Q0440596102

P.Bala Muraliet al. Int. Journal of Engineering Research and Applications www.ijera.com
ISSN : 2248-9622, Vol. 4, Issue 4( Version 5), April 2014, pp.96-102
www.ijera.com 96|P a g e
Simulation studies of premixed ch4/air Microcombustion
P.Bala Murali*
*(
Department of Mechanical Engineering, Thiagarajar College of Engineering, Madurai, TamilNadu– INDIA)
ABSTRACT
A numerical study of CH4-air premixed combustion in the micro combustors with a five step global mechanism is
performed by solving the two dimensional governing equations of continuity, momentum and species, coupled with the
energy equation. A reference case is defined as the combustion in a cylindrical tube with 1 mm inlet diameter and
length 10 times its inlet diameter with a uniform velocity profile at the inlet plane. Different physical and boundary
conditions have been applied in order to investigate their respective effects on the flame temperature. The conditions
studied in the current paper include the combustor size, geometry and inlet velocities. Downscaling the combustion
chamber and higher velocities leaded to reduction in residence time which results in lower combustion efficiency
causing insufficient heat generation unable to maintain the self-sustained combustion. The effect of variation in inlet
velocity has role in the determining the flame position in combination with given thermal conditions. The results of
this paper indicate that these various boundary and physical conditions have effects on the flame temperature to
different extent and should be carefully monitored when applied for different applications.
Keywords: Micro combustion, CH4–air mixture, premixed flame, flame temperature, K-e model
NOMENCLATURE
Ak -- pre-exponential factor of reaction rate
(consistent unit)
d-- Inner diameter (m)
D-- Diffusion coefficient (m2/s)
Di-- diffusion coefficient of the i-th species (m2/s)
Ek -- activation energy for the i-th reaction (J/ (kg
mol))
h-- Enthalpy (J/kg)
hconv--convective heat loss coefficient (non-
insulated wall) (W/ (m2K))
hi-- enthalpy of the ith species (J/kg)
hrad --radiative heat loss coefficient (non-insulated
wall) (W/ (m2K))
H-- Spacing between the parallel plates (m)
k-- Thermal conductivity of gas (W/ (mK))
kB--Boltzmann constant (1.380662×10!23 J/K)
L-- Combustor length (m)
P --Pressure (Pa)
q-- Volumetric heat generation rate (W/m3)
qw--heat loss from the non-insulated wall (W)
r-- Radial coordinate (m)
Ru-- universal gas constant (8314.41 J/ (kg mol K))
t-- Wall thickness (m)
T-- Temperature (K)
T0-- ambient temperature (K)
Tu-- temperature of unburned mixture (K)
Tw -- wall temperature at the interface (K)
Two -- temperature of the non-insulated wall (K)
u-- x velocity (m/s)
u0-- incoming flow velocity (m/s)
Ui--x velocity of the ith species (m/s)
V—yvelocity (m/s)
Vi-- y velocity of the ith species (m/s)
x-- xcoordinate (m)
y -- Coordinate for 2D parallel plates (m)
Yi --mass fraction of the ith species (kg/kg)
Greek symbols
βk--temperature exponent of the ith reaction
ρ-- Density of the mixture (kg/m3)
ρ-- Wall emissivity
ρ-- fuel–air equivalence ratio
ρ-- Stefan–Boltzmann constant (5.67×10 8 W/ (m2
K4))
µ-- Dynamic viscosity (N s/m2)
ρi--production rate of the ith
species (kmol/(m3 s))
I .INTRODUCTION
The last few years have experienced a
growing trend in the miniaturization of mechanical
and electromechanical engineering devices as a result
of the progress made in micro-fabrication techniques.
The interest in producing miniaturized mechanical
devices opens exciting opportunities in the field of
micro-power generation. MEMS-based power
generators prototyped, includes the micro gas turbine,
the micro-thermoelectric device and the micro-
thermo photovoltaic (𝜇TPV) system. The need to
reduce system weight, increase operational life times,
RESEARCH ARTICLE OPEN ACCESS

and reduce unit cost has resulted in development of
the field of micro-power generation, high-specific
energy micro-electromechanical power system. Such
work was mainly motivated by the fact that hydrogen
and most hydrocarbon fuels represent much higher
energy density than the most advanced lithium-ion
batteries. The characteristic length of micro
combustors using hydrocarbons as fuels may range
from several millimetres down to the sub millimetre
scale. As a result of the reduced size of the
combustors, combustion becomes less efficient due to
the intensified heat loss from the flame to the
combustor wall, radical destruction at the gas–wall
interface and reduced residence time, making the
system efficiency relatively low. Essentially, these
studies are aimed at achieving a stable combustion in
simple geometries such as cylindrical tubes or
rectangular channels. The effects and the relationship
between thickness and diameter of the tube with the
flame propagation were studied in the previous work,
and the quenching condition was obtained as a
function of the heat-loss parameter [1]. ‘Swiss roll’
combustors (SRC) were simulated to gain insight of
micro-scale combustion in prevention of the
occurrence of extinction. Increasing wall thermal
conductivity (or wall thickness) and emissivity causes
the extinction limit to rise [3]. The stability behaviour
of single flames stabilized on top of micro tubes
indicated that fuels exhibit critical equivalence ratios
below which no flame formed, and extinction
appeared above certain equivalence ratios [6-17]. The
heat exchange through the structure of the micro-
combustor can lead to a broadening of the reaction
zone. Heat loss to the environment decreases the
broadening effect and eventually results in flame
quenching [8]. As the combustor length increases, the
range of flow conditions for successful ignition
becomes smaller [9]. The wall effects such as
viscous, cooling and active species destruction shows
their prominent effect for decreased diameters of the
combustors. In addition, both the volumetric heat loss
and the wall shear stress increase with decreasing the
diameter [11]. Stable combustion was successfully
attained even for mixtures with equivalence ratios
outside the conventional flammability limits for
methane air mixture with externally heated micro
channel [13]. In case of micro flames, the diffusion
rate becomes very fast, so that the finite chemical
reaction rate starts to govern the phenomenon [14]. In
the context of micro combustion, the understanding
of flame temperature is necessary to choose the
proper material for a micro-combustor.
II. NUMERICAL MODEL
1. Geometry
Figure 1 shows the two - dimensional view
of the micro-channel (cylindrical tube and 2D
parallel plates) in which steady-state combustion of
a CH4– air mixture takes place. Symbols d or H
represents the diameter of the cylindrical tube or
vertical distance between 2D parallel plates,
respectively. An assumption is made that the swirl
velocity component is zero, meaning a symmetrical
flow with respect to the centreline. Thus, the case is
simplified to a 2D problem.
Fig. 1. Schematic of the computational domain with
some boundary conditions (not to scale).
2. Governing equations
As the characteristic length of the
combustor chamber is still sufficiently larger than
the molecular mean-free path of gases flowing
through the micro-combustor, fluids can be
reasonably considered as continuums and the
Navier-Stokes equations are still suitable in the
present study. Kuo and Ronnyreported that it is
more appropriate to predict the combustion
characteristics in micro-combustors by using a
turbulence model when the Reynolds number is
above 500. It is expected that in a micro-combustor,
the mixing of various kinds of species is enhanced
due to the small space. The turbulence model is
better than the laminar model to reflect the enhanced
mixing and its effect on combustion characteristics
as the main purpose of the micro-combustor fitted
with a bluff body is to stabilize the flame under
reduced dimensions .Therefore, the realizable k-e
turbulence model is adopted here. The governing
equations for the gaseous mixture are shown below:
2.1 Continuity Equation:
𝜕/𝜕𝑥(𝜌𝑣x) +𝜕/𝜕𝑦(𝜌𝑣y) = 0 -- (1)
2.2 Momentum Equation:
2.2.1 X – Direction:
𝜕/𝜕𝑥(𝑣𝑥𝑣𝑥 )
𝜕𝑥
+
𝜕/𝜕𝑦 (𝑣𝑥𝑣𝑦 )
𝜕𝑦
= -
𝜕𝑝
𝜕𝑥
+
𝜕𝜏𝑥𝑥
𝜕𝑥
+
𝜕𝜏𝑥𝑦
𝜕𝑦
--- (2)
2.2.2 Y – Direction:
𝜕/𝜕𝑥(𝑣𝑦𝑣𝑥 )
𝜕𝑥
+
𝜕/𝜕𝑦 (𝑣𝑦𝑣𝑦 )
𝜕𝑦
= -
𝜕𝑝
𝜕𝑦
+
𝜕𝜏𝑦𝑥
𝜕𝑥
+
𝜕𝜏𝑦𝑦
𝜕𝑦
--- (3)
2.3 Energy:
𝜕 𝜌𝑣𝑥ℎ
𝜕𝑥
+
𝜕 𝜌𝑣𝑦 ℎ
𝜕𝑦
=
𝜕 𝑘𝑓𝜕𝑇
𝜕𝑥2
+
𝜕 𝜌𝑣𝑥ℎ
𝜕𝑦2
+ [
𝜕(ℎ𝑖𝜌𝐷𝑖 ,
𝑚𝜕𝑌𝑖
𝜕𝑋
)
𝜕𝑥𝑖 +
𝜕(ℎ𝑖𝜌𝐷𝑖 ,
𝑚𝜕𝑌𝑖
𝜕𝑋
)
𝜕𝑦
] + ℎ𝑖𝑅𝑖𝑖 --- (4)

2.4 Species:
𝜕 𝜌𝑌𝑖𝑣𝑥
𝜕𝑥
+
𝜕 𝜌𝑌𝑖𝑣𝑦
𝜕𝑦
= −
𝜕 𝜌𝐷𝑖 ,𝑚
𝜕𝑌𝑖
𝜕𝑥
𝜕𝑥
+
𝜕 𝜌𝐷𝑖 ,𝑚
𝜕𝑌𝑖
𝜕𝑦
𝜕𝑦
--- (5)
As has been shown by many researches that heat
conduction in the solid phase exerts an important
effect on the combustion, it is necessary to consider
the heat transfer in combustor walls in the
computation. The energy equation for the solid
phase is given as:
𝜕𝑦 (𝑘𝑠𝜕𝑇 )
𝜕𝑥2
+
𝜕𝑦 (𝑘𝑠𝜕𝑇 )
𝜕𝑦2
=0 --- (6)
Where ks is the thermal conductivity of the wall.
3. Computation scheme
Because CH4 has much higher burning
velocity than other hydrocarbon fuels, it is selected
as the fuel in the present study. Because of burning
temperature of cH4 /air mixtures, lean mixtures with
equivalence ratios of 0.4, 0.6 and 0.8 and a
stoichiometric mixture of equivalence ratio 1 are
used to control the maximal temperature. The
equivalence ratio 𝜙, is a commonly used index to
indicate quantitatively whether the fuel-air mixture
for a chemical reaction is
Rich (𝜙> 1), Lean (𝜙< 1), or Stoichiometric
(𝜙 = 1).
The equivalence ratio is defined as
𝜙 =
(
𝐹
𝐴
)
𝐹
𝐴
𝑠𝑡𝑜𝑖
--- (7)
where (F/A) and (F/A) stoic are the real and
stoichiometric mass ratios of the fuel (F) to the air
(A).
To save the computational time only half of the
combustor volume is considered. In addition, the
following assumptions are made: 1. No work done
by pressure and viscous forces; 2. Steady-state. With
these assumptions, the Fluent 6.3 solves the
governing equations of continuity, momentum,
species and energy in the gas phase (for the
cylindrical micro-combustor). The 5-step global
mechanism used in [5] for CH4-air reaction is given
as below:
CH4 + 1.5O2 CO + 2H2O
R1= 1015.22
[CH4]1.46
[O2]0.5217
exp (-20643/T)
--- (8)
2. CO + 0.5O2  CO2
R2 = 1014.902
[CO] 1.6904 [
O2]1.57
exp (-11613/T)
--- (9)
3. CO2 CO + 0.5O2
R3 = 1014.349
[CO2] exp (-62281/T)
--- (10)
4. N2 + O2 2NO
R4=1023.946
[CO]0.7211
[O2]4.0111
exp (-53369/T)
--- (11)
5. N2 + O2 2NO
R5 = 1014.967
T_0.5
[N2] [O2]0.5
exp (-68899/T)
--- (12)
The skeletal mechanism (shown above) for methane
oxidation (7 species and 5 reactions) is employed in
the present study. Its application in the simulation of
combustion was found able to yield reasonable
results. Based on the above governing equations, the
2D simulations are performed. The governing
equations are discretized using the finite-volume
method and solved by Fluent Release 6.3. A second
order upwind scheme is used to discretize the
governing equations and SIMPLE algorithm is used
to deal with the pressure velocity coupling. The
equations are solved implicitly with a 2D pressure
based solver using an under-relaxation method. The
solver first solves the momentum equations, then the
continuity equation, followed by the updating of the
pressure and mass flow rates. The energy and
species equations are subsequently solved. Iterations
are monitored and checked until a converged
solution is obtained. The convergence criteria for
the scaled residuals are set to be 1×10-6
for
continuity, velocity, and energy and for species
concentration. The gas density is calculated using
the ideal gas law. The gas viscosity, specific heat
and thermal conductivity are calculated as a mass
fraction-weighted average of all species. The
specific heat of each species is calculated using a
piecewise polynomial fit of temperature. Numerical
convergence is generally difficult because of the
inherent stiffness of the matrix (chemistry). For
most cases, it was found that energy (temperature) is
the last parameter to get converged. The wall
thermal conductivity (k) is taken to be 20 W/ (mK)
(a typical value for stainless steel). The wall has a
thickness (t) of 0.2 mm and the combustor length
(L) is 10 times its inlet diameter (d or H). At the
inlet plane, the mixture enters the combustor with a
uniform temperature Tu= 300 K. At the outlet
boundary, the far-field pressure condition is
specified. Heat losses from the non-insulated wall to
the ambient are given by
qw= hconv (Two-To) +𝜀𝜎(Two
4
-To
4
) --- (13)

where the convective heat transfer coefficient hconv
and the wall emissivity 𝜀 are taken to be 50 W/
(m2K) and 0.2 (polished surface without
seriousoxidation), respectively.In the gas phase, the
mesh density wasfinalized to be 280 grids and 80
grids in the axialdirection and radial direction,
respectively. A hightemperature (~1600 K) is
imposed on the entirecomputational domain as an
initial guess for thenumerical iteration. It is
important to use atemperature high enough to ignite
the mixture.
Lower temperature may fail ignition for some cases.
The physical and boundary conditions summarized
above are applied to all cases in this study. Other
conditions may vary from case to case for the
purpose of comparison and will be stated in the
respective sections.
III. RESULTS AND DISCUSSION
1. Reference case
A ‘reference case’ needs to be defined in
order to facilitate comparison. The geometry of the
reference case is a cylindrical tube with an inner
diameter of 1 mm. The boundary conditions are
summarized as follows:
The boundary conditions are summarized as
follows:
 Inlet (x = 0): Tu= 300 K,u0 = 0.3,0.5,0.8,1
m/s, YcH4 = 0.034, (YO2 can be derived
from 𝜙= 0.6 and the air composition);
 Centreline(r= 0): 𝜕u/𝜕r= 0, 𝜕T/𝜕r= 0,
𝜕Yi/𝜕𝑟=0, v = 0 (no diffusion flux and zero
convective flux across the symmetry
plane);
 Gas–solid interface (r = r0): u = 0, v= 0
(nonslip wall), 𝜕Yi/𝜕y = 0 (zero diffusion
flux normal to the interface), and the heat
flux at the interface is computed using
Fourier’s law and continuity in temperature
and heat flux links the gas and solid phase;
 Non-insulated wall (y = Y0):
qw= hconv (Two-To) +𝜀𝜎(Two
4
-To
4
)
The above velocity range is used for methane,
owing to its lower burning velocity. Based on the
simulation results shown in Figure 2, it is noted that
as the inlet velocity increases the flame is blown
further downstream of the micro-combustor. Higher
velocity which implies higher mass flow rate
requires longer heating length (by the combustor
wall) for the mixture to be heated up to ignition
temperature. For u0 = 0.3 m/s, the flame is anchored
near the entrance and the highest temperature of
gases lies at the centreline of the combustor. For the
velocities 0.5 m/s and above, position of the
increased temperature zone of gases shifts from the
centreline to the wall. Figure 2 indicates that in the
pre-flame zone, the wall temperature is higher than
the mixture temperature, suggesting the direction of
heat transfer is from the wall to the fuel–air mixture.
The high temperature zone of the methane–air
flames occupies a wider span of the radial section.
Fig. 2. Contours of temperature with different
uniform inlet velocities, cylindrical tube of d = 1
mm, (a) u0 = 1.0 m/s (b) u0 = 0.8 m/s (c) u0 = 0.5
m/s (d) u0 = 0.3 m/s.
Fig. 3. Contours of (a) temperature, (b) methane
mass fraction and (c) axial velocity, d = 1mm, u0 =
0.5 m/s, for gas phase in cylindrical combustion
chamber.
Figure 3 shows the contours of temperature,
methane mass fraction and axial velocity for the
case of u0 = 0.5 m/s. It can be seen that a major part

of methane is consumed within a thin layer of
reactions. Axial velocity near the entrance gradually
increases in the region upstream of the flame front.
But in the region of high temperature the axial
velocity is highly accelerated which can be observed
along the centreline of the combustion chamber. The
normalized temperature profiles in the radial
direction for the case of u0 = 0.3 m/s is plotted in
Fig. 4. It can be seen from the difference in terms
temperature distribution in radial direction that for
axial distance 0.75 mm, the mixture is simply heated
up to the radial distance of 0.0003 mm. Further,
radial distance for that position has decreased value
of preheating. For axial distance beyond 1.0 mm
exothermic reactions are initiated, indicating high
temperature zone.
Fig. 4. Normalized temperature profiles, for d = 1
mm, u0 = 0.3 m/s.
2. Effect of combustor size and geometry
In order to investigate the effects of combustor size
for the methane–air mixture, a larger combustor (d =
2 mm) is modelled by keeping the same shape
aspect ratio. Other conditions (wall thickness,
boundary conditions, etc.) are identical to those for
the reference case (d = 1mm). By defining the flame
temperature as the highest temperature in the gas
phase, the effects of combustor size on the flame
temperature for given velocity range are shown in
Figure 5.
Fig. 5. Effects of combustor size on the flame
temperature cylindrical tube.
Lines connecting symbols are only for the
sake of visualization. For both combustors of
diameters 0.5 mm, and 1 mm, the increase of inlet
velocity results in higher flame temperature.
However, when the inlet velocity is higher than 0.5
m/s, the smaller combustor (d = 1mm) gives higher
flame temperature than the larger one (d = 2 mm).
Fig. 6. Contours of temperature with different
uniform inlet velocities, cylindrical tube of d = 2
mm, (a) u0 = 1.0 m/s (b) u0 = 0.8 m/s (c) u0 = 0.5
m/s (d) u0 = 0.3 m/s.
In order to understand this result, the flame structure
needs to be examined. For the d = 2 mm combustor,
the flame structure shows that the high temperature
zone is attached to the combustor wall. The
temperature contours for the d = 2 mm micro
combustor with medium (u0 = 0.5 m/s) and high (u0
= 1.0 m/s) velocities are shown in Figure 6.
Compared to Figure 2 (d = 1 mm), the difference in
terms of flame structure is obvious. As the
combustor diameter is increased from 1 to 2 mm,
the radial length for mass diffusion is doubled. As a
result, the temperature at the centreline zone of the
larger combustor is more controlled by axial
convection than radial diffusion. In the region of
reaction, heat diffuses in the radial direction to the
centreline zone, which accompanied with the
lowered flame temperature. In addition, another
factor that needs to be considered is that heat
recirculation through the combustor wall is more
significant in the smaller micro combustor. Apart
from the explanations given above, incomplete
combustion could also be a possible reason for the
lowered flame temperature in the larger combustor
(d = 2 mm).

Fig. 7. Centreline temperature profiles for
CylindricalCombustor of d = 1mm
Figure 7 shows the centreline temperature profiles
for different flow velocities. It can be seen that as
the velocity is increased to 0.8 m/s, the highest
centreline temperature approaches to or at the
combustor exit, implying that the combustion
process could be incomplete. Based on the limited
cases simulated in the present study, it is noted that
for CH4–air premixed combustion, when the flow
velocity is above a certain level, the conclusion that
‘smaller combustor gives lower flame temperature’
does not hold. The geometry is another important
factor for combustor design. Cylindrical tubes and
rectangular channels are the two commonly used
geometries. For simplicity, a model of 2D parallel
plates is employed to represent the rectangular
channels. In the simulation, the spacing (H) between
the plates is taken to be 1 mm, same as the inner
diameter in the reference case. Thus, the
hydrodynamic diameter (= 2H) of the 2D case is
twice that of the cylindrical tube (d = 1 mm). Other
physical and boundary conditions remain unchanged
from the reference case. A theoretical analysis
showed that the quenching distance for the parallel
plates is related to that for the cylindrical tube by a
factor of 0.65. In other words, when H = 0.65d, the
heat loss condition of a cylindrical tube is identical
to a 2D planar channel. The 2D case with the
spacing of H = 1 mm is modelled for comparison.
The variation of exit temperature with the flow
velocity for the two cases is plotted in Figure 8.
Fig. 8. Effect of combustor geometry on the flame
temperature.
Lines connecting symbols are only for the sake of
visualization. From Figure 8, it can be seen that the
H = 1 mm case has higher exit temperature than the
d = 1 mm case over the given velocity range, owing
to the difference in the hydrodynamic diameter.
Similar observations obtained for the comparison
between H = 2 mm and d = 2 mm. Other than the
factors (radial diffusion, heat recirculation and
incomplete combustion) discussed above, the
difference in terms of heat loss area between the two
geometries could be another reason. More in-depth
investigation on this result is needed, but it can be
concluded at this point that the hydrodynamic
diameter alone is not sufficient to correlate the two
combustor geometries. This conclusion could be
useful when attempting to alter the shape of the
micro-combustor without affecting the flame
temperature too much. However, it should be noted
that in practice, the result may not be strictly valid
due to the three-dimensional nature of a rectangular
planar channel.
3. Effect of inlet velocity
The temperature contours and profiles
obtained for the given uniform velocity range for
cylindrical diameter of 1 mm are plotted in Figure 2
and 7 respectively. Similar type of behaviour
obtained for the temperature profiles with increased
velocities for the other diameters also. The flame
position is essentially an overall result of the
thermal conditions and the flow field. In the pre-
flame zone, the inlet velocityprofile may affect the
heat transferfrom the wall to the unburned mixture,
thus affecting the heating length for the ignition to
occur. It is hard to predict the flame position due to
the close couplingbetween the thermal (both gases
and solid) and flow fields in the micro combustors.
IV. CONCLUSION
Flame temperature is one of the most
important parameters to characterize a combustion
process. A numerical study of CH4–air premixed
combustion in micro combustors was undertaken by
examining the effects of combustor size and
geometry, inlet velocities on the flame temperature.
A reference case was defined as a premixed CH4–
air combustion in a cylindrical tube (d = 1 mm) with
a uniform velocity profile at the inlet plane. It was
shown that a larger combustor (d = 2 mm) gives
higher flame temperature only when the flow
velocity is below a 0.5 m/s, whereas for diameters of
0.5 and 1 mm increase of inlet velocity results in
higher flame temperature. Downscaling the
combustion chamber and higher velocities leaded to
reduction in residence time which results in lower
combustion efficiency causing insufficient heat
generation unable to maintain the self-sustained
combustion. The effect of variation in inlet velocity

has role in the determining the flame position in
combination with given thermal conditions. With
regard to the combustor geometry, a 2D planar
channel (H = 1 mm) represents higher exit
temperature than a cylindrical tube with d = 1 mm,
over the inlet velocity range investigated in the
present study. Similar phenomenon was observed
for combustor of 2 mm passage. These conclusions
could be useful when attempting to alter the shape
of micro-combustion chambers with taking into
account the effect on the flame temperature to
different extent and should be carefully monitored
when applied in different applications.
ACKNOWLEDGEMENTS
Dr.P.Maran, Assistant Professor,
Department of Mechanical Engineering, Thiagarajar
college of Engineering , Madurai, Tamil Nadu,
India-625015.
Email:pmmech@tce.edu
PrashanthDevaraj, Mechanical
Engineering, Thiagarajar college of Engineering,
Madurai, Tamil Nadu, India-625015
Email: prashanthdevaraj@ymail.com
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