Influence of AM Generated Burner Surface Roughness on NOx Emissions and Operability of Hydrogen-Rich Fuels

The additive manufacturing (AM) technique enables the fabrication of advanced burner components to enhance the hydrogen capability of the existing gas turbines (GTs) and reduce the carbon footprints of the power generation sector. This technique produces rough surfaces that may require post-processing to maintain the desired functionality of a burner, particularly for hydrogen fuel with unique thermo-physical properties. This study, therefore, compared the stability of three swirlers of variable surface roughness manufactured using AM and traditional machining methods, with one of the AM swirler post-processed by grit-blasting. The comparison included a conventional benchmark (100% CH4), low carbon (23%volCH4/77%H-vol(2)) and zero carbon (100% H-2) fuels across a range of equivalence ratios. Additionally, the study quantified the flame topology and emissions performance of the fuel blends for each swirler using high-speed OH* chemiluminescence and exhaust gas emissions measurements, respectively. The experimental investigation concluded that the AM-generated surface roughness within the considered range does not detrimentally impact NOX emissions and the stability of the fuel mix. However, the flame location was observed to be influenced by surface roughness and shifted more toward the vertical centerline of the burner with increased roughness. From the practical perspective, the results showed that post-manufacturing surface finishing offers negligible performance advantages, indicating potential cost reductions. It is recommended that further studies should investigate the influence of increased surface roughness on burner performance, as well as numerical modeling techniques which could provide an insight into when AM surfaces are likely to be more influential.