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Ducting arrangement with injector assemblies arranged in an expanding cross-sectional area of a downstream combustion stage in a gas turbine engine
A ducting arrangement (10) in a combustion stage downstream of a main combustion stage of a gas turbine engine is provided. A duct (18) is fluidly coupled to receive a cross-flow of combustion gases from the main combustion stage. Duct (18) includes a duct segment (23) with an expanding cross-sectional area (24) where one or more injector assemblies (26) are disposed. Injector assembly (26) includes one or more reactant-guiding structures (27) arranged to deliver a flow of reactants into the downstream combustion stage to be mixed with the cross-flow of combustion gases. Disclosed injector assemblies are arranged in expanding cross-sectional area (24) to reduce total pressure loss while providing an effective level of mixing of the injected reactants with the passing cross-flow. Respective duct components or the entire ducting arrangement may be formed as a unitized structure, such as a single piece using a rapid manufacturing technology, such as 3D Printing/Additive Manufacturing (AM) technologies.
Design and Fabrication of Oxygen/RP-2 Multi-Element Oxidizer-Rich Staged Combustion Thrust Chamber Injectors
As part of the Combustion Stability Tool Development project funded by the Air Force Space and Missile Systems Center, the NASA Marshall Space Flight Center was contracted to assemble and hot-fire test a multi-element integrated test article demonstrating combustion characteristics of an oxygen/hydrocarbon propellant oxidizer-rich staged-combustion engine thrust chamber. Such a test article simulates flow through the main injectors of oxygen/kerosene oxidizer-rich staged combustion engines such as the Russian RD-180 or NK-33 engines, or future U.S.-built engine systems such as the Aerojet-Rocketdyne AR-1 engine or the Hydrocarbon Boost program demonstration engine. On the current project, several configurations of new main injectors were considered for the thrust chamber assembly of the integrated test article. All the injector elements were of the gas-centered swirl coaxial type, similar to those used on the Russian oxidizer-rich staged-combustion rocket engines. In such elements, oxidizer-rich combustion products from the preburner/turbine exhaust flow through a straight tube, and fuel exiting from the combustion chamber and nozzle regenerative cooling circuits is injected near the exit of the oxidizer tube through tangentially oriented orifices that impart a swirl motion such that the fuel flows along the wall of the oxidizer tube in a thin film. In some elements there is an orifice at the inlet to the oxidizer tube, and in some elements there is a sleeve or "shield" inside the oxidizer tube where the fuel enters. In the current project, several variations of element geometries were created, including element size (i.e., number of elements or pattern density), the distance from the exit of the sleeve to the injector face, the width of the gap between the oxidizer tube inner wall and the outer wall of the sleeve, and excluding the sleeve entirely. This paper discusses the design rationale for each of these element variations, including hydraulic, structural, thermal, combustion performance, and combustion stability considerations. This paper also discusses the fabrication and assembly of the injector components, including the injector body/interpropellant plate, the additive manufactured GRCop-84 faceplate, and the pieces that make up the injector elements including the oxidizer tube, an inlet to the oxidizer tube, and a facenut that includes the fuel tangential inlets and forms the initial recessed volume where oxidizer and fuel first interact. Hot-fire test results of these main injector designs in an integrated test article that includes an oxidizer-rich preburner are described in companion papers at this JANNAF meeting.
Flame tube parametric studies for control of fuel bound nitrogen using rich-lean two-stage combustion
An experimental parametric study of rich-lean two-stage combustion in a flame tube is described and approaches for minimizing the conversion of fuel-bound nitrogen to nitrogen oxides in a premixed, homogeneous combustion system are evaluated. Air at 672 K and 0.48 MPa was premixed with fuel blends of propane, toluene, and pyridine at primary equivalence ratios ranging from 0.5 to 2.0 and secondary equivalence ratios of 0.5 to 0.7. Distillates of SRC-II, a coal syncrude, were also tested. The blended fuels were proportioned to vary fuel hydrogen composition from 9.0 to 18.3 weight percent and fuel nitrogen composition from zero to 1.5 weight percent. Rich-lean combustion proved effective in reducing fuel nitrogen to NO sub x conversion; conversion rates up to 10 times lower than those normally produced by single-stage combustion were achieved. The optimum primary equivalence ratio, where the least NO sub x was produced and combustion efficiency was acceptable, shifted between 1.4 and 1.7 with changes in fuel nitrogen content and fuel hydrogen content. Increasing levels of fuel nitrogen content lowered the conversion rate, but not enough to avoid higher NO sub x emissions as fuel nitrogen increased.
Hot-Fire Test Results of an Oxygen/RP-2 Multi-Element Oxidizer-Rich Staged-Combustion Integrated Test Article
As part of the Combustion Stability Tool Development project funded by the Air Force Space and Missile Systems Center, the NASA Marshall Space Flight Center was contracted to assemble and hot-fire test a multi-element integrated test article demonstrating combustion characteristics of an oxygen/hydrocarbon propellant oxidizer-rich staged-combustion engine thrust chamber. Such a test article simulates flow through the main injectors of oxygen/kerosene oxidizer-rich staged combustion engines such as the Russian RD-180 or NK-33 engines, or future U.S.-built engine systems such as the Aerojet-Rocketdyne AR-1 engine or the Hydrocarbon Boost program demonstration engine. For the thrust chamber assembly of the test article, several configurations of new main injectors, using relatively conventional gas-centered swirl coaxial injector elements, were designed and fabricated. The design and fabrication of these main injectors are described in a companion paper at this JANNAF meeting. New ablative combustion chambers were fabricated based on hardware previously used at NASA for testing at similar size and pressure. An existing oxygen/RP-1 oxidizer-rich subscale preburner injector from a previous NASA-funded program, along with existing and new inter-connecting hot gas duct hardware, were used to supply the oxidizer-rich combustion products to the oxidizer circuit of the main injector of the thrust chamber. Results from independent hot-fire tests of the preburner injector in a combustion chamber with a sonic throat are described in companion papers at this JANNAF conference. The resulting integrated test article - which includes the preburner, inter-connecting hot gas duct, main injector, and ablative combustion chamber - was assembled at Test Stand 116 at the East Test Area of the NASA Marshall Space Flight Center. The test article was well instrumented with static and dynamic pressure, temperature, and acceleration sensors to allow the collected data to be used for combustion analysis model development. Hot-fire testing was conducted with main combustion chamber pressures ranging from 1400 to 2100 psia, and main combustion chamber mixture ratios ranging from 2.4 to 2.9. Different levels of fuel film cooling injected from the injector face were examined ranging from none to about 12% of the total fuel flow. This paper presents the hot-fire test results of the integrated test article. Combustion performance, stability, thermal, and compatibility characteristics of both the preburner and the thrust chamber are described. Another companion paper at this JANNAF meeting includes additional and more detailed test data regarding the combustion dynamics and stability characteristics.
Combustion Dynamics and Stability Modeling of a Liquid Oxygen/RP-2 Oxygen-Rich Staged Combustion Preburner and Thrust Chamber Assembly with Gas-Centered Swirl Coaxial Injector Elements
The Combustion Stability Tool Development (CSTD) project, funded by the Air Force Space and Missile Systems Center, began in March 2015 supporting a renewed interest in the development of a liquid oxygen/hydrocarbon, oxygen-rich combustion engine. The project encompasses the design, assembly, and hot-fire testing of the NASA Marshall Space Flight Center 40-klbf Integrated Test Rig (MITR). The test rig models a staged-combustion configuration by combining an oxygen-rich preburner (ORPB), to generate hot gas, with a thrust chamber assembly (TCA) using gas-centered swirl coaxial injector elements. There are five separately designed interchangeable injectors in the TCA that each contain 19- or 27- injector elements. A companion paper in this JANNAF conference describes the design characteristics, rationale, and fabrication issues for all the injectors. The data acquired from a heavily instrumented rig encompasses several injectors, several operating points, and stability bomb tests. Another companion paper in this JANNAF conference describes this test program in detail. In this paper, dynamic data from the hot-fire testing is characterized and used to identify the responses in the ORPB and TCA. A brief review of damping metrics are discussed and applied as a measure of stability margin for damped acoustic modes. Chug and longitudinal combustion stability models and predictions are described which includes new dynamic models for compressible flow through an orifice and a modification to incorporate a third feed line for inclusion of the fuel-film coolant. Flow-acoustics finite element modeling is used to investigate the anticipated TCA acoustics, the effects of injector element length on stability margin, and the potential use of an ORPB orifice trip ring for improving longitudinal stability margin.
Comparison of Single-Element and Multi-Element Oxygen/RP-1 Oxidizer-Rich Staged-Combustion Injector Hot-Fire Test Results
As part of the Combustion Stability Tool Development project funded by the Air Force Space and Missile Systems Center, the NASA Marshall Space Flight Center designed, fabricated, assembled and hot-fire tested an oxygen/hydrocarbon propellant multi-element integrated test article that included an oxidizer-rich oxygen/hydrocarbon propellant preburner and a staged-combustion main injector. Also as part of this project, the Air Force Research Laboratory fabricated single-element main injectors of the same designs as used in the NASA multi-element injectors, and tested them in a staged-combustion integrated test article that used an oxidizer-rich oxygen/hydrogen propellant preburner. Final results of the multi-element and single-element staged-combustion main injector test programs are described in companion papers at this JANNAF meeting. The design, development, and preliminary test results of these main injectors have also been described in previous JANNAF papers. The main injector element designs were all based on relatively conventional gas-centered swirl coaxial injector element configurations such as used in Russian RD-170 and NK-33 engines, and planned for use in future U.S.-built experimental engine systems such as the Hydrocarbon Boost program demonstration engine. Four different elements were tested in both the multi-element and single-element main injectors, at similar combustion chamber pressures, chamber contraction ratios, and mixture ratios. Variations of the element features included recess depth, fuel gap width, and the presence of the sleeve separating the swirling fuel flow from the axial oxidizer flow. This paper compares the hydraulics, combustion performance, stability, and compatibility characteristics of the single-element and multi-element injectors operated at similar conditions. The single-element hardware is shown to have captured a significant level of the operability of the multi-element hardware.
Preburner of Staged Combustion Rocket Engine
A regeneratively cooled LOX/hydrogen staged combustion assembly system with a 400:1 expansion area ratio nozzle utilizing an 89,000 Newton (20,000 pound) thrust regeneratively cooled thrust chamber and 175:1 tubular nozzle was analyzed, assembled, and tested. The components for this assembly include two spark/torch oxygen-hydrogen igniters, two servo-controlled LOX valves, a preburner injector, a preburner combustor, a main propellant injector, a regeneratively cooled combustion chamber, a regeneratively cooled tubular nozzle with an expansion area ratio of 175:1, an uncooled heavy-wall steel nozzle with an expansion area ratio of 400:1, and interconnecting ducting. The analytical effort was performed to optimize the thermal and structural characteristics of each of the new components and the ducting, and to reverify the capabilities of the previously fabricated components. The testing effort provided a demonstration of the preburner/combustor chamber operation, chamber combustion efficiency and stability, and chamber and nozzle heat transfer.
Performance, Stability and Compatibility of Oxygen/RP-1 Multi-Element Oxidizer-Rich Staged-Combustion Injectors
In 2015 and 2016, the National Aeronautics and Space Administration Marshall Space Flight Center designed, fabricated, assembled and hot-fire tested an oxygen/RP-1 propellant multi-element oxidizer-rich staged-combustion test article. The main objective was to provide thrust chamber combustion stability data as part of the Combustion Stability Tool Development program, although demonstration of performance and compatibility of oxidizer-rich main injectors was also important. Funding was provided by the Air Force Space and Missile Systems Center. Five configurations of main injectors were designed and fabricated, using conventional gas-centered swirl coaxial injector element designs generally similar to those used in oxygen/kerosene oxidizer-rich staged combustion engines such as the Russian RD-180 or NK-33 engines. Variations of element features included element size, recess depth, fuel gap width, and the presence of the sleeve separating the swirling fuel flow from the axial oxidizer flow. Ablative combustion chambers were fabricated based on hardware previously used at the NASA MSFC for testing at similar size and pressure. Existing oxygen/RP-1 oxidizer-rich subscale preburner injectors and hot gas ducts from a previous NASA-funded program were modified for use to supply the oxidizer-rich combustion products to the oxidizer circuit of the main injector of the thrust chamber. Testing of the resulting integrated test article - which included the preburner, inter-connecting hot gas duct, main injector, and ablative combustion chamber - was conducted at Test Stand 116 at the East Test Area of the NASA MSFC. The test article was well instrumented with static and dynamic pressure, temperature, and vibration sensors. This paper presents and discusses all the hot-fire test results of the integrated test article thrust chamber. Eighteen successful hot-fire tests of the integrated rig were conducted. Testing was accomplished with all five of the injector element concepts. Main combustion chamber pressures ranged from 710 to 2350 psia, and main combustion chamber mixture ratios ranged from 2.47 to 2.87. A chamber barrier fuel film coolant of about 2% to 4% of the total fuel flow was used for most tests. Characteristic exhaust velocity efficiency excluding the influence of the fuel film cooling ranged from 91% to 98% of theoretical. All tests of the thrust chamber exhibited stable combustion, even down to 40% of nominal operating pressures. Compatibility of the injector face and combustion chamber walls was acceptable. This paper is a follow-on to publication of preliminary test data presented at the 2016 JANNAF Liquid Propulsion Subcommittee meeting.
Solid-liquid staged combustion space boosters
NASA has begun to evaluate solid-liquid hybrid propulsion for launch vehicle booster. A three-phase program was outlined to identify, acquire, and demonstrate technology needed to approximate solid and liquid propulsion state of the art. Aerojet has completed a Phase 1 study and recommends a solid-liquid staged combustion concept in which turbopump fed LO2 is burned with fuel-rich solid propellant effluent in aft-mounted thrust chambers.These reasonably sized thrust chambers are LO2 regeneratively cooled, supplemented with fuel-rich barrier cooling. Turbopumps are driven by the resulting GO2 coolant in an expander-bleed-burnoff cycle. Turbine exhaust pressurizes the LO2 tankage directly, and the excess is bled into supersonic nozzle splitlines, where it combusts with the fuel rich boundary layer. Thrust vector control is enhanced by supersonic nozzle movement on flexseal mounts. Every hybrid solid-liquid concept examined improves booster energy management and launch propellant safety compared to current solid boosters. Solid-liquid staged combustion improves hybrid performance by improving both combustion efficiency and combustion stability, especially important for large boosters. These improvements result from careful fluid management and use of smaller combustors. The study shows NASA safety, reliability, cost, and performance criteria are best met with this concept, wherein simple hardware relies on several separate emerging technologies, all of which have been demonstrated successfully.
Two-stage combustion for reducing pollutant emissions from gas turbine combustors
Combustion and emission results are presented for a premix combustor fueled with admixtures of JP5 with neat H2 and of JP5 with simulated partial-oxidation product gas. The combustor was operated with inlet-air state conditions typical of cruise power for high performance aviation engines. Ultralow NOx, CO and HC emissions and extended lean burning limits were achieved simultaneously. Laboratory scale studies of the non-catalyzed rich-burning characteristics of several paraffin-series hydrocarbon fuels and of JP5 showed sooting limits at equivalence ratios of about 2.0 and that in order to achieve very rich sootless burning it is necessary to premix the reactants thoroughly and to use high levels of air preheat. The application of two-stage combustion for the reduction of fuel NOx was reviewed. An experimental combustor designed and constructed for two-stage combustion experiments is described.
Staged combustion with piston engine and turbine engine supercharger
A combustion engine method and system provides increased fuel efficiency and reduces polluting exhaust emissions by burning fuel in a two-stage combustion system. Fuel is combusted in a piston engine in a first stage producing piston engine exhaust gases. Fuel contained in the piston engine exhaust gases is combusted in a second stage turbine engine. Turbine engine exhaust gases are used to supercharge the piston engine.
Analysis of the longitudinal high frequency stability of a staged combustion cycle, Appendix B
Time lag theory for longitudinal high frequency stability analysis on staged combustion cycle of liquid propellant rocket engine
A semi-empirical NO x model for LES in pulverized coal air-staged combustion
Numerical simulation of pulverized coal combustion with the large eddy simulation (LES) method can provides important instructions on the design optimization of boilers. Because of its huge computational cost, a simple but reliable NO x prediction model is required in LES. Through the air-staged combustion experiments of six kinds of coals which conducted in an electric heated down-fired furnace (DFF), the relationship between NO x reduction and CO+H 2 generation in the fuel-rich zone was identified. Based on this observation, a semi-empirical modeling strategy was proposed: instead of CHi which is difficult to calculate, the concentration of CO+H 2 is used to quantify NO homogeneous reduction. An integrated NO x prediction model was proposed and implemented into LES simulation. Here, the results proved the new model can accurately predict different NO x evolution characteristics under various conditions. Furthermore, the comparison indicated the LES method performs better on NO x prediction than the RANS method, especially in the area where the turbulent fluctuation is relatively stronger.
Hydrodynamic Modeling of Oxidizer-Rich Staged Combustion Injector Flow
The main objective of this work is to determine the unsteady hydrodynamic characteristics of coaxial swirl atomizers of interest in oxidizer-rich staged combustion (ORSC) liquid rocket engines. To this end, the pseudo-density (homogeneous flow) treatment combined with the Marker-and-Cell (MAC) numerical algorithm has been used to develop an axisymmetric with swirl, two-phase, unsteady model. The numerical model is capable of assessing the time-dependent orifice exit conditions and internal mixing for arbitrary fuel and oxidizer gas injection conditions. Parametric studies have been conducted to determine the effect of geometry, gas properties, and liquid properties on the exit massflow rate and velocity. It has been found that the frequency at which the liquid film oscillates increases as the density ratio and thickness increase, decreases as film thickness and liquid swirl velocity increase, and is unaffected by the mixing length. Additionally, it has been determined that the variation in the massflow rate increases as the liquid swirl velocity and liquid film thickness increase, and decreases as the density ratio, collar thickness, and mixing length increase.
Lean-rich axial stage combustion in a can-annular gas turbine engine
An apparatus and method for lean/rich combustion in a gas turbine engine (10), which includes a combustor (12), a transition (14) and a combustor extender (16) that is positioned between the combustor (12) and the transition (14) to connect the combustor (12) to the transition (14). Openings (18) are formed along an outer surface (20) of the combustor extender (16). The gas turbine (10) also includes a fuel manifold (28) to extend along the outer surface (20) of the combustor extender (16), with fuel nozzles (30) to align with the respective openings (18). A method (200) for axial stage combustion in the gas turbine engine (10) is also presented.
Additively Manufactured Low Cost Upper Stage Combustion Chamber
Over the past two years NASA's Low Cost Upper Stage Propulsion (LCUSP) project has developed Additive Manufacturing (AM) technologies and design tools aimed at reducing the costs and manufacturing time of regeneratively cooled rocket engine components. High pressure/high temperature combustion chambers and nozzles must be regeneratively cooled to survive their operating environment, causing their design fabrication to be costly and time consuming due to the number of individual steps and different processes required. Under LCUSP, AM technologies in Sintered Laser Melting (SLM) GRCop-84 and Electron Beam Freeform Fabrication (EBF3) Inconel 625 have been significantly advanced, allowing the team to successfully fabricate a 25k-class regenerative chamber. Estimates of the costs and schedule of future builds indicate cost reductions and significant schedule reductions will be enabled by this technology. Characterization of the microstructural and mechanical properties of the SLM-produced GRCop-84, EBF3 Inconel 625 and the interface layer between the two has been performed and indicates the properties will meet the design requirements. The LCUSP chamber is to be tested with a previously demonstrated SLM injector in order to advance the Technology Readiness Level (TRL) and demonstrate the capability of the application of these processes. NASA is advancing these technologies to reduce cost and schedule for future engine applications and commercial needs.
Combustion Stages of a Single Heavy Oil Droplet in Microgravity
Heavy oil is a common fuel for industrial furnaces, boilers, marines and diesel engines. Previous studies showed that the combustion of heavy oil involves not only the complete burning of volatile matters but also the burn-out of coke residues. Detailed knowledge about heavy oil combustion therefore requires an understanding of the different burning stages of heavy oil droplets in the burner. This in turn, demands knowledge about the single droplet evaporation and combustion characteristics. This study measured the temperature and size histories of heavy oil (C glass) droplets burning in microgravity to elucidate the various stages that occur during combustion. The elimination of the gravity-induced gas convection in microgravity allows the droplet combustion to be studied in greater detail. Noting that the compositions of heavy oil are various, we also tested the fuel blends of a diesel light oil (LO) and a heavy oil residue (HOR).