MGT Turbec t100 CC

ASMETurboExpo2011 June 610,2011 Vancouver,Canada
GT201146090 ANALYSISOFAMICROGASTURBINEFEDBY NATURALGASANDSYNTHESISGAS: MGTTESTBENCHANDCOMBUSTORCFDANALYSIS

M.Cadorin1, M.Pinelli1,A.Vaccari1, R.Calabria2,F.Chiariello2,P.Massoli2, E.Bianchi3
1EngeneeringDepartmentofUniversityofFerrara,viaSaragat1,Ferrara,(Italy) 2
IstitutoMotori CNR,piazzaBarsantieMatteucci,Napoli(Italy) 3TurbecS.p.A.,viaStatale,CorporenodiCento(Italy)
GT201146090ANALYSISOFAMICROGASTURBINEFEDBYNATURALGASANDSYNTHESISGAS:MGTTESTBENCHANDCOMBUSTORCFDANALYSIS
M.Cadorin, M.Pinelli,A.Vaccari,R.Calabria,F.Chiariello,P.Massoli,E.Bianchi
SUMMARY
MGT Turbec T100 main features Test bench description CFD numerical simulation set-up combustion chamber geometry computational domain numerical models Comparison between experimental and numerical results (full load and part-load conditions) Natural gas feeding case Synthesis gas feeding case
TURBECT100MICROGASTURBINE
Turbec T100 Nominal Characteristics
Electrical output Electrical efficiency Pressure in combustion chamber Turbine Inlet Temperature Turbine Outlet Temperature Nominal speed NOx @ 15 % O2 CO @ 15 % O2 100 kW 30 % 4.5 bar 1200 K 620-650 C 70000 rpm 15 ppm 15 ppm
TURBECT100MICROGASTURBINE
Single stage radial compressor and turbine
Reverse flow tubular combustor

EXPERIMENTALTESTBENCH
Decompression plant based on a pressure reduction system from 200 bar to 10 bar. Distribution plant designed for a rated capacity of fuel gas equal to 100 Nm3/h. Environmental monitoring system able to detect leaks of flammable gases.
Air inlet Flue gas outlet
To allow the use of low calorific value fuel of variable composition (with a chosen percentage of hydrogen)
Turbine Compressor Turbec T100 MGT Combustion chamber
MGTCONTROLANDMONITORINGSYSTEM
line for data transfer, from the machine programmable logic controller (PLC) to the control room system for data acquisition PC calculation station, located in the control room asynchronous serial converter, that directly connects the MGT PLC signal with the PC.
ASYNCHRONOUS CONVERTER RS485/USB PC CALCULATION STATION
MICRO GAS TURBINE TURBEC T100
INTERNAL CONTROL MODE

The user is enabled to set only the required electrical power; All the operating parameters are calculated by the machine software.
MGT outlet temperature in external control mode
EXTERNAL CONTROL MODE

It allows the exercise of the machine in userdefined working points; Possibility to define set-point referred to the rotational speed, the opening level of the fuel supply system valves.
Time GT201146090ANALYSISOFAMICROGASTURBINEFEDBYNATURALGASANDSYNTHESISGAS:MGTTESTBENCHANDCOMBUSTORCFDANALYSIS
NUMERICALTOOLS
CAD 3D software: SolidWorks 2010
Gridgenerationsoftware:ANSYSICEM
Numerical simulation code: ANSYS CFX 12.0
COMBUSTOR3DGEOMETRY SOLIDDOMAIN
o Tubular combustor o Reverse flow o Two fuel supply lines: pilot line (diffusive combustion), main line (premixed combustion)
OUTER FLAME TUBE Air inlet Main fuel line Pilot fuel line
INNER FLAME TUBE
Air inlet
COMBUSTOR3DGEOMETRY GEOMETRYSEMPLIFICATION
1 2 3
1. locating pins have been removed; 2. ridges on inner flame tube have been removed;
Solid domain
3. extension of air inlet duct;

4
4. extension of the inner flame tube.
Fluid domain
COMBUSTOR3DGEOMETRY MESH
HYBRID VOLUME MESH
TETRAHEDRAL GRID For meshing the more complex combustor zone fuel supply lines swirler air and fuel mixing zone primary combustion zone
HEXAHEDRAL GRID For meshing the wider and more regular-sized zone secondary combustion zone liner air inlet zone
Tetrahedral and hexahedral meshes have been separately generated and then merged in a single unstructured grid of 1500000 cells
CFDANALYSIS NUMERICALMODELS
COMBUSTION MODEL Combined Eddy Dissipation Model (EDM) / Finite Rate Chemistry (FRC) Based on the comparison of the characteristic time time of the two models: FRC in which chemical reaction rate is determined through the Arrhenius law and EDM in which the rate of reaction is depends on the time needed to mix the reagents at molecular level.
Reaction scheme
Methane 2 Step - Westbrook-Dryer (1981)

3 CH 4 + O2 CO + 2H 2O 2 1 CO + O2 CO2 2
Hydrogen 1 Step - Westbrook-Dryer (1981)

1 H 2 + O2 H 2O 2
NO Zeldovich mechanism
TURBULENCE MODEL Reynolds Stress Models (RSM): all Reynolds stress transport equations are solved, without any simplifications high accuracy and robustness low flexibility and high complexity in the resolution of mathematical models BSL Omega Based RSM (Omega Based Reynolds Stress Model)
Solution of Reynolds stress transport equations for each of the 6 tensor components Solution of the transport equation
PRELIMINARYCFDANALYSIS
o Sensitivity grid analysis Tetrahedral grid of about 1100000 Hexahedral grid of about 2000000 Hybrid (tetrahedral-hexahedral) grid of about 1500000 o Sensitivity analysis of turbulence models Standard Two-equation models (k-, k-, SST k-) Reynolds stress models (BSL-RSM, SSG-RSM) o Sensitivity analysis of combustion models Eddy Dissipation (EDM) Finite Rate Chemistry (FRC) Combined EDM-FRC
CFDANALYSIS BOUNDARYCONDITIONS
WALL OUTER FLAME TUBE Fixed temperature
Mainfuelline FUEL INLET Mass flow rate Temperature Composition Pilotfuelline
AIR INLET Mass flow rate Temperature Composition
OUTLET Averaged static pressure
WALL PRIMARY COMBUSTION ZONE Adiabatic
WALL INNER FLAME TUBE Fixed temperature
CFDRESULTS:NATURALGASFEEDING
o Natural gas feeding o Full load working condition (100 kWel) o Reference fuel distribution: 15 % pilot line, 85 % main line
Counter-rotating vortexes located in correspondence of the secondary combustion zone (before the dilution holes)
Corner vortexes located in the corner regions between the secondary swirler and the liner
CFDRESULTS:NATURALGASFEEDING
o Natural gas feeding o Full load working condition (100 kWel) o Reference fuel distribution: 15 % pilot line, 85 % main line
Temperature
Higher temperature in the primary combustion zone (diffusive zone). Flame bifurcation in the central zone of the combustion chamber.
Temperature
Strong temperature reduction due to the dilution air.
CFDRESULTSANDPRELIMINARYEXPERIMENTALRESULTS
The experimental tests are conducted on the test rig installed in the laboratory of Istituto Motori - CNR of Naples The experimental tests have been carried on in internal control mode, just setting electrical power reference; The maximum electrical power output obtained is lower than the nominal value (100 kWel) due to the higher air inlet temperature.
Electrical power [kWel] Fuel volume flow rate [Nm3/h] Turbine Outlet Temperature [C] Air Inlet Temperature [C] Rotational speed [rpm] Turbine Inlet Temperature* [C] NOx [ppm@15%O2] CO [ppm@15%O2]
80.3 27.4 641.9 28.5 66780 1180 11 2
90.1 30.7 642.2 28.3 69300 1193 9 2
* TIT is inferred through the TOT by means of a Cycle Deck calculation
NUMERICAL 3D SIMULATION: BASELINE CASE Natural gas feeding case; the simulation has been performed using the same numerical models and boundary conditions of the full operational load; the fuel mass flow rate has been varied for a fixed air mass flow coming from the compressor, in order to obtain the power output of the operating point chosen; the air mass flow rate is the design one, m = 0.7658 kg/s
Temperature
100 kWel
Similar temperature distribution; temperature levels are lower because of the reduced thermal power input and the more diluted mixture.
90.1 kWel
No air mass flow measurement
Setting of different fuel distributions and air inlet mass flow rate values To assess the effectiveness of the simulation in reproducing the variations of the actual operating conditions
Baseline: air mass flow and fuel distribution as in full load Case a: air mass flow as in full load, the measured fuel distribution values have been used Case b: lower air mass flow rate value and standard fuel distribution between the supply lines In order to have a more reliable air mass flow, a Cycle Deck calculation has been performed Case c: lower air mass flow rate and measured values of fuel distribution
Air mass flow rate [kg/s] Fuel distribution 15 % pilot- 85 % main 13 % pilot- 87 % main 15 % pilot- 85 % main 13 % pilot- 87 % main
Baseline Case a Case b Case c
0.7658 0.7658 0.7012 0.7012
Temperature
TIT [K]
CO [ppm@15%O2]
NO [ppm@15%O2]
Baseline
Case a: m=0.7658 kg/s; P13%-M87%
1163 1162 1187 1187 1193*
1 1 1 1 2
4 1 13 7 9
Numerical
Case a Case b Case c
Experimental
* TIT of the experimental case is inferred through the TOT by means of a Cycle Deck calculation
Case b: m=0.70 kg/s; P15%-M85%
Reducing the inlet air mass flow produces an increment in TIT values. Reducing the fuel mass flow rate to the pilot line contributes to the reduction of NOx values to the outlet section of the combustion chamber.
Case c: m=0.70 kg/s; P13%-M87%
o According to the above considerations, air mass flow rate for 80.3 kW has been determined by means of the Cycle Deck calculation o Fuel distribution was set as the measured values of fuel distribution
Load
Parameter TIT [K]
Numerical results 1178 1 10
Experimental results 1180 2 11 Temperature
80.3 kWel
CO [ppm@15%O2] NO [ppm@15%O2]
Good agreement between the numerical and the experimental data, in particular in terms of TIT and NOx concentration.
90.1 kWel
80.3 kWel
CFDRESULTS:FUELDISTRIBUTION
o Natural gas feeding o Full load operation condition (100 kWel) o Variation of the fuel distribution
Fuel MAIN
Simulation of different fuel distribution between the two supply lines have been provided, in order to determine the behavior of the combustor
Fuel PILOT
Fuel distribution Pilot line P15-M85 (Reference) P20-M80 P30-M70 15 % 20 % 30 % Main line 85 % 80 % 70 %
REFERENCE CASE 15 % PILOT - 85 % MAIN
the fluid dynamic behavior is not strongly affected by the increasing of fuel percentage to the pilot line; the morphology and position of the vortexes do not vary; in all the cases there are two symmetric vortexes in the central zone of the combustor.
Velocity [m/s] GT201146090ANALYSISOFAMICROGASTURBINEFEDBYNATURALGASANDSYNTHESISGAS:MGTTESTBENCHANDCOMBUSTORCFDANALYSIS
REFERENCE CASE 15 % PILOT - 85 % MAIN
With the increasing of fuel percentage to pilot line: temperature reduction in the primary combustion zone (diffusive zone); flame displacement towards the combustor axial position; flame bifurcation due to the vortex located in the central area.
Temperature
TIT [K] NO [ppm@15%O2]
Pilot 15 % Main 85 % Numerical Pilot 20 % Main 80% Pilot 30 % Main 70 % Nominal Pilot 15 % Main 85 %
1202 1199 1200 1200
15.2 26.8 7.8 15
The overall energy balance does not present significant differences between the studied cases. The thermal power output developed within the combustion chamber and the temperature of gases at the outlet of the combustor are not influenced by the fuel distribution.
Temperature
NO molar fraction
CFDRESULTS:SYNTHESISGASFEEDING
o Synthesis gas feeding o Full load operation condition (100 kWel) o Reference fuel distribution: 15 % pilot line, 85 % main line
Synthesis gas derived from the pyrolysis of forestry biomass. Lower heating value equal to 9400 kJ/kg.
% CH4 21 % CO2 38 % CO 29 % H2 7 % H2O 5 %vol
Neither the combustor geometry nor the fuel system geometry have been modified; the simulation has been performed using the same numerical models and boundary conditions of the natural gas supply case; the fuel mass flow has been varied for a fixed air mass flow coming from the compressor, in order to obtain the same power output of natural gas supply case.
CFDRESULTS:SYNTHESISGASFEEDING
Uniform temperature decrease in the primary combustion zone; similar configuration of the temperature field.
Decrease of NO formation in relation to the temperature decrease; CO increase located in the fuel injection ducts due to the fuel composition. These results are in accordance with the phenomena related to the combustion process of LHV fuel.
FINALCONSIDERATIONS
From the CFD analyses: the fluid dynamic behavior is not strongly affected by fuel distribution, while the temperature field is strongly influenced by the fuel distribution and consequently the NOx concentration. The synthesis gas feeding allows to reduce the NOx concentration. The comparison between CFD and the preliminary experimental results at different operating points suggests that the numerical simulation is able to reproduce the combustion chamber overall behavior.
Thanks for your attention.

Anna Vaccari anna.vaccari@unife.it

MGT Turbec t100 CC

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ASMETurboExpo2011 June 610,2011 Vancouver,Canada

GT201146090 ANALYSISOFAMICROGASTURBINEFEDBY NATURALGASANDSYNTHESISGAS: MGTTESTBENCHANDCOMBUSTORCFDANALYSIS

IstitutoMotori CNR,piazzaBarsantieMatteucci,Napoli(Italy) 3TurbecS.p.A.,viaStatale,CorporenodiCento(Italy)

Single stage radial compressor and turbine

Reverse flow tubular combustor

Turbine Compressor Turbec T100 MGT Combustion chamber

ASYNCHRONOUS CONVERTER RS485/USB PC CALCULATION STATION

MICRO GAS TURBINE TURBEC T100

INTERNAL CONTROL MODE

MGT outlet temperature in external control mode

EXTERNAL CONTROL MODE

CAD 3D software: SolidWorks 2010

Numerical simulation code: ANSYS CFX 12.0

INNER FLAME TUBE

3. extension of air inlet duct;

4. extension of the inner flame tube.

Methane 2 Step - Westbrook-Dryer (1981)

Hydrogen 1 Step - Westbrook-Dryer (1981)

WALL OUTER FLAME TUBE Fixed temperature

Mainfuelline FUEL INLET Mass flow rate Temperature Composition Pilotfuelline

AIR INLET Mass flow rate Temperature Composition

OUTLET Averaged static pressure

WALL PRIMARY COMBUSTION ZONE Adiabatic

WALL INNER FLAME TUBE Fixed temperature

Strong temperature reduction due to the dilution air.

80.3 27.4 641.9 28.5 66780 1180 11 2

90.1 30.7 642.2 28.3 69300 1193 9 2

* TIT is inferred through the TOT by means of a Cycle Deck calculation

Baseline Case a Case b Case c

0.7658 0.7658 0.7012 0.7012

1163 1162 1187 1187 1193*

Case a Case b Case c

Case b: m=0.70 kg/s; P15%-M85%

Parameter TIT [K]

Numerical results 1178 1 10

Experimental results 1180 2 11 Temperature

REFERENCE CASE 15 % PILOT - 85 % MAIN

REFERENCE CASE 15 % PILOT - 85 % MAIN

1202 1199 1200 1200

15.2 26.8 7.8 15

Thanks for your attention.

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