Dynamics of Lean Premixed Systems: Measurements for Large Eddy Simulation
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1 Dynamics of Lean Premixed Systems: Measurements for Large Eddy Simulation D. Galley 1,2, A. Pubill Melsió 2, S. Ducruix 2, F. Lacas 2 and D. Veynante 2 Y. Sommerer 3 and T. Poinsot 3 1 SNECMA Moteurs, Département YKC, Moissy Cramayel, france 2 Laboratoire EM2C, CNRS UPR Ecole Centrale Paris, Chatenay-Malabry,France 3 CERFACS, CFD team, 42 Av. G. Coriolis, Toulouse CEDEX, France ABSTRACT Lean Premixed Prevaporized (LPP) injection systems have been designed to offer a minimum NOx and soot emissions. The basic principle of LPP systems is to optimize combustion through an efficient mixing of fuel and air. This can be achieved by vaporizing the initially liquid fuel and then mixing it with the air before combustion using for example a swirling flow. It is well known that premixed combustion can reduce pollutant emissions more than non-premixed combustion [1]. Moreover, a lean mixture allows to control the flame temperature and then NOx production since it increases with temperature. However, LPP systems are known to be very sensitive to couplings leading to many kind of unstable behaviors. This work is a contribution to the understanding of the dynamical phenomena occurring in a LPP combustor, using advanced laser diagnostics. This paper presents an experimental and numerical study of a Laboratory-scale gas turbine combustion chamber designed and operated at laboratoire EM2C. These results are compared with large eddy simulations (LES) performed at CERFACS. KEYWORDS Gas Turbine, Lean Premixed Prevaporized (LPP) burner, Planar Laser Induced Fluorescence (PLIF), Large Eddy Simulation (LES), Thickened Flame model, Flashback, Precessing Vortex Core (PVC).
2 EXPERIMENTAL FACILITY The facility is a lean premixed burner operated at atmospheric pressure, using gaseous propane. Burner Air Flowmeter Heater Filter Propane Flowmeter Filter Figure 1: Experimental Setup The experimental setup is fed with dry compressed air and propane (see Figure 1). The flow rates are monitored through two electronic mass flow meters. Air and propane are injected in the premixing tube of the combustion chamber presented in Figure 2. Premixing tube and combustion chamber are made in high quality quartz (fused silica) allowing visible and UV optical access. Main dimensions are provided on Figure 2. Characteristic numbers of the combustion facility are summarized in Table 1. The Reynolds number given in Table 1 is based on the bulk velocity and the diameter of the premixing tube. TABLE 1 CHARACTERISTIC NUMBERS OF THE COMBUSTION FACILITY Max. Air mass flow rate 300 m 3 /h Max. Propane mass flow rate 15 m 3 /h Max. Reynolds Number From 40,000 up to 280,000 Rated thermal power 300 kw Figure 2 : Swirler, Premixing tube, Combustion Chamber (dimensions in mm)
3 Mixing is enhanced using a radial-type swirl generator. Air and propane are introduced separately in the premixing tube. The 6 mm diameter jet of propane is injected axially and sheared by the surrounding swirling flow of air. Tangential air velocity in the premixing tube is produced using a radial-type swirl generator (radial guide-vane cascades). Eighteen constant-section vanes, which impart a helicoidal movement to the airflow, compose the swirl generator. The detailed geometry and dimensions of the swirl generator are given in Figure 3. The mixture is ignited in the combustion chamber using a spark plug. Figure 3: Characteristics of the swirl generator (dimensions in mm) COMBUSTION REGIMES Depending on the swirl and Reynolds numbers, large-scale spatial fluctuations of the swirling flow are coupled with a Central Toroidal Recirculation Zone (CTRZ) [2]. This recirculation zone plays an important role in flame stabilization as it locally supplies the flame front with hot burned gases to sustain combustion [3]. An example of swirl-stabilized flame is displayed in Figure 4 (a). Figure 4 shows OH * spontaneous emission of the flame, obtained with a ICCD camera using UV filters WG305 and UG5. In this case, the flame is stabilized in the combustion chamber by the central recirculation zone created by the swirl ( compact flames ). In some situations, the flame propagates upstream in the premixing tube as shown in Figure 4 (b). This phenomenon, called flashback, can lead to catastrophic failure in real gas turbine, but is a stable regime of the facility ( flashback flames ). Since both swirl stabilized flame and flashback can be safely investigated, this facility gives the opportunity to understand the dynamics of partially premixed swirling flames and the phenomena leading to flashback. Flame regimes mainly de p e n ds o n a i r a n d propane m a s s - f l o w r a t e s, and are s u m m a r i z e d i n F i g u r e 5. F o r l o w a n d i n t e r m e d i a t e e q u i v a l e n c e r a t i o s ( a n d i n t e r m e d i a t e a i r f l o w s ), t h e f l a m e i s s t a b i l i z e d i n t h e c o m b u s t i o n c h a m b e r d u e t o t h e C T R Z ( compact flames ). F o r h i g h e r v a l u e s o f t h e e q u i v a l e n c e r a t i o, t h e s t r u c t u r e o f t h e f l a m e c a n b e e i t h e r f l a s h b a c k o r c o m p a c t d e p e n d i n g o n i n i t i a l and transient c o n d i t i o n s ( h y s t e r e s i s r e g i o n ). T h e t r a n s i t i o n f r o m f l a s h b a c k t o c o m p a c t f l a m e t a k e s p l a c e a t a p p r o x i m a t e l y t h e s a m e e q u i v a l e n c e r a t i o, = , w h a t e v e r t h e a i r f l o w r a t e. C o n s i d e r i n g t h e c o m p a c t f l a m e s i t u a t i o n, d e c r e a s i n g e q u i v a l e n c e r a t i o l e a d s t o a d e t a c h e d f l a m e, s t a b i l i z e d d o w n s t r e a m i n t h e c o m b u s t i o n c h a m b e r. T h e n, f o r a l o w e r e q u i v a l e n c e r a t i o, t h e f l a m e i s s p r e a d a l l o v e r t h e c o m b u s t i o n c h a m b e r. F u r t h e r d e c r e a s e o f t h e e q u i v a l e n c e r a t i o l e a d s t o blow off [4].
4 Figure 4 (a): Compact flame Figure 4 (b): Flashback flame Figure 5: Burner Regimes Laser Induced Fluorescence Imaging and Measurements The phenomena occurring in LPP devices, such as flashback, are intrinsically unsteady. Diagnostics used to understand these phenomena must take this into consideration. The key points of LPP behavior are mixing efficiency and flame dynamics, which can be linked to acoustic couplings. Planar laser induced fluorescence (PLIF) gives an instantaneous insight of these two aspects. The mixing is quantified by seeding the propane flow with acetone vapor. PLIF of acetone as tracer, under restrictive and well-controlled conditions, provides quantitative measurements of fuel mass fraction [5]. OH radical displays the instantaneous position of flame front and burned gases. These two diagnostics allows to study the flow dynamics either in the combustion chamber or in the premixing tube. The imaging plane may be parallel or perpendicular to the symmetry axis of the experiment. In the last case, as shown in figure 6, a cooled mirror is placed in the burned gases to transmit the fluorescence
5 signal to the camera. Longitudinal images have already been studied in [4]. In the present paper, we focus on the transversal case. Both OH or acetone vapor PLIF can be carried out in this situation. Quantitative results in the longitudinal situation can be found in [4]. Experimental setup The whole experimental setup, including lasers and acetone seeding, are given in Figure 6. Figure 6: Experimental setup and diagnostics Results The mixing process is first analyzed. Propane is seeded with acetone (10% in mass of acetone vapor in propane) and a tranverse cut is made 5 mm downstream the exit plane of the premixing tube. Examples of PLIF images of acetone is displayed Figure 7. These images show a very coherent structure: a comet plume of fuel rotating in the same direction as the swirl movement created by the blades. This offset structure seems to turn in the combustion chamber, feeding the flame front. As the laser frequency is limited to 10 Hz, the images are not temporally connected. The direction of rotation is deduced from the shape of the propane core, since the plume is at the rear part of the structure due to the rotating movement. The rotation center is also slightly rotating (as can be deduced from the mean field). Such coherent structure, known in the field of non reactive swirling flows, is called Precessing Vortex Core (PVC) [2]. Figure 7 emphasizes the importance of unsteady structures. The average image (top left) does not present any of them: from the mean point of view, the fuel concentration field is isotropic in the radial direction. Nevertheless, instantaneous images show anisotropic structures that control the flame behavior. As a consequence, the OH instantaneous images exhibit a similar behavior. Indeed, even 2.5 cm downstream the premixing tube, the reacting zone is not uniform. In each image (Figure 8), OH signal presents a zone of weak signal, which also rotates from one image to another. This is because the
6 flame is stabilized on the PVC, the only region where fuel concentration exceeds the lean extinction limit. This gives us information on the stabilization process of partially premixed swirled flame in this kind of configuration. Due to the swirl movement of the airflow, a vortex is created in the premixing tube and convected by the flow. This vortex presents a decreasing fuel concentration profile along its radius. The inner core is fuel rich whereas the outer cell is lean [4]. Due to the swirl effects and the sudden expansion in the combustion chamber, this vortex precesses in the combustion chamber. The flame is then stabilized in a precessing way. This mode of stabilization has been confirmed using a high-speed ICCD camera, recording spontaneous emission of the flame up to 10,000 images per seconds. The precessing movement of the reactive zones has been confirmed, and a rotating frequency has been estimated to 660 Hz. The combination of these two diagnostics, OH and acetone PLIF, has permitted to explain the stabilization mechanisms of swirled turbulent flame in this particular configuration. The mechanisms controlling the flame stabilization are non-stationary. As a consequence, simulations of such burner must be intrinsically unsteady. Reynolds Average Numerical Simulations (RANS) could only give results corresponding to the mean propane concentration profile (Figure 7 top left) whereas the reality is quite different as shown in Figure 7. Large Eddy Simulations (LES) resolves the structures of the flow and thus is an adequate tool to simulate these phenomena. Figure 7: Acetone LIF, transversal visualization of propane mass fraction 5 mm downstream the premixing tube. First image: mean image obtained over 100 images. R e g i m e : m 3 / h of air and 3 m 3 / h of propane ; Equivalence ratio: = 0. 6, compact flame.
7 Figure 8: OH LIF, transversal visualization of reactive zones, 2.5 cm downstream the premixing tube. 3 3 R e g i m e : 60 m / h of air and 1.5 m / h of propane ; Equivalence ratio: = 0. 6, compact flame. LARGE EDDY SIMULATIONS The numerical solver for turbulent reacting flows T h e c a l c u l a t i o n s a r e c a r r i e d o u t w i t h t h e L E S p a r a l l e l s o l v e r A V B P d e v e l o p e d b y C E R F A C S [6]. T h e f u l l c o m p r e s s i b l e N a v i e r S t o k e s e q u a t i o n s a r e s o l v e d o n s t r u c t u r e d, u n s t r u c t u r e d o r h y b r i d g r i d s a l l o w i n g t h e s i m u l a t i o n o f r e a c t i v e t u r b u l e n t f l o w s o n c o m p l e x g e o m e t r i e s b y u s i n g r e f i n e d g r i d c e l l s o n l y i n t h e m i x i n g a n d r e a c t i v e r e g i o n s o f t h e f l o w. T h e n u m e r i c a l s c h e m e p r o v i d e s t h i r d - o r d e r s p a t i a l a c c u r a c y o n h y b r i d m e s h e s [7]. T h i s p o i n t i s i m p o r t a n t b e c a u s e h i g h o r d e r n u m e r i c a l s c h e m e s a r e p a r t i c u l a r l y d i f f i c u l t t o i m p l e m e n t o n h y b r i d m e s h e s b u t r e q u ir e d t o p e r f o r m p r e c i s e L E S. T h e t i m e i n t e g r a t i o n i s d o n e b y a t h i r d o r d e r a c c u r a t e e x p l i c i t m u l t i s t a g e R u n g e - K u t t a s c h e m e. T h e N a v i e r S t o k e s c h a r a c t e r i s t i c b o u n d a r y c o n d i t i o n s ( N S C B C ) h a v e b e e n i m p l e m e n t e d [8] t o e n s u r e a p h y s i c a l r e p r e s e n t a t i o n o f t h e a c o u s t i c w a v e p r o p a g a t i o n. T h e o b j e c t i v e o f L E S i s t o c o m p u t e t h e l a r g e s c a l e m o t i o n s o f t h e t u r b u l e n c e w h i l e t h e e f f e c t s o f s m a l l s c a l e s a r e m o d e l e d. T h e W A L E m o d e l [9] i s c h o s e n t o e s t i m a t e s u b g r i d s c a l e s t r e s s e s, w h e r e a s t h e f l a m e - t u r b u l e n c e i n t e r a c t i o n i s d e s c r i b e d b y t h e d y n a m i c t h i c k e n e d f l a m e m o d e l [10-12] w h i c h w a s f o u n d r e l e v a n t t o a c c u r a t e l y p r e d i c t p a r t i a l l y p r e m i x e d f l a m e s. T h e g r i d m e s h u s e d f o r t h i s s i m u l a t i o n i s v e r y f i n e i n t h e m i x i n g t u b e i n o r d e r t o r e s o l v e w e a k l y t h i c k e n e d f l a m e. T h e t h i c k e n i n g f a c t o r h a s b e e n s e t t o F = 5 ( i. e. t h e t h i c k n e s s o f t h e r e s o l v e d f l a m e f r o n t i s a b o u t f i v e t i m e s t h e u n s t r e t c h e d l a m i n a r f l a m e t h i c k n e s s ). T h i s l o w v a l u e i s r e q u i r e d t o a l l o w f l a s h b a c k s i n c e a t o o t h i c k f l a m e would n o t b e a b l e t o p e n e t r a t e i n t h e m i x i n g t u b e due to t h e q u e n c h i n g d i s t a n c e. A n o n p r e m i x e d f l a m e is e x p e c t e d n e a r t h e i n j e c t o r n o z z l e b e c a u s e m i x i n g z o n e s
8 b e t w e e n f u e l a n d a i r a r e t o o s m a l l, w h i l e a w e l l - p r e m i x e d f l a m e s h o u l d o c c u r i n t h e c o m b u s t i o n c h a m b e r. T h e u s e o f a s m a l l t h i c k e n i n g f a c t o r i n c r e a s e s t h e a c c u r a c y o f t h e t h i c k e n e d f l a m e m o d e l a n d r e d u c e s t h e i m p o r t a n c e o f t h e s u b g r i d s c a l e m o d e l. I n s u c h a c a s e t h e m o d e l h a n d l e s a c c u r a t e l y b o t h m i x i n g a n d p e r f e c t l y p r e m i x e d combustion, but also c o r r e c t l y r e p r o d u c e s p u r e d i f f u s i o n f l a m e s. F o r t h e p r e s e n t s t u d y, a n h y b r i d g r i d c o m b i n i n g h e x a h e d r a l, p r i s m a t i c a n d tetrahedral elements is used with a total of about 600,000 cells (Figure 9). The walls are assumed to be adiabatic, and the gaseous fuel injected is propane. A single step chemistry is used. The total physical time simulated for each transition is about 0.05s corresponding to 3000 hours CPU time on a SGI O3800 R Mhz. The computations are typically performed on 32 processors. Numerical results Figure 9: 3D view of the mesh The simulations are carried out for the regimes explored experimentally [13]. Snapshots of a compact and flashback regimes are given in figures 10 and 11. The burner dynamics are well reproduced. Both compact and flashback flames can be simulated. Moreover, transitions between these regimes are also well reproduced. Details are given in [13] and focus is put in the present paper on the mixing process. Figure 12 compares propane mass fraction from simulations (left) and acetone LIF signal (right). The coherent structure of mixing is well reproduced by the simulation. Moreover, Figure 10 reveals the high dynamics of reactive zones (symbolized by the white temperature iso-surface) which is observed experimentally in Figure 8 ([4]). Figure 10: Instantaneous visualization of the compact flame. Iso-surface: temperature (T=1600K); vertical plane: axial velocity; black iso-line: zero axial velocity (U=0); gray iso-line: stoechiometric mixture fraction. R e g i m e : m 3 / h of air and 3 m 3 / h of propane ; Equivalence ratio: = 0. 6
9 Figure 11: Instantaneous visualization of the flashback flame. Iso-surface: temperature (T=1600K); vertical plane: axial velocity; black iso-line: zero axial velocity (U=0); gray iso-line: stoechiometric 3 3 mixture fraction. R e g i m e : 21 m / h of air and 0.75 m / h of propane ; Equivalence ratio: = 0.89 Figure 12: Numerical (left) and experimental visualizations of propane mass fraction, 5mm downstream the combustion chamber. R e g i m e : m 3 / h of air and 3 m 3 / h of propane ; Equivalence ratio: = 0. 6, compact flame. CONCLUSION We have presented a numerical and experimental combined study. Advanced diagnostics have been used to improve our understanding of the phenomena occurring in lean premixed prevaporized (LPP) burners. Laser induced fluorescence of OH radical shows the high dynamics of the flame and its chaotic behavior due to high turbulence levels. Laser induced fluorescence of acetone demonstrates the presence of highly coherent structures in the mixing process (PVC). These structures are due to the swirl movement imparted to the airflow. These unsteady phenomena, which explain the stabilization process of swirled burners, are well reproduced by Large Eddy Simulations (LES). Further calculations are presently carried out and close comparisons between experiments and simulations will be presented.
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