Search Results (53)

The use of additive manufacturing (AM) has seen increased utilization over the last decade, thanks to well-documented advantages such as lower startup costs, reduced wastage, and the ability to rapidly prototype. The poor surface finish of unprocessed AM components is one of the major drawbacks of this technology, with the research literature suggesting a measurable impact on flow characteristics and burner operability. For instance, surface roughness has been shown to potentially increase resistance to boundary layer flashback—an area of high concern, particularly when utilizing fuels with high hydrogen content. A more detailed understanding of the underlying thermophysical mechanisms is, therefore, required. Computational fluid dynamics can help elucidate the impact of these roughness effects by enabling detailed data interrogation in locations not easily accessible experimentally. In this study, roughness effects on a generic gas turbine swirler were numerically modeled using a low-y+ detached eddy simulation (DES) approach. Three DES models were investigated utilizing a smooth reference case and two rough cases, the latter employing a literature-based and novel equivalent sand-grain roughness (k_s) correlation developed for this work. Existing experimental isothermal and CH₄ data were used to validate the numerical simulations. Detailed investigations into the effects of roughness on flow characteristics, such as swirl number and recirculation zone position, were subsequently performed. The results show that literature-based k_s correlations are unsuitable for the current application. The novel correlation yields more promising outcomes, though its effectiveness depends on the chosen turbulence model. Moreover, it was demonstrated that, for identical k_s values, while trends remained consistent, the extent to which they manifested differed under reacting and isothermal conditions. Full article

Reducing the anthropogenic impact on the environment is an increasingly urgent challenge, particularly in the energy and heat generation sectors. This study presents the results of an experimental investigation into the combustion characteristics of four nozzle types in a burner system. The experiments focused on emissions of NOx and CO under varying equivalence ratios. This study presents an experimental investigation of combustion with one swirl-stabilized nozzle and two multihole plates under varying equivalence ratios (φ). The swirl-stabilized configuration produced the highest NOx, reaching 54.4 ppm at φ = 0.9, which we attribute to higher flame temperatures and longer effective residence. In contrast, the multihole plates—122 holes of 1.0 mm and 36 holes of 4.0 mm in a 100 mm insert—exhibited lower NOx and lower temperatures owing to more effective fuel–air mixing. CO showed a strong dependence on both geometry and φ; the lowest levels occurred near φ ≈ 0.9, consistent with optimal combustion. The findings underscore the importance of nozzle geometry and air–fuel ratio in optimizing combustion efficiency and minimizing harmful emissions, providing valuable insights for the development of low-emission combustion systems in modern energy applications. Full article

Hydrogen is a promising fuel in the current transition to zero-net CO₂ emissions. However, most practical combustion equipment is not yet ready to burn pure hydrogen without adaptation. In the meantime, blending hydrogen with natural gas is an interesting option. This work reports a computational study of the performance of swirl-stabilized natural gas/hydrogen flames in a novel combustion chamber design. The combustor employs an air-staging strategy, introducing secondary air through a top-mounted plenum in a direction opposite to the fuel jet. The thermal load is fixed at 5 kW, and the effects of fuel composition (hydrogen molar fraction ranging from zero to one), excess air coefficient (λ = 1.3, 1.5 or 1.7), and primary air fraction (α = 50–100%) on the velocity, temperature, and emissions are analysed. The results show that secondary air changes the flow pattern, reducing the central recirculation zone and lowering the temperature in the primary reaction zone while increasing it further downstream. Secondary air improves the performance of the combustor for pure hydrogen flames, reducing NO emissions to less than 50 ppm for λ = 1.3 and 50% primary air. For natural gas/hydrogen blends, a sufficiently high excess air level is required to keep CO emissions within acceptable limits. Full article

Ammonia (NH₃) and hydrogen (H₂) are considered promising fuels for the power sector’s decarbonization. Their combustion is capable of producing energy with zero direct CO₂ emissions, and ammonia can act as a stable energy H₂ carrier. This study numerically investigates the design and implementation of staged combustion of a mixture of NH₃/H₂ by means of CFD simulations. The investigation employed the single-phase flow RANS governing equations and the eddy dissipation concept (EDC) combustion model, with the incorporation of a detailed kinetic mechanism. The combustion chamber operates under the RQL (rich–quench–lean) combustion regime. The first stage operates under rich conditions, firing mixtures of ammonia in air, enriched by hydrogen (H₂) to enhance combustion properties in a swirl and bluff-body stabilized burner. The secondary stage injects additional air and hydrogen to mitigate unburnt ammonia and NO_x emissions. Simulations of the first stage were performed for a thermal input ranging from 4 kW to 8 kW and flames with an equivalence ratio of 1.2. In the second stage, additional hydrogen is injected with a thermal input of either 1 kW or 2 KW, and air is added to adjust the global equivalence ratio to 0.6. Full article

The last decades have offered new challenges to researchers worldwide through the problems our planet is facing both in the environmental protection field and the need to replace fossil fuels with new environmentally friendly alternatives. Bioenergy, as a form of renewable energy, is an acceptable option from all points of view, and biofuels, due to their biological origin, have the ability to satisfy the new needs of humanity. As they release non-polluting combustion products into the atmosphere, biofuels have already been adopted as additives in traditional liquid fuels, intended mainly for the internal combustion engines of automobiles. The current work proposes an extension of the biofuel application in combustion processes specific to industrial furnaces. This technical concern has not been found in the literature, except for the achievements of the research team involved in this work, who performed the previous investigations. A 51.5 kW burner was designed to operate with glycerin originating from the triglycerides of plants and animals, mixed with ethanol, an alcohol produced by the chemical industry recently used as an additive in gasoline for automobile engines. Industrial oxygen was chosen as the oxidizing agent necessary for the liquid mixture combustion, allowing us to obtain much higher flame temperatures compared with the usual combustion processes using air. Mixing glycerin with ethanol in an 8.8 ratio allowed for growing flame stability, also accentuated by creating swirl currents in the flame through the speed regime of fluids at the exit from the burner body. Results were excellent in both the flame stability and low level of polluting emissions. Full article

Biogas, derived from human waste or industrial byproducts, is considered one of the most environmentally acceptable fuels. However, such fuels often exhibit relatively low efficiency, making it essential to develop technologies that facilitate their effective combustion. This article investigates the combustion of biogas with the addition of hydrogen at varying degrees of flow swirling. For this purpose, a burner was used in which methane, hydrogen and CO₂ were mixed in a mixer. The studies revealed that increasing the proportion of hydrogen in biogas leads to an average 15% rise in the NO_x concentration. Additionally, an increase in the degree of swirling has a positive effect on NO_x generation. On the other hand, a higher proportion of hydrogen reduces the concentration of CO in the exhaust gases. The presence of ballast gases, such as CO₂, generally results in relatively low NO_x levels when combined with a high swirling number. The analysis of combustion products for CO₂ indicates a 14% increase in CO₂ proportion. The highest concentrations of CO₂ were observed in biogas with the highest CO₂ ballast content. In terms of reducing NO_x and CO, SW = 1.3 is the most successful. On the other hand, this angle leads to an increase in the CO₂ concentration. Full article

Large-scale industrial burners are essential components in various industries including power generation and chemical processing. Enhancing their energy efficiency and reducing emissions, particularly nitrogen oxides (NOx), requires a combination of experimental research and computational fluid dynamics (CFD) simulations. While there exist numerous emission control techniques, the main focus of the present review study was the passive control technique. The result of this review indicates that biodiesel fuel crude palm oil (CPO) was found to reduce emission components, particularly carbon components and particulate matter (PM). Moreover, it also mitigates cavitation within the injector’s orifice, reducing wear and tear. Although cavitation enhances spray atomization and creates finer droplets for improved combustion, it can damage injector orifices. Optimizing the orifice design, such as by adopting conical orifices over cylindrical ones, can significantly reduce cavitation and its adverse effects. Furthermore, innovations such as swirling fuel–air premixing within injectors enhance combustion efficiency and lower emissions by improving fuel–air mixing. However, spray characteristics, particularly the Sauter mean diameter (SMD), remain critical for predicting combustion performance. Further investigations into spray fineness and its impact on combustion dynamics are essential for advancing emission control and performance optimization. Full article

The global shift toward renewable fuels and the reduction in anthropogenic environmental impact have become increasingly critical. However, the current challenges in fully transitioning to environmentally friendly fuels necessitate the use of transitional fuel mixtures. While many alternatives have been explored, the combination of hydrogen and LPG appears to be the most practical under the conditions specific to Kazakhstan. This study presents experimental findings on a novel burner system that utilizes the airflow swirl and hydrogen enrichment of LPG. It evaluates the effects of hydrogen addition, fuel supply methods, and swirl intensity—achieved by adjusting the outlet vanes—on flame stabilization as well as NO_x and CO emissions. The results show that the minimum NO_x concentration achieved was 12.08 ppm, while the minimum CO concentration was 101 ppm. Flame stabilization studies indicate that supplying the fuel at the center of the burner, rather than at the base, improves stabilization by 23%. Additionally, increasing the proportion of hydrogen positively affects stabilization. However, the analysis also reveals that, as the hydrogen content in the fuel rises, NO_x concentrations increase. These findings highlight the importance of balancing the hydrogen enrichment, airflow swirl, and fuel supply methods to achieve optimal combustion performance. While hydrogen-enriched LPG offers enhanced flame stabilization, the associated rise in NO_x emissions presents a challenge that requires careful management to maintain both efficiency and environmental compliance. Full article

In this work, we attempt to explain the phenomenon of sulfur corrosion of power boiler water walls under the conditions of large fluctuations in carbon monoxide concentrations. To assess the conditions required for corrosion formation, a criterion based on the chemical and flow field parameters of the flue gas is proposed. The formulated sulfur corrosion criterion is based on the mixture fraction variance and the turbulence time scale. Numerical modeling of coal combustion in a 250 MW power boiler is performed using ANSYS. Two cases of combustion in a boiler are analyzed, with the first simulating the boiler operated using classic high-swirl burners and the second one accounting for boiler operation with modified low-swirl burners. Calculations of pulverized coal combustion are performed using the standard k-$\epsilon$ turbulence model and the combustion described by the mixture fraction. The simulation results reveal that the low-swirl burner is characterized by higher values of the mixture fraction variance and a higher frequency of fluctuation of the velocity field, which is strongly related to an increased corrosion rate. The study outcomes show the validity of using the criterion of the mixture fraction variance and velocity field fluctuations to determine the areas at risk of sulfur corrosion. Full article

We conducted a numerical study of the effects of a vortex generator (VG) on the combustion characteristics and physical fluid flow of LPG on a porous bluff-body slot burner (PBSB) model, validating the numerical and experimental results of the temperature distribution and mixture flow velocity. The VG position (fuel (F) and air (A) slots), direction (clockwise, CW, and counterclockwise, CCW), aspect ratio (AR), and distance (S) were investigated parametrically in our porous vortex generator slot burner (PVGSB) model. According to our results, the VGSB model with a VG angle of 60°, CW direction, aspect ratio of 0.4, and VG distance of 0 mm enhanced the flame temperature by 24.4% due to a greater vortex influence. Moreover, applying a reverse triangular bluff body to the VGSB model had a stronger effect on the vortices and swirl flow of the mixture compared to the cylindrical bluff body, achieving 34.9% higher combustion temperatures compared to the referenced PBSB model. This numerical study of using LPG combustion on a slot burner with VGs and a reverse triangular bluff body, which we refer to as the VGSB model, could be applied to enhancing physical air–fuel flow and the flame temperature as characteristics of combustion. Full article

The current investigation aims to develop a validated numerical model of a confined, swirl-stabilized diffusion flame. This model will assist in designing and optimizing novel combustion chambers while reducing computational costs. To achieve this objective, experimental and numerical studies were conducted on NH₃/natural gas combustion using a laboratory-scale burner capable of operating under fuel-flexible conditions. The burner fired 5 kW flames of blended ammonia with natural gas in concentrations up to 100% NH₃. The burner’s performance for relevant industrial applications was assessed through measurements of axial temperature profiles, exhaust temperature, and gas emissions. Numerical simulations were conducted by employing the commercial CFD software STAR-CCM+ 2020.2.1. Numerical simulations for steady-state were performed using a realizable k-$ϵ$ turbulence model coupled with the EDC (eddy dissipation concept) for combustion. The investigation utilized a 3D periodic domain for the simulations and investigated mesh independence and the influence of the flame dynamics. The burner was able to operate with different fuel mixtures while maintaining stabilized flames under every condition. However, the appearance of increased ammonia slip was observed for 100% NH₃ up to 1250 ppm (dry vol.). The present work demonstrates and assesses the readiness and potential of fuel-flexible burners as cost-effective and efficient transitional technologies for integrating ammonia and other sustainable fuels into combustion applications. Full article

In this study, a novel gas burner combining air swirl and an inverse diffusion flame (IDF) is designed for industrial applications. Numerical simulations using the Reynolds-averaged Navier–Stokes (RANS) method and simplified reaction mechanisms are conducted to predict the turbulent flow and combustion performance of the burner. Detailed flow structures, flame structures and effects of burner configurations are examined. The simulation results indicate that the swirl action of the burner creates a central recirculation zone and two external recirculation zones at the burner head, which stabilize combustion. The tangential velocity is minimal at the center of the burner and decreases with increasing distance from the outlet. As the distance from the exit increases, the maximum tangential velocity gradually decreases, and the peak value shifts towards the wall. This decrease in tangential velocity with axial distance signifies the gradual dissipation of the swirl effect, which disappears near the chamber outlet. The comparisons reveal that altering the number of burner fuel nozzles is more effective in reducing NO emissions than changing the inclination angle of the fuel nozzles, in the given conditions. Favorable combustion conditions are achieved when there are 16 fuel nozzles and the nozzle inclination angle is 60°, resulting in a 28.5% reduction in NO emissions at the outlet, compared to the reference condition. Full article

The spray and combustion characteristics of a gas-centered swirl coaxial (GCSC) injector used in oxidizer-rich staged combustion cycle engines were analyzed. The study focused on varying the recess ratio, presence of gas swirl, and swirl direction to improve injector performance. The impact of the recess ratio was assessed by increasing it for gas jet-type injectors with varying momentum ratios. Gas-swirl effects were studied by comparing injectors with and without swirl against a baseline of a low recess ratio gas injection. In atmospheric pressure-spray experiments, injector performance was assessed using backlight photography, cross-sectional imaging with a structured laser illumination planar imaging technique (SLIPI), and droplet analysis using ParticleMaster. Increasing the recess ratio led to reduced spray angle and droplet size, and trends of gas swirl-type injectors were similar to those of high recess ratio gas jet-type injectors. Combustion tests involved fabricating combustion chamber heads equipped with identical injectors, varying only the injector type. Oxidizer-rich combustion gas, produced by a pre-burner, and kerosene served as propellants. Combustion characteristics, including characteristic velocity, combustion efficiency, and heat flux, were evaluated. Elevated recess ratios correlated with increased characteristic velocity and reduced differences in the momentum–flux ratios of injectors. However, increasing the recess ratio yielded diminishing returns on combustion efficiency enhancement beyond a certain threshold. Gas swirling did not augment characteristic velocity but notably influenced heat flux distribution. The trends observed in spray tests were related to combustion characteristics regarding heat flux and combustion efficiency. Additionally, it was possible to estimate changes in the location and shape of the flame according to the characteristics of the injector. Full article

In the modern world, issues related to the use of alternative fuels are becoming increasingly pressing. These fuels offer the potential to achieve significantly improved environmental and technological performance. Currently, among such fuels, biodiesel, ammonia, LPG, and hydrogen are considered the most promising options. LPG and hydrogen exhibit a high Lower Heating Value (LHV) and have a relatively low environmental impact. This article investigates the combustion of hydrogen-LPG mixtures in a diffusion burner. The main parameters under study include the proportion of hydrogen in the fuel, equivalence ratio, and vane angle. The analyzed parameters encompass NOx and CO concentrations. The studies have demonstrated that the addition of hydrogen can reduce greenhouse gas emissions, as the combustion product is clean water. The primary focus of this research is the examination of combustion processes involving flow swirl systems and alternative fuels and their mixtures. The studies indicate that flame stabilization is significantly influenced by several factors. The first factor is the amount of hydrogen added to the fuel mixture. The second factor is the degree of mixing between the fuel and oxidizer, along with hydrogen. Lastly, the equivalence ratio plays a crucial role. As the studies have shown, the maximum stabilization for a speed of 5 m/s is achieved at an angle of 60° and a hydrogen fraction of 40%, resulting in φ_LBO = 0.9. This represents an 8.0% improvement in stabilization compared to the baseline mode, primarily due to the substantial proportion of hydrogen. An analysis of flame photographs reveals that as the twist angle increases, a recirculation zone becomes more apparent. Increasing the blade angle and incorporating hydrogen leads to a reduction in CO concentrations in the exhaust gases. The analysis indicates that increasing the hydrogen proportion to 50%, compared to the absence of hydrogen, results in a 30% decrease in CO concentration. In our case, for the option φ = 0.3 and blade angles of 60°, the reduction in CO concentration was 28.5%. From the authors’ perspective, the most optimal vane angle is 45°, along with a hydrogen fraction of 30–40%. With these parameters, it was possible to achieve concentrations of NOx = 17–25 ppm, φ_LBO = 0.66, and CO = 130–122 ppm. Full article

A detailed experimental study of ethanol spray swirling flames was performed in an axial bluff body stabilized burner. The characteristics of the non-reacting and reacting sprays were recorded by particle imaging velocimetry (PIV) and planar laser-induced fluorescence (PLIF) of the OH radical. A few typical flames with different structures (outer-side-flame-lifting, stable, and near-blow-off) were compared and analyzed. The parameters of the spray, including the spray half-angle (α) and droplet number density (n_d), are quantified, and it has been found the flame structure and stability were strongly correlated with the droplet distribution. Several parameters of the flow field, such as velocity magnitude ($\left|U\right|$ vorticity (ω_z), and turbulent kinetic energy (TKE), are quantitively analyzed, and it is observed that the local strain rate rose as the air flow rate increased, which is not conducive to local flame stability. Regarding the flame, quantities such as progress variable (<c>), flame height (L_f), lift–off height (h_lf), and symmetry factor (S_nd and S_<c>) are calculated, and it can be observed that the flame symmetry keeps worsening when approaching blow–off, and the inner flame branch exhibits a worse stabilization than the outer one. Our comprehensive investigations offer a deeper understanding of stable combustion in such two–phase flames. Full article