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DOE OSTI2024

Breakup dynamics in a pressure-swirl injector for urea-water solution applications: A computational study

The co-optimization of in-cylinder combustion and after-treatment technology has become a major aspect in engine design and development, with the goal of meeting the increasingly restrictive emission regulations in the transportation industry. Selective Catalytic Reduction is a robust technology to control the emission of NO x , and the injection of urea in water solution is the exhaust tailpipe is a key aspect of its operation. The proposed work uses high-fidelity Computational Fluid Dynamics to characterize the atomization dynamics of the liquid jet in relevant cross-flow conditions. The study focuses on a commercial low-pressure (9 bar) pressure-swirl injector which is characterized in its internal geometry through high-resolution X-ray micro-computational tomography. The internal two-phase flow has been modeled according to the volume-of-fluid approach in a large eddy simulation framework and validated against near-nozzle X-ray radiography measurement. Moreover, characterizing the breakup dynamics for the swirling hollow cone formation, and assessing the influence of the cross-flow in the breakup dynamics was completed. The results have been reported proposing Re-Oh maps and probability density functions of the spray kinematics. Higher cross-flow momentum generates an increase in the jet intact length and a reduction of the liquid droplet diameters. The axial momentum of the jet is affected by the cross-flow already in the near-nozzle region, determining a relevant deviation of the spray velocities. In conclusion, this work aims to inform the initialization of Eulerian-Lagrangian spray models through the assignment of droplet kinematics and static one-way coupling between volume-of-fluid results and Lagrangian spray parcels, to be used for system-size domain simulations.

33 ADVANCED PROPULSION SYSTEMS↗

NASA NTRSDate not supplied

Determining the Cause of Reduced Concurrent Flame Spread over Thin Solid Fuels in Low Pressure and Low Gravity

The spread of flames over the surface of solid combustible materials is affected by the environmental conditions. Variables such as flow velocity, oxygen concentration, ambient pressure, partial gravity or microgravity, may change the material flammability and influence the fire dynamics. This is an important fire safety issue for space exploration vehicles and space habitats which will very likely have different environments than those currently used on the International Space Station, such as reduced pressure and enriched oxygen concentration (SEA). However, testing experimentally the materials to be used and qualified for space exploration under these conditions is a difficult and expensive task. Here, numerical modeling is used to understand the dominant physico-chemical processes on the concurrent flame spread over thin fabrics under reduced ambient pressure (and in turn, buoyancy) and variable gravitational conditions. The numerical model uses the Fire Dynamics Simulator (FDS6) code with a single-step Arrhenius reaction rate for the solid phase decomposition. Different models are tested for the gas phase combustion kinetics. The model results are validated with experimental results obtained at similar reduced ambient pressure and flow conditions at 1 g. It is shown that as ambient pressure is reduced the flame spread rate over a thin fabric is also reduced, both experimentally and numerically. Numerical results are compared to an analytical approach previously developed to explain the experimental trends. Further interpretation of the model results provides information regarding the physics of the process and how they are affected by the lower pressure environments and gravity conditions. The results of this work provide guidance for potential on-earth testing for fire safety design in spacecraft and space habitats.

Fire Safety↗

NASA NTRSDate not supplied

Determining the Cause of Reduced Concurrent Flame Spread over Thin Solid Fuels in Low Pressure and Low Gravity

microgravity↗

NASA NTRS1969

Combustion Processes in the Aerospace Environment

The aerospace environment introduces new and enhanced fire hazards because the special atmosphere employed may increase the frequency and intensity of fires, because the confinement associated with aerospace systems adversely affects the dynamics of fire development and control, and because the hostile external environments limit fire control and rescue operations. Oxygen enriched atmospheres contribute to the fire hazard in aerospace systems by extending the list of combustible fuels, increasing the probability of ignition, and increasing the rates of fire spread and energy release. A system for classifying atmospheres according to the degree of fire hazard, based on the heat capacity of the atmosphere per mole of oxygen, is suggested. A brief exploration of the dynamics of chamber fires shows that such fires will exhibit an exponential growth rate and may grow to dangerous size in a very short time. Relatively small quantities of fuel and oxygen can produce a catastrophic fire in a closed chamber.

Huggett, Clayton↗

DOE OSTI2023

A unified non-equilibrium phase change model for injection flow modeling

The homogenous relaxation model (HRM) is one of the most widely used models to describe the liquid- gas phase transition. However, in its original formulation, it is unable to handle multispecies vapor-liquid equilibrium (VLE), which limits its applicability to single-component fluids. In this work, a unified non-equilibrium phase change model that considers the VLE of multicomponent mixtures is proposed building upon the HRM's structure. A time factor is introduced to mimic the effect of different phase change timescales due to different mechanisms, e.g., cavitation, flash-boiling, and evaporation. Here to assess the model's performance, computational fluid dynamics simulations of the internal and near-nozzle injection flow of the Engine Combustion Network's Spray G injector were performed using the nine-component PACE-20 fuel with both the unified model and the original HRM. The predicted fuel density in the near-nozzle region matched well with X-ray tomography measurements. The simulation results indicated that, whereas the HRM failed to capture the vaporization due to convective mixing between the fuel and ambient gas, the unified model performed well in predicting the mixing-driven vaporization and the corresponding evaporative cooling. Further comparisons using the nine-component fuel formula and a single-component fuel surrogate demonstrated the unified model's ability to predict preferential vaporization, which affects the predictions of local mixture composition and rate of vaporization. Finally, it is shown that the unified model is capable of representing multiple phase change mechanisms, and the relaxation time factor plays an important role in determining the degree of phase change due to the different mechanisms.

33 ADVANCED PROPULSION SYSTEMS↗

DOE OSTI2026

Persistent Elevated Soot Emissions Induced by Clustered Stochastic Preignition Events

Stochastic Preignition (SPI) is an abnormal combustion phenomenon that can occur in spark-ignition engines particularly under high-load operation. SPI is characterized by uncontrolled initiation of combustion prior to spark discharge, an abnormal combustion process that can lead to severe knock events and significant engine damage. SPI has been associated with fuel properties, lubricant composition, and engine design and operation. Here, in this work, a single-cylinder test engine with a dry-sump oil system was utilized to study the SPI response of E10 and E25 fuels with a range of Reid Vapor Pressure (RVP). An automated test procedure was employed, consisting of ten square-waved load profile segments, with each segment composed of 5 min of low-load operation followed by 25 min of sustained high-load operation. These tests were replicated across multiple days of testing including a lubricant triple flush between tests, and an online Fuel in Oil diagnostic measurement. Exhaust particulate emissions were continuously measured by an AVL microsoot sensor (MSS). Elevated particulate matter emissions were observed to occur concurrently with SPI events as blooms of soot. Particularly after clustered events (i.e., multiple SPI cycles occurring within 10 consecutive engine cycles), high soot emissions were observed to persist over several days of sequential operation despite daily lubricant changes, a complete warm-up procedure, and sustained low-load operation between test segments. This result implies that the particulate emissions trends may be dominated by deposit-based effects, where higher load operation is needed to alter deposition and formation processes. The observed soot blooms were also found to correspond to a reduction in the engine fueling and the fuel engine oil dilution rate despite the engine exhaust remaining at stoichiometric exhaust operation. These observations suggest that post-SPI events, pathways for lubricant migration and consumption into the combustion chamber may occur until these pathways are closed from deposit formation or ring dynamics during extended operation. These observed sooting propensity persisted with all fuels tests, but a linear correlation was observed between the summation of soot and particulate matter index (PMI) value for each fuel as well as SPI events, proving that PMI is a crucial fuel property for reducing SPI.

Splitter, Derek [Oak Ridge National Laboratory (OR↗

NASA NTRS1980

Advanced Gas Turbine (AGT) powertrain system development for automotive applications

Progress in the development of a gas turbine engine to improve fuel economy, reduce gaseous emissions and particulate levels, and compatible with a variety of alternate fuels is reported. The powertrain is designated AGT101 and consists of a regenerated single shaft gas turbine engine, a split differential gearbox and a Ford Automatic Overdrive production transmission. The powertrain is controlled by an electronic digital microprocessor and associated actuators, instrumentation, and sensors. Standard automotive accessories are driven by engine power provided by an accessory pad on the gearbox. Component/subsystem development progress is reported in the following areas: compressor, turbine, combustion system, regenerator, gearbox/transmission, structures, ceramic components, foil gas bearing, bearings and seals, rotor dynamics, and controls and accessories.

Source record↗

NASA NTRS1983

The performance of an annular vane swirler

In connection with the desirability of optimizing the design of a gas turbine combustion chamber, there exists a need for a more complete understanding of the fluid dynamics of the flow in such chambers. In order to satisfy this need, experimental and theoretical research is being conducted with the objective to study two-dimensional axisymmetric geometries under low speed, nonreacting, turbulent, swirling flow conditions. The flow enters the test section and proceeds into a larger chamber. Inlet swirl vanes are adjustable to a variety of vane angles. The present investigation concentrates on the time-mean flow characteristics which are generated by the upstream annular swirler. The investigation makes use of a five-hole pitot probe technique. A theoretical analysis of swirl numbers associated with several idealized exit velocity profiles is included, and values of the ratio of maximum swirl velocity to maximum axial velocity at different swirl strengths are given for each case.

Lilley, D. G.↗

NASA NTRS1994

NASA Propulsion Engineering Research Center, Volume 2

This is the second volume in the 1994 annual report for the NASA Propulsion Engineering Research Center's Sixth Annual Symposium. This conference covered: (1) Combustors and Nozzles; (2) Turbomachinery Aero- and Hydro-dynamics; (3) On-board Propulsion systems; (4) Advanced Propulsion Applications; (5) Vaporization and Combustion; (6) Heat Transfer and Fluid Mechanics; and (7) Atomization and Sprays.

Source record↗

NASA NTRS1993

Numerical Study of Base Pressure Characteristic Curve for a Four-Engine Clustered Nozzle Configuration

Excessive base heating has been a problem for many launch vehicles. For certain designs such as the direct dump of turbine exhaust in the nozzle section and at the nozzle lip of the Space Transportation Systems Engine (STME), the potential burning of the turbine exhaust in the base region has caused tremendous concern. Two conventional approaches have been considered for predicting the base environment: (1) empirical approach, and (2) experimental approach. The empirical approach uses a combination of data correlations and semi-theoretical calculations. It works best for linear problems, simple physics and geometry. However, it is highly suspicious when complex geometry and flow physics are involved, especially when the subject is out of historical database. The experimental approach is often used to establish database for engineering analysis. However, it is qualitative at best for base flow problems. Other criticisms include the inability to simulate forebody boundary layer correctly, the interference effect from tunnel walls, and the inability to scale all pertinent parameters. Furthermore, there is a contention that the information extrapolated from subscale tests with combustion is not conservative. One potential alternative to the conventional methods is computational fluid dynamics (CFD), which has none of the above restrictions and is becoming more feasible due to maturing algorithms and advancing computer technology. It provides more details of the flowfield and is only limited by computer resources. However, it has its share of criticisms as a predictive tool for base environment. One major concern is that CFD has not been extensively tested for base flow problems. It is therefore imperative that CFD be assessed and benchmarked satisfactorily for base flows. In this study, the turbulent base flowfield of a experimental investigation for a four-engine clustered nozzle is numerically benchmarked using a pressure based CFD method. Since the cold air was the medium, accurate prediction of the base pressure distributions at high altitudes is the primary goal. Other factors which may influence the numerical results such as the effects of grid density, turbulence model, differencing scheme, and boundary conditions are also being addressed. Preliminary results of the computed base pressure agreed reasonably well with that of the measurement. Basic base flow features such as the reverse jet, wall jet, recompression shock, and static pressure field in plane of impingement have been captured.

Wang, Ten-See↗

NASA NTRS2000

A Design Tool for Liquid Rocket Engine Injectors

A practical design tool which emphasizes the analysis of flowfields near the injector face of liquid rocket engines has been developed and used to simulate preliminary configurations of NASA's Fastrac and vortex engines. This computational design tool is sufficiently detailed to predict the interactive effects of injector element impingement angles and points and the momenta of the individual orifice flows and the combusting flow which results. In order to simulate a significant number of individual orifices, a homogeneous computational fluid dynamics model was developed. To describe sub- and supercritical liquid and vapor flows, the model utilized thermal and caloric equations of state which were valid over a wide range of pressures and temperatures. The model was constructed such that the local quality of the flow was determined directly. Since both the Fastrac and vortex engines utilize RP-1/LOX propellants, a simplified hydrocarbon combustion model was devised in order to accomplish three-dimensional, multiphase flow simulations. Such a model does not identify drops or their distribution, but it does allow the recirculating flow along the injector face and into the acoustic cavity and the film coolant flow to be accurately predicted.

Farmer, R.↗

NASA NTRS2002

Fundamental Mixing and Combustion Experiments for Propelled Hypersonic Flight

Two experiments have been conducted to acquire data for the validation of computational fluid dynamics (CFD) codes used in the design of supersonic combustors. The first experiment is a study of a supersonic coaxial jet into stagnant air in which the center jet is of a light gas, the coflow jet is of air, and the mixing layer between them is compressible. The jet flow field is characterized using schlieren imaging, surveys with Pitot, total temperature and gas sampling probes, and RELIEF velocimetry. VULCAN, a structured grid CFD code, is used to solve for the nozzle and jet flow. The second experiment is a study of a supersonic combustor consisting of a diverging duct with single downstream-angled wall injector. Entrance Mach number is 2 and enthalpy is nominally that of Mach 7 flight. Coherent anti-Stokes Raman spectroscopy (CARS) has been used to obtain nitrogen temperature in planes of the flow, and surface pressures and temperatures have also been acquired. Modern-design-of-experiment techniques have been used to maximize the quality of the data set.

Cutler, A. D.↗

NASA NTRS2001

Hydrogen/Air Fuel Nozzle Emissions Experiments

The use of hydrogen combustion for aircraft gas turbine engines provides significant opportunities to reduce harmful exhaust emissions. Hydrogen has many advantages (no CO2 production, high reaction rates, high heating value, and future availability), along with some disadvantages (high current cost of production and storage, high volume per BTU, and an unknown safety profile when in wide use). One of the primary reasons for switching to hydrogen is the elimination of CO2 emissions. Also, with hydrogen, design challenges such as fuel coking in the fuel nozzle and particulate emissions are no longer an issue. However, because it takes place at high temperatures, hydrogen-air combustion can still produce significant levels of NOx emissions. Much of the current research into conventional hydrocarbon-fueled aircraft gas turbine combustors is focused on NOx reduction methods. The Zero CO2 Emission Technology (ZCET) hydrogen combustion project will focus on meeting the Office of Aerospace Technology goal 2 within pillar one for Global Civil Aviation reducing the emissions of future aircraft by a factor of 3 within 10 years and by a factor of 5 within 25 years. Recent advances in hydrocarbon-based gas turbine combustion components have expanded the horizons for fuel nozzle development. Both new fluid designs and manufacturing technologies have led to the development of fuel nozzles that significantly reduce aircraft emissions. The goal of the ZCET program is to mesh the current technology of Lean Direct Injection and rocket injectors to provide quick mixing, low emissions, and high-performance fuel nozzle designs. An experimental program is planned to investigate the fuel nozzle concepts in a flametube test rig. Currently, a hydrogen system is being installed in cell 23 at NASA Glenn Research Center's Research Combustion Laboratory. Testing will be conducted on a variety of fuel nozzle concepts up to combustion pressures of 350 psia and inlet air temperatures of 1200 F. Computational fluid dynamics calculations, with the Glenn developed National Combustor Code, are being performed to optimize the fuel nozzle designs.

Smith, Timothy D.↗

NASA NTRS2005

A Study of Cavitation-Ignition Bubble Combustion

We present the results of an experimental and computational study of the physics and chemistry of cavitation-ignition bubble combustion (CIBC), a process that occurs when combustible gaseous mixtures are ignited by the high temperatures found inside a rapidly collapsing bubble. The CIBC process was modeled using a time-dependent compressible fluid-dynamics code that includes finite-rate chemistry. The model predicts that gas-phase reactions within the bubble produce CO and other gaseous by-products of combustion. In addition, heat and mechanical energy release through a bubble volume-expansion phase are also predicted by the model. We experimentally demonstrate the CIBC process using an ultrasonically excited cavitation flow reactor with various hydrocarbon-air mixtures in liquid water. Low concentrations (< 160 ppm) of carbon monoxide (CO) emissions from the ultrasonic reactor were measured, and found to be proportional to the acoustic excitation power. The results of the model were consistent with the measured experimental results. Based on the experimental findings, the computational model, and previous reports of the "micro-diesel effect" in industrial hydraulic systems, we conclude that CIBC is indeed possible and exists in ultrasonically- and hydrodynamically-induced cavitation. Finally, estimates of the utility of CIBC process as a means of powering an idealized heat engine are also presented.

Nguyen, Quang-Viet↗

NASA NTRS2011

More-Accurate Model of Flows in Rocket Injectors

An improved computational model for simulating flows in liquid-propellant injectors in rocket engines has been developed. Models like this one are needed for predicting fluxes of heat in, and performances of, the engines. An important part of predicting performance is predicting fluctuations of temperature, fluctuations of concentrations of chemical species, and effects of turbulence on diffusion of heat and chemical species. Customarily, diffusion effects are represented by parameters known in the art as the Prandtl and Schmidt numbers. Prior formulations include ad hoc assumptions of constant values of these parameters, but these assumptions and, hence, the formulations, are inaccurate for complex flows. In the improved model, these parameters are neither constant nor specified in advance: instead, they are variables obtained as part of the solution. Consequently, this model represents the effects of turbulence on diffusion of heat and chemical species more accurately than prior formulations do, and may enable more-accurate prediction of mixing and flows of heat in rocket-engine combustion chambers. The model has been implemented within CRUNCH CFD, a proprietary computational fluid dynamics (CFD) computer program, and has been tested within that program. The model could also be implemented within other CFD programs.

Hosangadi, Ashvin↗

NASA NTRS1993

Computational/experimental studies of isolated, single component droplet combustion

Isolated droplet combustion processes have been the subject of extensive experimental and theoretical investigations for nearly 40 years. The gross features of droplet burning are qualitatively embodied by simple theories and are relatively well understood. However, there remain significant aspects of droplet burning, particularly its dynamics, for which additional basic knowledge is needed for thorough interpretations and quantitative explanations of transient phenomena. Spherically-symmetric droplet combustion, which can only be approximated under conditions of both low Reynolds and Grashof numbers, represents the simplest geometrical configuration in which to study the coupled chemical/transport processes inherent within non-premixed flames. The research summarized here, concerns recent results on isolated, single component, droplet combustion under microgravity conditions, a program pursued jointly with F.A. Williams of the University of California, San Diego. The overall program involves developing and applying experimental methods to study the burning of isolated, single component droplets, in various atmospheres, primarily at atmospheric pressure and below, in both drop towers and aboard space-based platforms such as the Space Shuttle or Space Station. Both computational methods and asymptotic methods, the latter pursued mainly at UCSD, are used in developing the experimental test matrix, in analyzing results, and for extending theoretical understanding. Methanol, and the normal alkanes, n-heptane, and n-decane, have been selected as test fuels to study time-dependent droplet burning phenomena. The following sections summarizes the Princeton efforts on this program, describe work in progress, and briefly delineate future research directions.

Dryer, Frederick L.↗

NASA NTRS1999

Combustion of a Polymer (PMMA) Sphere in Microgravity

A series of low gravity, aircraft-based, experiments was conducted to investigate the combustion of supported thermoplastic polymer spheres under varying ambient conditions. The three types of thermoplastic investigated were polymethylmethacrylate (PMMA), polypropylene (PP). and polystyrene (PS). Spheres with diameters ranging from 2 mm to 6.35 mm were tested. The total initial pressure varied from 0.05 MPa to 0. 15 MPa whereas the ambient oxygen concentration varied from 19 % to 30 % (by volume). The ignition system consisted of a pair of retractable energized coils. Two CCD cameras recorded the burning histories of the spheres. The video sequences revealed a number of dynamic events including bubbling and sputtering, as well as soot shell formation and break-up during combustion of the spheres at reduced gravity. The ejection of combusting material from the burning spheres represents a fire hazard that must be considered at reduced gravity. The ejection process was found to be sensitive to polymer type. All average burning rates were measured to increase with initial sphere diameter and oxygen concentration, whereas the initial pressure had little effect. The three thermoplastic types exhibited different burning characteristics. For the same initial conditions, the burning rate of PP was slower than PMMA, whereas the burning rate of PS was comparable to PMMA. The transient diameter of the burning thermoplastic exhibited two distinct periods: an initial period (enduring approximately half of the total burn duration) when the diameter remained approximately constant, and a final period when the square of the diameter linearly decreased with time. A simple homogeneous two-phase model was developed to understand the changing diameter of the burning sphere. Its value is based on a competition between diameter reduction due to mass loss from burning and sputtering, and diameter expansion due to the processes of swelling (density decrease with heating) and bubble growth. The model relies on empirical parameters for input, such as the burning rate and the duration of the initial and final burning periods.

Yang, Jiann C.↗

NASA NTRS2018

Three Stage Cool Flame Droplet Burning Behavior of n-Alkane Droplets at Elevated Pressure Conditions: Hot, Warm and Cool Flame

Transient, isolated n-alkane droplet combustion is simulated at elevated pressure for helium-diluent substituted-air mixtures. We report the presence of unique quasi-steady, three-stage burning behavior of large sphero-symmetric n-alkane droplets at these elevated pressures and helium substituted ambient fractions. Upon initiation of reaction, hot-flame diffusive burning of large droplets is initiated that radiatively extinguishes to establish cool flame burning conditions in nitrogen/oxygen “air” at atmospheric and elevated pressures. However, at elevated pressure and moderate helium substitution for nitrogen ( X He > 20%), the initiated cool flame burning proceeds through two distinct, quasi-steady-state, cool flame burning conditions. The classical “Hot flame ” ( ∼1500 K) radiatively extinguishes into a “Warm flame ” burning mode at a moderate maximum reaction zone temperature ( ∼ 970 K), followed by a transition to a lower temperature ( ∼765 K), quasi-steady “Cool flame ” burning condition. The reaction zone (“flame”) temperatures are associated with distinctly different yields in intermediate reaction products within the reaction zones and surrounding near-field, and the flame-standoff ratios characterizing each burning mode progressively decrease. The presence of all three stages first appears with helium substitution near 20%, and the duration of each stage is observed to be strongly dependent on helium substitutions level between 20–60%. For helium substitution greater than 60%, the hot flame extinction is followed by only the lower temperature cool flame burning mode. In addition to the strong coupling between the diffusive loss of both energy and species and the slowly evolving degenerate branching in the low and negative temperature coefficient (NTC) kinetic regimes, the competition between the low-temperature chain branching and intermediate-temperature chain termination reactions control the “Warm” and “Cool ” flame quasi-steady conditions and transitioning dynamics.

Droplet Combustion↗