Академический Документы
Профессиональный Документы
Культура Документы
G.V.S. Rao
Department of Mech. Engineering, PIRM E C, Chevella, A.P., India
T
S. Rajesham
Department of Mechanical Engineering, PRRM EC, Shabad, A.P., India,
J. Narasaiah
Department of Mech. Engineering, PRRM EC, Shabad, A.P., India
Abstract
Oscillating combustion is a simple,
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innovative, low-cost technology can be
applied as a retrofit in the heat transfer
investigations confirm the benefits of
introducing the oscillations during the
combustion and effects of oscillating
combustion on performance characteristics
industries such as steel mills, glass plants, such as heat transfer rate, melting time,
forging shops and foundry process furnaces to specific energy consumption (SEC) and
enhance the performance characteristics. furnace efficiency.
Different kinds of oscillating mechanism to
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create oscillations in the combustion used Keywords: Oscillating combustion,
earlier in the research were electrostrictive oscillating valve, crucible furnace, heat
actuators, cyclic valves, solenoid based transfer rate, specific energy consumption
(EGR) exhaust gas recirculation valves,
rotatory plug valves.
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environmental friendly technologies to burn modifications were carried out. These include
wide range of fuels using oscillating stream lining the flue gas passage in the
combustion. The principle on which the valve furnace, incorporating manometers, 3-way
works to introduce oscillations in the cock along with burette, piezometer tubes,
combustion is based on cyclical perturbation thermo-couples with digital temperature
of the fuel line. GTI tests in late 1980‟s used a indicators and sensing probe. The oscillating
solenoid valve or solenoid-based exhaust gas valve has been tested at a frequency of 5 and
recirculation valve. Air Liquide Chicago 10 Hz, amplitude of 100 and 200, different air-
research centre used rotatory plug valve. fuel ratios varying from 13:1 to 17:1 above
These valves did not have enough life and and below the stoichiometric ratio using 10,
were expensive, thereby unsuitable for 15 and 20 kg of aluminum loads. The results
industrial applications. Ceramphysics, Inc. indicate the optimization at certain parameters
Ohio, developed a low cost long life valve used in the tests. The main focus in this paper
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known as Solid State Proportionate valve with is on the proposed oscillating valve on the
a flow capacity of only 40 scf/h operating at kinematics profile of the cam, variable speed
high frequency of 20 Hz was used and found actuator, system modeling, design and control
virtually noise free. GTI laboratories are considerations, fluid mechanical and thermal
producing SSP valves with variable flow considerations and variation in fuel flow
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capacity. Experiments on the oscillating
combustion technology were conducted on
natural gas with variable conditions.
In this article, the author developed
indigenously an electro-mechanical cam
operated valve which is simple, low-cost,
during the fuel-rich and fuel-lean zones.
Nomenclature
A = ampere
reliable in operation and incorporated in a a.c. = alternating current
crucible furnace to experiment the oscillating A/F = air-fuel ratio
combustion especially on liquid fuel. The D = diameter
oscillations of the fuel create alternately d.c = direct current
A
successive fuel-rich and fuel-lean zones EGR = exhaust gas recirculation
within the furnace. The fuel-rich zones are F = force
more luminous, longer in length and causes f = friction factor, frequency
more heat transfer from flame to the load. g = acceleration due to gravity, gram
Both the zones mix in the furnace only when GTI = gas technology institute
kg/h = kilogram per hour
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v = velocity
Z = datum
Greek symbol
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∆ = small distance
Π = radian
Fig. 1. Displacement, velocity and
acceleration diagrams.
Subscripts
Fn = natural frequency
stroke
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Fo = maximum acceleration of follower out
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Fig.3. S.H.M of the follower diagrams It is seen from the Figure 1 that, during the
period θd1 the displacement remains
unchanged and so is the case during θd2 Thus,
during θd1 and θd2 the velocity of the follower
is zero. During θ0 interval, velocity has a
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zero.θ0+ θd1+θr+θd2 = 3600 or one complete
revolution of the cam. It may be pointed out
here that at point A, the velocity of the
follower is changed from to a finite value in
an infinitely small interval of time therefore
the acceleration to be produced will be
infinitely large. For any small mass of the
follower the inertia forces produced will be
infinitely large causing the high stress levels
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and wear. Therefore, uniform velocity of the
Fig.4. Cam with angles cam is not a practical proposition. It is
therefore, necessary to modify the conditions
which govern the follower motion, reducing
the values of acceleration to finite value this
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causes noise, shortens life due to wear and Vo = π ω/ θ0 *S/2 (2)
fatigue.
and it occurs at point when cam has turned by
an angle
2.3. Simple Harmonic Motion θ = θ0/2
Fo = V02 / (S/2)
= (πω/θ S/2)2 */S/2
(3)
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amplitude and frequency of the valve. The
swivel disc positioned at an angle or partially
in closed position and allows the amount of
fuel required as per the air-fuel ratio. From
this position it can be further partially closed
requirement.
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of fully closed to suit to the furnace operation
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= (2П DNF) / (120) X (10)
Therefore the velocity of the follower is given
Spring force or restoring force = S.*X by,
downward (11) V=dS/dt
V=dS/ dθ * dθ/dt
time t)
V=dS/d θ *ω
V= ω dS/dθ
..
[(2П DNF) / (120) ] X + S.*X = 0 (12) velocity of ω radians/sec.
dθ/dt =ω
When the motor starts, the spring would start Acceleration of the follower is given by
oscillating above and below the equilibrium F=dV/dt = dV/d θ * d θ/dt = ω dV/dθ
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position. These oscillations would tend to = ω d2S/d θ2 m/sec2
continue till the motor is stopped. = ω dV/d θ
The above equation can be written as, (18)
.. = (Slope of the velocity curve at angle θ or
X + { S /[(2П DNF)/ (120)] } *X = 0. (13) time t)
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Where τ θ, is torque in the θ domain and Fs is There are number of important issues in the
the force in the S domain. At the end of the design of the oscillating combustion valve.
stroke, the slope of the cam characteristic dS/
dθ is very small. This characteristic makes it 1. The fuel flow regulations are to be keenly
easier to control the motor velocity near the monitored. The amount of the discharge
end of the stroke. A mechanical design in of fuel before installation of the valve
which the smooth operation follows natural should be maintained after installation
dynamic trajectories require no longer too. This was ensured by calculating the
actuator forces to apply control is the required flow before and after the valve‟s
means of reducing peak actuator power. installation.
2. There was a slight pressure drop in the
The kinematics of the cam are described by fuel system when the valve was
Inertial force + Spring force = 0 positioned. This was taken care by
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The inertia represents the mass of the cam adjusting the fuel flow lever into higher
and actuator‟s inertia. When the inertia and position and also the fuel level in the fuel
spring forces are linear, the force balance drum.
becomes 3. Importance is given to precise control of
m d2s/dt2 + ks = 0 (21) the cam operation with the follower for
stiffness, respectively.
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where „m‟ is the mass inertia and „k‟ is spring
The input supply is fed to the motor through a is in the angle of cam and „S‟ domain is the
potential differentiometer or through variable shift of follower from its equilibrium
resistance as per the requirement of the speed. position].
The motor sets into motion and makes the Since the mass and inertia of the moving
cam to rotate (cam is fixed on the spindle of components in the oscillating valve apparatus
the motor). The cam which is in contact with are as small as possible, the required spring
the follower which operates against the mass- constants and forces grow proportionally with
spring mechanism acts as non-linear the mass and inertia of any components of
mechanical transformer. The swivel valve any system. Since the mass and inertia of the
positioned in the fuel flow chamber is swivel disc which restricts the fuel flow in the
actuated by the non-linear mechanical valve happened to be very small, soft and
transformer thereby restricting the fuel flow light spring was employed with low spring
inducing the oscillations. constant. This was enabled to employ a small
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Fig. 11. Schematic of oscillating valve 3
D view
Fig.8. Experimental setup
A
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4. Fluid Mechanical Considerations position, due to the cam and follower action it
causes reduction in the volume. Thereby,
The pressure drop or loss of head in the restricts the fuel flow through the valve to the
system due to the installation of the burner. When the cam resumes its normal
oscillating valve in the system may not be so position, the spring attached to the follower
important but is considered. brings back the swivel disc to its original
According to Hagen-Poiseuille law the loss of position or to its starting point. The swivel
heat or pressure drop for a laminar flow valve could open and close in 1/10th of a
second, and can vary according to the control
(P1 – P2 )/ ω = 32 μvl / ωd2 (21) by potentiometer. The oscillations of the
swivel disc are adjusted electromechanically
and Darcy- WeischBack gives and the amplitude of the swivel disc is
HL = (4flv2) / 2gd (22) adjusted according to the size of the cam or
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cam profile. When the oscillating valve was
Here, the pressure drop is directly tested at different oscillations, the fuel flow
proportional to the length of the pipe which is was scaled up from 3.0 kg/h average flow to
used is a major concern. Since the pipe used 4.50 kg/h depending upon the air-fuel ratios
for the oscillating valve was very small. and furnace loads. The valve in the position
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Thereby pressure drop can be neglected.
Since the fuel is incompressible applying the
law of Bernoulli‟s Equation and choosing a
reference line between the oscillating valve
and the fuel drum, the pressure loss can be
found.
but without oscillations it was tested from 3.0
kg/h to 5.0 kg/h at ambient conditions.
When oscillations occur, the pressure
amplitude is sufficient enough to produce
significant variations in axial velocity within
the nozzle annulus. These axial velocities can
i.e. (P1 – P2 )/ ω= (V22 / 2g) + Z2 ; (23) vary during the oscillating combustion. The
swirl vanes on the surface of the fuel gun of
( where ω = eg ) the burner would provide combustion air with
e = density of fluid ; a tangential velocity of high swirl. Due to this
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g = acceleration due to gravity the flow around the nozzle‟s annulus is
V2 = velocity at the oscillating valve; having high and low regions of tangential
Z2 = datum line above height. velocity convected along the main axial flow
of the fuel. The magnitude of heat release
The calculations gave small amount of depends upon the variations in the axial
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pressure drop which was taken care by velocity of the fuel due to the variations in
adjusting the fuel lever at the entry and by amplitude and frequency of oscillations
increasing the fuel level in the fuel drum. introduced by the oscillating valve and the
variations in the tangential velocity of
5. Results and comments combustion air. The load heats up faster since
heat transfer rate from flame to load increases
The proposed oscillating valve has a swivel due to more luminous fuel-rich zones. The
disc incorporated on the fuel flow pipe. The increased turbulence and high luminous
axis of the swivel disc is perpendicular to the flames created by the flow oscillations break
axis of fuel flow through the pipe. When the up the thermal boundary layer
swivel valve is actuated, it rotates either side In oscillating modes of operation the
of its axis and controls the volume of the pipe. oscillating valve is able to open and close
When the swivel disc is oscillated from its steadily at higher amplitude and lower
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and below the stoichiometric ratio, producing supported by thermo-couples, digital
alternatively fuel-rich and fuel-lean zones in temperature indicators and sensing probe
the flame resulting in improved efficiency. along with mechanical apparatus, and to carry
Some of the visual observations made after out experiments to improve performance
the retrofit of oscillating valve and characteristics of a furnace from steady state
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experimentation are shown here. Distinct
difference can be noticed between the steady
state combustion to oscillating combustion
flames. The oscillating combustion flame was
found to be highly turbulent, radiative and
more luminous to that of the steady state
mode to oscillating mode of combustion. The
oscillating valve developed was found to be
ideal for the oscillating combustion as the
experiments carried out on liquid fuel at
varying air-fuel ratios, amplitude, frequency
and load have shown promising results. The
flame. amplitude of the flow rate, the oscillations
produced by this valve were adjusted
mechanically and electrically, thereby the
valve is considered to be flexible and appear
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to be easier to scale up for any furnace.
To help the heat transfer industry to
switch on to newer combustion concepts,
especially the oscillating combustion which is
(a) (b) (c) an advanced technology, introduction of
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