In this study, two Inconel 625 swirl nozzle inserts with identical bulk geometry were constructed via additive layer manufacturing (ALM) for use in a generic gas turbine swirl burner. Further postprocessing by grit blasting of one swirl nozzle insert results in a quantifiable change to the surface roughness characteristics when compared with the unprocessed ALM swirl nozzle insert or a third nozzle insert which has been manufactured using traditional machining methods. An evaluation of the influence of variable surface roughness effects from these swirl nozzle inserts is therefore performed under preheated isothermal and combustion conditions for premixed methane-air flames at thermal power of 25 kW. High-speed velocimetry at the swirler exit under isothermal conditions gives evidence of the change in near-wall boundary layer thickness and turbulent fluctuations resulting from the change in nozzle surface roughness. Under atmospheric combustion conditions, this influence is further quantified using a combination of dynamic pressure, high-speed OH* chemiluminescence, and exhaust gas emissions measurements to evaluate the flame stabilization mechanisms at the lean blowoff and rich stability limits. Notable differences in flame stabilization are evident as the surface roughness is varied, and changes in rich stability limit were investigated in relation to changes in the near-wall turbulence intensity. Results show that precise control of in-process or postprocess surface roughness of wetted surfaces can positively influence burner stability limits and NOx emissions and must, therefore, be carefully considered in the ALM burner design process as well as computational fluid dynamics (CFD) models.

The combustion process of both pure NH3 and a NH3/H2 fuel blends is here analyzed using two kinetics processors, i.e., Chemkin-Pro-and CANTERA: detailed kinetic mechanisms have been tested and compared in terms of laminar flame speed and ignition delay time (IDT) with the aim to identifying the most suitable ones for the evaluation of NOx emissions. The generic swirl burner being used in Cardiff University's Gas Turbine Research Center has been considered as validation test case. In addition, this paper presents an experimental campaign followed by a computational fluid dynamics (CFD) approach for the assessment of NOx emission using axisymmetric Reynolds-Averaged Navier–Stokes (RANS) simulations, leading to a significant reduction of the computational time. Different pressures and mass flow rates are evaluated to understand correlations of NOx formation for pollutants reduction purpose. A direct comparison between experimental and numerical results is carried out in terms of flow field, flame shape, and NOx emissions. Results show that the increase in pressure from 1.1 bar to 2 bar results in reduction of NOx emissions from 2515 ppmv to 885 ppmv, also indicating guidelines for using a simplified RANS analysis, which leads to improved computational efficiency, allowing wide sensitivity and optimization analysis to support the design development of an industrial combustion system.

It has become increasingly cost-effective for the steel industry to invest in the capture of heavily carbonaceous basic oxygen furnace or converter gas, and use it to support the intensive energy demands of the integrated facility, or for surplus energy conversion in power plants. As industry strives for greater efficiency via ever more complex technologies, increased attention is being paid to investigate the complex behavior of by-product syngases. Recent studies have described and evidenced the enhancement of fundamental combustion parameters such as laminar flame speed due to the catalytic influence of H2O on heavily carbonaceous syngas mixtures. Direct formation of CO2 from CO is slow due to its high activation energy, and the presence of disassociated radical hydrogen facilitates chain branching species (such as OH), changing the dominant path for oxidation. The observed catalytic effect is nonmonotonic, with the reduction in flame temperature eventually prevailing, and overall reaction rate quenched. The potential benefits of changes in water loading are explored in terms of delayed lean blow-off (LBO), and primary emission reduction in a premixed turbulent swirling flame, scaled for practical relevance at conditions of elevated temperature (423 K) and pressure (0.1–0.3 MPa). Chemical kinetic models are used initially to characterize the influence that H2O has on the burning characteristics of the fuel blend employed, modeling laminar flame speed and extinction strain rate across an experimental range with H2O vapor fraction increased to eventually diminish the catalytic effect. These modeled predictions are used as a foundation to investigate the experimental flame. OH* chemiluminescence and OH planar laser-induced fluorescence (PLIF) are employed as optical diagnostic techniques to analyze changes in heat release structure resulting from the experimental variation in water loading. A comparison is made with a CH4/air flame and changes in LBO stability limits are quantified, measuring the incremental increase in air flow and again compared against chemical models. The compound benefit of CO and NOx reduction is quantified also, with production first decreasing due to the thermal effect of H2O addition from a reduction in flame temperature, coupled with the potential for further reduction from the change in lean stability limit. Power law correlations have been derived for change in pressure, and equivalent water loading. Hence, the catalytic effect of H2O on reaction pathways and reaction rate predicted and observed for laminar flames are appraised within the challenging environment of turbulent, swirl-stabilized flames at elevated temperature and pressure, characteristic of practical systems.

As alternative fuels are designated for future energy applications, flexible combustor designs require considerable development to ensure stable operation with reduced NOx emissions. A non-premixed variable swirl burner was used to experimentally appraise changes in NO production pathways, with CH₄ NH₃, and H₂ flames, alongside intermediate fuel blends. Maintaining an equivalent thermal power and flame temperature between fuels, preheated reactants (500 K) were supplied to the burner, with parametric changes made to pressure (1 - 6 bara) and swirl number (0.8 - 2.0). NO production was characterized, alongside variations in flame structure and topology, with a correlation demonstrated for exhaust emissions. NO production was shown to be sensitive to combustor pressure, providing an expected increase for CH₄ and H₂ flames. Emission profiles from both NH₃ and H₂ flames are shown to be significantly augmented by a change in swirl number. As NH₃ fractions were increased in the H₂ blend, a decaying trend in NO emissions was observed with an increase in pressure, and as a function of mixture ratio. However, this behaviour was markedly augmented by a change in swirl number and suggests that further reductions may be possible at increased pressure. At the low swirl/high pressure condition the NH₃/H₂ blend outperformed pure H₂, providing lower NO concentrations. Emissions data were normalised using the traditional dry/O₂ correction, alongside mass scaled by thermal power, with a comparison provided. The corresponding differences in emission formation pathways were investigated, alongside high-speed OH* chemiluminescence to further elucidate findings.

The lean premixed technology is a very convenient combustion strategy to progressively move from natural gas to high hydrogen content fuels in gas turbines limiting the pollutants emissions at the same time. The enabling process that will allow the combustor to manage a full H2 operation requires relevant design modifications, and in this framework, the numerical modeling will be a pivotal tool that will support this transition. In this work, high-fidelity simulations of perfectly premixed swirl stabilized flames have been performed varying the H2 content in the fuel from 0 to 100% to investigate the effect of the hydrogen addition on the methane flame. The artificially thickened flame model (ATFM) has been used to treat the turbulent chemistry interaction. The numerical results have been compared with the detailed experimental data performed at Cardiff University's Gas Turbine Research Center. After the numerical model validation against experimental OH* chemiluminescence maps has been presented, a deep numerical investigation of the effect of the H2 addition on the flame has been performed. In this way, the work aims to highlight the good prediction capability of the ATFM, and, at the same time, highlight the change in the different contributions that govern the flame reactivity moving from 100% CH4 to 100% H2 in very lean conditions.

This study examines the high-temperature degradation of Hastelloy C276, a corrosion-resistant nickel-based alloy, during exposure to combustion products generated by methane and 99% cracked ammonia. Using a high-pressure optical combustor (HPOC) at 4 bar and exhaust temperatures of 815–860 °C, standard tensile specimens were exposed for five hours to fully developed post-flame exhaust gases, simulating real industrial turbine or burner conditions. The surfaces and subsurface regions of the samples were analysed using scanning electron microscopy (SEM; Zeiss Sigma HD FEG-SEM, Carl Zeiss, Oberkochen, Germany) and energy-dispersive X-ray spectroscopy (EDX; Oxford Instruments X-MaxN detectors, Oxford Instruments, Abingdon, United Kingdom), while mechanical properties were evaluated by tensile testing, and the gas-phase compositions were tracked in detail for each fuel blend. Results show that exposure to methane causes moderate oxidation and some grain boundary carburisation, with localised carbon enrichment detected by high-resolution EDX mapping. In contrast, 99% cracked ammonia resulted in much more aggressive selective oxidation, as evidenced by extensive surface roughening, significant chromium depletion, and higher oxygen incorporation, correlating with increased NO_x in the exhaust gas. Tensile testing reveals that methane exposure causes severe embrittlement (yield strength +41%, elongation −53%) through grain boundary carbide precipitation, while cracked ammonia exposure results in moderate degradation (yield strength +4%, elongation −24%) with fully preserved ultimate tensile strength (870 MPa), despite more aggressive surface oxidation. These counterintuitive findings demonstrate that grain boundary integrity is more critical than surface condition for mechanical reliability. These findings underscore the importance of evaluating material compatibility in low-carbon and hydrogen/ammonia-fuelled combustion systems and establish critical microstructural benchmarks for the anticipated mechanical testing in future work.