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At least 19 records
All sourcesNASA NTRSDOE OSTI
DOE OSTI2021

Partial Premixing Effects on the Reacting Jet of a High-Pressure Axially Staged Combustor

The effects of partial premixing on a reacting jet-in-crossflow is investigated in a five atmosphere axially staged combustor at stationary gas turbine relevant conditions. The facility consists of a dump style headend burner that provides a crossflow with a quasi-uniform velocity and temperature profile to the axial stage to isolate the effects of the jet-in-crossflow. The headend burner is run with methane and air at a lean equivalence ratio to match industry emission standards. For this work, the total air to the headend and axial stage is kept constant, and fuel is split between the headend and axial stage to represent different gas turbine loading conditions. For the cases analyzed, the fuel split to the axial stage went up to 25%. The axial stage consists of an optically accessible test section with a coaxial injector that provides variability to how long the methane and air can mix before entering the facility. Three different premixed levels are studied: fully premixed, nonpremixed, and partially premixed. The flow-field characteristics of the reacting jet-in-crossflow are analyzed using particle image velocimetry (PIV), and flame behavior is quantified by employing CH* chemiluminescence. NO measurements are made at the exit of the facility using a Horiba emissions analyzer. Furthermore, two different flames are observed: flames that burn in the leeward recirculation region and flames that burn at the core of the jet.

03 NATURAL GAS↗
DOE OSTI2021

Preheating and premixing effects on NO x emissions in a high-pressure axially staged combustor

NO x emissions remain a primary concern for modern and future gas turbines, particularly as we progress towards a net-zero carbon future. It is critical to identify novel strategies to mitigate environmental pollutants for both modern turbines operated on natural gas and future turbines projected to use carbon-free fuels (such as hydrogen). In the current study, NO x emissions of a reacting methane-air jet in a vitiated crossflow are experimentally investigated in a model axially staged combustor at 5 atm. The combustion products from the main stage combustor flow into the axial stage at temperatures ranging from 1580 to 1650 °C. The axial stage contains a reacting jet in crossflow, which provides an overall temperature rise ranging from 50 to 220 °C to generate exit temperatures similar to gas turbine engines. The focus of this paper is to explore the effects of flame liftoff and ignition timescales on the NO x contribution of this secondary jet. This is done by varying the premixed level and preheat temperature of the axial jet. The effects are explored at different momentum flux ratios (J), jet equivalence ratios (φ jet ), exit temperatures (T exit ), and main stage (headend) temperatures (T HE ). High-speed CH* chemiluminescence imaging is employed for each test case to determine the flame stabilization point. For a given temperature rise and combustor exit temperature, an increase in ignition delay was observed with a decrease in jet temperature. This provided a NO x benefit, particularly for jets that are injected at or close to an ignitable mixture fraction. Similarly, the coaxial injector caused a significant ignition delay compared to the fully premixed injector; this also led to a NO x benefit. Overall, the results show that a thermally driven delay in the axial stage provides a greater NO x reduction than a mixing delay.

03 NATURAL GAS↗
DOE OSTI2021

Combustor with axially staged fuel injection

A combustor with axially staged fuel injection includes an endcover and a fuel injector that extends axially downstream from the endcover. The fuel injector includes a cylindrical shell formed by an outer wall and an inner wall. A first plurality of outlets is circumferentially spaced across the inner wall. A first plurality of premix channels is defined between the outer wall and the inner wall. Each premix channel of the first plurality of premix channels is in fluid communication with a fuel supply, a compressed air supply and a respective outlet of the first plurality of outlets.

Berry, Jonathan Dwight↗
DOE OSTI2020

Combustor with axially staged fuel injection

A combustor with axially staged fuel injection includes a plurality of nozzle segments annularly arranged about a center fuel nozzle. Each nozzle segment includes a fuel plenum partially defined between a forward plate and an aft plate and a plurality of tubes that extends through the fuel plenum and the aft plate. A panel fuel injector extends axially downstream from the aft plate and includes an outer wall, an inner wall, a plurality of outlets defined along at least one of the outer wall and the inner wall and a plurality of premix channels defined between the outer wall and the inner wall. Each premix channel is in fluid communication with a fuel supply, a compressed air supply and a respective outlet of the plurality of outlets.

42 ENGINEERING↗
NASA NTRS2004

NASA Glenn's Single-Stage Axial Compressor Facility Upgraded

NASA Glenn Research Center's Single-Stage Axial Compressor Facility was upgraded in fiscal year 2003 to expand and improve its research capabilities for testing high-speed fans and compressors. The old 3000-hp drive motor and gearbox were removed and replaced with a refurbished 7000-hp drive motor and gearbox, with a maximum output speed of 21,240 rpm. The higher horsepower rating permits testing of fans and compressors with higher pressure ratio or higher flow. A new inline torquemeter was installed to provide an alternate measurement of fan and compressor efficiency, along with the standard pressure and temperature measurements. A refurbished compressor bearing housing was also installed with bidirectional rotation capability, so that a variety of existing hardware could be tested. Four new lubrication modules with backup capability were installed for the motor, gearbox, torquemeter, and compressor bearing housing, so that in case the primary pump fails, the backup will prevent damage to the rotating hardware. The combustion air supply line for the facility inlet air system was activated to provide dry air for repeatable inlet conditions. New flow conditioning hardware was installed in the facility inlet plenum tank, which greatly reduced the inlet turbulence. The new inlet can also be easily modified to accommodate 20- or 22-in.-diameter fans and compressors, so a variety of existing hardware from other facilities (such as Glenn's 9- by 15-Foot Low-Speed Wind Tunnel) can be tested in the Single-Stage Axial Compressor Facility. An exhaust line was also installed to provide bleed capability to remove the inlet boundary layer. To improve the operation and control of the facility, a new programmable logic controller (PLC) was installed to upgrade from hardwired relay logic to software logic. The PLC also enabled the usage of human-machine interface software to allow for easier operation of the facility and easier reconfiguration of the facility controls when necessary. Finally, a new health-monitoring system was installed to measure shaft speed, shaft movement, and machine vibration on all of the rotating equipment. The system also provides automatic alarms and shutdown of the equipment when required. An integrated systems test for checkout of the facility was completed on June 17, 2003. Research testing resumed on June 30 with data obtained in support of the Ultra-Efficient Engine Technology Project's Compressor Casing Treatment Project.

Brokopp, Richard A.↗
NASA NTRSDate not supplied

Flow Physics at a Large Rotor Tip Gap in a Multi-Stage Axial Compressor

The flow physics in a large rotor tip gap in a 1.5-stage axial compressor is investigated in the current study. The flow structure in the rotor tip region is complex with several dominant vortical structures of opposite rotation, resulting in inhomogeneous and highly anisotropic turbulence. Earlier measurements show that eddy viscosity is negative over large parts of the tip region and eddy viscosity varies among stress/strain components. The present study aims to understand how the complex nature of rotor tip leakage flow affects compressor performance when the tip gap size is greater than 4–5% of the rotor span, which is typical of advanced small core engines. Unsteady Reynolds-averaged Navier-Stokes (URANS) and Large Eddy Simulation (LES) techniques are applied to study flow physics in a large rotor tip gap (5.5% of rotor span) in a 1.5-stage axial compressor. Calculated flow fields from the two different approaches are compared with available measurements and examined in detail. LES calculates the pressure rise in the present compressor fairly well, while URANS with a standard two-equation turbulence closure underpredicts the pressure rise by 15-20% of the measured values. The current study shows that URANS with the current turbulence closure produces much higher all-positive eddy viscosity in the tip-gap region compared to measurements and LES. The distribution of eddy viscosity in the URANS simulation is also wrong. Consequently, the flow in the tip region is highly damped with significantly larger blockage generation, which results in the tip leakage vortex (TLV) staying closer to the blade suction side compared to the measurement. When the TLV stays closer to the blade, both flow turning and the pressure rise across the compressor are reduced compared to the measurements. It appears that this effect is amplified by a large rotor tip gap.

tip gap↗
DOE OSTI2022

Improving NO x Entitlement with Axial Staging

Manufacturers are constantly under pressure to increase the efficiency of air breathing gas turbines for the next generation of ground based combined cycle power plants without a significant increase in NO x emissions. Axially staging some of the fuel and air is one method manufacturers are exploring to increase the firing temperature with a minimal NO x increase. This project used a high-pressure combustion facility to systematically explore the axial stage design space at conditions relevant to engine manufacturers. Chemiluminescence and PIV images of the reacting jets were obtained as well as exit emissions. This data was used to create correlations for reacting jets-in-crossflow, analogous to what currently exists for non-reacting jets-in-crossflow. Two CFD programs were used to model these results to quantifying the accuracy of the codes and help elucidate the underlying physics that governs the high-pressure reacting jet in crossflow. This report indicates a change in flame/flow-field behavior, and emissions characteristics with increasing pressure from 1-5.5 atm. Additionally, the effects of preheating and premixing the axial jet are explored at various conditions and show increased jet liftoff leads to a decrease in NO x emissions.

03 NATURAL GAS↗
NASA NTRS2014

Investigation of Unsteady Flow Field in a Low-Speed One and a Half Stage Axial Compressor: Effects of Tip Gap Size On the Tip Clearance Flow Structure at Near Stall Operation - Part 2

The primary focus of this paper is to investigate the effect of rotor tip gap size on how the rotor unsteady tip clearance flow structure changes in a low speed one and half stage axial compressor at near stall operation (for example, where maximum pressure rise is obtained). A Large Eddy Simulation (LES) is applied to calculate the unsteady flow field at this flow condition with both a small and a large tip gaps. The numerically obtained flow fields at the small clearance matches fairly well with the available initial measurements obtained at the Johns Hopkins University with 3-D unsteady PIV in an index-matched test facility which renders the compressor blades and casing optically transparent. With this setup, the unsteady velocity field in the entire flow domain, including the flow inside the tip gap, can be measured. The numerical results are also compared with previously published measurements in a low speed single stage compressor (Maerz et al. [2002]). The current study shows that, with the smaller rotor tip gap, the tip clearance vortex moves to the leading edge plane at near stall operating condition, creating a nearly circumferentially aligned vortex that persists around the entire rotor. On the other hand, with a large tip gap, the clearance vortex stays inside the blade passage at near stall operation. With the large tip gap, flow instability and related large pressure fluctuation at the leading edge are observed in this one and a half stage compressor. Detailed examination of the unsteady flow structure in this compressor stage reveals that the flow instability is due to shed vortices near the leading edge, and not due to a three-dimensional separation vortex originating from the suction side of the blade, which is commonly referred to during a spike-type stall inception. The entire tip clearance flow is highly unsteady. Many vortex structures in the tip clearance flow, including the sheet vortex system near the casing, interact with each other. The core tip clearance vortex, which is formed with the rotor tip gap flows near the leading edge, is also highly unsteady or intermittent due to pressure oscillations near the leading edge and varies from passage to passage. For the current compressor stage, the evidence does not seem to support that a classical vortex breakup occurs in any organized way, even with the large tip gap. Although wakes from the IGV influence the tip clearance flow in the rotor, the major characteristics of rotor tip clearance flows in isolated or single stage rotors are observed in this one and a half stage axial compressor.

Unsteady↗
NASA NTRSDate not supplied

Characterization of the Upgraded NASA GRC Single Stage Axial Compressor and Fan Facility

In order to meet the emissions and efficiency goals established by the aviation community, next generation aircraft engines will require low pressure ratio, distortion tolerant fans. Maturation of the necessary technologies will require facilities which are capable of accurately testing the fan performance. To achieve this, the Single Stage Axial Compressor and Fan facility at NASA Glenn Research Center was upgraded. Details of the goals and upgrades undertaken were documented in the 2022 Turbo Expo paper, “Upgrades to the Single Stage Axial Compressor and Fan Facility for Low Pressure Ratio Boundary Layer Ingesting Fan Research.” The performance of the upgraded facility will be documented in this paper. This paper will review the challenges associated with testing low pressure ratio and distortion tolerant fans and briefly review the upgrades undertaken and their goals. Then the performance of the facility upgrades and the extent to which they were able to achieve the stated goals will be discussed. This includes mass flow measurements, test section temperature, pressure, flow angle at two axial locations, and turbulence levels at the inlet and test section. The paper also documents the performance of distortion generating swirl vanes and total pressure screens to achieve desired distorted conditions at the Aerodynamic Interface Plane.

BLI↗
NASA NTRSDate not supplied

Characterization of the Upgraded NASA GRC Single Stage Axial Compressor and Fan Facility

In order to meet the emissions and efficiency goals established by the aviation community, next generation aircraft engines will require low pressure ratio, distortion tolerant fans. Maturation of the necessary technologies will require facilities capable of accurately testing the fan performance are needed. To achieve this, the Single Stage Axial Compressor and Fan facility at NASA Glenn Research Center was upgraded. Details of the goals and upgrades undertaken were documented in the 2022 Turbo Expo paper, “Upgrades to the Single Stage Axial Compressor and Fan Facility for Low Pressure Ratio Boundary Layer Ingesting Fan Research.” The performance of the upgraded facility will be documented in this paper. This paper will review the challenges associated with testing low pressure ratio and distortion tolerant fans and briefly review the upgrades undertaken and their goals. Then the performance of the facility upgrades and the extent to which they were able to achieve the stated goals. This includes mass flow measurements, test section temperature, pressure, flow angle at two axial locations, and turbulence levels at the inlet and test section. The paper also documents the performance of distortion generating swirl vanes and total pressure screens to achieve desired distorted conditions at the Aerodynamic Interface Plane.

BLI↗
NASA NTRSDate not supplied

Design and Optimization of a 3-Stage Axial Supercritical CO2 Compressor

This paper presents the detailed design and optimization of a three-stage axial supercritical carbon dioxide (sCO2) compressor to support the advancement of sCO 2 power cycles, recognized for their efficiency and compactness in energy conversion. The three-stage design is a scaled model of the original nine-stage 100 MW design. The aerodynamic design and structural analysis were performed at the University of Cincinnati, and the results are presented. The first stage of the design has been meticulously manufactured and experimentally tested at University of Notre Dame Turbomachinery Laboratory. The design process starts with the preliminary design process, considering the required operating boundary conditions and geometrical constraints for full stage design. The design is then scaled down to 3-stage based on the power limitation. The definition for design parameters has been inspired from the EEE HPC design and tweaked to fit the sCO 2 operation. Axisymmetric analysis is performed next and the parametric geometry modeler -Tblade3 has been used to create 3D blade geometry from the results which can then be exported for the 3D CFD analysis and optimization. An efficiency of 89.85% is predicted for the final design at the design point.

Compressor↗
NASA NTRS2018

Orifice Mass Flow Calculation in NASA's W-8 Single Stage Axial Compressor Facility

Updates to the orifice mass flow calculation for the W-8 Single Stage Axial Compressor Facility at NASA Glenn Research Center are provided to include the effect of humidity and incorporate ISO 5167. A methodology for including the effect of humidity into the inlet orifice mass flow calculation is provided. Orifice mass flow calculations provided by ASME PTC-19.5-2004, ASME MFC-3M-2004, ASME Fluid Meters, and ISO 5167 are compared for W-8's atmospheric inlet orifice plate. Differences in expansion factor and discharge coefficient given by these standards give a variation of about +/- 75% mass flow except for a few cases. A comparison of the calculations with an inlet static pressure mass flow correlation and a fan exit mass flow integration using test data from a 2017 turbofan rotor test in W-8 show good agreement between the inlet static pressure mass flow correlation, ISO 5167, and ASME Fluid Meters. While W-8's atmospheric inlet orifice plate violates the pipe diameter limit defined by each of the standards, the ISO 5167 is chosen to be the primary orifice mass flow calculation to use in the W-8 facility.

Aerodynamics↗
NASA NTRS2017

NOx Emissions Characteristics and Correlation Equations of Two P and W's Axially Staged Sector Combustors Developed Under NASA Environmentally Responsible Aviation (ERA) Project

Two P&W (Pratt & Whitney)'s axially staged sector combustors have been developed under NASA's Environmentally Responsible Aviation (ERA) project. One combustor was developed under ERA Phase I, and the other was developed under ERA Phase II. Nitrogen oxides (NOx) emissions characteristics and correlation equations for these two sector combustors are reported in this article. The Phase I design was to optimize the NOx emissions reduction potential, while the Phase II design was more practical and robust. Multiple injection points and fuel staging strategies are used in the combustor design. Pilot-stage injectors are located on the front dome plate of the combustor, and main-stage injectors are positioned on the top and bottom (Phase I) or on the top only (Phase II) of the combustor liners downstream. Low power configuration uses only pilot-stage injectors. Main-stage injectors are added to high power configuration to help distribute fuel more evenly and achieve lean burn throughout the combustor yielding very low NOx emissions. The ICAO (International Civil Aviation Organization) landing-takeoff NOx emissions are verified to be 88 percent (Phase I) and 76 percent (Phase II) under the ICAO CAEP/6 (Committee on Aviation Environmental Protection 6th Meeting) standard, exceeding the ERA project goal of 75 percent reduction, and the combustors proved to have stable combustion with room to maneuver on fuel flow splits for operability.

sector combustor test↗