The Effect of Variable Air–Fuel Ratio on Thermal NOx Emissions and Numerical Flow Stability in Rotary Kilns Using Non-Premixed Combustion

One of the quickest ways to influence both the wall temperature and thermal NOx emissions in rotary kilns is to change the air–fuel ratio (AFR). The normalized counterpart of the AFR, the equivalence ratio, is usually associated with premixed flames and studies of its influence on diffusion flames are inconsistent, depending on the application. In this paper, the influence of the AFR is investigated numerically for rotary kilns by conducting steady-state simulations. We first conduct three-dimensional simulations where we encounter statistically unstable flow at high inflow conditions, which may be caused by vortex stretching. As vortex stretching vanishes in two-dimensional flow, the 2D simulations no longer encounter convergence problems. The impact of this simplification is shown to be acceptable for the thermal behaviour. It is shown that both the wall temperature and thermal NOx emissions peak at the fuel-rich and fuel-lean side of the stoichiometric AFR, respectively. If the AFR continues to increase, the wall temperature decreases significantly and thermal NOx emissions drop dramatically. The NOx validation, however, shows different results and indicates that the simulation model is simplified too much, as the measured NOx formation peaks at significantly fuel-lean conditions.

Emission Characteristics of Hazardous Air Pollutants from Medium-Duty Diesel Trucks Based on Driving Cycles

Studies on the characteristics of hazardous air pollutants (HAPs) in the emissions of medium-duty diesel trucks are significantly insufficient compared to those on heavy-duty trucks. This study investigated the characteristics of regulated pollutants and HAPs, such as volatile organic compounds (VOCs), aldehydes, and polycyclic aromatic hydrocarbons (PAHs), and estimated non-methane hydrocarbon (NMHC) speciation in the emissions of medium-duty diesel trucks. Ten medium-duty diesel trucks conforming to Euros 5 and 6 were tested for four various driving cycles (WLTC, NEDC, CVS-75, and NIER-9) using a chassis dynamometer. In an urban area such as Seoul, CO and NMHC emissions were increased because of its longer low-speed driving time. NOx emissions were the highest in the high-speed phase owing to the influence of thermal NOx. PM emissions were almost not emitted because of the DPF installation. Alkanes dominated non-methane volatile compound (NMVOC) emissions, 36–63% of which resulted from the low reaction of the diesel oxidation catalyst. Formaldehyde emissions were the highest for 35–53% among aldehydes irrespective of driving cycles. By sampling the particle-phase of PAHs, we detected benzo(k)fluoranthene and benzo(a)pyrene and estimated the concentrations of the gas-phase PAHs with models to obtain the total PAH concentrations. In the particle portion, benzo(k)fluoranthene and benzo(a)pyrene were over 69% and over 91%, respectively. The toxic equivalency quantities of benzo(k)fluoranthene and benzo(a)pyrene from NIER-9 (cold) for both Euro 5 and Euro 6 vehicles were more than five times higher than those of NIER (hot) and NEDC. In the case of NMHC speciation, formaldehyde emissions were the highest for 10–45% in all the driving cycles. Formaldehyde and benzene must be controlled in the emissions of medium-duty diesel trucks to reduce their health threats. The results of this study will aid in establishing a national emission inventory system for HAPs of mobile sources in Korea.

Mitigating Thermal NOx by Changing the Secondary Air Injection Channel: A Case Study in the Cement Industry

This work studies how non-premixed turbulent combustion in a rotary kiln depends on the geometry of the secondary air inlet channel. We target a kiln in which temperatures can reach values above 1800 degrees Kelvin. Monitoring and possible mitigation of the thermal nitric-oxide (NOx) formation is of utmost importance. The performed reactive flow simulations result in detailed maps of the spatial distribution of the flow, thermodynamics and chemical conditions of the kiln. These maps provide valuable information to the operator of the kiln. The simulations show the difference between the existing and the newly proposed geometry of the secondary air inlet. In the existing configuration, the secondary air inlet is rectangular and located above the base of the burner pipe. The secondary air flows into the furnace from the top of the flame. The heat release by combustion is unevenly distributed throughout the flame. In the new geometry, the secondary air inlet is an annular ring placed around the burner pipe. The secondary air flows circumferentially around the burner pipe. The new secondary air inlet geometry is shown to result in a more homogeneous spatial distribution of the heat release throughout the flame. The peak temperatures of the flame and the production of thermal NOx are significantly reduced. Further research is required to resolve limitations of various choices in our modeling approach.

Numerical Investigation of the Plasma-Assisted MILD Combustion of a CH4/H2 Fuel Blend Under Various Working Conditions

The effects of plasma injection upon MILD combustion of a mixture of methane and hydrogen are investigated numerically. The injected plasma includes the flow of a highly air-diluted methane including C2H2, C2H4, C2H6, CH, CH2, CH3, CO, and CO2. The results show that among all the constitutes of plasma, CH3 is the most effective in improving the characteristics of MILD combustion. Injection of this radical leads to the occurrence of reactions at a closer distance to the burner inlet and thus provides longer time for completion of combustion. Further, mass fractions of OH, CH2O, and HCO are considerably affected by the injections of CH3, indicating structural modifications of the reacting flow. Importantly, as Reynolds number of the plasma flow increases, the volume and width of the flame decrease, while the formations of prompt and thermal NOx are intensified. However, injection of CH3, as plasma, reduces the emission of thermal NOx.

Numerical Investigation of NOx Emissions Characteristics of a Natural Gas Premixed Burner Based on Chemical Reactor Network Model

Numerical optimization of nitrogen oxides (NOx) formation is an essential factor during developing low pollution combustor of gas turbine. The Computational Fluid Dynamics-Chemical Reactor Network (CFD-CRN) hybrid method has a great advantage in fast and accurate prediction of combustor NOx emissions. In this work, a hybrid CFD-CRN approach is established to predict pollutant emissions of a lean premixed model burner for gas turbine applications. Several criteria are compared for separating the combustor into chemically and physically homogeneous zones, and the crucial parameters such as residence time and flue gas recirculation ratio are calculated. The CRN model is preliminarily verified with experimental data. The effects of pressure and fuel-air unmixedness on NOx formation are subsequently investigated. In addition, the effects of changes in fuel/air flow distribution and crucial parameters of CRN model on NOx emissions are also estimated under different pressures and fuel-air unmixedness. The combustor is divided into several zones including reaction preheating region, flame front region, flame transition region, post flame region, main recirculation region and corner recirculation region based on CFD results of fuel-air mixing characteristics, velocity field, temperature field, distribution of OH mass fraction and Damkohler number. The complex CRN model has the advantage of predicting NOx emission characteristics under higher Tad conditions compared with the simple model, and its prediction of NOx emission shows good agreement with experimental data under various equivalence ratio conditions. The structure and distribution of several regions of CRN model are analogous but not significant when Reynolds number exceeds 105 under high pressure. The pathway analysis shows that the NOx emission gradually decreases through N2O and NNH mechanisms, resulted from the decreasing concentration of O radical under low Tad and high pressure. However, the pressure could significantly promote thermal NOx formation resulting form increase of temperature. The fuel-air unmixedness results in the increase of maximum flame temperature, which has significant effect on change of the CRN regions-separating. The fuel-air unmixedness causes the significant increasing of thermal NOx formation.

FEATURES OF THE INFLUENCE OF RECIRCULATION OF COMBUSTION PRODUCTS ON THE FORMATION OF NITROGEN OXIDES IN BOILERS DURING BURNING NATURAL GAS

During the combustion of natural gas and the supply of exhaust gases recirculation like a ballast was shown. It is necessary to take into account that they contain nitrogen oxides, mainly in the form of NO, which does not decompose in the combustion zone, but is added to nitrogen oxides that has been produced during burning of fuel. The combustion products are affordable, but not ideal ballast. As on the one side, they reduce the maximum temperature in the combustion zone and the concentration of reagents, i.e. reduces the formation of «thermal» NOx, on the other side, they add to the combustion zone an additional amount of nitric oxide, which is summed up with that has been formed during burning in the combustion chamber and also reducing the efficiency of the method. When the maximum temperature in the combustion zone is the highest and the entire volume of fuel and ballast before to the combustion is best mixed during recirculation of exhaust gases, their effect on the formation of nitrogen oxides is the highest. The most effective ballast that reduces the formation of NO during combustion is carbon dioxide, provided it is well pre-molecularly mixed with natural gas before to the combustiontion zone. Bibl. 16, Tab. 4, Fig. 2.

Water/Steam Injection for NOx Reduction in Process Burners

Liquid water or steam injection is a technique that has been used for years to reduce NOx primarily by reducing the flame temperature which reduces thermal NOx. There is also evidence to suggest it reduces NOx by modifying the flame chemistry. While it is well proven for reducing NOx, there are some potential disadvantages including reduced thermal efficiency, flame instability, and increased emissions of other pollutants such as CO and unburned hydrocarbons. Water/steam injection has been used in a wide range of applications, particularly in boilers and gas turbines. Much less information is available on using this technique in process heaters which have some key differences compared to most combustors which include a highly varying fuel composition and natural draft to provide the combustion air. This paper will consider how water or steam may be injected into process burners including some predictive methods for determining NOx.

Effect of Operational Parameters on Combustion and Emissions in an Industrial Gas Turbine Combustor

Enhancing a combustion system requires increased combustion efficiency, fuel savings, and reduction of combustion emissions. In this paper, the combustion of CH4 in the combustor of an industrial gas turbine is studied and NO and CO formation/emission is simulated numerically. The objective of the current work is to investigate the influence of combustive parameters and varying the percentage of distributed air flow rate via burning, recirculation, and dilution zone on the reactive flow characteristics, NOx and CO emissions. The governing equations of mass, momentum, energy, turbulence quantities Renormalized group (RNG) (k–ε), mixture fraction and its variance are solved by the finite volume method. The formation and emission of NOx is numerically simulated in a postprocessing fashion, due to the low concentration of the pollutants as compared to the main combustion species. The present work focuses on different physical mechanisms of NOx formation. The thermal-NOx and prompt-NOx mechanism are considered for modeling the NOx source term in the transport equation. Results show that in a gaseous-fueled combustor, the thermal NOx is the dominant mechanism for NOx formation. Particularly, the simulation provides more insight into the correlation between the maximum combustor temperature, exhaust average temperatures, and the thermal NO concentration. Results indicate that the exhaust temperature and NOx concentration decrease while the excess air factor increases. Moreover, results demonstrate that as the combustion air temperature increases, the combustor temperature increases and the thermal NOx concentration increases dramatically. Furthermore, results demonstrate that the NO concentration at the combustor exit is at maximum value in a swirl angle of 55 deg and a gradual rise in the NOx concentration is detected as the combustion fuel temperature increases. In addition, results demonstrate that the air distribution of the first case at laboratory conditions is optimal where the mass fractions of NO and CO are minimum.