solution. In this context, the integration of Concentrated Solar Power (CSP) technologies has been proposed in this research not primarily to improve the overall performance efficiency of power plants as other recent studies entail, but to ensure continuous power generation throughout summer days, improving stability. This research aims to address this issue by conducting an extensive study covering the different scenarios in which Concentrated Solar Power (CSP) can be integrated into the power plant. Multiple scenarios for integration were defined including CSP integration in the Heat Recovery Steam Generator, CSP-powered chiller for Gas Turbine Compressor Cooling and Gas Turbine Combustion Chamber Preheating using CSP, and scenarios with inlet air fog cooling and hybrid scenarios were studied. This systematic analysis resulted in the selection of the scenario where the CSP is integrated into the combined cycle power plant in the HRSG section as the best case. The selected scenario was benchmarked against its equivalent model operating in Seville’s ambient conditions. By comparing the final selected model, both Yazd and Seville experience a noticeable boost in power and efficiency while reaching the maximum integration capacity at different reflector lengths (800 m for Seville and 900 m for Yazd). However, both cities reach their minimum fuel consumption at an approximate 300 m total reflector length. Full article

Micro-combustion-powered thermoelectric generators (μ-CPTEGs) combine the high energy density of hydrocarbons with solid-state conversion, offering compact and refuelable power for long-endurance electronics. Such characteristics make μ-CPTEGs particularly promising for aerospace systems, where conventional batteries face serious limitations. Their achievable performance hinges on how a swirl-stabilized flame transfers heat into the hot ends of thermoelectric modules. This study uses a conjugate CFD framework coupled with a lumped parameter model to examine how input power and equivalence ratio shape the flame/flow structure, temperature fields, and hot-end heating in a swirl combustor-powered TEG. Three-dimensional numerical simulations were performed for the swirl combustor-powered TEG, varying the input power from 1269 to 1854 W and the equivalence ratio from φ = 0.6 to 1.1. Results indicate that the combustor exit forms a robust “annular jet with central recirculation” structure that organizes a V-shaped region of high modeled heat release responsible for flame stabilization and preheating. At φ = 1.0, increasing Q_in from 1269 to 1854 W strengthens the V-shaped hot band and warms the wall-attached recirculation. Heating penetrates deeper into the finned cavity, and the central-plane peak temperature rises from 2281 to 2339 K (≈2.5%). Consistent with these field changes, the lower TEM pair near the outlet heats more strongly than the upper module (517 K to 629 K vs. 451 K to 543 K); the inter-row gap widens from 66 K to 86 K, and the incremental temperature gains taper at the highest power, while the axial organization of the field remains essentially unchanged. At fixed Q_in = 1854 W, raising φ from 0.6 to 1.0 compacts and retracts the reaction band toward the exit and weakens axial penetration; the main-zone temperature increases up to φ = 0.9 and then declines for richer mixtures (peak 2482 K at φ = 0.9 to 2289 K at φ = 1.1), cooling the fin section due to reduced transport, thereby identifying φ = 0.9 as the operating point that best balances axial penetration against dilution/convective-cooling losses and maximizes the TEM hot-end temperature at the fixed power. Full article

The growing dependence on fossil fuels has raised concerns over energy security, resource depletion, and environmental impacts, driving the need for renewable alternatives. Coffee husk, a widely available agro-industrial residue, represents an underutilized feedstock for biodiesel production. In this study, biodiesel was synthesized from coffee husk oil using a two-step transesterification process to address its high free fatty acid content (21%). Physicochemical analysis showed that Coffee Husk Oil Methyl Ester (CHOME) possessed a density of 863 kg m⁻³, viscosity of 4.85 cSt, and calorific value of 33.51 MJ kg⁻¹, compared to diesel with 812 kg m⁻³, 2.3 cSt, and 42.4 MJ kg⁻¹. FTIR analysis confirmed the presence of ester carbonyl and C–O functional groups characteristic of CHOME, influencing its combustion behavior. Engine tests were then conducted using B0, B10, B30, B50, and B100 blends under different loads, both with and without fuel preheating. Results showed that neat CHOME (B100) exhibited 11.8% lower brake thermal efficiency (BTE) than diesel, but preheating at 95 °C improved BTE by 5%, with preheated B10 slightly surpassing diesel by 0.5%. Preheating also reduced brake-specific fuel consumption by up to 7.75%. Emission analysis revealed that B100 achieved reductions of 6.4% CO, 8.3% HC, and 7.0% smoke opacity, while NOx increased only marginally (2.86%). Overall, fuel preheating effectively mitigated viscosity-related drawbacks, enabling coffee husk biodiesel to deliver competitive performance with lower emissions, highlighting its potential as a sustainable waste-to-energy fuel. Full article

To reduce the impact of renewable energy generation on power grid stability, preheating combustion technology is introduced to maintain coal-fired boiler efficiency at low loads. A 330 MW coal-fired boiler is retrofitted with preheating combustion devices to improve combustion performance and lower NO_x emissions. The device is installed in the reduction zone between the furnace burnout zone and the burner zone. The combustion characteristics of the boiler with and without these devices are examined at 50% rated load. Numerical simulations are conducted to analyze the effects of preheating coal input and burner arrangement on temperature and species distribution within the boiler. Results show that increasing preheating coal input from 0 to 30 t/h enhances NO_x reduction due to a higher flow rate of preheated products. At a preheating coal input of 20 t/h, the combustion efficiency reaches 96.9%. The NO_x concentration at the furnace exit rises from 122.4 to 171.3 mg/Nm³ as the height of the burner arrangement increases. The middle three-layer burner arrangement achieves a uniform temperature distribution and a peak combustion efficiency of 97.6%. The bottom and middle three-layer burner arrangements are recommended for efficient and clean combustion. Compared to the original boiler, the retrofitted boiler’s combustion efficiency increases from 96.3% to a maximum of 97.6%, while the NO_x concentration at the furnace outlet drops from 168.1 to 93.2 mg/Nm³, showing that installing preheating combustion devices promotes efficient and clean combustion. Full article

The effect of ore pre-heating on the operation of a 300 kVA Submerged Arc Furnace (SAF) for high carbon ferromanganese (HCFeMn) alloy was investigated. The two types of Mn ores from the Kalahari Manganese Field (KMF) were used in the investigation (Ore #1 and Ore #2). Quartz and coke sourced from South Africa were used as a fluxing agent and a reductant, respectively. The Mn ores, reductant and fluxing agent were delivered to Mintek with a size range of +6–20 mm and were sent to our in-house laboratories to determine the chemical and physical properties. The samples were taken for Inductively Coupled Plasma Optical Emission Spectroscopy (ICP-OES), combustion method (LECO), proximate analysis and quantitative X-ray diffraction (QXRD). A newly designed and constructed pilot facility at Mintek was used in the investigation. The facility included a 1 t/h rotary kiln coupled to an electric arc furnace supplied with an alternating current (AC) with a 300 kVA tap-changer transformer. The main aim of the investigation was to demonstrate the effect of ore pre-heating to 600 °C on the furnace energy consumption and CO/CO₂ emissions. The experimental approach adopted involved feeding Mn ore to establish baseline operating conditions, followed by feeding of Mn ore pre-heated with a rotary kiln to compare operational parameters. The pilot campaign experienced several operational challenges but there were periods of stable operation that enabled data collection for furnace energy consumption and CO/CO₂ emissions. The effect of pre-heating the ore to 600 °C on the SAF energy consumption and CO/CO₂ emissions was demonstrated successfully and revealed that energy savings and reduction in furnace CO₂ emissions is achievable. Pre-heating Mn ore to 600 °C lowered the furnace energy consumption by an average of 22.5% and CO₂ emissions by an average of 37%. The campaign also achieved an overall manganese recovery of 86%. Operating the furnace with hot feed increased the heat losses through the roof by 300% compared to heat losses observed during cold feed. There were also no significant changes in the furnace electrical parameters observed between the two feed modes. Full article

At present, the characteristics of supercritical hydrothermal combustion for heavy oils remain unclear, which severely limits the application of this process. In this work, the effect of key parameters on the characteristics of supercritical hydrothermal combustion of heavy oil are studied. The heat value at a heavy oil concentration of 30 wt.% is 12.21 MJ·kg⁻¹, significantly higher than that of an alcohol–water mixture with an equivalent mass fraction. Thus, the minimum ignition temperature of heavy oil can reach the subcritical temperature of 300 °C. Appropriately increasing pressure and the oxidation coefficient can enhance burnout efficiency, but an excessively high oxidation coefficient will produce adverse effects. The optimized parameters for heavy oil supercritical hydrothermal combustion are a preheating temperature of 350 °C, a fuel concentration of 30 wt.%, an oxidation coefficient of 1.5, and a reaction pressure of 25 MPa, resulting in a burnout rate of 99.15%. Full article

Cupola furnaces rank among the oldest melting technologies in steelmaking, relying predominantly on coke as the primary fuel. In this study, a detailed energy analysis was conducted on a cupola unit used for gray and ductile iron production. Energy and thermal analyses were performed on the furnace to improve efficiency and minimize energy losses in the system. Computational simulations with an equation solving program quantified an exhaust-gas heat loss of 1.5 Gigajoules. To recover this waste heat, a heat exchanger was proposed to preheat the incoming combustion air. Numerical simulations of the modified system demonstrate a 3% increase in overall furnace efficiency and a reduction of about ten percent of coke per charge, equivalent to 716 kg per day for the unit under evaluation. Full article

Efficient utilization of low-calorific-value gases reduces emissions but remains challenging. Self-heat-maintained combustion uses fuel’s exothermic heat to sustain stability without external heat, yet the feed gas typically requires preheating (typically 573–673 K). This study innovatively proposes a compact regenerative catalytic reactor featuring an integrated helical heat-recovery structure and replaces empirical preheating with a user-defined function (UDF) programmed heat transfer efficiency model. This dual innovation enables self-sustained combustion at 0.16 vol.% methane, the lowest reported concentration for autonomous operation. Numerical results confirm stable operation under ultra-lean conditions, with significantly reduced preheating energy demand and accelerated thermal response. Transient analysis shows lower space velocities enable self-maintained combustion across a broader range of methane concentrations. However, higher methane concentrations require higher inlet temperatures for self-heat maintenance. This study provides significant insights for recovering energy from low-calorific-value gases and alleviating global energy pressures. Full article

In recent decades, pollutant emissions from the combustion of fossil fuels have become increasingly serious for the environment. The present paper reports experimental results for research carried out under laboratory conditions for a Selective Catalytic Reduction (SCR) system, implemented in different configurations on an ISUZU 4JB1 diesel engine. The obtained results allow for a comparative analysis of NOx formation as a function of diesel engine load (χ = 25–100%), at 1350, 2100, 2850, and 3600 rpm, with the engine operating under either cold (T < 343 K) or warm (T > 343 K) regimes. A preheating system for AdBlue droplets, in the form of a metal honeycomb that uses electromagnetic induction and incorporates a high-frequency generator, was introduced in the flow path of the combustion gases and tested to compare the experimental results. This system enabled temperatures of up to 643 K. A magneto-strictive system was also introduced in the SCR structure to atomize the AdBlue droplets to a minimum diameter of 3.5 μm. Using this principle, combined with preheating, the effect of calefaction was compared with the classical case of the internal heating of the SCR catalyst. For experimental purposes, piezoelectric cells dedicated to the transformation of the AdBlue solution into micro- or nano-droplets, which were entrained into the SCR by an ejector, were also used. Experimental results are presented in graphical form and reveal that the use of preheating, heating, or piezoelectric cells leads to improved NOx conversion. The tested solutions showed reductions in NOx emissions of up to eight times depending on the diesel engine load, demonstrating their strong impact on NOx reduction. Full article