SEARCH · Engineering Papers
Search indexed NASA NTRS and DOE OSTI research on propulsion, heat transfer, battery materials and energy systems. Follow report and document links to the original sources.
Quote a phrase for an exact phrase match. Source license links do not imply unrestricted reuse.
Validation of a CFD model for Membrane-based carbon capture. We compare our high-fidelity 3D CFD Model to a conventional cross-flow 1D model. We show that for high-performing membranes, the 1D model is very limited and struggles to represent the separation system.
Inorganic membrane-based systems are a promising technology for precombustion CO2 capture with simultaneous H2 production. State-of-the-art packages for high temperature and pressure service consist of multiple tube membrane bundles prepared in a "candle filter" configuration, in which the membrane tubes are open at one end and sealed at the other. This configuration is used for practical reasons, specifically the need to minimize problems due to thermal expansion mismatch between the ceramic tube bundle and the steel housing. However, the primary technical problem with the candle filter format for commercial-scale installations is the inability to purge the tube side (typically the permeate side), a feature that is crucial for high H2 recovery. In this study, the focus is to design and fabricate the first dual-end open full ceramic multiple tube membrane bundle that enables tube side (permeate) purge for gas separation applications. An additional key feature of this design is the simplified module layout, as the membrane bundles can be installed end-to-end with tube side (permeate) flow directly from one bundle to the next. This layout simplifies the membrane to housing seals and yields significant improvement in membrane packing density. Detailed focus areas in our studies include: (i) Materials development and preparation of the tube-to-tube sheet potting for the dual-ended bundle; (ii) the sealing and optimal module configuration design to minimize membrane stress upon module mounting; (iii) the demonstration, via the fabrication of CMS and Pd-alloy membranes supported on full-size, dual-ended ceramic support bundles, of the first example of a purgeable ceramic membrane and module; and (iv) development of a CFD model of the membrane module for calculation of feed flow distribution, and for use in scale-up, and capital cost estimating. The CFD model was validated using experimental data with the multi-tubular membrane system, employing He/N2 as a model gas mixture (surrogate for H2/CO2), and has been shown to be quite accurate. Employing the model, we are able to study the effects of operating pressure and temperature, feed and sweep gas flow rates, and the choice of membrane tube configuration on system performance.
Inorganic membranes show promise for application in pre-combustion CO2 capture with simultaneous H2 production. State-of-the-art systems for use under high temperature and pressure conditions consist of multiple membrane tube bundles prepared in a "candle-filter" configuration, in which the membrane tubes are open at one end and sealed at the other. This configuration is used for practical reasons, specifically the need to minimize potential problems due to thermal expansion mismatch, at high temperatures, between the ceramic tube bundle and the steel housing. The primary technical problem with the candle-filter configuration for use in commercial-scale installations is the inability to purge the permeate side (typically the tube side), a feature that is crucial for high H2 recovery. In this study, we fabricated dual-end open, commercial-size ceramic multiple-tube bundles made of zeolite, palladium (Pd), and carbon molecular sieve (CMS) membranes that enable permeate-side (tube-side) purge for gas separation applications. Experimental gas separation data with these membrane bundles under harsh operating conditions (temperatures up to 350 and pressures up to 800 psig), to be presented at the meeting, manifest excellent performance. Parallel to the membrane bundle construction and testing efforts, we have also developed a detailed 3D CFD modeling package using COMSOL Multiphysics software to gain more insight into the effect on the H2 purity and recovery of the detailed geometry of the multi-tubular membrane system, including the number of tubes used, their dimensions, and placement in the bundle, as well as the number, type, and positioning of internal baffles and other flow-enhancement accessories. The CFD package is validated with experimental data from different systems (1-tube, 3-tube, and 19-tube bundles), and shows high accuracy in predicting the experimental results (<5 % error in all cases). The results of our study show that the detailed internal geometry of these multi-tubular membrane systems has a considerable impact on the performance of the system as the flow maldistribution within the shell-side can substantially decrease (>40%) the H2 recovery.
The ongoing efforts to convert High-Performance Research Reactors (HPRRs) using Highly Enriched Uranium (HEU) to Low-Enriched Uranium (LEU) fuel require reliable thermal–hydraulic assessments of modified core designs. The involute-shaped fuel plates used in several major HPRRs present unique modeling challenges due to their compact core geometries and high heat flux conditions. This study evaluates the capability of three commercial CFD tools, STAR-CCM+, COMSOL, and ANSYS CFX, to predict cladding-to-coolant heat transfer using Reynolds-Averaged Navier–Stokes (RANS) methods within the thermal–hydraulic regimes of involute-shaped plate reactors. Broad sensitivity analysis was conducted across a range of reactor-relevant parameters using two turbulence models (k−ϵ and k−ω SST) and different near-wall treatment strategies. The results were benchmarked against the Sieder–Tate correlation and experimental data from historic studies. The codes produced consistent results, showing good agreement with the empirical correlation of Sieder–Tate and the experimental measurements. The findings support the use of these commercial CFD codes as effective tools for assessing the thermal–hydraulic performance of involute-shaped plate HPRRs and guide future LEU core development.
If a CO 2 reservoir or transmission pipeline were to leak, both the surrounding ecology and maritime traffic safety could be put at risk. To better understand and prepare for this risk, multiphase Computational Fluid Dynamics (CFD) models were built in ANSYS Fluent to capture the behavior of a leak once it enters the water. A 3D Eulerian–Eulerian model was used for validation, while a simplified 2D model was applied to simulate conditions at a 50-m depth. The models integrate bubble dynamics, gas holdup, CO 2 dissolution, dissolved species transport, and seawater acidification into a unified CFD framework. Mass transfer was calculated using the Hughmark correlation, and local seawater temperature and salinity were factored in to determine dissociation behavior and the relevant Henry’s Law constant. To confirm the 3D model’s accuracy, results were checked against two experimental datasets: the QICS field study and the Hauser Tank experiments. The team also modeled a hypothetical release scenario at the High Island 10L site and compared the results with earlier published work. The results show that at a depth of 50 m, the surrounding water column can completely absorb a CO 2 release at a rate of 35 kg/s, since the gas dissolves into the seawater as it rises toward the surface. Beyond confirming this mitigation capacity, the simulations shed light on how a leak would actually unfold in the environment, including the shape and movement of the rising bubble plume, how much CO 2 dissolves along the way, and the resulting shifts in seawater pH and pCO 2 . Together, this provides a practical framework for assessing how CO 2 leaks could affect marine environments in the Gulf of Mexico.
Ever since computations have been used to simulate aerodynamics the need to ensure that the computations adequately represent real life has followed. Many experiments have been performed specifically for validation and as computational methods have improved, so have the validation experiments. Validation is also a moving target because computational methods improve requiring validation for the new aspect of flow physics that the computations aim to capture. Concurrently, new measurement techniques are being developed that can help capture more detailed flow features pressure sensitive paint (PSP) and particle image velocimetry (PIV) come to mind. This paper will present various wind-tunnel tests the author has been involved with and how they were used for validation of various kinds of CFD. A particular focus is the application of advanced measurement techniques to flow fields (and geometries) that had proven to be difficult to predict computationally. Many of these difficult flow problems arose from engineering and development problems that needed to be solved for a particular vehicle or research program. In some cases the experiments required to solve the engineering problems were refined to provide valuable CFD validation data in addition to the primary engineering data. All of these experiments have provided physical insight and validation data for a wide range of aerodynamic and acoustic phenomena for vehicles ranging from tractor-trailers to crewed spacecraft.
Understanding, predicting, and controlling fluid slosh dynamics is critical to safety and improving performance of space missions when a significant percentage of the spacecrafts mass is a liquid. Computational fluid dynamics simulations can be used to predict the dynamics of slosh, but these programs require extensive validation. Many CFD programs have been validated by slosh experiments using various fluids in earth gravity, but prior to the ISS SPHERES-Slosh experiment1, little experimental data for long-duration, zero-gravity slosh existed. This paper presents the current status of an ongoing CFD validation study using the ISS SPHERES-Slosh experimental data.
Understanding, predicting, and controlling fluid slosh dynamics is critical to safety and improving performance of space missions when a significant percentage of the spacecrafts mass is a liquid. Computational fluid dynamics simulations can be used to predict the dynamics of slosh, but these programs require extensive validation. Many CFD programs have been validated by slosh experiments using various fluids in earth gravity, but prior to the ISS SPHERES-Slosh experiment, little experimental data for long-duration, zero-gravity slosh existed. This paper presents the current status of an ongoing CFD validation study using the ISS SPHERES-Slosh experimental data.
A computational study of the Adaptive Deployable Entry and Placement Technology (ADEPT) Sounding Rocket (SR-1) Test is presented using the US3D flow solver. ADEPT SR-1 is intended, in part, to assess the dynamic stability of this entry vehicle architecture. Given that no dynamic stability data exists for the ADEPT geometry, a limited ballistic range campaign has been performed to characterize the vehicle's stability characteristics pre-flight for Mach numbers between 1.21 and 2.5. Here, this data is used to assess the accuracy of US3D's free-flight CFD capability. Computed trajectories from US3D and experimental data show that the flow solver compares well in vehicle oscillation frequency, downrange distance, and oscillatory amplitude during high Mach number flight (Mavg = 2.36). For Mach numbers below 1.5, the solver under predicts total angle-of-attack by an average of 16%, but compares well in oscillatory frequency and downrange distance. Additionally, a capability for simulating the trajectory of the flight article through the atmosphere using CFD is presented. This capability couples US3D's free-flight capability to an atmosphere model that accounts for changes in free-stream density and temperature as the vehicle descends. Two simulations for the purpose of demonstrating the capability and viability of this approach are applied to SR-1 flight article, and some unique challenges are discussed.
A system identification analysis was performed to determine reduced-order models of a computational fluid dynamics (CFD) solver for linear aeroelastic analysis and control design. The application was to the FUN3D code and the flexible half-span wind tunnel test article, in transonic flow conditions, used in the NASA-Boeing collaboration called the Integrated Adaptive Wing Technology Maturation (IAWTM) project. Multiple inputs (structural mode displacements and control surface deflections) were simultaneously excited with orthogonal phase-optimized multisines and multiple outputs (generalized aerodynamic forces) were recorded, from which the matrix of frequency responses were computed using a single CFD run. A state-space model was then fit to the frequency response data using a maximum-likelihood estimator.
This paper evaluates simulation predictions against experimental test data of icing clouds that were produced during 2018 ice crystal icing physics tests conducted at the NASA Propulsion Systems Laboratory icing wind tunnel. Aero-thermal and cloud parameters are set and known upstream at the tunnel inlet and spray system, but change as the cloud and air thermodynamically interact as the flowing masses reach the tunnel test section. Utilizing the ANSYS Fluent Discrete Phase Model function, 3D computational fluid dynamics (CFD) simulations were performed, capturing the thermodynamic interactions between the test parameters, and providing predictions of the aero thermal and cloud conditions at the tunnel test section. Simulation predictions were compared with test data that were measured at the tunnel exit plane. Evaluations focused on the cloud concentration (total water content), humidity content, and air temperature. CFD simulation predictions showed areas of agreement and disagreement. Simulations showed that cloud concentration profiles at the test section are strongly related to the initial spray nozzle pattern used at the tunnel inlet. Experimental data suggest that greater dispersion of the cloud occurred as the simulated cloud predicted areas of high and low cloud concentration compared to test data profiles. Simulations, however, captured the magnitude and location of the change in humidity content and the change in air temperature due to the presence of the cloud reasonably well, when compared to test data. This result would suggest that while the ANSYS simulation did not fully predict the spreading of the cloud as measured during experiment, it did capture evaporation and the molecular movements of air and vapor relatively well.
This paper evaluates simulation predictions against experimental test data of icing clouds that were produced during 2018 ice crystal icing physics tests conducted at the NASA Propulsion Systems Laboratory icing wind tunnel. Aero-thermal and cloud parameters are set and known upstream at the tunnel inlet and spray system, but change as the cloud and air thermodynamically interact as the flowing masses reach the tunnel test section. Utilizing the ANSYS Fluent Discrete Phase Model function, 3D computational fluid dynamics (CFD) simulations were performed, capturing the thermodynamic interactions between the test parameters, and providing predictions of the aero thermal and cloud conditions at the tunnel test section. Simulation predictions were compared with test data that were measured at the tunnel exit plane. Evaluations focused on the cloud concentration (total water content), humidity content, and air temperature. CFD simulation predictions showed areas of agreement and disagreement. Simulations showed that cloud concentration profiles at the test section are strongly related to the initial spray nozzle pattern used at the tunnel inlet. Experimental data suggest that greater dispersion of the cloud occurred as the simulated cloud predicted areas of high and low cloud concentration compared to test data profiles. Simulations, however, captured the magnitude and location of the change in humidity content and the change in air temperature due to the presence of the cloud reasonably well, when compared to test data. This result would suggest that while the ANSYS simulation did not fully predict the spreading of the cloud as measured during experiment, it did capture evaporation and the molecular movements of air and vapor relatively well.
Future NASA architectures have baselined cryogenic propulsion systems as well as cryogenic fluid management to support lunar missions and ultimately to support future missions to Mars. These missions will require chilling hardware down prior to engine restart as well as chilling lines and tanks prior to transferring and refueling these propulsion elements in orbit. In lieu of expensive tests conducted on-orbit, accurate predictive computational models of these chilldown processes can be used to reduce system and propellant mass as well as mission risk. To gain confidence in these computational models, appropriate anchoring and validation to experimental data in a relevant environment needs to be performed. Recent ground and sub-orbital flight experiments conducted by the Japan Aerospace Exploration Agency (JAXA) investigated chilldown of a complex channel resembling a turbopump bearing cavity at low flow rates. This work presents Computational Fluid Dynamics (CFD) model development of the chilldown experiment employing two-phase flow boiling models available in commercial CFD software STAR-CCM+ using Volume of Fluid (VOF) and the traditional Euler-Euler multiphase flow solvers. Comparisons of the numerical and experimental results under normal and low-gravity conditions are presented. An assessment of solid wall temperatures and phase distribution yielded important insights into multiphase solver choice, dependence on gravity environment, and challenges associated with cryogenic flow boiling prediction and validation.
Computational fluid dynamics (CFD) has matured to the point where it is becoming ubiquitous in the design and analysis of aerospace vehicles and their propulsion systems. The current state-of-the-art of CFD in hypersonic propulsion design and analysis as well as a historical perspective of its development over the last 50 years is presented. The current state-of-the-art for the design of finite rate chemically reacting turbulent hypersonic flow is shown to currently be Reynolds averaged simulations (RAS) where the Reynolds averaged Navier-Stokes (RAS) equations are solved to obtain steady state solutions. An overview of the physical modeling techniques employed by RAS for the simulation of hypersonic chemically reacting flow are presented. However, scale resolving simulation techniques, such as detached eddy simulation (DES), large eddy simulations (LES), hybrid RAS/LES and direct numerical simulations (DNS), are becoming becoming powerful tools for point design analysis. One example of such a scale resolving technique, hybrid RAS/LES, will be briefly described as well as how it can be used to help address model form uncertainties in RAS.
This paper presents an overview of the state-of-the-art two-phase CFD models that have been developed for various propellant tank storage and transfer operations in 1g, partial gravity and microgravity. The models are developed in the framework of the industry standard ANSYS/Fluent CFD code, the capabilities of which have been significantly enhanced and customized through incorporation of unique submodels via User Defined Functions (UDF)s to satisfy the requirements of its intended variable gravity Cryogenic Fluid Management (CFM) applications. These models/submodels have been validated against experimental data that cross spatial scales, fluid types, and gravity levels in order to properly anchor the models’ physical and numerical fidelity. The CFM application/processes that have been modeled include tank self-pressurization, tank autogenous pressurization, tank pressure control using both subcooled jet mixing and droplet spray injection mechanisms, tank chilldown/filling, tank drainage, tank slosh for both volatile and non-volatile fluids. The strength and shortcomings of the two-phase models for each application is highlighted and discussed briefly.
Hypersonic planetary entry flows span a wide range of Knudsen numbers between rarefied and continuum flows. While computational fluid dynamics (CFD) techniques cannot provide an accurate solution for flows in the rarefied regime, the direct simulation Monte Carlo (DSMC) method is capable of providing accurate solutions for flows in both in the rarefied and continuum regimes but becomes prohibitively expensive as the Knudsen number decreases. For the purpose of thermal protection systems (TPS) design and post-flight reconstruction, various selected points along an entry trajectory are often solved using hypersonic solvers. The quantities of interest that are obtained from that exercise are generally surface quantities, such as pressure, heat flux and enthalpy. Then, material response solvers are used to either design the heat shield to an optimal thickness based on a choice of material, or to provide in-depth heating profiles through the material at various select locations, and compare with flight instrumentation such as the ones that flew on NASA’s two most recent Mars missions, MSL and Mars2020. While most of the heating is generally experienced during the continuum part of the entry, the heating within the rarefied regime is significant for some atmospheres, and hence the flow solutions need to be computed using the DSMC method. Ensuring consistency between hypersonic CFD and the DSMC is crucial so that reliable surface quantities can be passed to material response solvers. Studies were performed to compare the two methods at various select locations, for both non-reacting argon flows as well reacting CO2/N2 flows. Preliminary conclusions show that, for non-reacting flows, the agreement between the two methods for surface heating is excellent (within expected uncertainties) for a freestream Knudsen number of 0.0006, and gets progressively worse as the Knudsen number increases to 0.06. Continuum breakdown analyses were performed and showed that, in general, the Gradient Length Local Knudsen number (KnGLL) from Boyd [1] and associated criteria (KnGLL > 0.05) can be accurately used to predict zones of breakdown in the flow, and associated errors for surface quantities. Furthermore, when studying reacting flow, our studies showed that while flow quantities are highly dependent on relaxation parameters and chemistry rates, it is possible to obtain a good agreement for surface heating, as long as the continuum breakdown in minimal (see Fig. 1). Finally, we studied the impact of the grid refinement on the surface quantities in DSMC.
Single and coaxial rotor performance simulations for the Mars Helicopter Ingenuity rotor are performed for representative Mars atmospheric conditions. Analyses are presented using both a high-fidelity 3D CFD model of the rotor and 2D CFD models of the airfoil sections for comprehensive analyses that use CAMRADII (Comprehensive Analytical Model of Rotorcraft Aerodynamics and Dynamics). When available, the airfoil performance calculations are generated using a numerical approach identical to that used in the high-fidelity 3D model, allowing for a direct comparison between the approaches. Experimental data from a validation campaign to explore higher thrust from an Ingenuity rotor is provided to substantiate a discussion on the simulation fidelity required for both coaxial and single rotor performance predictions. The data is in support of the Sample Recovery Helicopter (SRH) element that serves as the primary backup for tube retrieval as part of the Mars Sample Return (MSR) Campaign. Insights on modeling turbulence at low Reynolds numbers and its influence on the rotor figure of merit are discussed. Key rotor performance metrics are compared. A detailed investigation into differences between 2D and 3D rotor performance predictions, spanwise loading, and rotor stall behavior is included.
Hypersonic planetary entry flows span a wide range of Knudsen numbers between rarefied and continuum flows. While computational fluid dynamics (CFD) techniques cannot provide an accurate solution for flows in the rarefied regime, the direct simulation Monte Carlo (DSMC) method is capable of providing accurate solutions for flows in both in the rarefied and continuum regimes but becomes prohibitively expensive as the Knudsen number decreases. For the purpose of thermal protection systems (TPS) design and post-flight reconstruction, various selected points along an entry trajectory are often solved using hypersonic solvers. The quantities of interest that are obtained from that exercise are generally surface quantities, such as pressure, heat flux and enthalpy. Then, material response solvers are used to either design the heat shield to an optimal thickness based on a choice of material, or to provide in-depth heating profiles through the material at various select locations, and compare with flight instrumentation such as the ones that flew on NASA’s two most recent Mars missions, MSL and Mars2020. While most of the heating is generally experienced during the continuum part of the entry, the heating within the rarefied regime is significant for some atmospheres, and hence the flow solutions need to be computed using the DSMC method. Ensuring consistency between hypersonic CFD and the DSMC is crucial so that reliable surface quantities can be passed to material response solvers. Studies were performed to compare the two methods at various select locations, for both non-reacting argon flows as well reacting CO2/N2 flows. Preliminary conclusions show that, for non-reacting flows, the agreement between the two methods for surface heating is excellent (within expected uncertainties) for a freestream Knudsen number of 0.0006, and gets progressively worse as the Knudsen number increases to 0.06. Continuum breakdown analyses were performed and showed that, in general, the Gradient Length Local Knudsen number (KnGLL) from Boyd and associated criterion (KnGLL > 0.05) seems conservative in predicting zones of breakdown in the flow, and associated errors for surface quantities. Updated criteria of KnGLL = 2.0 and 0.5 appear to be more appropriate for surface and flow quantities, respectively. Furthermore, when studying reacting flows, our studies showed that while flow quantities are highly dependent on relaxation parameters and chemistry rates, it is possible to obtain a good agreement for surface heating, as long as the continuum breakdown is minimal.