Aviation Particle Emissions Reductions From Lean-Burn Engines Burning Sustainable Aviation Fuel
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A major portion of the energy produced in the world today comes from the burning of liquid hydrocarbon fuels in the form of droplets. Understanding the fundamental physical processes involved in droplet combustion is not only important in energy production but also in propulsion, in the mitigation of combustion-generated pollution, and in the control of the fire hazards associated with handling liquid combustibles. Microgravity makes spherically symmetric combustion possible, allowing investigators to easily validate their droplet models without the complicating effects of gravity. The Fiber-Supported Droplet Combustion (FSDC-2) investigation was conducted in the Microgravity Glovebox facility of the shuttles' Spacelab during the reflight of the Microgravity Science Laboratory (MSL- 1R) on STS-94 in July 1997. FSDC-2 studied fundamental phenomena related to liquid fuel droplet combustion in air. Pure fuels and mixtures of fuels were burned as isolated single and duo droplets with and without forced air convection. FSDC-2 is sponsored by the NASA Lewis Research Center, whose researchers are working in cooperation with several investigators from industry and academia. The rate at which a droplet burns is important in many commercial applications. The classical theory of droplet burning assumes that, for an isolated, spherically symmetric, single-fuel droplet, the gas-phase combustion processes are much faster than the droplet surface regression rate and that the liquid phase is at a uniform temperature equal to the boiling point. Recent, more advanced models predict that both the liquid and gas phases are unsteady during a substantial portion of the droplet's burning history, thus affecting the instantaneous and average burning rates, and that flame radiation is a dominant mechanism that can extinguish flames in a microgravity environment. FSDC-2 has provided well-defined, symmetric droplet burning data including radiative emissions to validate these theoretical models for heptane, decane, ethanol, and methanol fuels. Since most commercial combustion systems burn droplets in a convective environment, data were obtained without and with convective flow over the burning droplet (see the following photos).
Effect of fuel distribution and flame stabilization techniques on combustion stability limits for swirl-can combustor modules
Activities performed in order to provide an R&T data base for utility gas turbine systems burning coal-derived fuels are described. Experiments were run to determine the corrosivity effects of trace metal contaminants (and potential fuel additives) on gas turbine materials and these results were correlated in a corrosion-life prediction model. Actual fuels were burned in a burner rig hot corrosion test to verify the model. A deposition prediction model was assembled and compared with results of actual coal-derived fuel deposition tests. Thermal barrier coatings were tested to determine their potential for protecting gas turbine hardware from the corrosive contaminants. Several coatings were identified with significantly improved spallation-resistance (and, hence, corrosion resistance).
Modification of fossil-fueled industrial gas turbines to accept no/low carbon fuels (Hydrogen, H2/natural gas blends) is a significant undertaking. Successful deployment of this technology sits at the intersection of three design criteria (1) new functional fuel injectors that can burn these fuels, (2) manufacturability to meet cost and time-to-market targets, and (3) durability in the harsh environment of an operating turbine. Additive manufacturing (AM) provides accelerated product development. However, uncertainty remains around the durability of parts with rough AM surfaces. A fully experimental approach towards quantifying fatigue performance of rough AM microstructures is costly and laborious. Instead, Solar Turbines Incorporated (Solar) proposes the use of a crystal plasticity finite element (CPFE) model to quantify the factors that drive AM surface fatigue behavior. Solar will use the CPFE results, along with targeted experimental data, to train a computationally efficient surrogate model that can be incorporated into existing turbine part lifing methods.
An experimental program was conducted to track the variation in soot loading in a generic gas turbine combustor. The burner is a 12.7-cm dia cylindrical device consisting of six sheet-metal louvers. Determination of soot loading along the burner length is achieved by measurement at the exit of the combustor and then at upstream stations by sequential removal of liner louvers to shorten burner length. Alteration of the flow field approaching and within the shortened burners is minimized by bypassing flow in order to maintain a constant linear pressure drop. The burner exhaust flow is sampled at the burner centerline to determine soot mass concentration and smoke number. Characteristic particle size and number density, transmissivity of the exhaust flow, and local radiation from luminous soot particles in the exhaust are determined by optical techniques. Four test fuels are burned at three fuel-air ratios to determine fuel chemical property and flow temperature influences. Particulate concentration data indicate a strong oxidation mechanism in the combustor secondary zone, though the oxidation is significantly affected by flow temperature. Soot production is directly related to fuel smoke point.
Variation in soot loading along the centerline of a generic gas turbine combustor was experimentally investigated. The 12.7-cm dia burner consisted of six sheet-metal louvers. Soot loading along the burner length was quantified by acquiring measurements first at the exit of the full-length combustor and then at upstream stations by sequential removal of liner louvers to shorten the burner length. Alteration of the flow field approaching removed louvers, maintaining a constant liner pressure drop. Burner exhaust flow was sampled at the burner centerline to determine soot mass concentration and smoke number. Characteristic particle size and number density, transmissivity of the exhaust flow, and local radiation from luminous soot particles in the exhaust flow were determined by optical techniques. Four test fuels were burned at three fuel-air ratios to determine fuel chemical property and flow temperature influences. Data were acquired at two combustor pressures. Particulate concentration data indicated a strong oxidation mechanism in the combustor secondary zone, though the oxidation was significantly affected by flow temperature. Soot production was directly related to fuel smoke point. Less soot production and lower secondary-zone oxidation rates were observed at reduced combustor pressure.
A theory of evaporation, ignition, and burning of moderately dense spherical drop clusters has been developed. The theory takes into account burning of premixed air and fuel internal to the cluster at ignition and subsequent burning of fuel emitted from the cluster by a flame sheet surrounding it. The model considers interdrop interaction, momentum exchange between drops and gas, and turbulent exchange processes between the cluster and its surroundings. Calculations are performed for varying initial air-to-fuel-mass ratios, initial cluster radii, ambient gas temperatures and initial drop temperatures. Results are presented for ratios of fuel mass burned to fuel mass lost from the cluster between drop ignition and drop disappearance, fuel burned fractions at ignition and at the moment of drop disappearance, and jump conditions at ignition.
The hydrodynamics of the dense confining fuel shell is of great importance in defining the behavior of the burning plasma and burn propagation regimes of inertial confinement fusion experiments. However, it is difficult to probe due to its low emissivity in comparison with the central fusion core. In this work, we utilize the backscattered neutron spectroscopy technique to directly measure the hydrodynamic conditions of the dense fuel during fusion burn. Experimental data are fit to obtain dense fuel velocities and apparent ion temperatures. Trends of these inferred parameters with yield and velocity of the burning plasma are used to investigate their dependence on alpha heating and low mode drive asymmetry. It is shown that the dense fuel layer has an increased outward radial velocity as yield increases, showing that burn has continued into re-expansion, a key signature of hotspot ignition. A comparison with analytic and simulation models shows that the observed dense fuel parameters are displaying signatures of burn propagation into the dense fuel layer, including a rapid increase in dense fuel apparent ion temperature with neutron yield.
Modifying fossil-fueled industrial gas turbines to utilize low or zero-carbon fuels, such as hydrogen or hydrogen-natural gas blends, is a complex endeavor. The successful implementation of this technology hinges on three key design criteria: (1) developing new fuel injectors capable of efficiently burning alternative fuels, (2) ensuring manufacturability to meet cost and time-to-market goals, and (3) achieving component durability in the demanding environment of an operating gas turbine. Additive manufacturing (AM) accelerates product development, yet concerns persist regarding the durability of parts with rough AM surfaces. A fully experimental approach to quantify the fatigue performance of rough AM microstructures is both costly and labor-intensive. To address this, ORNL and Solar Turbines Incorporated (Solar) employed a crystal plasticity finite element (CPFE) model to identify the factors influencing AM surface fatigue behavior. These CPFE findings, combined with targeted experimental data, were used to develop a computationally efficient surrogate model suitable for assessing the lifespan of gas turbine engine components.
An analytical/numerical model is developed for single droplet evaporation and burning in a convective flowfield. The model is based on the boundary-layer approach, and chemical reaction kinetics are represented by a one-step, finite-rate reaction mechanism, while variation of gas properties with temperature and gas composition is based on the kinetic theory of gases. Four droplet models differing in the degree of complexity concerning property variation and chemistry are compared. Comparisons are also provided with existing empirical correlations for convective droplet evaporation and burning.
An annular gas turbine combustor was tested with heated ASTM Jet-A fuel to determine the effect of increased fuel temperature on the formation of oxides of nitrogen. Fuel temperature ranged from ambient to 700 K. The NOx emission index increased at a rate of 6 percent per 100 K increase in fuel temperature.
As NASA's mission evolves, new spacecraft and habitat environments necessitate expanded study of materials flammability. Most of the upward burning tests to date, including the NASA standard material screening method NASA-STD-6001, have been conducted in small chambers where the flame often terminates before a steady state flame is established. In real environments, the same limitations may not be present. The use of long fuel samples would allow the flames to proceed in an unhindered manner. In order to explore sample size and chamber size effects, two large chambers were developed at NASA GRC under the Flame Prevention, Detection and Suppression (FPDS) project. The first was an existing vacuum facility, VF-13, located at NASA John Glenn Research Center. This 6350 liter chamber could accommodate fuels sample lengths up to 2 m. However, operational costs and restricted accessibility limited the test program, so a second laboratory scale facility was developed in parallel. By stacking additional two chambers on top of an existing combustion chamber facility, this 81 liter Stacked-chamber facility could accommodate a 1.5 m sample length. The larger volume, more ideal environment of VF-13 was used to obtain baseline data for comparison with the stacked chamber facility. In this way, the stacked chamber facility was intended for long term testing, with VF-13 as the proving ground. Four different solid fuels (adding machine paper, poster paper, PMMA plates, and Nomex fabric) were tested with fuel sample lengths up to 2 m. For thin samples (papers) with widths up to 5 cm, the flame reached a steady state length, which demonstrates that flame length may be stabilized even when the edge effects are reduced. For the thick PMMA plates, flames reached lengths up to 70 cm but were highly energetic and restricted by oxygen depletion. Tests with the Nomex fabric confirmed that the cyclic flame phenomena, observed in small facility tests, continued over longer sample. New features were also observed at the higher oxygen/pressure conditions available in the large chamber. Comparison of flame behavior between the two facilities under identical conditions revealed disparities, both qualitative and quantitative. This suggests that, in certain ranges of controlling parameters, chamber size and shape could be one of the parameters that affect the material flammability. If this proves to be true, it may limit the applicability of existing flammability data.
A theory of evaporation, ignition, and burning of moderately dense spherical drop clusters has been developed. The theory takes into account burning of premixed air and fuel internal to the cluster at ignition and subsequent burning of fuel emitted from the cluster by a flame sheet surrounding it. The model considers interdrop interaction, momentum exchange between drops and gas, and turbulent exchange processes between the cluster and its surroundings. Calcualtions are performed for varying initial air to fuel mass ratios, initial cluster radii, ambient gas temperatures, and initial drop temperatures. Results are presented for fuel burn fractions at ignition and at the moment of drop disappearance, as well as jump conditions at ignition.
Nuclear reactions in stars have transformed the universe since the Big Bang, turning hydrogen and helium into all of the elements we see around us today. These reactions fuel a star throughout its lifetime. When the star burns out, its ashes are ejected into space to enrich the next generation of stars so to understand the origin of the elements in the cosmos, we must learn how stars burn their fuel. In this stellar burning, the rates of nuclear reactions are key. The rates can be determined by recreating the reactions in the laboratory, but often they occur too rarely to measure at the low energies characteristic of stellar burning. Novel, indirect measurements must be used. With support from the Department of Energy Office of Science, a research program has been developed to perform such measurements, primarily using the Enge split-pole spectrograph at the Triangle Universities Nuclear Laboratory (TUNL). High-energy nuclear reactions coupled with theoretical models were used to ascertain the rate of the low-energy nuclear reactions occurring in stars. Detailed analysis of the data reveals the structure of nuclei and how they affect stellar burning. In parallel to these experimental efforts, theoretical tools were developed to identify which nuclear reactions are most critical for understanding stars, thus discovering priorities for future measurements. This complementary suite of experiments and theoretical calculations can be used to help answer one of the key questions facing the physics community: How did visible matter come into being and how did it evolve?
A parallel-burn version of a single-stage vehicle for transport from the earth to low-earth orbit using two fuels and rocket propulsion is considered. New engine results were incorporated in vehicle performance and design studies. The results indicate that a hydrogen-cooled gas generator cycle engine provides attractive vehicle performance and that there is little incentive for increasing the chamber pressure beyond 27 MPa.
Thorium has been considered as a possible alternative to uranium for nuclear fuel for many decades. It is three to four times more abundant in the earth than uranium and produces significantly less long-lived transuranic nuclear waste. Some claim thorium poses fewer proliferation concerns than other fuel types largely due to 232 U buildup (and associated high energy gamma-emitting decay products) in the irradiated thorium fuel. However, to fully explore potential proliferation concerns, generation and subsequent decay of 233 Pa produced in the reactor core still must be studied. With its half-life of 27 days, 233 Pa decays to 233 U, which is an International Atomic Energy Agency (IAEA) defined special fissionable material that can be used for nuclear weapons production. With more research being dedicated to thorium-fueled reactors, and several of these reactor designs possessing online fuel processing (allowing for on-site protactinium separation), it is important to understand this potential proliferation pathway. In particular, it is theoretically possible to extract protactinium from the irradiated fuel salt before it decays into 233 U. This hypothetical potential diversion can become an even greater proliferation concern if the extracted protactinium is purified through a second separation of protactinium approximately ten days later to remove the short half-life decay products of 232 Pa and 234 Pa, thus resulting in a higher concentration of the 233 Pa isotope, which decays into weapons usable 233 U with hardly any 232 U or 234 U in it. To estimate the concern of this potential proliferation challenge of thorium, different nuclear material accountancy techniques were reviewed for their viability to quantify 233 Pa if extracted from used thorium fuel. Characteristics of interest included technology maturity, cost, precision, and time taken to acquire results. Some technologies, like hybrid K-edge densitometry and passive gamma spectroscopy, appear to be viable techniques based on current literature. Due to the limited scope of this project, only passive gamma spectroscopy was further investigated. Three different reactor types (PWR, CANDU, MSR) were modeled with mixed thorium-uranium oxide fuels that were burned until the fuel was spent. The protactinium in the used fuel was extracted at the time of shutdown and the change in isotopic content of the protactinium quantified. Gamma spectroscopy simulations were performed for the protactinium isotopes and their decay products at various decay times. Given the simplicity of the models and large assumptions made (e.g. no background, no shielding, no self-attenuation), the initial results indicate that though 233 Pa is detectible for all the reactor types modeled at all decay times (0 to 300 days), more work should be done with higher fidelity models.