Flamelet Versus Detailed Chemistry LES for a Liquid Fueled Gas-Turbine Combustor: A Comparison of Accuracy and Computational Cost

A Honeywell liquid-fueled gas turbine test combustor, at idle conditions is numerically investigated in Simcenter STAR-CCM+. This work presents Large Eddy Simulation (LES) results using both the Flamelet Generated Manifold (FGM) and Complex Chemistry (CC) combustion models. Both take advantage of a hybrid chemical mechanism (HyChem) which has previously demonstrated very good accuracy for real fuels such as Jet-A with only 47 species. The objective of this work is to investigate the ability of FGM and CC to capture pollutant formation in an aero-engine. Comparisons for NOx, CO, Unburned Hydrocarbons, and Soot are made, along with the radial temperature pro?le. Computational costs are assessed by comparing the performance and scalability of the simulations with each of the combustion models. It is found that the CC case with clustering can reproduce nearly identical results to that without acceleration if CO is added as a clustering variable. With the Lagrangian model settings chosen for this study, the CC results compared more favorably with the experimental data than FGM, however there is uncertainty in the secondary breakup parameters. Sensitivity of the results to a key parameter in the spray breakup model are provided for both FGM and CC. By varying this breakup rate, the FGM case can predict CO, NOx, and Unburned Hydrocarbons equally well. The smoke number, however, is predicted most accurately by CC. The cost for running CC with clustering is found to be about 4 times that of FGM for this combustor and chemical mechanism.

A Data-Driven Methodology for the Simulation of Turbulent Flame Speed across Engine-Relevant Combustion Regimes

Turbulent combustion modelling in internal combustion engines (ICEs) is a challenging task. It is commonly synthetized by incorporating the interaction between chemical reactions and turbulent eddies into a unique term, namely turbulent flame speed sT. The task is very complex considering the variety of turbulent and chemical scales resulting from engine load/speed variations. In this scenario, advanced turbulent combustion models are asked to predict accurate burn rates under a wide range of turbulence–flame interaction regimes. The framework is further complicated by the difficulty in unambiguously evaluating in-cylinder turbulence and by the poor coherence of turbulent flame speed (sT) measurements in the literature. Finally, the simulated sT from combustion models is found to be rarely assessed in a rigorous manner. A methodology is presented to objectively measure the simulated sT by a generic combustion model over a range of engine-relevant combustion regimes, from Da = 0.5 to Da = 75 (i.e., from the thin reaction regime to wrinkled flamelets). A test case is proposed to assess steady-state burn rates under specified turbulence in a RANS modelling framework. The methodology is applied to a widely adopted combustion model (ECFM-3Z) and the comparison of the simulated sT with experimental datasets allows to identify modelling improvement areas. Dynamic functions are proposed based on turbulence intensity and Damköhler number. Finally, simulations using the improved flame speed are carried out and a satisfactory agreement of the simulation results with the experimental/theoretical correlations is found. This confirms the effectiveness and the general applicability of the methodology to any model. The use of grid/time resolution typical of ICE combustion simulations strengthens the relevance of the proposed dynamic functions. The presented analysis allows to improve the adherence of the simulated burn rate to that of literature turbulent flames, and it unfolds the innovative possibility to objectively test combustion models under any prescribed turbulence/flame interaction regime. The solid data-driven representation of turbulent combustion physics is expected to reduce the tuning effort in ICE combustion simulations, providing modelling robustness in a very critical area for virtual design of innovative combustion systems.

Flamelet Versus Detailed Chemistry LES for a Liquid Fueled Gas-Turbine Combustor: A Comparison of Accuracy and Computational Cost

A Honeywell liquid-fueled gas turbine test combustor, at idle conditions is numerically investigated in Simcenter STAR-CCM+ version 2020.3. This work presents Large Eddy Simulation (LES) results using both the Flamelet Generated Manifold (FGM) and detailed chemistry combustion models. Both take advantage of a hybrid chemical mechanism (HyChem) which has previously demonstrated very good accuracy for real fuels such as Jet-A with only 47 species. The objective of this work is to investigate the ability of FGM and detailed chemistry modeling to capture pollutant formation in an aero-engine combustor. Comparisons for NOx, CO, Unburned Hydrocarbons, and Soot are made, along with the radial temperature profile. To fully capture potential emissions, a soot moment model, and Zeldovich NOx model are employed along with radiation. A comparison of results with and without chemistry acceleration techniques for detailed chemistry is included. Then, computational costs are assessed by comparing the performance and scalability of the simulations with each of the combustion models. It is found that the detailed chemistry case with clustering can reproduce nearly identical results to detailed chemistry without any acceleration if CO is added as a clustering variable. With the Lagrangian model settings chosen for this study, the detailed chemistry results compared more favorably with the experimental data than FGM, however there is uncertainty in the secondary breakup parameters. Sensitivity of the results to a key parameter in the spray breakup model are provided for both FGM and Complex Chemistry (CC). By varying this breakup rate, the FGM case can predict CO, NOx, and Unburned Hydrocarbons equally well. The smoke number, however, is predicted most accurately by CC. The cost for running detailed chemistry with clustering is found to be about 4 times that of FGM for this combustor and chemical mechanism.

Comparison of Performance of Flamelet Generated Manifold Model With That of Finite Rate Combustion Model for Hydrogen Blended Flames

International Air Transport Association (IATA) sets a 50% reduction in 2005 CO2 emissions levels by 2050, with no increase in net emissions after 2020 [1]. The association also expects the global aviation demand to double to 8.2 billion passengers per year by 2037. These issues have prompted the aviation industry to focus intensely on adopting sustainable aviation fuels (SAF). Further, reduction in CO2 emission is also an active area of research for land-based power generation gas turbine engines. And fuels with high hydrogen content or hydrogen blends are regarded as an essential part of future power plants. Therefore, clean hydrogen and other hydrogen-based fuels are expected to play a critical role in reducing greenhouse gas emissions in the future. However, the massive difference in hydrogen’s physical properties compared to hydrocarbon fuels, ignition, and flashback issues are some of the major concerns, and a detailed understanding of hydrogen combustion characteristics for the conditions at which gas turbines operate is needed. Numerical combustion analyses can play an essential role in exploring the combustion performance of hydrogen as an alternative gas turbine engine fuel. While several combustion models are available in the literature, two of the most preferred models in recent times are the flamelet generated manifold (FGM) model and finite-rate (FR) combustion model. FGM combustion model is computationally economical compared to the detailed/reduced chemistry modeling using a finite-rate combustion model. Therefore, this paper aims to understand the performance of the FGM model compared to detailed chemistry modeling of turbulent flames with different levels of hydrogen blended fuels. In this paper, a detailed comparison of different combustion characteristics like temperature, species, flow, and NOx distribution using FGM and finite rate combustion models is presented for three flame configurations, including the DLR Stuttgart jet flame [2], Bluff body stabilized Sydney HM1 flame [3] and dry-low-NOx hydrogen micro-mix combustion chamber [4]. One of the FGM model’s essential parameters is to select a suitable definition of the reaction progress variable. The reaction progress variable should monotonically increase from the unburnt region to the burnt region. The definition is first studied using a 1D premixed flame with different blend ratios and then used for the actual cases. 2D/3D simulations for the identified flames are performed using FGM and finite rate combustion models. Numerical results from both these models are compared with the available experimental data to understand FGM’s applicability. The results show that the FGM model performs reasonably well for pure hydrogen and hydrogen blended flames.

Assessment of Turbulent Combustion Models for Simulating Pre-Chamber Ignition in a Natural Gas Engine

Lean combustion in an internal combustion engine is a promising strategy to increase thermal efficiency by leveraging a more favorable specific heat ratio of the fresh mixture and simultaneously suppressing the heat losses to the cylinder wall. However, unstable ignition events and slow flame propagation at fuel-lean condition lead to high cycle-to-cycle variability and hence limit the high-efficiency engine operating range. Pre-chamber ignition is considered an effective concept to extend the lean operating limit, by providing spatially distributed ignition with multiple turbulent flame-jets and enabling faster combustion rate compared to the conventional spark ignition approach. From a numerical modeling perspective, to date, still the science base and available simulation tools are inadequate for understanding and predicting the combustion processes in pre-chamber ignited engines. In this paper, conceptually different RANS combustion models widely adopted in the engine modeling community were used to simulate the ignition and combustion processes in a medium-duty natural gas engine with a pre-chamber spark-ignition system. A flamelet-based turbulent combustion model, i.e., G-equation, and a multi-zone well-stirred reactor model were employed for the multi-dimensional study. Simulation results were compared with experimental data in terms of in-cylinder pressure and heat release rate. Finally, the analysis of the performance of the two models is carried out to highlight the strengths and limitations of the two formulations respectively.

Review of engine control-oriented combustion models

As requirements for continuously improving internal combustion engine fuel economy with satisfactory emissions, model-based control strategies are often used to optimize the combustion process. To apply advanced control techniques for closed-loop engine combustion control, control-oriented engine combustion models are necessary and they are physics-based, accurate enough for model-based control, computationally low cost, and capable of real-time simulations. In addition, control-oriented combustion model with adequate fidelity may need to adapt to physical system and environment changes over time to maintain model-based control performance, such as model-reference (guided) control, where the control-oriented combustion model runs in real-time to generate an error signal between physical system and reference-model output for feedback control. This paper provides a review of existing control-oriented engine combustion models, along with their associated applications. Three main groups of control-oriented combustion models are reviewed from simple to sophisticated physics-based dynamic models, including mean-value, Wiebe function-based, and reaction-based models. The fundamental principle of each model group is reviewed briefly and its applications are also addressed. At the macro level, a control-oriented engine model can be used for crank angle-based and/or cycle-based control. As the engine control hardware performance continuous improving with reduced cost, model-reference (guided) combustion control shall become reality since now it is feasible to run a physics-based control-oriented engine combustion model inside an engine control module. On the other hand, each model group, even for the simple mean-value model, has its own applicable scenarios.