Combustion Instability and Active Control: Alternative Fuels, Augmentors, and Modeling Heat Release

Experimental and analytical studies were conducted to explore thermo-acoustic coupling during the onset of combustion instability in various air-breathing combustor configurations. These include a laboratory-scale 200-kW dump combustor and a 100-kW augmentor featuring a v-gutter flame holder. They were used to simulate main combustion chambers and afterburners in aero engines, respectively. The three primary themes of this work includes: 1) modeling heat release fluctuations for stability analysis, 2) conducting active combustion control with alternative fuels, and 3) demonstrating practical active control for augmentor instability suppression. The phenomenon of combustion instabilities remains an unsolved problem in propulsion engines, mainly because of the difficulty in predicting the fluctuating component of heat release without extensive testing. A hybrid model was developed to describe both the temporal and spatial variations in dynamic heat release, using a separation of variables approach that requires only a limited amount of experimental data. The use of sinusoidal basis functions further reduced the amount of data required. When the mean heat release behavior is known, the only experimental data needed for detailed stability analysis is one instantaneous picture of heat release at the peak pressure phase. This model was successfully tested in the dump combustor experiments, reproducing the correct sign of the overall Rayleigh index as well as the remarkably accurate spatial distribution pattern of fluctuating heat release. Active combustion control was explored for fuel-flexible combustor operation using twelve different jet fuels including bio-synthetic and Fischer-Tropsch types. Analysis done using an actuated spray combustion model revealed that the combustion response times of these fuels were similar. Combined with experimental spray characterizations, this suggested that controller performance should remain effective with various alternative fuels. Active control experiments validated this analysis while demonstrating 50-70\% reduction in the peak spectral amplitude. A new model augmentor was built and tested for combustion dynamics using schlieren and chemiluminescence techniques. Novel active control techniques including pulsed air injection were implemented and the results were compared with the pulsed fuel injection approach. The pulsed injection of secondary air worked just as effectively for suppressing the augmentor instability, setting up the possibility of more efficient actuation strategy.

Development and testing of innovative methodologies for modelling and control of normal and knocking combustion and implementation of novel rapid prototyping solutions

The thesis work deals with topics that led to the development of innovative control-oriented models and control algorithms for modern gasoline engines. Knock in boosted spark ignition engines is the widest topic discussed in this document because it remains one of the most limiting factors for maximizing combustion efficiency in this kind of engine. First chapter is thus focused on knock and a wide literature review is proposed to summarize the preliminary knowledge that even represents the background and the reference for discussed activities. Most relevant results achieved during PhD course in the field of knock modelling and control are then presented, describing every control-oriented model that led to the development of an adaptive model-based combustion control system. The complete controller has been developed in the context of the collaboration with Ferrari GT and it allowed to completely redefine the knock intensity evaluation as well as the combustion phase control. The second chapter is focused on the activity related to a prototyping Port Water Injection system that has been developed and tested on a turbocharged spark ignition engine, within the collaboration with Magneti Marelli. Such system and the effects of injected water on the combustion process were then modeled in a 1-D simulation environment (GT Power). Third chapter shows the development and validation of a control-oriented model for the real-time calculation of exhaust gas temperature that represents another important limitation to the performance increase in modern boosted engines. Indeed, modelling of exhaust gas temperature and thermocouple behavior are themes that play a key role in the optimization of combustion and catalyst efficiency.

A study of combustion phenomena in circulating fluidized beds by developing and applying experimental and modelling methods for laboratory-scale reactors

The results shown in this thesis are based on selected publications of the 2000s decade. The work was carried out in several national and EC funded public research projects and in close cooperation with industrial partners. The main objective of the thesis was to study and quantify the most important phenomena of circulating fluidized bed combustors by developing and applying proper experimental and modelling methods using laboratory scale equipments. An understanding of the phenomena plays an essential role in the development of combustion and emission performance, and the availability and controls of CFB boilers. Experimental procedures to study fuel combustion behaviour under CFB conditions are presented in the thesis. Steady state and dynamic measurements under well controlled conditions were carried out to produce the data needed for the development of high efficiency, utility scale CFB technology. The importance of combustion control and furnace dynamics is emphasized when CFB boilers are scaled up with a once through steam cycle. Qualitative information on fuel combustion characteristics was obtained directly by comparing flue gas oxygen responses during the impulse change experiments with fuel feed. A one-dimensional, time dependent model was developed to analyse the measurement data Emission formation was studied combined with fuel combustion behaviour. Correlations were developed for NO, N2O, CO and char loading, as a function of temperature and oxygen concentration in the bed area. An online method to characterize char loading under CFB conditions was developed and validated with the pilot scale CFB tests. Finally, a new method to control air and fuel feeds in CFB combustion was introduced. The method is based on models and an analysis of the fluctuation of the flue gas oxygen concentration. The effect of high oxygen concentrations on fuel combustion behaviour was also studied to evaluate the potential of CFB boilers to apply oxygenfiring technology to CCS. In future studies, it will be necessary to go through the whole scale up chain from laboratory phenomena devices through pilot scale test rigs to large scale, commercial boilers in order to validate the applicability and scalability of the, results. This thesis shows the chain between the laboratory scale phenomena test rig (bench scale) and the CFB process test rig (pilot). CFB technology has been scaled up successfully from an industrial scale to a utility scale during the last decade. The work shown in the thesis, for its part, has supported the development by producing new detailed information on combustion under CFB conditions.

Development and experimental validation of a knock induced damage model and real-time implementation of model-based strategies to control knock intensity in boosted gasoline engines

This PhD thesis reports the main activities carried out during the 3 years long “Mechanics and advanced engineering sciences” course, at the Department of Industrial Engineering of the University of Bologna. The research project title is “Development and analysis of high efficiency combustion systems for internal combustion engines” and the main topic is knock, one of the main challenges for boosted gasoline engines. Through experimental campaigns, modelling activity and test bench validation, 4 different aspects have been addressed to tackle the issue. The main path goes towards the definition and calibration of a knock-induced damage model, to be implemented in the on-board control strategy, but also usable for the engine calibration and potentially during the engine design. Ionization current signal capabilities have been investigated to fully replace the pressure sensor, to develop a robust on-board close-loop combustion control strategy, both in knock-free and knock-limited conditions. Water injection is a powerful solution to mitigate knock intensity and exhaust temperature, improving fuel consumption; its capabilities have been modelled and validated at the test bench. Finally, an empiric model is proposed to predict the engine knock response, depending on several operating condition and control parameters, including injected water quantity.

Development and Validation of a Model-Based Combustion Controller for Water Injection Management

This manuscript reports the overall development of a Ph.D. research project during the “Mechanics and advanced engineering sciences” course at the Department of Industrial Engineering of the University of Bologna. The project is focused on the development of a combustion control system for an innovative Spark Ignited engine layout. In details, the controller is oriented to manage a prototypal engine equipped with a Port Water Injection system. The water injection technology allows an increment of combustion efficiency due to the knock mitigation effect that permits to keep the combustion phasing closer to the optimal position with respect to the traditional layout. At the beginning of the project, the effects and the possible benefits achievable by water injection have been investigated by a focused experimental campaign. Then the data obtained by combustion analysis have been processed to design a control-oriented combustion model. The model identifies the correlation between Spark Advance, combustion phasing and injected water mass, and two different strategies are presented, both based on an analytic and semi-empirical approach and therefore compatible with a real-time application. The model has been implemented in a combustion controller that manages water injection to reach the best achievable combustion efficiency while keeping knock levels under a pre-established threshold. Three different versions of the algorithm are described in detail. This controller has been designed and pre-calibrated in a software-in-the-loop environment and later an experimental validation has been performed with a rapid control prototyping approach to highlight the performance of the system on real set-up. To further make the strategy implementable on an onboard application, an estimation algorithm of combustion phasing, necessary for the controller, has been developed during the last phase of the PhD Course, based on accelerometric signals.

Reduction of nitrogen oxide emissions in lime kiln

Different nitrogen oxide removal technologies for rotary lime kiln are studied in this thesis, the main focus being in commercial technologies. Post-combustion methods are investigated in more detail as potential possible NOx removal with combustion methods in rotary lime kiln is more limited or primary methods are already in use. However, secondary methods as NOx scrubber, SNCR or SCR technologies are not listed as the Best Available Technologies defined by European Union. BAT technologies for NOx removal in lime kiln are (1) Optimised combustion and combustion control, (2) Good mixing of fuel and air, (3) Low-NOx burner and (4) Fuel selection/low-N fuel. SNCR method is the most suitable technique for NOx removal in lime kiln when NOx removal from 50 % to 70 % is required in case primary methods are already in use or cannot be applied. In higher removal cases ammonia slip is an issue in SNCR. By using SCR better NOx reduction can be achieved but issues with catalyst materials are expected to arise because of the dust and sulphur dioxide which leads to catalyst poison formation in lower flue gas temperatures. NOx scrubbing has potential when simultaneous NOx and SO2 removal is required. The challenge is that NO cannot be scrubbed directly, but once it is oxidized to NO2 or further scrubbing can be performed as the solubility of NO2 is higher. Commercial installations have not been made regarding SNCR, SCR or NOx scrubbing regarding rotary lime kiln. For SNCR and SCR the closest references come from cement industry.

Estudio de la aplicación de sistemas basados en el conocimiento a la operación de una planta de tratamiento de residuos sólidos urbanos por valorización energética

Una de las actuaciones posibles para la gestión de los residuos sólidos urbanos es la valorización energética, es decir la incineración con recuperación de energía. Sin embargo es muy importante controlar adecuadamente el proceso de incineración para evitar en lo posible la liberación de sustancias contaminantes a la atmósfera que puedan ocasionar problemas de contaminación industrial.Conseguir que tanto el proceso de incineración como el tratamiento de los gases se realice en condiciones óptimas presupone tener un buen conocimiento de las dependencias entre las variables de proceso. Se precisan métodos adecuados de medida de las variables más importantes y tratar los valores medidos con modelos adecuados para transformarlos en magnitudes de mando. Un modelo clásico para el control parece poco prometedor en este caso debido a la complejidad de los procesos, la falta de descripción cuantitativa y la necesidad de hacer los cálculos en tiempo real. Esto sólo se puede conseguir con la ayuda de las modernas técnicas de proceso de datos y métodos informáticos, tales como el empleo de técnicas de simulación, modelos matemáticos, sistemas basados en el conocimiento e interfases inteligentes. En [Ono, 1989] se describe un sistema de control basado en la lógica difusa aplicado al campo de la incineración de residuos urbanos. En el centro de investigación FZK de Karslruhe se están desarrollando aplicaciones que combinan la lógica difusa con las redes neuronales [Jaeschke, Keller, 1994] para el control de la planta piloto de incineración de residuos TAMARA. En esta tesis se plantea la aplicación de un método de adquisición de conocimiento para el control de sistemas complejos inspirado en el comportamiento humano. Cuando nos encontramos ante una situación desconocida al principio no sabemos como actuar, salvo por la extrapolación de experiencias anteriores que puedan ser útiles. Aplicando procedimientos de prueba y error, refuerzo de hipótesis, etc., vamos adquiriendo y refinando el conocimiento, y elaborando un modelo mental. Podemos diseñar un método análogo, que pueda ser implementado en un sistema informático, mediante el empleo de técnicas de Inteligencia Artificial.Así, en un proceso complejo muchas veces disponemos de un conjunto de datos del proceso que a priori no nos dan información suficientemente estructurada para que nos sea útil. Para la adquisición de conocimiento pasamos por una serie de etapas: - Hacemos una primera selección de cuales son las variables que nos interesa conocer. - Estado del sistema. En primer lugar podemos empezar por aplicar técnicas de clasificación (aprendizaje no supervisado) para agrupar los datos y obtener una representación del estado de la planta. Es posible establecer una clasificación, pero normalmente casi todos los datos están en una sola clase, que corresponde a la operación normal. Hecho esto y para refinar el conocimiento utilizamos métodos estadísticos clásicos para buscar correlaciones entre variables (análisis de componentes principales) y así poder simplificar y reducir la lista de variables. - Análisis de las señales. Para analizar y clasificar las señales (por ejemplo la temperatura del horno) es posible utilizar métodos capaces de describir mejor el comportamiento no lineal del sistema, como las redes neuronales. Otro paso más consiste en establecer relaciones causales entre las variables. Para ello nos sirven de ayuda los modelos analíticos - Como resultado final del proceso se pasa al diseño del sistema basado en el conocimiento. El objetivo principal es aplicar el método al caso concreto del control de una planta de tratamiento de residuos sólidos urbanos por valorización energética. En primer lugar, en el capítulo 2 Los residuos sólidos urbanos, se trata el problema global de la gestión de los residuos, dando una visión general de las diferentes alternativas existentes, y de la situación nacional e internacional en la actualidad. Se analiza con mayor detalle la problemática de la incineración de los residuos, poniendo especial interés en aquellas características de los residuos que tienen mayor importancia de cara al proceso de combustión.En el capítulo 3, Descripción del proceso, se hace una descripción general del proceso de incineración y de los distintos elementos de una planta incineradora: desde la recepción y almacenamiento de los residuos, pasando por los distintos tipos de hornos y las exigencias de los códigos de buena práctica de combustión, el sistema de aire de combustión y el sistema de humos. Se presentan también los distintos sistemas de depuración de los gases de combustión, y finalmente el sistema de evacuación de cenizas y escorias.El capítulo 4, La planta de tratamiento de residuos sólidos urbanos de Girona, describe los principales sistemas de la planta incineradora de Girona: la alimentación de residuos, el tipo de horno, el sistema de recuperación de energía, y el sistema de depuración de los gases de combustión Se describe también el sistema de control, la operación, los datos de funcionamiento de la planta, la instrumentación y las variables que son de interés para el control del proceso de combustión.En el capítulo 5, Técnicas utilizadas, se proporciona una visión global de los sistemas basados en el conocimiento y de los sistemas expertos. Se explican las diferentes técnicas utilizadas: redes neuronales, sistemas de clasificación, modelos cualitativos, y sistemas expertos, ilustradas con algunos ejemplos de aplicación.Con respecto a los sistemas basados en el conocimiento se analizan en primer lugar las condiciones para su aplicabilidad, y las formas de representación del conocimiento. A continuación se describen las distintas formas de razonamiento: redes neuronales, sistemas expertos y lógica difusa, y se realiza una comparación entre ellas. Se presenta una aplicación de las redes neuronales al análisis de series temporales de temperatura.Se trata también la problemática del análisis de los datos de operación mediante técnicas estadísticas y el empleo de técnicas de clasificación. Otro apartado está dedicado a los distintos tipos de modelos, incluyendo una discusión de los modelos cualitativos.Se describe el sistema de diseño asistido por ordenador para el diseño de sistemas de supervisión CASSD que se utiliza en esta tesis, y las herramientas de análisis para obtener información cualitativa del comportamiento del proceso: Abstractores y ALCMEN. Se incluye un ejemplo de aplicación de estas técnicas para hallar las relaciones entre la temperatura y las acciones del operador. Finalmente se analizan las principales características de los sistemas expertos en general, y del sistema experto CEES 2.0 que también forma parte del sistema CASSD que se ha utilizado.El capítulo 6, Resultados, muestra los resultados obtenidos mediante la aplicación de las diferentes técnicas, redes neuronales, clasificación, el desarrollo de la modelización del proceso de combustión, y la generación de reglas. Dentro del apartado de análisis de datos se emplea una red neuronal para la clasificación de una señal de temperatura. También se describe la utilización del método LINNEO+ para la clasificación de los estados de operación de la planta.En el apartado dedicado a la modelización se desarrolla un modelo de combustión que sirve de base para analizar el comportamiento del horno en régimen estacionario y dinámico. Se define un parámetro, la superficie de llama, relacionado con la extensión del fuego en la parrilla. Mediante un modelo linealizado se analiza la respuesta dinámica del proceso de incineración. Luego se pasa a la definición de relaciones cualitativas entre las variables que se utilizan en la elaboración de un modelo cualitativo. A continuación se desarrolla un nuevo modelo cualitativo, tomando como base el modelo dinámico analítico.Finalmente se aborda el desarrollo de la base de conocimiento del sistema experto, mediante la generación de reglas En el capítulo 7, Sistema de control de una planta incineradora, se analizan los objetivos de un sistema de control de una planta incineradora, su diseño e implementación. Se describen los objetivos básicos del sistema de control de la combustión, su configuración y la implementación en Matlab/Simulink utilizando las distintas herramientas que se han desarrollado en el capítulo anterior.Por último para mostrar como pueden aplicarse los distintos métodos desarrollados en esta tesis se construye un sistema experto para mantener constante la temperatura del horno actuando sobre la alimentación de residuos.Finalmente en el capítulo Conclusiones, se presentan las conclusiones y resultados de esta tesis.

Emissions Characterisation of residential pellet boilers during start-up and stop periods

In this study, gaseous emissions and particles are measured during start-up and stop periods for an over-fed boiler and an under-fed boiler. Both gaseous and particulate matter emissions are continuously measured in the laboratory. The measurement of gaseous emissions includes oxygen (O2), carbon dioxide (CO2), carbon monoxide (CO), nitrogen oxide and (NO). The emissions rates are calculated from measured emissions concentrations and flue gas flow. The behaviours of the boilers during start-up and stop periods are analysed and the emissions are characterised in terms of CO, NO, TOC and particles (PM2.5 mass and number). The duration of the characterised periods vary between two boilers due to the difference in type of ignition and combustion control. The under-fed boiler B produces higher emissions during start-up periods than the over-fed boiler A. More hydrocarbon and particles are emitted by the under-fed boiler during stop periods. Accumulated mass of CO and TOC during start-up and stop periods contribute a major portion of the total mass emitted during whole operation. However, accumulated mass of NO and PM during start-up and stop periods are not significant as the duration of emission peak is relatively short.

Experimental aspects of biomass fuels in a bubbling fluidized bed combustor

This work presents experimental information relevant to the combustion of biomass in a bubbling fluidized bed. The biomass distribution in a fluidized bed was studied through tests performed in a cold bed, while the volatiles released in the biomass pyrolysis, the burning rate of the resulting charcoal, and the combustion control regime, were studied through tests performed in a high temperature bed.Visual examination of photographs taken from a transparent walls bed, with a rectangular cross-section, showed that the large fuel particles, typical of biomass processing, were distributed in the bubbles, in the splash zone, and in the emulsion phase. The occurrence of biomass in the emulsion phase was favored by burning biomass particles of greater density and smaller size-expetimentally determined in each case. Decreasing the fuel particle size improved the biomass distribution inside the bed. The same was accomplished by increasing the superficial gas velocity as high as possible, compatibly with the acceptable elutriation.Burning tests showed that the biomass fuels have the advantage of reaching the diffusional regime at temperatures that can be lower than 1000 K, which ensures that the biomass fuels burn in a stable regime. (C) 2007 Elsevier B.V. All rights reserved.

Study of utilization of petrol engine equipped with exhaust gas recirculation (EGR) and catalytic converter to reduce consumption and NOx emission

Study of consumption rate and gaseous pollutant emission from engine tests simulating real work conditions, using spark point manually controlled and exhaust gas recirculation (EGR) in diverse proportion levels. The objective of this work is to re-examine the potential of the EGR conception, a well-known method of combustion control, employed together electronic fuel injection and three-way catalytic converter closed-loop control at a spark ignition engine, verifying the performance characteristics and technical availability of this conception to improve pollution control, fuel economy at low torque drive condition and to improve the engine exhaust components useful life. The pollutant emissions and consumption levels under operational conditions simulations were analysed and compared with the expected by concerning theory and real tests performed by EGR equipped engines by factory. Copyright © 2006 Society of Automotive Engineers, Inc.

The use of molecular spectra simulation for diagnostics of reactive flows

The C 2 * radical is used as a system probe tool to the reactive flow diagnostic, and it was chosen due to its large occurrence in plasma and combustion in aeronautics and aerospace applications. The rotational temperatures of C 2 * species were determined by the comparison between experimental and theoretical data. The simulation code was developed by the authors, using C++ language and the object oriented paradigm, and it includes a set of new tools that increase the efficacy of the C 2 * probe to determine the rotational temperature of the system. A brute force approach for the determination of spectral parameters was adopted in this version of the computer code. The statistical parameter c 2 was used as an objective criterion to determine the better match of experimental and synthesized spectra. The results showed that the program works even with low-quality experimental data, typically collected from in situ airborne compact apparatus. The technique was applied to flames of a Bunsen burner, and the rotational temperature of ca. 2100 K was calculated.

Sviluppo di algoritmi di RCP per la stima della coppia indicata erogata da un motore a combustione interna.

Combustion control is one of the key factors to obtain better performances and lower pollutant emissions for diesel, spark ignition and HCCI engines. An algorithm that allows estimating, as an example, the mean indicated torque for each cylinder, could be easily used in control strategies, in order to carry out cylinders trade-off, control the cycle to cycle variation, or detect misfires. A tool that allows evaluating the 50% of Mass Fraction Burned (MFB50), or the net Cumulative Heat Release (CHRNET), or the ROHR peak value (Rate of Heat Release), could be used to optimize spark advance or to detect knock in gasoline engines and to optimize injection pattern in diesel engines. Modern management systems are based on the control of the mean indicated torque produced by the engine: they need a real or virtual sensor in order to compare the measured value with the target one. Many studies have been performed in order to obtain an accurate and reliable over time torque estimation. The aim of this PhD activity was to develop two different algorithms: the first one is based on the instantaneous engine speed fluctuations measurement. The speed signal is picked up directly from the sensor facing the toothed wheel mounted on the engine for other control purposes. The engine speed fluctuation amplitudes depend on the combustion and on the amount of torque delivered by each cylinder. The second algorithm processes in-cylinder pressure signals in the angular domain. In this case a crankshaft encoder is not necessary, because the angular reference can be obtained using a standard sensor wheel. The results obtained with these two methodologies are compared in order to evaluate which one is suitable for on board applications, depending on the accuracy required.

AN INVESTIGATION OF VARIABLE VALVE TIMING EFFECTS ON HCCI ENGINE PERFORMANCE

The Homogeneous Charge Compression Ignition (HCCI) engine is a promising combustion concept for reducing NOx and particulate matter (PM) emissions and providing a high thermal efficiency in internal combustion engines. This concept though has limitations in the areas of combustion control and achieving stable combustion at high loads. For HCCI to be a viable option for on-road vehicles, further understanding of its combustion phenomenon and its control are essential. Thus, this thesis has a focus on both the experimental setup of an HCCI engine at Michigan Technological University (MTU) and also developing a physical numerical simulation model called the Sequential Model for Residual Affected HCCI (SMRH) to investigate performance of HCCI engines. The primary focus is on understanding the effects of intake and exhaust valve timings on HCCI combustion. For the experimental studies, this thesis provided the contributions for development of HCCI setup at MTU. In particular, this thesis made contributions in the areas of measurement of valve profiles, measurement of piston to valve contact clearance for procuring new pistons for further studies of high geometric compression ratio HCCI engines. It also consists of developing and testing a supercharging station and the setup of an electrical air heater to extend the HCCI operating region. The HCCI engine setup is based on a GM 2.0 L LHU Gen 1 engine which is a direct injected engine with variable valve timing (VVT) capabilities. For the simulation studies, a computationally efficient modeling platform has been developed and validated against experimental data from a single cylinder HCCI engine. In-cylinder pressure trace, combustion phasing (CA10, CA50, BD) and performance metrics IMEP, thermal efficiency, and CO emission are found to be in good agreement with experimental data for different operating conditions. Effects of phasing intake and exhaust valves are analyzed using SMRH. In addition, a novel index called Fuel Efficiency and Emissions (FEE) index is defined and is used to determine the optimal valve timings for engine operation through the use of FEE contour maps.

Identification of atmospheric pollutants control mechanisms during co-combustion of coal and non-toxic wastes

Doctoral dissertation for Ph.D. degree in Sustainable Chemistry

Internal Combustion Engine's Throttle Control as a Motivational Theme for Teaching Microprocessors Systems Lab Classes

The increased fuel economy and driveability of modern internal combustion engine vehicles (ICEVs) are the result of the application of advanced digital electronics to control the operation of the internal combustion engine (ICE). Microprocessors (and micro controllers) play a key role in the engine control, by precisely controlling the amount of both air and fuel admitted into the cylinders. Air intake is controlled by utilizing a throttle valve equipped with a motor and gear mechanism as actuator, and a sensor enabling the measurement of the angular position of the blades. This paperwork presents a lab setup that allows students to control the throttle position using a microcontroller that runs a program developed by them. A commercial throttle body has been employed, whereas a power amplifier and a microcontroller board have been hand assembled to complete the experimental setup. This setup, while based in a high-tech, microprocessor-based solution for a real-world, engine operation optimization problem, has the potential to engage students around a hands-on multidisciplinary lab activity and ignite their interest in learning fundamental and advanced topics of microprocessors systems.