Professional Documents
Culture Documents
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The Combustor Designer’s Dilemma
•Cost of Experiments
•Mechanism Size
•CFD Complexity
•Cost of Design Mistakes
•Design Complexity
•Fuel Options
•Emissions Regulations
•Fuel Consumption
•Design Cycle Time
•Design Resources
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Boiler Combustion Challenges
● Burner interactions
– Staging or BOOS
● Low NOx strategies
– Overfire air
– NOx Reburn
– SNCR injection
● Retrofit combustion optimization
● Particulate/Char burnout
CO (ppm, wet)
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Individual Burner Design Challenges
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Flare System Design Challenges
Flame length
Particulate Formation
and Smoke
Flame stability
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Costs and Risks Keep Rising
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Design Changes May Cause Instability
● Lean-premixed combustion with low
flame temperature slows burn rates
– Lean Blow Off (LBO) when mixing
overpowers burning
– Flashback in premixed systems when
flow velocity is less than flame velocity
– Ignition more difficult with lean mixtures
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Comparison of CFD and Sophisticated
Reactor Modeling
NOx
NOx Measured
Measured
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Introducing:
ENERGICO™
Designers Say They Need:
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Equivalent Reactor Networks (ERNs)
Provide Accuracy and Speed
Air
Flame
Equivalent
Reactor Network
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ENERGICO Adds Chemistry to the Design
Flow (Patent Pending)
3-D CFD Solution
Use algorithm to
divide flow field
Automatically
into reactor zones
create ERN
Map chemistry
Improve your results onto
CFD model with geometry view
greater kinetic
understanding
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Combustor Zones Automatically Created
CO
Identify where CO
emissions are quenched
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Assess Lean Blow Off (LBO) (Patent Pending)
LBO Index Unstable
● Capture the flame
● Conduct detailed
in-flame chemistry
analysis
– Chemistry from
reaction mechanism
– Mixing from CFD Stable
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ENERGICO has Completed a Rigorous
Validation Program on Real Turbine Designs
● Prior to release, RD conducted extensive internal
benchmarking with industry-supplied designs
● Three major gas turbine manufacturers involved in
Program
– Mitsubishi Heavy Industries
– Kawasaki Heavy Industries
– Large United States manufacturer
● Program included validation of ENERGICO on well
understood designs
– Emissions predictions
– Lean Blow Off assessments
● Validation partners represent over 60% of power
generation gas turbine market
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Sample of ENERGICO Validation Results
Class of Combustor NO CO
Fuel Type
(all CO less than 10ppm) Variance Variance
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Validation Test Feedback
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ENERGICO Improves CFD Accuracy
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Use ENERGICO to Simulate Alternative Fuels
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Comparison of Applications Engineering
Between CFD and ENERGICO
CFD ENERGICO
● Grid ● Detailed Chemical Mechanism
● Turbulence Models ● ERN algorithm development
– K-epsilon – Filter variable type
(standard, RNG, etc.) – Filter minimum zone size
– LES – Order of filter application
● Combustion Models ● ERN solution
– Non-Premixed – Reactor type (PSR or PFR)
– Premixed – Constant temperature
● Kinetic Mechanism – Energy equation
– Global
– Severely Reduced Both CFD and ENERGICO
● Heat Transfer Models require applications
– Convection engineering and experience
27 – Radiation for accurate results
Some Common Questions?
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Identifying the Best Algorithm
● Comparing algorithms and energy equation
identifies optimum algorithm for future modeling
Nominal Case
based on CFD
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ENERGICO Addresses Combustion
Challenges
Current Industry Concerns
Burner Sustainable
designs are fuels
becoming introduce
more complex combustion
uncertainty
Mechanisms
become more
detailed to
capture
required
effects
ENERGICO:ENERGICO:
Revolutionary Simulation
Revolutionary Simulation Package Software
● ENERGICO Software
● ENERGICO Maintenance
– Dedicated Applications Support
● On-Site Training
– Free in first year of license
– Theory and Functionality
– Hands on training on your applications
● Pre-requisite Software:
– CHEMKIN-PRO
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Thank You