CRANFIELD INSTITUTE OF TECHNOLOGY SCHOOL OF MECHANICAL ENGINEERING Ph.D THESIS ACADEMIC YEAR 1987-88 JN MURTHY GAS TURBINE COMBUSTOR MODELLING FOR DESIGN SUPERVISOR : RITI SINGH FEBRUARY 1988SUMMARY The design and development of gas turbine combustors is a crucial but uncertain part of an engine development process. Combustion within a gas turbine is a complex interaction of, among other things, fluid dynamics, heat and mass transfer and chemical kinetics. At present, the design process relies upon a wealth of experimental data and correlations. The proper use of this information requires experienced combustion engineers and even for them the design process is very time consuming. Some major engine manufacturers have attempted to address the above problem by developing one dimensional computer programs based on the above test and empirical data to assist combustor designers. Such programs are usually proprietary. The present work, based on this approach has yielded DEPTH, a combustor design program. DEPTH ( Design and Evaluation of Pressure, Temperature and Heat transfer in combustors) is developed in Fortran-77 to assist in preliminary design and evaluation of conventional gas turbine combustion chambers. DEPTH can be used to carry out a preliminary design along with prediction of the cooling slots for a given metal temperature limit or to evaluate heat transfer and temperatures for an existing combustion chamber. Analysis of performance parameters such as efficiency, stability and Nox based on stirred reactor theories is also coupled. DEPTH is made sufficiently interactive/user-friendly such that no prior expertise is required as far as computer operation is concerned. The range of variables such as operating conditions, geometry, hardware, fuel type can all be effectively examined and their contribution towards the combustor performance studied. Such comprehensive study should provide ample opportunity for the designer to make the right decisions. It should also be an effective study aid. Returns in terms of higher thermal efficiencies is an incentive to go for combined cycles and cogeneration. In such cases, opting for higher cycle pressures together with a second or reheat combustor promise higher thermal efficiencies and exhaust temperatures and hence such designs are likely to be of interest. The concepts that are needed for understanding a double or reheat combustor are also addressed using the programme. A specific application of the programme is demonstrated through the design of a double combustor.ii ACKNOWLEDGMENTS I wish to express my deep sense of gratitude to my supervisor, Mr Riti Singh for his continuous guidance and invaluable suggestions during the entire work. I am thankful for his help and continuous encouragement. I wish to thank my Organization, the Indian Air Force for providing me with this opportunity to further my knowledge. My thanks are also due to various members of the School of Mechanical Engineering and the Computer Center for providing assistance in relevant specialist topics, especially to Prof. JB Moss for putting up with my nagging discussions and providing the assistance in conceptual understanding of various aspects. I am grateful to my wife, Subha who has been understanding and supportive throughout my entire period of study. I thank all my family members in contributing in their own respect for the fulfillment of this research work.SUMMARY CONTENTS ACKNOWLEDGEMENTS CONTENTS NOTATION CHAPTER 1. CHAPTER 2. CHAPTER 3. CHAPTER 4. INTRODUCTION STATUS 2.1 BACKGROUND 2.2 MODELS EMPIRICAL MODULAR APPROACH FINITE DIFFERENCE APPROACH CLOSURE COMPUTATIONAL CODE NNNND 2.3 CHOICE OF MODEL 2.4 SCOPE PROGRAMME PHILOSOPHY 3.1 FOREWORD 3,2 STRUCTURED PROGRAMMING LANGUAGE GRAPHICS INTERACTIVE INPUT/OUTPUT 3.3 AXIOMS FOR ALGORITHM 3.3.1 MAJOR ASSUMPTIONS 3.3.2 GRIDDING 3.3.3 PROGRAMME HIERARCHY PRELIMINARY DESIGN 4.1 INTRODUCTION PAGE NO ii aii xiCHAPTER 5. 4.9 iv BASIC DESIGN FEATURE COMBUSTOR REQUIREMENTS COMBUSTOR TYPES SELECTION REFERENCE CONDITIONS 4.6.1 THETA PARAMETER APPROACH 4.6.2 PRESSURE LOSS APPROACH DIFFUSER SIZING LINER CROSS_SECTIONAL AREA LINER LENGTH EQUIVALENCE RATIO FLAME TEMPERATURE EXIT TEMPERATURE PROFILE FLAME STABILIZATION ronan aan SWIRLER 4.10 FUEL INJECTION 4.10.1 NUMBER OF FUEL INJECTORS FLOW EVALUATION 5.1 5.2 5.3 5.4 FLOW CONDITIONS 5.1.1 PRECONDITIONS PROPERTIES SPECIES CONCENTRATION THERMODYNAMIC PROPERTIES TRANSPORT PROPERTIES EFFECT OF PRESSURE STATE aun DIFFUSER LINER EVALUATION 5.4.1 LINER HOLES 5.4.1.1 DOME HOLES 5.4.1.2 SECONDARY HOLES 5.4.1.3 DILUTION HOLES 5.4.1.4 COEFFICIENT OF DISCHARGECHAPTER 6. CHAPTER 7. CHAPTER 8. LINER PRESSURE DROP COMBUSTION COLD FLOW LINER ANALYSIS SUDDEN EXPANSION LOSSES MASS BALANCE CONTROL VOLUME wuanawn 5.5 PATTERN FACTOR HEAT TRANSFER 6.1 INTRODUCTION 6.2 RADIATION NON-LUMINOUS RADIATION LUMINOUS RADIATION +3 RADIATION MODELS 4 SCOPE 6.2.1 6.2.2 6.2 6.2. 6.3 HEAT BALANCE METHOD OF SOLUTION INTERNAL RADIATION ANNULAR RADIATION INTERNAL CONVECTION EXTERNAL CONVECTION WALL CONDUCTION ADDITIONAL MEASURES PROPERTIES eUuanaure EFFICIENCY AND STABILITY 7.1 REQUIREMENT 7.2 BACKGROUND 1 COMBUSTION CHAMBER 2.2 EFFICIENCY 7.2.2.1 CLOSURE 7.2.3 STABILITY 7.2.2.1 CLOSURE 7.3 REQUIREMENT 7.3.1 EFFICIENCY CORRELATION 7.3.2 KINETIC TIME APPROACH 7.3.3 STABILITY RELATION EMISSIONS 8.1 SCOPE 115 115 115 116 121 121 123 124 124 129 133 138 138vi 8.2 NOx- BURNING ZONE 139 8.2.1 CHOICE OF KINETIC RACTION SCHEME 142 8.3 NOx- MIXING ZONE 144 : CHAPTER 9. DOUBLE COMBUSTOR 146 9.1 WHY REHEAT ? 146 9.2 STATE-OF-ART 146 9.2.1 ANALYSIS 147 9.2.2 CONCLUSIONS 148 9.2.3 RELEVANT COMBUSTOR FEATURES 149 9.3 DESIGN CONCEPTS OF SECOND COMBUSTOR 150 9.3.1 PROPERTIES 150 9.3.2 COMBUSTION 150 9.3.2.1 AFRS 151 9.3.2.2 ADIABATIC FLANE TEMPERATURE 151 9.3.2.3 COMBUSTION EFFICIENCY 152 9.3.2.4 FLAMMABILITY LIMITS 152 9.3.3 HEAT TRANSFER 153 9.3.4 NOx 153 9.3.5 SIZING CRITERIA 156 9.3.6 STARTING 156 CHAPTER 10. PROGRAMME DESCRIPTION 157 10.1 FOREWORD 157 10.2 INPUT 157 10.2.1 INTERACTIVE 157 10.2.2 NEW DESIGN 157 10.2.3 CONTINUATION FROM LAST TERMINATION 163 10.3 OUTPUT 163 10.3.1 TABULAR 163 10.3.2 GRAPHICAL 163 10.4 PC ADAPTABILITY 164 CHAPTER 11. CASE STUDIES AND DISCUSSION 165 11.1 VALIDATION 165CHAPTER 12. REFERENCES vii 11.2 DIscussion 11.3 CLOSURE CONCLUSIONS LIST OF APPENDICES APPENDIX APPENDIX APPENDIX APPENDIX APPENDIX APPENDIX APPENDIX APPENDIX APPENDIX APPENDIX APPENDIX APPENDIX APPENDIX APPENDIX APPENDIX APPENDIX APPENDIX APPENDIX A B c o oz ze STOICHIOMETRIC AIR-FUEL RATIO EVALUATION REFERENCE AREA EVALUATION SIMPLE METHOD TO EVALUATE FLAME TEMPERATURE PROCEDURE TO ESTIMATE THE NUMBER OF FUEL INJECTORS COEFFICIENTS FOR THERMODYNAMIC PROPERTIES COLLISSION DIAMETERS AND LENNARD-JONES POTENTIAL PARAMETERS COEFFICIENTS FOR SPECIES VISCOSITY DATA ISOENTROPIC PROPERTY EVALUATION RAYLEIGH EQUATION SOLUTION ONE DIMENSIONAL STEADY FLOW EVALUATION NAG LIBRARY FOR HEAT TRANSFER SOLUTION HEAT TRANSFER SOLUTION FLOW AREA - WIGGLE STRIP MATERIAL PROPERTIES CONVERSION FOR TRACE SPECIES INTEGRATION TECHNIQUE FOR NOx EQUATIONS FLOW CHARTS RESULTS OF CASE STUDIES 165 172 174 176 188 189 191 203 204 206 207 208 209 210 217 220 224 225 226 228 230 232viii LIST OF FIGURES Fig 2.1 Schematic of Modular Model of Swithenbank et al. (1973) Stream_tube model of Mosier & Roberts Exhaust Emission for the PéW JT9D combustor Comparison of one equation model prediction for center velocity decay, reacting H2-air jet Nox model of Fletcher & Heywood (1971) Nox model of Hung (1975) Types of recirculation zones Summary of the accuracy of prediction of the various regions of the flow field NAN BUN mua Stairstep Coordinate system Programme Hierarchy Fig Stages in evolution of a conventional Gas Turbine combustor Main components of a Gas Turbine combustor Various tyoes of straight flow combustors Design curves for conventional combustors Types of Diffusers Influence of diffuser angle on pressure loss Flow pattern downstream of prediffuser Liner in its modular form Primary zone airflow patterns Fig vo muanaud Fig Effect of pressure on transport properties Energy conversion in diffuser Simulation of velocity profile with equivalent rectangular profile Sudden expansion in a duct Outline of flow evaluation Jet in cross flow Flow through a liner hole Correlations by Adkins & Gueroui (1986) Curvature corrections 0 Electrical analogy for a flow through a hole 1 Electrical analogy for thr front end 2 Sudden Expansion in the anulus Wan aeeeenee bbe lone Mawar Fig Intensity of Radiation Basic Heat Transfer Processes Heat Balance Configurations Effect of Fuel C/H ratio on flame luminosity Trends in amount of cooling air employed Cross section of liner cooling devices Elastci buckling geometry relationship Sturgess (1980) Schematic of film wooling process Basic impingement model geometry and nomenclature an anaaaaa be aba6. 6. Fig Fig 8. Fig Fig 10 Fig 11 Fig PLATE ix 10 Impingement injection type 11 Typical convective channel arrangement 12 Heat transfer characteristics of artificially roughened surfaces 13 Flow area fractions 14 Heat transfer by conduction +15 Effect of Coating on wall temperatures +1 Simplified schematic of various primary zones 2 107 108 110 111 112 113 119 Schematic diagram of the relation of mixing layer to the primary zone and exhaust efficiency The adiabatic stirred reactor heat balance Combustion efficiency- Moonlight project AFRS & Tadiabatic under vitiation Efficiency under vitiation- Modified Theta Parameter 7 Variation of activation energy for methane 8 Stability curves- Moonlight combustor for E/R = 16000 K 9 Stability curves- Moonlight combustor for E/R = 20000 K 120 122 125 126 128 131 134 135 10 Conceptual representation of combustion volume136 1 Schematic representation of stirred reactors 1 Reheat Gas turbine schematic diagram 2 Intercooled reheat Gas Turbine schematic 3 Specific humidity versus vitiation 4 APRS & Tadiabatic under vitiation 5 Effect of vitiation on weak extinction in a double combustor 6 NOx under vitiation 7 Schematic representation of NOx production in aa system with a double combustor +1 Combustor Geometry +2 Slot Specification +1 Mass flow splits CASE 3 «2 Basic configuration of Reheat Combustor (Mori (1983)) .3 Air Distribution of RC (Mori (1983)) .4 Air Distribution of RC by DEPTH 1 Combustor Geometry 1 Adiabatic flame temperature comparision 1 Schematic of fuel spary pattern 1 Rayleigh curve for simple T change 1 Control surfaces defined for several methods of gas injection and liquid evaporation R-1 TEST LINER (CASE 3) RUN WITH THERMAL PAINT R-2 TEST LINER (CASE 3) IN WATER FLOW VISUALISATION 140 147 148 151 151 152 154 155 159 162 166 168 170 170 189 202 203 209 210 285 286LIST OF TABLES Table Table 2.2 2.2 2.3 wale BRewmedy a4 m7 one Extended C-H-O chemical kinetic reaction mechanism Models for Gas Turbine Combustors Mellor (1979) Finite Difference Model comparisons in recirculating flow An overview of Gas turbine combustors Relative merits of various chamber types Relative merits of varius diffuser types Relative zonal lengths Influence of various primary zone mixture strengths Relative merits of fuel injectors Dry air composition Constants for correlation for impingement cooling Nusselt number comparision for parallel plates and pipe analogy Characteristic Time Scales (Mellor(1976)) Combustor air/fuel flow distribution Moonlight Project Kinetic times for Moonlight combustors Blow_Out values for M1 combustor Nox Reaction Mechanism Nox mass fractions for different mixedness Concepts - Double Combustor Input for Preliminary design Input for flow Evaluation Collision diameter and Lennard_Jones Potential parameters value of KT/e and 9/1?) Influence Coefficients Representative Properties of typical materials Coefficients for temperature dependent Emissivity Ubhi(1987) Values for 6 point Gaussian quadrature 125 133 135 143 145 150 158 160 206 206 214 225 225 229AR AFRS “1 to 6 cp cp; ij DDL Dét D2L xi NOTATION Area (m2) Area Ratio Stoichiometric Air fuel ratio Mass Transfer Number, Blockage Factor Convective Flux (W/m?) Mass fraction of species « Mixture specific heat at constant pressure (J/kg K) Specific heat at constant pressure of species i Coefficient of diffusion (m2/s) Sauter Mean Diameter (m) Diffuser to dome length (m) Flame tube diameter (m) Dilution Zone length (m) Activation Energy (J/kg-mol) Emissive power of a radiating body (W/m?) Emissive power of a black body (W/m?) monochromatic Emissive power (W/m? m) fraction of total combustor airflow : Fuel to air mass ratio Fuel lower calorific value (J/kg) Gravitational acceleration vector Slot crossflow mass velocity based on slot cross sectiona area (eU) cy 64 Jet mass velocity based on hole area (6U) 594 Mixture specific enthalpy (J/kg) Enthalpy of species i Hydraulic diameter (m) Intensity of radiation per unit solid angle (w/sr) Heat conducted through the wall 1-2 (watts) Lewis Number «/D Liner Length (Zone) (m) mass velocity ratio (eU) 2mco + y/2 H According to the above reaction (Haynes and Wagner (1981)), the formation of soot should start when x becomes equal to or larger than 2m, i.e, when the C/O atomic ratio exceeds unity. However, since soot formation is essentially a non- equilibrium phenomenon, soot is reported to be observed at C/o ratios much less than unity for temperatures less than 2000 K. + (x-2m)C(s) ++ (2.30) The amount of soot produced is generally too small to influence the rate of heat release and, in principle, its rate of formation can be calculated from a knowledge of hydrocarbon and oxygen concentrations if an approximate correlation equation is known. In general, soot concentration is given by dc dc. aco. —-—f _ —oxid (2.31) at dat dt f£ i formation, oxid : oxidisation A simple representative correlation based on test data proposed by Lefebvre (1985) is of the form: 1.5.2.0 F/A | = S¢- Soyiq = (18-H) P , ~ ¢./—— £ ~ Soxia 2 57S pe F/M Ten «+ (2.32) Cg and Cg are experimentally evaluated for each combustor