高性能大功率天然气发动机燃烧系统开发研究
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摘要
面对能源和环保两大问题的严峻挑战,世界各国都开始认真思考能源利用结构的调整和可持续发展问题。天然气具有资源丰富、排放污染低、价格低廉等方面的优点,日益受到重视,是一种很有发展前景的内燃机燃料,在满足能源需求方面越来越重要。我国自上世纪八十年代开始天然气发动机的研发和推广工作,并取得了巨大进步,但在高性能大功率天然气发动机研发方面与国外先进水平尚有不小的差距,导致了我国自主品牌高性能大功率天然气发动机的产品的欠缺,制约了在更广泛区域推广应用天然气应用。
本文结合某大功率天然气发动机研发项目,采用理论分析、数值模拟和试验验证相结合的方法开展了整机性能开发研究,实现了该项目的预期研发目标；并对未来满足更高排放标准的发动机的研发途径进行了一些探索,论文的主要工作包括：
(1)提出了基于热力学性能仿真与单缸机试验相结合的研究方法进行多缸大功率天然气发动机的整机性能开发,大大提高了开发进程和精度,并有效降低开发成本。参考同类型发动机的相关参数,并根据经验确定多缸整机的一些参数,建立整机热力学性能仿真模型；根据多缸机仿真结果建立单缸机热力学仿真模型,并设计开发单缸试验机,进行性能试验和部件开发试验,试验的初始参数和边界条件通过单缸机热力学仿真模型获得；应用单缸试验机测试得到的放热率等结果标定后再移植到多缸机热力学计算模型中,从而实现多缸机整机性能的精确预测。
(2)结合CH4的简化化学反应动力学模型,通过三维数值分析手段,详细研究了预燃室式燃烧系统中预燃室与主燃烧室之间的喷孔对于燃烧的影响。当总流通截面积相等时,过多的小直径喷孔,由于节流严重；当喷孔个数较少时,火焰覆盖面不够,燃烧速度也会受到影响；对于该燃烧系统来说,相比10个和6个喷孔而言,8个2mm直径的喷孔能够获得最快速的燃烧。
(3)通过研究发现,过小的喷孔截面直径不利于预燃室内的火焰向主燃烧室内的传播,稍大些的喷孔直径有利于主燃烧室内稀混合气的快速燃烧,但过大的直径由于预燃室内泄压过快也会影响主燃烧室内的燃烧速度。
(4)对于不同夹角的研究表明,小的夹角使火焰在活塞运动轴线方向上传播较快；而大的夹角,在气缸半径方向上传播速度会快些。由于天然气发动机的缸径较大,并且没有组织缸内涡流,加上燃烧室形状为浅盆形,稍大些的夹角更有利于该气体发动机缸内稀混合气的快速燃烧。
(5)对不同预燃室容积的仿真研究发现,在相同预燃室燃气供应量的情况下,小些的预燃室容积能够获得较浓的混合气,预燃室点火燃烧后能够获得较高的压力,可以更快的引燃主燃烧室内的稀混合气。
(6)针对天然气发动机开发过程中必须面对的爆震现象,提出了爆震指数的概念,并用其来监测和评价天然气发动机的爆震程度。通过试验获得了该发动机的爆震极限。
(7)经过优化的预燃室燃烧系统,在单缸试验机上进行了预燃室式燃烧系统的开发试验。试验研究了不同开启压力对整机燃烧的影响。试验结果表明同样的燃气供应量情况下,小的燃气喷射阀开启压力可以使预燃室内的混合气获得较长的混合形成时间,更有利于形成均匀的混合气,从而在点火后尽快燃烧,可以获得较高的能量引燃主燃烧室内的稀混合气,因此较小的开启压力会对整体燃烧更有利些。文中还试验研究了预燃室容积和主燃烧室凹坑形状对燃烧性能的影响,确定了发动机的预燃室式燃烧系统具体结构。通过验证试验表明开发的预燃室式燃烧系统能够满足IMO TierⅡ排放标准,达到了预期的性能设计目标。
(8)为了探索满足更高排放标准的技术途径,对比分析了发动机缸内气流运动的评价方法,并应用瞬态涡流比、瞬态滚流比和瞬态挤流比等瞬态评价参数对该发动机的进气、压缩过程进行了细致的分析,并探讨了其对于燃烧的影响。
(9)提出了火焰贯穿度的概念,并用其评价预燃室式燃烧系统中主燃烧室内稀混合气的燃烧速度。通过数值仿真手段研究了气流组织对于不同浓度稀混合气燃烧的影响,结果表明在缸内混合气过量空气系数为1.8以下时,缸内气流运动对于燃烧的影响不大,主燃烧室内稀混合气燃烧的主要驱动力为预燃室内浓混合气燃烧产生的高压火焰束,高压火焰通过喷孔喷入主燃烧室；在过量空气系数不大于1.8时,过量空气系数越小,火焰贯穿度越大,燃烧速度越快,就可以不组织缸内的涡流运动。当火焰贯穿度较小时,要想获得理想的燃烧速度,适当的气流组织是不可或缺的。
(10)进行了配气系统与燃烧系统的匹配研究,数值仿真结果表明采用预燃室式燃烧系统、高增压、强米勒、恰当的涡流和大λ技术将是应对更高排放标准的有效技术途径。
论文对大功率天然气发动机整机性能开发方法、高性能燃烧系统、爆震评价、稀混合气组织等方面进行了研究,将对预燃室式高性能大功率天然气发动机的开发提供一定的理论和试验基础。
Facing the serious challenges of energy and environmental protection, all the countries in the world began to think about adjustment and sustainable development of the energy utilization structure seriously. Natural gas has the advantages of rich resources, low emission, and low price and so on, which should be a suitable alternative fuel for engine, is playing more and more important role in meeting energy demands. Researchers began to research natural gas engine in our country and have made tremendous progress since the eighty's of last century, and have made tremendous progress. But there is still a big gap with foreign advanced technology in the research and development of big power natural gas engine, which restricted the use of natural gas engine in the fixed purpose, such as power generation applications, so R&D technology of high power natural gas engines are the big problems that we desiderate to solve.
Based on a large bore natural gas engine, the pre-combustion chamber type combustion system which can fulfil IMO Tier Ⅱ was studied by the methods of theoretical analysis, the combination of numerical simulation and experimental verification; and the combustion system meets Tier III emission standard was researched. The main jobs of this thesis include:
(1) The new R&D method of performance for multi-cylinder large bore natural gas engine was put forward in this thesis combining the thermodynamic simulation and single cylinder testing engine, it.improve the development process and the accuracy greatly. Firstly, based on the parameters of similar engine and R&D experience, the thermodynamic model of multi-cylinder engine was established; secondly, the thermodynamic model of single cylinder engine was established according to the simulation results of multi cylinder engine and the single cylinder testing engine was designed and created, the operation boundary conditions are all come form the thermodynamic simulation of single cylinder engine, and then the performance test and components test are carried in this engine; thirdly, the testing results such as the heat release rate was used to modify the thermodynamic model of single cylinder engine, and then the calibrated model was explanted to multi-cylinder engine model, and the performance parametes were forcasted accurately using this thermodynamic model.
(2) Combined with reduced chemical kinetic model of CH4, the effects of connecting channels between the pre-chamber and the main chamber of the pre-chamber combustion system to overall combustion were studied in detail using the three-dimensional numerical method. The more channels with smaller diameter are adverse to the burning velosity as the throttle is serious when the total flow area fixed. On the other hand, the fewer channels with bigger diameter will affected the combustion speed because the vortex motion in cylinder is weak. Compared to the10and6connecting channels,8channels with2mm diameter can obtain the most rapid combustion.
(3) The smallest channel section would not conductive to the flame propagation from the pre-chamber to main combustion chamber; the biiger channel diameter should beneficial to the rapid combustion of lean mixture in main combustion chamber.
(4) The flame will be spread faster along with the direction of the movement of the piston with the smaller channel angle; while he flame will be spread faster along with the direction of the diameter of the cylinder with the larger channel angle. Slightly larger channel angle is more conducive to the rapid combustion of the gas mixture in main combustion chamber because of the larger diameter, weak swirl and shallow basin shape combustion chamber.
(5) Numerical studies of different precombustion chamber volume to combustion found that the smaller pre-chamber volume can obtain richer mixture than bigger one in the same chamber gas supply, so the higher combustion pressure in the pre-chamber could be achieved, which can accelerate the flame propagation velocity of lean mixture in main combustion chamber.
(6) The concept of knock index was put forward to detect and evaluate the detonation of natural gas engine, and the detonation limit of this engine was achived by the test. The last verification testing found the developed combustion system can meet the IMO Tier II standard, and achieved all the requirements.
(7) Based on the numerical results of combustion system, the exploitative tests of combustion system were carried on the test bench of single cylinder testing engine. The effects of two open pressures of check valve to combustion were investigated, the results show that lower opern pressure will bring more time for gas mixture in pre-chamber, so the combustion speed is faster than that of bigger open pressure, so it will have more energy to ignite the lean mixture in the main combustion chamber.
(8) The gas movement in the cylinder was investigated in order to study the combustion system which can meet more strict emission standard. The different steady evaluation methodologies were comparative analyzed, and the instant evaluation parameters were used to study the gas movement of intake stroke and compression stroke, and the effects to combustion were discussed.
(9) The concept of flame penetration was put forward to evaluate the combustion speed of lean mixture in main combustion chamber. And the effects of different swirl rate and concentration of mixture to combustion were studied. The results show that the swirl ratio nearly no effect on combustion speed when the λ less than1.8, the driving force of the lean mixture burning in main combustion chamber is the higher differential pressure between pre-chamber and main combustion chamber which is achieved by combustion in pre-chamber. The swirl ratio is benefit to the faster propagation of flame in lean mixture.
(10)The matching studies of gas movement and combustion system were carried on. And a new project was put forward which could meet IMO Tier III standard, it include the combustion system with pre-chamber, higher intake swirl ratio, strong Miller cycle in which the intake valve close at520deg, and higher pressure ratio with3.8.
Bsed on CAE and testing, the developing method of multi-cylinder bigger bore natural gas engine and the combustion system was studied, at the same time the evaluation of detonation and the relationship between the gas movement and the excess air factor were investigated in this thesis. These would give some theoretic and experimental references for the researches and the development of high performance, large power pre-chamber type natural gas engines.
本文结合某大功率天然气发动机研发项目,采用理论分析、数值模拟和试验验证相结合的方法开展了整机性能开发研究,实现了该项目的预期研发目标；并对未来满足更高排放标准的发动机的研发途径进行了一些探索,论文的主要工作包括：
(1)提出了基于热力学性能仿真与单缸机试验相结合的研究方法进行多缸大功率天然气发动机的整机性能开发,大大提高了开发进程和精度,并有效降低开发成本。参考同类型发动机的相关参数,并根据经验确定多缸整机的一些参数,建立整机热力学性能仿真模型；根据多缸机仿真结果建立单缸机热力学仿真模型,并设计开发单缸试验机,进行性能试验和部件开发试验,试验的初始参数和边界条件通过单缸机热力学仿真模型获得；应用单缸试验机测试得到的放热率等结果标定后再移植到多缸机热力学计算模型中,从而实现多缸机整机性能的精确预测。
(2)结合CH4的简化化学反应动力学模型,通过三维数值分析手段,详细研究了预燃室式燃烧系统中预燃室与主燃烧室之间的喷孔对于燃烧的影响。当总流通截面积相等时,过多的小直径喷孔,由于节流严重；当喷孔个数较少时,火焰覆盖面不够,燃烧速度也会受到影响；对于该燃烧系统来说,相比10个和6个喷孔而言,8个2mm直径的喷孔能够获得最快速的燃烧。
(3)通过研究发现,过小的喷孔截面直径不利于预燃室内的火焰向主燃烧室内的传播,稍大些的喷孔直径有利于主燃烧室内稀混合气的快速燃烧,但过大的直径由于预燃室内泄压过快也会影响主燃烧室内的燃烧速度。
(4)对于不同夹角的研究表明,小的夹角使火焰在活塞运动轴线方向上传播较快；而大的夹角,在气缸半径方向上传播速度会快些。由于天然气发动机的缸径较大,并且没有组织缸内涡流,加上燃烧室形状为浅盆形,稍大些的夹角更有利于该气体发动机缸内稀混合气的快速燃烧。
(5)对不同预燃室容积的仿真研究发现,在相同预燃室燃气供应量的情况下,小些的预燃室容积能够获得较浓的混合气,预燃室点火燃烧后能够获得较高的压力,可以更快的引燃主燃烧室内的稀混合气。
(6)针对天然气发动机开发过程中必须面对的爆震现象,提出了爆震指数的概念,并用其来监测和评价天然气发动机的爆震程度。通过试验获得了该发动机的爆震极限。
(7)经过优化的预燃室燃烧系统,在单缸试验机上进行了预燃室式燃烧系统的开发试验。试验研究了不同开启压力对整机燃烧的影响。试验结果表明同样的燃气供应量情况下,小的燃气喷射阀开启压力可以使预燃室内的混合气获得较长的混合形成时间,更有利于形成均匀的混合气,从而在点火后尽快燃烧,可以获得较高的能量引燃主燃烧室内的稀混合气,因此较小的开启压力会对整体燃烧更有利些。文中还试验研究了预燃室容积和主燃烧室凹坑形状对燃烧性能的影响,确定了发动机的预燃室式燃烧系统具体结构。通过验证试验表明开发的预燃室式燃烧系统能够满足IMO TierⅡ排放标准,达到了预期的性能设计目标。
(8)为了探索满足更高排放标准的技术途径,对比分析了发动机缸内气流运动的评价方法,并应用瞬态涡流比、瞬态滚流比和瞬态挤流比等瞬态评价参数对该发动机的进气、压缩过程进行了细致的分析,并探讨了其对于燃烧的影响。
(9)提出了火焰贯穿度的概念,并用其评价预燃室式燃烧系统中主燃烧室内稀混合气的燃烧速度。通过数值仿真手段研究了气流组织对于不同浓度稀混合气燃烧的影响,结果表明在缸内混合气过量空气系数为1.8以下时,缸内气流运动对于燃烧的影响不大,主燃烧室内稀混合气燃烧的主要驱动力为预燃室内浓混合气燃烧产生的高压火焰束,高压火焰通过喷孔喷入主燃烧室；在过量空气系数不大于1.8时,过量空气系数越小,火焰贯穿度越大,燃烧速度越快,就可以不组织缸内的涡流运动。当火焰贯穿度较小时,要想获得理想的燃烧速度,适当的气流组织是不可或缺的。
(10)进行了配气系统与燃烧系统的匹配研究,数值仿真结果表明采用预燃室式燃烧系统、高增压、强米勒、恰当的涡流和大λ技术将是应对更高排放标准的有效技术途径。
论文对大功率天然气发动机整机性能开发方法、高性能燃烧系统、爆震评价、稀混合气组织等方面进行了研究,将对预燃室式高性能大功率天然气发动机的开发提供一定的理论和试验基础。
Facing the serious challenges of energy and environmental protection, all the countries in the world began to think about adjustment and sustainable development of the energy utilization structure seriously. Natural gas has the advantages of rich resources, low emission, and low price and so on, which should be a suitable alternative fuel for engine, is playing more and more important role in meeting energy demands. Researchers began to research natural gas engine in our country and have made tremendous progress since the eighty's of last century, and have made tremendous progress. But there is still a big gap with foreign advanced technology in the research and development of big power natural gas engine, which restricted the use of natural gas engine in the fixed purpose, such as power generation applications, so R&D technology of high power natural gas engines are the big problems that we desiderate to solve.
Based on a large bore natural gas engine, the pre-combustion chamber type combustion system which can fulfil IMO Tier Ⅱ was studied by the methods of theoretical analysis, the combination of numerical simulation and experimental verification; and the combustion system meets Tier III emission standard was researched. The main jobs of this thesis include:
(1) The new R&D method of performance for multi-cylinder large bore natural gas engine was put forward in this thesis combining the thermodynamic simulation and single cylinder testing engine, it.improve the development process and the accuracy greatly. Firstly, based on the parameters of similar engine and R&D experience, the thermodynamic model of multi-cylinder engine was established; secondly, the thermodynamic model of single cylinder engine was established according to the simulation results of multi cylinder engine and the single cylinder testing engine was designed and created, the operation boundary conditions are all come form the thermodynamic simulation of single cylinder engine, and then the performance test and components test are carried in this engine; thirdly, the testing results such as the heat release rate was used to modify the thermodynamic model of single cylinder engine, and then the calibrated model was explanted to multi-cylinder engine model, and the performance parametes were forcasted accurately using this thermodynamic model.
(2) Combined with reduced chemical kinetic model of CH4, the effects of connecting channels between the pre-chamber and the main chamber of the pre-chamber combustion system to overall combustion were studied in detail using the three-dimensional numerical method. The more channels with smaller diameter are adverse to the burning velosity as the throttle is serious when the total flow area fixed. On the other hand, the fewer channels with bigger diameter will affected the combustion speed because the vortex motion in cylinder is weak. Compared to the10and6connecting channels,8channels with2mm diameter can obtain the most rapid combustion.
(3) The smallest channel section would not conductive to the flame propagation from the pre-chamber to main combustion chamber; the biiger channel diameter should beneficial to the rapid combustion of lean mixture in main combustion chamber.
(4) The flame will be spread faster along with the direction of the movement of the piston with the smaller channel angle; while he flame will be spread faster along with the direction of the diameter of the cylinder with the larger channel angle. Slightly larger channel angle is more conducive to the rapid combustion of the gas mixture in main combustion chamber because of the larger diameter, weak swirl and shallow basin shape combustion chamber.
(5) Numerical studies of different precombustion chamber volume to combustion found that the smaller pre-chamber volume can obtain richer mixture than bigger one in the same chamber gas supply, so the higher combustion pressure in the pre-chamber could be achieved, which can accelerate the flame propagation velocity of lean mixture in main combustion chamber.
(6) The concept of knock index was put forward to detect and evaluate the detonation of natural gas engine, and the detonation limit of this engine was achived by the test. The last verification testing found the developed combustion system can meet the IMO Tier II standard, and achieved all the requirements.
(7) Based on the numerical results of combustion system, the exploitative tests of combustion system were carried on the test bench of single cylinder testing engine. The effects of two open pressures of check valve to combustion were investigated, the results show that lower opern pressure will bring more time for gas mixture in pre-chamber, so the combustion speed is faster than that of bigger open pressure, so it will have more energy to ignite the lean mixture in the main combustion chamber.
(8) The gas movement in the cylinder was investigated in order to study the combustion system which can meet more strict emission standard. The different steady evaluation methodologies were comparative analyzed, and the instant evaluation parameters were used to study the gas movement of intake stroke and compression stroke, and the effects to combustion were discussed.
(9) The concept of flame penetration was put forward to evaluate the combustion speed of lean mixture in main combustion chamber. And the effects of different swirl rate and concentration of mixture to combustion were studied. The results show that the swirl ratio nearly no effect on combustion speed when the λ less than1.8, the driving force of the lean mixture burning in main combustion chamber is the higher differential pressure between pre-chamber and main combustion chamber which is achieved by combustion in pre-chamber. The swirl ratio is benefit to the faster propagation of flame in lean mixture.
(10)The matching studies of gas movement and combustion system were carried on. And a new project was put forward which could meet IMO Tier III standard, it include the combustion system with pre-chamber, higher intake swirl ratio, strong Miller cycle in which the intake valve close at520deg, and higher pressure ratio with3.8.
Bsed on CAE and testing, the developing method of multi-cylinder bigger bore natural gas engine and the combustion system was studied, at the same time the evaluation of detonation and the relationship between the gas movement and the excess air factor were investigated in this thesis. These would give some theoretic and experimental references for the researches and the development of high performance, large power pre-chamber type natural gas engines.
引文
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