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Design andModelling Aspects in Premixed Gas Burners Development

Conference Paper · September 2016

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0383-1

Design andModelling Aspects in Premixed Gas Burners Development

PetarGvero
Faculty of Mechanical Engineering
University of Banja Luka, Bosnia and Herzegovina
email: gvero.petar@gmail.com

SretenLekic
Faculty of Natural Sciences and Mathematics
University of Banja Luka, Bosnia and Herzegovina
email: slekic0@gmail.com
DjordjeVojinovic
Faculty of Technology
University of Banja Luka, Bosnia and Herzegovina
email: djolev@blic.net

Biljana Prochaska
Faculty of Mechanical Engineering
University of Banja Luka, Bosnia and Herzegovina
email: biljanaproch@gmail.com

ABSTRACT
Premixed gas burners are common in use for household boilers, and due this fact they are
devices suitable for mass production.This paper describes steps taken in the development of
the cylindrical premixed burner, in order to fulfil market requirements as well as
environmental standards, taking in to consideration that the fuels thatcan be used can have
different quality levels.As a first step, the preliminary CFD model of premixed combustion
with minimal necessary geometry and technical details was created by using solid modelling
tools.After testing the basic dynamics of cold flow and flame properties, more complex CFD
mechanisms were introduced in an advanced model, including the reduction of chemical
reaction mechanisms.Chemical mechanisms are the one of the most challenging aspects for
calculating chemical reactions pathways and knowledge of chemical mechanisms is crucial
for correct calculations.A combustion mechanism of methane was used to simulate the model
of natural gas combustion, and due to thecomplexity of the chemical reactionsand limited
computer potential, simplified mechanisms were used.The level of simplifications was
madeto allow the integration of chemical mechanisms in an overall CFD model of premixed
combustion in this specific analysed burner.Flame structure and emissions have been
modelled primarily with the use of CHEMKIN code.Simulation of the combustion process
was made using a selected reduced model for modelling of combustion processes for real
natural gas (natural gas from Serbia and Russia), as well as biogas.After the simulations
process, a real burner was tested on a field using an experimental set up, which was ableto
simulate real working conditions.At the end of the development cycle, the whole CFD
modelling process was tested on a supercomputer with two aims: to work with less
simplifications and restrictions imposed by available resources, as was before, and to use an
open source CFD tool (OpenFOAM). The results were comparedwith the results achieved by
using commercial tools, used in a previous cycle (FLUENT and partly StarCDAdapco).

KEYWORDS
Premixed, burner, gas, combustion, CFD

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INTRODUCITON

Gas premixed burners are widely used in household appliances, particularly condensing
boilers, with a rising number of appliances every year. Normally, premixed flames have
shorter flame lengths than non-premixed flames and partially premixed flames; thus, they also
have the advantage of having low NOx emissions as a result of the low flame temperature due
to differences in the equivalence ratio [1].
From the other side, in recent years, there are requirements for high-efficiency, flexibility
from the aspect of modulation range, and the ability to work with fuels of different quality, all
of which raise environmental problems. Air pollution is the one of the major problems, and
due to that more attention has to be focused on the burner design. The mainidea of this paper
is to show the crucial phases in the development and design of a flexible premix burner as a
mass product. This means the incorporation ofproper procedures and implementation of CFD
codes, and solid modelling tools, in order to get appropriate outcomes, which may make the
development process shorter and cheaper.
The aim of the particular project is the developmentof low-cost, fuel-flexible, efficient and
low-pollutingpremix burners for domestic heating appliances by means of advanced
modelling and design tool.The major aims of the project were:the development of 1:5 power
modulating fully premixed metal burner (5-50 kW), optimized burner materialcomposition
and pollutants emissions below 40 mg/kWh over the entire power modulation range,
achievement of enhanced fuel flexibility, i.e. capability of handling different gases as
feedstock(e.g. natural gas, LPG), with a special focus on the direct use of low heating value
resources (biogas,low methane-containing natural gas, blast furnace gases), whilst fulfilling
emission standards. As well as that, developed burners should guarantee the usual durability
targets for suchappliances of at least 30,000 hrs.and 200,000 thermal cycles.A fully-validated
modelling and design platform, including simultaneous CFD modelling offlames and finite-
elements modelling of burner stress and strain, primarily aimed at tailoring theburner
geometry, the slits and holes shape and distribution pattern. Pollutants emission and
flamestability) are also included.

CHEMISTRY OF GAS COMBUSITON PROCESS

In recent times, significant progress was made regarding the understanding of detailed
mechanism of oxidation reaction of hydrocarbons (CH).
In this article, the focus is on the combustion mechanism (chemistry) of methane, which
includes discussion on oxidation mechanism of formaldehyde (CH2O) as an integral part of
the methane oxidation process. The combustion mechanism of methane is usually the most
commonly used for simulation of the model for natural gas combustion, but can be used also
to simulate the combustion of hydrocarbons with a lower number of C atoms, including the
biogas. The reason for this is that the real combustion process scheme, even for
simplestpossible CH fuel like methane, is too complex andmust be reduced for practical use
[2,3].
A full and detailed mechanism of chemical reactions for natural gas combustion includes over
100 species and more than 1000 elementary chemical reactions presented in Arrhenius form,
what gives a complex system of nonlinear differential equations [5]. Correct analytical
solutions are rare and complicated,therefore the only acceptable and applicable methods are
an asymptotic or numerical approach. Because of limited computer resources, as well as cost,
these systems are very often essentially simplified, but even so theseproduce acceptable
results. This is the reason why efficient CFD calculations have to be based on reduced
chemical mechanisms with a lower number of compound and reactions.

2
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There are different techniques for chemistry reduction, starting from fully automated
algorithms to specifically developed heuristic techniques. These reduction techniques are
based on analyses of species concentration, production velocity and sensitivity coefficient.
There are reduced chemistry’s for methane and propane combustion that give excellent results
in comparison with full chemistry. Also, if NOxformation is subject of analysis, than N
chemistry has to be included in reduced chemistry.
In this article, the following approved chemistries were used to model of emissions and flame
structure:
1. GRI-Mech 1.2
2. GRI –Mech 2.11
3. GRI-Mech 3.0
4. Chemical-kinetic Mechanisms for Combustion Applications, developed by The
Combustion Division of the Centre for Energy Research at the University of
California-San Diego
5. Reaction mechanism from early works developed in Sandia National Laboratories
[7,8,9]

In this analysis GRI-Mech2.11 and GRI-Mech 3.0 were used, as GRI-Mech 2.11 is
representing an improved version of GRI-Mech 1.2that includes nitrogen chemistry’s relevant
for natural gas chemistry and accept and respect chemistry C-H-O in ignition and combustion
process of natural gas, but it is not fully optimized for the modelling of pure chemistry N-H-
O, either for any process of NOxremoval. GRI-Mech 2.11 includes 277 elementary chemical
reactions with 49 species.
GRI-Mech 3.0 is an update of 2.11 versions and is fully optimized for the modelling
of natural gas combustion, including NOxformation. Improvements were made in categories
of kinetics update, including some new and updated experiments for optimization, spreading
chemistry and selection of targeted species as well as control of thermodynamics that
describes chemistry. The new version includes 325 elementary chemical reaction (out of 3 are
duplicated) and 53 species (including Argon). Full optimization changed 31conversion
parameter in relation to the previous version.

Taking into consideration the above mentioned,the limitation of CFD tools and inability of
easy application of listed mechanisms, the main question is further reduction of presented
mechanisms. In this article, particular attention was put on reduced models developed by
Sung and Chen that are developed from above listed GRI Mechchemistry as follows [4]:
 12 step reduced chemistry developed from GRI Mech 2.11,
 13 step reduced chemistry developed from GRI Mech 3.0,
 15 step reduced chemistry developed from GRI Mech 3.0.

These 3 reduced chemistry mechanisms were used, and all of them include nitrogen
chemistry, beside the fact that they are simplified and reduced from more than 100 reactions
to only 12-15 elementary chemical reactions.

During further research of combustion model of gas fuels and its possible reduction, a
combustion model was used for the combustion of natural gas from Russia and Serbia with
determined chemical composition, as well as biogas. Composition of these gaseous fuels is
given in following table:

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Table 1.Chemical composition of natural gas and biogas (vol %).

Russian gas Serbian gas Biogas
C1 97.34 84.37 60.00
C2 0.67 3.15
C3 0.22 0.44
C4 0.07 0.07
C5+ 0.02 0.02
N2 1.00 1.95
CO2 0.68 10.01 40.00

Results achieved for all of the used reaction mechanisms showedvery similar trends and
profiles for the majority of species, temperature profiles and flame velocity.
It is very important to emphasize that only calculations using GRI Mech 2.11 i GRI Mech 3.0
give a possibility of fine calculation of mole fraction of NOx. This is very important reason to
include these mechanism in a CFD model as a next step.Our experience shows that is possible
to include GRI Mech 2.11 chemistry in a further CFD model due to the lower number of
species and the appropriate number of chemical reactions.
Results achieved using GRI Mech 3.0 and 2.11 can be very useful for the development of
semi-empiric models, bearing in mind that the majority of calculated mole fractions and
profiles can be easily prepared by some nonlinear mathematical functions.

Flame structure and emissions have been modelled by the use of CHEMKIN code. In the
version CHEMKIN 4.0.2 there are various reactor models and among them are models of
Premixed Burner and Flame Speed Calculator which are appropriate for application in
simulations of burner-stabilized and freely propagating, laminar, lean methane/air premixed
flames. These reactor models are one-dimensional and allow calculation of temperature
profile, concentrations of main species CH4, O2, CO2, H2O, CO, H2, NO, NO2but also of
intermediates such as H, OH, O, CH, HO2, H2O2, and flame propagation velocity, as a
function of distance [9].
Verification of selected reduced model for chemical kinetic in combustion process is done by
application of the selected model: 15 step reduced chemistry developed from GRI Mech 3.0
for modelling of combustion of real natural gas (from Serbia and Russia) as well as for
biogas.
The flame structure and emissions of burner-stabilized, lean methane-air premixed laminar
flames, at initial temperature of 298 K, and pressure of 1.01E5 Pa, were calculated.
Calculations were performed on 10 cm domain which is much bigger than the flame
thickness. The air coefficient varied from stoichiometric value (λ=1.0) to lean mixture
(λ=1.4). Flame propagation velocity calculator-reactor model was used for determination of
temperature profiles and laminar flame propagation velocities. Concentrations of species have
been calculated using the above mentioned kinetics model, whilst temperature and flame
propagating velocity have been calculated using reduced mechanisms. The initial temperature
profile for stoichiometric mixture obtained from previous measurements and archived
CHEMKIN samples were chosen. After running the code, the obtained results were used for
initiations of the next case calculations.

Bearing in mind that the use of reduced 15-step chemistry for simulation of combustion for
real gases with different chemical composition gives satisfactory results, in the following
research this chemistry was used in CFD tools package for simulation of combustion process.

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Results atstoichiometric valueλ=1.0

2500
0.1

2000
Temperature (K)

reduced15

CH4 mole fractions

1500
reduced15 0.01 ruskigas
ruskigas srpskigas
srpskigas biogas
biogas
1000

1E-3

500

0
0.0 0.1 0.2 0.3 0.00 0.05 0.10 0.15 0.20 0.25 0.30
distance (cm) distance (cm)

Figure1.Temperature profilesFigure 2. Mole fractions CH4

0.1
0.1

0.01
0.01
CO2 mole fractions

CO mole fractions

reduced15
1E-3 ruskigas 1E-3
srpskigas reduced15
biogas ruskigas
srpskigas
1E-4 1E-4 biogas

1E-5 1E-5

1E-6 1E-6
0.00 0.05 0.10 0.15 0.20 0.25 0.30 0.00 0.05 0.10 0.15 0.20 0.25 0.30
distance (cm) distance (cm)

Figure 3.Mole fractions CO2 Figure 4.Mole fractions CO

In our research it was not possible to calculate concentrations of all these mentioned species,
due to a limitation of detailed reduced skeletal chemical reaction mechanisms. So, we focused
our research on calculating the temperature profiles, axial velocity and concentrations of
species: CH4, O2, CO2, H2O, CO, H2, NO, but also of intermediates such as H and OH.
All these results, calculated with reduced chemistry were compared with results calculated
with proven chemistry and demonstrated good compliance and consistency.

CFD MODELLING OF PREMIXED BURNER

A model of the analysed cylindrical premix burner with highly perforated double mantles is
shown on Figure 5, together with a small segment of burner perforation which was used in
initial solid and CFD analysis, due to the high complexity of the burner geometry.

Mesh development and CFD modes

After CFD calculation on volume mesh with a more simple geometry, we improved mesh
design in control volume. Burner mantle segments of radial symmetry and control volume
were divided on tetrahedral cells. Initial mesh with more than 700,000 volume (Figure 6) cells
was adapted to 1,200,000 cells during the CFD calculation and with better solution
convergence for numerous parameters.
In the first and second year of the project the most complicated simulation of complex
chemistry mode, parallel processing was executedon three computers: one computer with two

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processors (Opteron) and two other with single processors. Metis partitioning divided the job
on four equal files with 1.6 gigabyte of RAM per processor. This has been the maxima of our
computer capability. Four new processor computers now accelerate the computing by about
three times. In most calculations, we have used the modified EBU model, Species transport
model with k - εturbulent mechanism and Chemical reaction mode. These modes have three
mechanisms for calculating the NOx emission.

Figure 5. CAD model of the cylindrical premix burner with the segment of burner mantle
(diameter of the burner is 70 mm, height 154mm, wall thickness 0.5mm).

. a) b)
Figure 6. Surfaces of the volume mesh with a few ignition cells (red colour)(a) and cross
section through the volume mesh (720,000 tetrahedral cells) (b)

The field of many physical values could be present in 3-D control volume with arbitrary
number of sketch plains as in example below (Figure7 and 8), but for better understanding
and easier compare of contours, only one sketch put on the plane through the 3-D burner
mantle.

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Figiure 7. Vector representation of coloured velocity contours for methane combustion.

Figure 8.Contours of static temperature distribution on cross-sections of six parallel and

orthogonal plains.

The influence of excess air ratio λ on combustion processes and flame and burner parameter
was analysed.
Russian and Serbian natural gaswere treated in CFD modelling and after that field burner
testing and validation of the modelling results were performed on the gas condensing boiler.
Comparison ofthe results of the CFD modelling with Chemical kinetics results and
measurement on pilot burner show wide spectra of agreement in some crucial parameters.
Some variations of lambda and power were presented. The figures of the more interesting
results were elaborated (Figure 9 and 10).

a) b)
Figure 9. Contours of temperature for λ → λ = 1.0 and P = 15 kW (Russian gas) λ (a) and
contours of temperature for λ, λ = 1.0 and P = 12 kW (Serbian gas) (b).

In parallel analyses, the mass flux of both gases has the same value. In Figure 9 (a and b) for
λ, λ = 1.0 Serbian natural gas burns at a lower temperature (Tmax is about 1910 K) than
Russian (Tmax about 2000 K), and integration the thermal flux over outlet aperture give the
power ratio 12 : 15 respectively. Serbian natural gas contains10% of CO2(Russian 1%) and
this is a ballast which causes this behaviour.
From the numerous power and λ combination, maybe the most interesting is the limit in
maxima. In modelling, for λ between 1,6 -1,7 burning Serbian gas reaches blow-off
conditions.

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Temperature contours on Figure 4 show that the burning processes above the slots were
finished and that the blow-off conditions will start sooner for Serbian natural gas.
Temperature decreaseduring combustion process is very sensitive onλ increasing. If we hold
the power near constant (about 30 kW), with an increase of λ temperature is reducing. For λ =
1.1, T max =2140 K, and for λ = 1.4 T max =1690 K (Figure 10)

Figure 10.Temperature distribution for λ = 1.0 and λ = 1.4

Reaction profiles

By analysing the most important reaction processes (CH4 and O2 in CO and H2, CO oxidation
and H2 in H2O) assigned as Arrhenius 1,2 and 3 order reactions,it can be seen that the
intensity of all reactions decreases, but reaction volume increases and lifts up, and as result
the power increase too.
From blue mode, theburning goes toward the radiation mode, but the reaction region is below
and near the thermal exchanger. Figures 11 and 12 show Arrhenius reactions on 15 kW and
48 kW power consumption respectively for Russian gas and for =1.0. Lifting the region of
reactions and velocitiesover 3 m/s causes the blow-off at first above the slits. Inhomogeneous
distribution of reaction volume and velocities caused appearance of local region with high
intensity emission of NO, but not so important after averaging the total flux on inlet. Figure
11 shows that reaction is stronger on the holes and slits directly above the pressure
distribution plate.

Figure11. 3-D picture of Arrhenius rate reaction.

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Figure 12.Vertical observation lines for determination radial and axial field values.

Comparative presentation of radiation effect on burner mantle segment

During the burning process, the thermal contribution comes almost from the radiation
processes. In CFD modelling a discrete ordinate module is included. For an average
coefficient of absorption of air, c about 0.4 (three values for emissive coefficient for gray
body in three wavelength regions) the temperature field of mantle surfaces for various
working conditions was calculated.

Figure 13.Mantle temperatures at the end of burner for Russian and Serbian natural gas P=30
kW, =1.0

.
Figure 14.Mantle temperature at the end of burner for Russian gas P=48 kW, =1.4.

The mantle temperature fall-down in spite of the strong radiation effect, because the cooling
fuel and air stream conductive influences are more dominant.

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NOx concentrations

The figure below (Figure 15) shows the strong influence of the configuration of theholes and
slits on the burner mantle and inner mantle.On NO profiles-this produces areas of stronger
turbulence.
Results of CFD analyses of NO concentration show stronger values near the slits,
especiallyaround the slits with large holes below.

(a) (b)
Figure 15. NO concentration for Russian gas for =1.4 and P=30kW (a) and for=1.6
P=30 kW (b)

FURTHER CFD DEVELOPMENTS

Our aim was to develop a more sophisticated simulation model by computation simulation on
a supercomputer. In the frame of the HP-SEE initiative (High-Performance Computing
Infrastructure for South EAST Europe’s Research Communities), we used open source
OpenFOAM software packages on a UNIX-LINUX supercomputer platform and simulated
the full profile of burner. We simulated 3D dynamics of combustion, and various fields,
species and pollutions distribution.
At first, we simulated cold flow on a small scale model (approx. 1 million elements) and
achievement very well scalability (32 CPUs -cores). In order to test scalability to larger
number of CPUs, we used full scale model (over 22 million elements) with steady-state and
transient solvers and 128 CPUs (PARADOX –Institute of Physics –Belgrade) Figures 16, 17,
18.

Figure 16. Burner mantle and mantle mesh.

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Figure 17.Velocity distribution on the burner mantle [10].

Figure 18. Scalability of the computer clusters.

We expect a better insight into real chemical reactions during the combustion process and
better control of fluid dynamics parameters in geometry design. In actual OpenFOAM
software configuration, the Eddy concept theory is included in modules, and we expect
further steps in nonlinear and acoustic influence in burning dynamics.

HEAT STRESS AND BURNER GEOMETRY

Investigations of premix burners provided by different authors strongly emphasize the relation
between burner geometry design and burner efficiency and emission of the gases, as well as
burner durability11. Besides that,some of the authors emphasize the importance of a CFD
modelling process in a case of optimal geometry search, which is adequate for the fulfilment
of requested burner performances with a high power modulation and low emission
[12].Understanding of border conditions of the premix burner design, consideration of heat
resistance on a different unevenly heat load, investigation of the materials with different
thermal expansion coefficients, which is in correlation with mantle deflection, fatigue and
cracking. Due to this, FEA simulations were proposed in order to predict burner behavior
during explanation [13].

Gas burner model

Testing and measurements of the achieved temperatures on the outer premix burner mantle
were provided with the aim of the confirmation of the numerical results achieved by using

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simulation tools. Inthis way input data of the heat loads and distribution on the axis of outer
mantle were achieved. The stationary and non-stationary regime of the burner functioning
was analysed.
As a part of the investigationsrelatingto the premix burner heat durability, which was built
from different new material types with the improved thermal characteristics, with high
oscillations in burner working regime and high level of model perforation, some
approximations were applied.
Heat load was varied in the range from 5 to 50 kW, with the request combustion in the blue
flame regime (low emission). High geometry complexity required previous analysis of the
burner segments (Figure 5),because a high perforation level (more than 7,000 holes on the
outer burner mantle, which distribution has influence on burner behaviour under the
loads)creates a problem for CAD and FEA software tools, regardless of computer resources.
The inner burner mantle has a less demanding perforation than outer.

Proceeding from the conditions that is basic form sheet metal mantle with thickness of 0.5
mm, surface 3D model, when is volume component is very small, and then that model is
axially symmetric relative to the reference axis, than shape of mechanical and heat mantle
load, it is possible to select small axisymmetric excerpt, segment of 36owhich covers repeated
series of the holes on the whole burner height, which is shown on Figure 19. A model reduced
in this way is adequate, possible and is acceptable for the simulation of the behaviour of the
whole burner [14].

axisymmetric
excerpt

Figure 19.Axisymetric angle excerpt of the outer mantle

The approach to the parameters selection was provided in two ways, by the introduction of
bothexpected mechanical and thermal strains on the selected burner’s segment.
Heat analysis was provided by using results taken from CFD simulation results, expressed as
thermal flux.
Model loads also consider the effects of the ambient temperature, effects of convective
cooling caused by the fuel gas approaching to the burner and radiation of the grey body as
border conditions, which values were also varied in dependence on the conditions defined by
the inlet parameters.

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After precise defined and established parameters relevant for the analysis were set, analysis
was performed by using FEA program package, which are components of the program
systems of the general purpose (as SolidWorks).
By using FEA program system, a mesh of finite elements was created (Figure 20) and then
analysis was performed.

Figure 20.An excerpt of the burner mantle model with display of the finite elements network

Results of the numerical simulation of the heat transfer trough burner

mantle of premix burner

Heat analysis for short load Short load considers a high burner load of 50 kW, which is
achieved after 5 s, since burner start for Russian gas and 40 kW. For Serbian gas the total
analyzed period was for 15 s. Results were shown for the analyzed group of materials;
thecheapest material, AKsteel18SRand the most expensive material Haynes230, (Figure 21,
22, 23 and Table 2).

a) Russian gas b) Serbian gas

Figure 21.Temperature field for short and intensive load and material AKsteel18SR.

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Figure 22. Short load–Russian gas. Figure 23. Short load–Serbian gas.

Table 2.Comparative results for two different materials for two gas typesand short load.
Min. load. Max. load.
materials node locaiton node locaiton
(K) (K)
(28.7215, 46.6061, - (34.1219, 0, -
Russian

AKsteel18SR 468.657 2607 480.526 10495

20.3498) 6.30777)
gas

(29.647, 106.735, - (34.1219, 0, -

Haynes230 431.363 15967 448.645 10495
18.9761) 6.30777)
(28.7215, 46.6061, - (34.1219, 0, -
Serbian

AKsteel18SR 411.379 2607 423.22 10495

20.3498) 6.30777)
gas

(29.6471, 104.864, - (34.1219, 0, -

Haynes230 379.358 15972 396.367 10494
18.976) 6.30777)

Analysis of the results shows noticeable differences in behaviour of the material on the set
load, where it is noticed that the numerical model of the premix gas burner with Haynes230,
achieved smaller heat load then model with material Aksteel18SR.
There is a difference in the achieved maximal temperatures on the same location, node of the
finite elements network, under the same load is around 32 Kfor Russian and around 27 Kfor
Serbian gas.
Heat analysis for low load. Low load considers a burner load of 15 kWfor Russian gas and 12
kW for Serbian gas, (Figure 24 and 25) initially for a period of 576 s, then switching-off,
causing an interruption of the load for a period of 576 s, then continuation of the burner until
the end of the analysed period of 2305 s. Achieved results for the material Aksteel18R,
dependent on gas type are shown on Table 3.
Analysis of the results shows significant differences in behaviour of the same material
Aksteel18SR depending on the gas type.
It is noticed that the numerical model of the gas burner with this material, achieves
significantly lower thermal stress and much lower values of temperatures on the analysed
location for Serbian gas than for Russian.

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Figure 24. Low load – Russian gas. Figure 25. Low load – Serbian gas.

Table 3. Comparative results for AKsteel18SR materials for two gas typesand low load.
Min. load Max.
materiala node location Node location
(K) load(K)
Russian

(33.886,
(34.1219, 0,
gas

AKsteel18SR 904.549 18052 82.6618,- 904.643 10495

-6.30777)
9.52775)
Serbian

(34.2765,
(34.1219, 0,
gas

AKsteel18SR 811.957 17203 89.9651, - 812.025 10495

-6.30777)
8.01007)

Heat analysis for high load. Heat analysis for high load consider load which is in burner at a
start of 50 kWfor Russian gas and 40 kW for Serbian gas (Figure 26 and 27)during the period
of 576 s, than interruption of the load for a period of 576 s, then continuation of burning with
the initial load until the end of analysed period of 2305 s. Results were shown for the cheapest
material AKsteel18SR and the most expensive material Haynes230, (Table 4).
Analysis of the results shows differences in material behaviour, where is noticed that that
numerical model of the burner with material Haynes230 achieves lower thermal stress than
the model of the burner with material Aksteel18SR.
There was a difference in achieved maximal temperatures on the same location, node of the
mesh of the finite elements, under the same load of 4.3 K for Russian and around 3.8 Kfor
Serbian gas.
It is evident that the biggest differences in behaviour of two material during the short high
loads, is at the beginning of the burner start when load rises from 0 to a maximum value for
each gas, in the first 15sof work, and this difference is significantly lower when the load is
maximal for thelonger period of 2300s, than when is load is “switched-on then switched–off”.
It was noticed that by using different gases, the same material achieves differences of up to 92
Kduring the low load.

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Figure 26. High load – Russian gas. Figure 27. High load – Serbian gas.

Table 4.Comparative results for two different materials and two gas types and high load.
Min. Max.
materials node location node location
load (K) load(K)

(34.1435, 154, - (26.3158, 19.7465,

Russian

AKsteel18SR 853.619 10931 8.55943) 853.701 642 -22.6179)

gas

(33.886, 71.3382, (24.7163, 6.79412,

Haynes230 849.2 17889 -9.52775) 849.352 22159 -24.3555)

(33.886, 71.3382, (26.3158, 34.1465,

Serbian

749.615 17889 -9.52775) 749.669 1650 -22.6179)

gas

AKsteel18SR
(33.886, 71.3382, (34.1219, 0, -
Haynes230 745.879 17889 -9.52775) 745.982 10495 6.30777)

CONCLUSIONS
This paperpresents thestarting point in the process of analysis of chemical reaction
mechanisms for methane-air premixed laminar flames in order for their application in CFD
modelling.
A lot of effort was made to provide adequate results for reduced and detailed, skeletal
chemical reaction mechanism methane-air premixed laminar flames for implementation in
CFD codes. Reasons for this arethe limits in CFD codes concerning a number of chemical
reactions, elements and species.
After a review and analysis of the achieved results, including the results of other institutions
working on the same issue, the following conclusions and recommendations were suggested
in order to enable further modelling of CFD models:
 The reduced chemical reaction mechanism described in GRI-Mech 3.0 gives the most
appropriate results regarding methane-air combustion;
 Due to the limits in CFD codes concerning the number of chemical reactions and species, it
is not possible practically to use the reduced chemical reaction mechanism described in
GRI-Mech 3.0;
 The reduced chemical reaction described in GRI-Mech 2.11 gives results that are in
accordance with results obtained with GRI-Mech 3.0;
 Bearingin mind limits in CFD codes, the reduced chemical reaction mechanism described
in GRI-Mech 2.11 can be used for calculation of heat transfer, thermo-mechanical

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behaviour of the burner mantle and other calculations. The one and only problem in these
calculations is in the time period that is proven in laboratory conditions;
 Results obtained using detailed skeletal chemical reaction mechanisms related to
temperature profiles and flame velocity are in accordance with results achieved by using
GRI Mech 3.0 and can be taken as credible;
 Testing the full mechanisms together with reduced mechanisms, we chose the 15 steps
Chen’s reduced mechanism as input for CFD calculation. Calculation results for laminar
flames have been fundamental for further calculation in appropriate CFD mode. In our
work, we were modelling the burning of Russian and Serbian natural gases. Our valuator
used these gases in prototype burners. In this report attention is directed toward the
modelling of the combustion of Russian gasand Serbian natural gas. We simulated
radiation and convective effects which are important for the calculation of the thermal
loads and burner mantle stress.
 Further development on open source software is limited by available combustion
mechanisms. The Eddy concept theory modules are the most vanguard now. Customer
intervention on source code subroutines is a partial solution.
 Analysis of the temperature field, temperature values and mechanical loads, shows that
exceptionally dense geometry of the perforation on burner mantle with a small thickness,
caused critical strain on the larger part of the burner.
 Redesign of the burner regardless on the material quality, with already existing
longitudinal fields without perforation, requires the introduction of transverse fields
without perforation ofthe burner openings. In combination with an increased heat sink by
using heat conduction, it can strengthenthe mechanical resistance of the middle part of the
burner.

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Ackgnowlement
This paper is result of research work on the projects:

FP6 – “Flexible Permixed Burners for Low-cost Domestic Heating Systems” (FlexHeat), EC
INCO-CT-2004-509165, 2004-2007.
FP7 – “High-Performance Computing Infrastructure for South East Europe’s Research
Communities” HP-SEE Contract n°: RI-261499, 2010.

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