Exploitable results
An idealised boiler has been developed and characterised, able to mimic characteristics of a practical domestic boiler while having a simplified 2D geometry. Four units of that burner have been manufactured and delivered to partners involved in the measurement. Very detailed local measurements in the flame of the idealised boiler, for 5 selected test cases have been made: velocity, temperature, main compounds (CH4, CO2, O2, CO, NO) and radical (OH, CH, CN) concentration fields. In addition, CO, OH and temperature experimental data have been acquired in a commercial wall-mounted boiler.
A reduced combustion kinetic mechanism for mixture of methane and ethane has been developed and validated by Imperial College against an enhanced detailed mechanism for both rich and lean flames. It includes nitrogen oxides chemistry.
BG PLC has adapted an in-house code, COBRA, to handle the simulation of the idealised boiler. Calculations for four of the five test cases defined in Task 1 have been done with a reduced kinetic mechanism already available in COBRA.
A user-friendly graphical interface has been developed between the ESTET commercial CFD code and BISCUIT, (Gaz de France kinetic library) resulting in a new code called ESTET-CC (Complex Chemistry). The resulting version has been validated for four of the five test cases defined in Task 1, with a detailed combustion kinetic mechanism. An improvement in the calculation efficiency by a factor of 10 000 has been obtained compared to the PHOENICS-CHEMKIN previous coupling.
The general design and assembly process of a boiler has been examined under the influence of different parameters considered as important for defining the burner/ boiler system performances: most of the parameters that influence the flame pattern in the combustion chamber have been checked and evaluated. Samples of burners have been tested in commercial combustion chambers with respect to the variation of the design and of the components of the boiler. Correlations have been obtained for two types of domestic boilers, between the boiler operating conditions and all the relevant combustion parameters influencing the characteristics of the flame and the NOx and CO emissions, such as combustion chamber geometry, burner geometry, mixture distribution, flue gases exhaust and combustion chamber secondary aeration and distribution.
Design Guidelines have been elaborated from data obtained in both the idealised and practical boilers. It also includes experimental procedures for the efficient use of advanced measurement techniques. The new Design Tools have been successfully validated during a real exercise of development of a low-cost, low-NOx (50 mg NOx/kWh) burner/boiler. A cost benefit/analysis has demonstrated the progress made compared to the current state of the art.
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