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The design of an annular combustion chamber

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 Aerospace Europe
6th CEAS Conference

The design of an annular combustion chamber

Marius Enache
Junior Researcher
National Research and Development Institute for Gas Turbines COMOTI
220 D Iuliu Maniu Bd., sector 6, cod 061126, OP 76, CP174, Bucharest, Romania
marius.enache@comoti.ro

Andreea Mangra
Scientific Researcher

Razvan Carlanescu
Scientific Researcher

Florin Florean
Scientific Researcher

ABSTRACT

The design of an annular combustion chamber for a micro gas turbine engine is presented in
this paper. The combustion chamber is designed for using biogas as fuel. It is designed based on the
constant pressure, enthalpy addition process. The present methodology deals with the computation of
the initial design parameters and arriving at optimized values. Then the dimensions of the combustor
are calculated based on different empirical formulas. The air mass flow is then distributed across the
zones of the combustor. The cooling requirement is met using the cooling holes. The whole
combustion chamber is modeled using Catia V5. The model is then analyzed using various parameters
at various stages and levels to determine the optimized design. The aerodynamic flow characteristics
are numerically simulated by means of the ANSYS CFX software. The air-fuel mixture, combustion-
turbulence, the thermal and cooling analysis is carried out. The results are then presented in image
outputs and graphs.

KEYWORDS: Aerodynamic design; annular combustion chamber; CFD (computational fluid

dynamics) analysis.

NOMENCLATURE

LATIN GREEK
S-section area [𝑚𝑚2 ]; 𝛼-excess air;
T-temperature [K]; 𝑘𝑔
𝜌-density [ 3 ];
𝑚̇-mass flow [kg/s]; 𝑚
𝜙-hole diameter [mm];
v-velocity [m/s];
r-radius [mm];

1. INTRODUCTION

The scope of this article is to present a design methodology for a combustor which will be
part of a micro gas turbine for a 350 kW cogeneration power plant which works after a Brayton
recovery cycle. The compressor and the turbine are the single-stage centrifugal type. The combustion
chamber is of annular type. The micro gas turbine is designed to function using biogas as fuel.
The combustion chamber, or combustor, of a gas turbine, is the device that receives the
pressurized air from the compressor and promotes its mixture with the fuel in order to release the
heat energy through a combustion reaction. Gas turbines work with a high excess of air, usually out
of the flammability limits, and so a flame tube, or liner, is used to improve the distribution of air

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The design of an annular combustion chamber
M. Enache, A. Mangra,R.Carlanescu,F.Florean Copyright © 2017 by author(s)
 Aerospace Europe
6th CEAS Conference
through the reactor. Basically, the liner divides the combustion chamber into three zones: primary
zone, secondary or intermediate zone and dilution zone. At the primary zone, a recirculation zone
shall be developed to ensure the stability of the flame. The main function of the primary zone is to
anchor the flame and provide sufficient time, temperature, and turbulence to achieve essentially
complete combustion of the incoming fuel-air mixture. The primary-zone a portion of the hot
combustion gases are entrained and recirculated in order to provide continuous ignition to the
incoming air and fuel. If the primary-zone temperature is higher than around 2000 K, dissociation
reactions will result in the appearance of significant concentrations of carbon monoxide (CO) and
hydrogen (H2) in the efflux gases. Should these gases pass directly to the dilution zone and be rapidly
cooled by the addition of massive amounts of air, the gas composition would be “frozen,” and CO,
which is both a pollutant and a source of combustion inefficiency, would be discharged from the
combustor unburned. Thus in the secondary zone, the temperature is dropped to an intermediate
level by the addition of small amounts of air encourages the burnout of soot and allows the
combustion of CO and any other unburned hydrocarbons (UHC) to proceed to completion. The role of
the dilution zone is to admit the air remaining after the combustion and wall-cooling requirements
have been met and to provide an outlet stream with a temperature distribution that is acceptable to
the turbine.
Combustion chamber design methodologies have been proposed by Lefebvre [1] and
Melconian & Modak [2]. However, these methodologies have been developed for the design of
aeronautical and large industrial gas turbine combustors. These methods have been successfully
used to design combustion chambers [3, 5, 6] and there has even been developed software in which
these methods have been implemented [4].
Mohammad and Jeng [7] have developed a computer code for annular combustor design.
The design algorithm employs empirical and semi-empirical models which include diffuser section
design, air distribution computations, combustor sizing, fuel nozzle design, axial swirler design, heat
transfer calculations (with/without cooling, thermal barrier coating) and dilution holes design.
Conrado et al [8] present a methodology for gas turbine combustor basic design. Criteria for
selecting a suitable combustor configuration are examined followed by design calculations for the
dimensions of the casing, the liner, the diffuser, and the swirler. Calculations of gas temperature in
the various zones of the combustor and liner wall temperatures in the presence of film cooling are
performed along with design calculations for the dimensions of the air admission holes. A
computational program was developed based on the sequence of equations discussed in the paper.
In [9] is presented a combustion chamber design methodology using a software developed
for this purpose. The software developed calculates the dimension for a straight through tubular
combustion chamber that operates with gaseous fuel. This software allows visualizing the main
aerodynamics parameters that are involved in the project of a simple combustor. The equations
involved on the calculus of the program are based on the methodology developed by Lefebvre.

2. DESIGN METHODOLOGY

The first step in designing the combustor was the determination of the excess air and fuel
mass flow starting from the input data presented in Table 1 and Table 2.

Table 1: Parameters of the gas turbine cycle

Parameter Value Units
Compression ratio 5:1
Intake temperature of Turbine (T3) 1173 K
Output temperature of Compressor (T2) 750 K
Air Mass flow 2.6 kg/s
Efficiency of air compressor 80 %
Efficiency of turbine 85 %

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The design of an annular combustion chamber Page | 2
M. Enache, A. Mangra,R.Carlanescu,F.Florean Copyright © 2017 by author(s)
 Aerospace Europe
6th CEAS Conference
Table 2: Chemical composition of the fuel
Volume percent (%) Density (kg/Nm3)

CH4 50 0,656
CO2 45 1.842
N2 3 1.165
O2 0.8 1.331
NH4 0.6 0.73
H2 0.2 0.089
CO 0.2 1.14
H2S 0.2 1.434

The density of the biogas, according to the chemical composition in Table 2 is 1.21 kg/Nm3.
The low calorific power of the biogas was determined using Eq. 1:
𝐻𝑖 = 12720 ∙ (𝐶𝑂) + 10800 ∙ (𝐻2 ) + 35910 ∙ (𝐶𝐻4 ) + 23400 ∙ (𝐻2 𝑆), 𝑘𝐽/𝑁𝑚3 (1)
where (CO), (H2), (CH4) and (H2S) represent the volume percent for each component of the biogas
[10]. Thus a low calorific power of 18048 kJ/Nm3 was obtained. Or taking into account the biogas
density, a low calorific power of 14889 kJ/kg.
Eq. 2 was used for determining the theoretical quantity of oxygen necessary for complete
combustion [10]:
3
𝑛 𝑚𝑁
𝑂𝑚𝑖𝑛 = 0,5 ∙ [(𝐶𝑂) + (𝐻2 )] + ∑(𝑚 + ) ∙ (𝐶𝑚𝐻𝑛) + 1,5 ∙ (𝐻2𝑆) − (𝑂2) [ 3 ] (2)
4 𝑚𝑁

where (CO), (H2), (CmHn), (H2S) and (O2) represent the volumetric participations for each component
of the biogas [10]. Using Eq. 2, for m=1 and n=4, the following value was obtained: Omin=0.997.
The theoretical quantity of air necessary for complete combustion was determined using Eq. 3:
𝑂𝑚𝑖𝑛 (3)
𝐿𝑚𝑖𝑛 =
0,21

obtaining the value: 4.74.

The excess of air was determined using Eq. 4:

𝐻𝑖 − 𝑐𝑝𝑔 ∙ 𝑇3
𝛼=
𝑐𝑝𝑔 ∙ 𝑇3 ∙ 𝐿𝑚𝑖𝑛 − 𝑐𝑝𝑎 ∙ 𝑇2 ∙ 𝐿𝑚𝑖𝑛 (4)

where cpa represents the specific heat of air and cpg represents the specific heat of exhaust gases [9].
For T2=750 K and T3 = 1173 K an air excess of 5.37 was obtained.
For an air mass flow of 2.6 kg/s and using Eq. 5:
𝑚𝑎 𝑘𝑔 (5)
𝑚𝑐 = [ ]
𝛼 ∙ 𝐿𝑚𝑖𝑛 𝑠

a fuel mass flow of 0.092453 kg/s was obtained.

The next step in designing the combustor was to determine the excess of air and the
temperature alongside the liner.
For this purpose the combustor was divided into three regions:
1. The fuel injectors region;
2. The primary zone;
3. The dilution zone;

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The design of an annular combustion chamber
M. Enache, A. Mangra,R.Carlanescu,F.Florean Copyright © 2017 by author(s)
 Aerospace Europe
6th CEAS Conference

Figure 1: The three regions of the combustion chamber

Taking into consideration the information presented in the specialty literature [1], it was
considered that 10% of the total air mass flow enters the fuel in the injectors region, 18% of the total
air mass flow enters in the primary zone and the rest of 72% enters the dilution zone.

Table 3: Parameters resulted for the three regions of the combustion chamber
Regions 1 2 3
ma(kg/s) 0.260 0.468 1.872
𝛼 (excess air) 0.593 1.661 5.932

The temperature along the combustion chamber was determined using Eq. 6:
efic  H i    Lmin  T2  H i
T [K] (6)
(1    Lmin )  c p _ g
where efic represents the combustion efficiency. Its values were taken according to [11]. As expected
the temperature maximum value is obtained in the primary zone.

Figure 2: Temperature distribution

The final step in the design process was to determine the velocities outside and inside the fire
tube and the liner holes diameters based on the jet penetration.
The pressure at the compressor’s exit is 500000 Pa (p2). Since the distance from the
compressor exit to the combustor entrance is considerable due to the micro gas turbine constructive
solution, it was considered that the air pressure at the combustor entrance is 475000 Pa.
The velocities outside and inside the fire tube have been calculated using Eq. 7:
𝑚̇
𝑣 = 𝜌∙𝑆 [𝑚𝑠] (7)
where S represents the section area.

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The design of an annular combustion chamber Page | 4
M. Enache, A. Mangra,R.Carlanescu,F.Florean Copyright © 2017 by author(s)
 Aerospace Europe
6th CEAS Conference
Table 4: Repartition of velocity exterior of the fire tube
Exterior air annular section
rext (mm) rint (mm) mc (kg/s) ma (kg/s)
322 311 0.092453 2.6
S=21863.82 mm 2

Interior air annular section

rext (mm) rint (mm) mc (kg/s) ma (kg/s)
261 250 0.092453 2.6
S=17649.94 mm 2

Region 1 2 3
Pressure loss (dp%) 1 2 3
Pressure (Pa) 467775 463050 458325
Air density (ρa) 2.1797 2.1577 2.1357
Mass flow (kg/s) 2.6 2.34 1.872
v(m/s) 30.1862 27.4448 22.1822

Table 5: Repartition of velocity interior of the fire tube

rext (mm) rint (mm) mc (kg/s) ma (kg/s)
311 261 0.092453 2.6
S=89804 mm 2

Region 1 2 3
Pressure loss (dp%) 1.25 2.25 3.25
Pressure (Pa) 466593.75 461868.8 457143.8
Fuel density (ρg) 0.9359 0.8344 1.3338
Mass flow (kg/s) 0.3524 0.8204 2.6924
v(m/s) 4.1934 10.9490 22.4776

The jet penetration was calculated using Eq. 8 [11]:

𝑉𝑎
𝐻𝑗𝑖 = 3.1 ∙ 𝜙 ∙ (0.3 + 0.415 ∙ ) (8)
𝑉𝑔

Table 6: Jet penetration

Region 1 2 3
Air Velocity(𝑉𝑎 ) 30.18 27.44 22.18
Fuel Velocity(𝑉𝑔) 4.19 10.94 22.47
Hole diameter 𝜙 (mm) 2.5 5 6.5
Jet penetration (𝐻𝑗𝑖 ) 25.49 20.78 14.29

Based on the calculations presented above a first version of the combustor geometry,
presented in Fig. 3, has resulted.

CEAS 2017 paper no. 810 Page | 5

The design of an annular combustion chamber
M. Enache, A. Mangra,R.Carlanescu,F.Florean Copyright © 2017 by author(s)
 Aerospace Europe
6th CEAS Conference

Figure 3: Fire tube

Figure 4: Combustion chamber assembly

3. Three-dimensional numerical simulation results

In order to obtain quicker results due computing limitation, the model was simplified into a
22.5-degree cut section for the combustor. The computational aerodynamic analysis is carried out to
validate theoretical results and to obtain a detailed preview of the outcome design.
The numerical simulations were carried out using ANSYS CFX software. An RANS approach
was used with an unstructured type mesh has been generated for the computational domain and with
the Domain Motion Stationary. Number of Tetrahedral Elements: 8231719.
The following boundary conditions were used. At air inlet, there were imposed the air mass
flow and temperature, at fuel inlet there were imposed the fuel mass flow and temperature and at
the outlet, the pressure was imposed.
The Eddy Dissipation combustion model was used, in combination with the K-epsilon
turbulence model. This model was chosen because it allows accurate simulation of the heat release
and the distribution of the main chemical species.
The velocity distribution presented in Fig. 5 shows high velocity in the central region. Jet
penetration is very strong, thus the created turbulence will affect combustion process.

CEAS 2017 paper no. 810

The design of an annular combustion chamber Page | 6
M. Enache, A. Mangra,R.Carlanescu,F.Florean Copyright © 2017 by author(s)
 Aerospace Europe
6th CEAS Conference

Figure 5: Velocity distribution

From Fig. 6 it can be observed that the flame temperature presents high values mainly near
the combustor’s walls. This is in good correlation with the velocity profile presented in Fig. 5. The
high-velocity values from the central region of the fire tube make difficult the mixing of the air and
fuel in the primary region.

Figure 6: Total temperature distribution

In Fig. 7 are presented 4 temperature isosurfaces inside the fire tube (red=2200 K,
orange=2000 K, yellow=1800 K, green 1500 K). As it was observed before, the high flame
temperatures are developing near the walls. This is not a good sign. It can lead to serious damage to
the fire tube. It also can be seen that the flame has a very irregular structure.

CEAS 2017 paper no. 810 Page | 7

The design of an annular combustion chamber
M. Enache, A. Mangra,R.Carlanescu,F.Florean Copyright © 2017 by author(s)
 Aerospace Europe
6th CEAS Conference

Figure 7: Total temperature Isosurface distribution

The average temperature at the exit of the combustor was 1150K. Even though this
temperature value is very close to the one imposed in Table 1, based on the results obtained so far it
was concluded that same changes have to be done to the combustor geometry.
A deflector was added to the original geometry in order to concentrate the flow in the central
region of the fire tube and to prevent flame adhesion to the walls of the combustor. The
improvement can be observed in Fig. 8 and Fig. 9. The flow velocity has diminished and the flame is
concentrated in the center of the fire tube.

Figure 8: Velocity distribution

CEAS 2017 paper no. 810

The design of an annular combustion chamber Page | 8
M. Enache, A. Mangra,R.Carlanescu,F.Florean Copyright © 2017 by author(s)
 Aerospace Europe
6th CEAS Conference

Figure 9: Total temperature distribution

In Fig. 10 the temperature distribution along the fire tube is presented. As it can be seen, the
temperature rise up to 1400 K in the region of the injectors, afterward reaching a maximum of 2100
K in the primary zone. After that, the addition of air leads to a decrease of the flame temperature.

Figure 10: Total temperature distribution

Form Fig. 11 it can be seen that the flame has a uniform structure and the flame does not
exceed the fire tube length. Thus it won’t affect the turbine.

Figure 11: Total temperature Isosurface distribution

The average outlet temperature is of 1180 K, being close to the required value.

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The design of an annular combustion chamber
M. Enache, A. Mangra,R.Carlanescu,F.Florean Copyright © 2017 by author(s)
 Aerospace Europe
6th CEAS Conference

4.Conclusions

The complete annular combustor design using just the initial design parameters has been
discussed in this paper. This is a design methodology which can be used for the preliminary design.
The transparent and detailed approach is focused on reducing design time and complexity. This gives
an overall advantage in total design time and prototype building. Using the methodology, a practical
design is presented. The obtained values are used for modeling and further simplified for analysis.
The analysis was also carried out with higher accuracy using the combustion-turbulence interaction
model and the results show that the optimum gas exit temperature was obtained for the present
design. The design was successfully calculated and modeled.

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