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At least 19 records
All sourcesNASA NTRSDOE OSTI
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 NTRS1996

Spray Combustion Modeling with VOF and Finite-Rate Chemistry

A spray atomization and combustion model is developed based on the volume-of-fluid (VOF) transport equation with finite-rate chemistry model. The gas-liquid interface mass, momentum and energy conservation laws are modeled by continuum surface force mechanisms. A new solution method is developed such that the present VOF model can be applied for all-speed range flows. The objectives of the present study are: (1) to develop and verify the fractional volume-of-fluid (VOF) cell partitioning approach into a predictor-corrector algorithm to deal with multiphase (gas-liquid) free surface flow problems; (2) to implement the developed unified algorithm in a general purpose computational fluid dynamics (CFD) code, Finite Difference Navier-Stokes (FDNS), with droplet dynamics and finite-rate chemistry models; and (3) to demonstrate the effectiveness of the present approach by simulating benchmark problems of jet breakup/spray atomization and combustion. Modeling multiphase fluid flows poses a significant challenge because a required boundary must be applied to a transient, irregular surface that is discontinuous, and the flow regimes considered can range from incompressible to highspeed compressible flows. The flow-process modeling is further complicated by surface tension, interfacial heat and mass transfer, spray formation and turbulence, and their interactions. The major contribution of the present method is to combine the novel feature of the Volume of Fluid (VOF) method and the Eulerian/Lagrangian method into a unified algorithm for efficient noniterative, time-accurate calculations of multiphase free surface flows valid at all speeds. The proposed method reformulated the VOF equation to strongly couple two distinct phases (liquid and gas), and tracks droplets on a Lagrangian frame when spray model is required, using a unified predictor-corrector technique to account for the non-linear linkages through the convective contributions of VOF. The discontinuities within the sharp interface will be modeled as a volume force to avoid stiffness. Formations of droplets, tracking of droplet dynamics and modeling of the droplet breakup/evaporation, are handled through the same unified predictor-corrector procedure. Thus the new algorithm is non-iterative and is flexible for general geometries with arbitrarily complex topology in free surfaces. The FDNS finite-difference Navier-Stokes code is employed as the baseline of the current development. Benchmark test cases of shear coaxial LOX/H2 liquid jet with atomization/combustion and impinging jet test cases are investigated in the present work. Preliminary data comparisons show good qualitative agreement between data and the present analysis. It is indicative from these results that the present method has great potential to become a general engineering design analysis and diagnostics tool for problems involving spray combustion.

Chen, Yen-Sen↗
NASA NTRS1995

Numerical modeling of spray combustion with an advanced VOF method

This paper summarizes the technical development and validation of a multiphase computational fluid dynamics (CFD) numerical method using the volume-of-fluid (VOF) model and a Lagrangian tracking model which can be employed to analyze general multiphase flow problems with free surface mechanism. The gas-liquid interface mass, momentum and energy conservation relationships are modeled by continuum surface mechanisms. A new solution method is developed such that the present VOF model can be applied for all-speed flow regimes. The objectives of the present study are to develop and verify the fractional volume-of-fluid cell partitioning approach into a predictor-corrector algorithm and to demonstrate the effectiveness of the present approach by simulating benchmark problems including laminar impinging jets, shear coaxial jet atomization and shear coaxial spray combustion flows.

Chen, Yen-Sen↗
NASA NTRS1994

Atomization simulations using an Eulerian-VOF-Lagrangian method

This paper summarizes the technical development and validation of a multiphase computational fluid dynamics (CFD) numerical method using the volume-of-fluid (VOF) model and a Lagrangian tracking model which can be employed to analyze general multiphase flow problems with free surface mechanism. The gas-liquid interface mass, momentum and energy conservations are modeled by continuum surface mechanisms. A new solution method is developed such that the present VOF model can be applied for all-speed flow regimes. The objectives of the present study are to develop and verify the fractional volume-of-fluid cell partitioning approach into a predictor-corrector algorithm and to demonstrate the effectiveness of the present innovative approach by simulating benchmark problems including the coaxial jet atomization.

Chen, Yen-Sen↗
DOE OSTI2026

Two-phase flow numerical analysis of electrode geometry for alkaline water electrolyzers

Hydrogen is a promising component of a future energy-secure and efficient economy, but its competitiveness depends on reducing production costs. One strategy is to operate alkaline water electrolyzers at higher current densities to increase output. However, this intensifies performance losses due to gas bubble accumulation, which blocks transport pathways and deactivates electrochemically active surfaces. Enhancing bubble evacuation through electrode design is therefore essential. Previous studies have explored various approaches — such as modifying surface morphology, applying sonication or pressure modulation, and introducing surfactants — but these efforts have addressed a limited range of conditions due to the complexity of two-phase flow and electrode geometries. Experiments have also largely been focused on either cell level improvements, which lack the information necessary to isolate each contributing factor, or on modified geometries that are not relevant to practical cell operation. From a modeling perspective, conventional Eulerian multiphase models do not track the complex gas–liquid interfacial dynamics and often neglect surface tension and contact angle effects, reducing their predictive accuracy. To provide insights on the effects of different electrode geometries on the performance of alklaine water electrolyzers this work employs an immersed boundary volume-of-fluid method to simulate bubble behavior in 3D porous electrodes. Multiple base electrode geometries, typically used in practice, with varying porosity are evaluated under a constant surface gas generation rate. Simulation data is analyzed to quantify electrode gas coverage, bubble size dynamics and other relevant metrics. Results show that porosity strongly influences bubble accumulation on electrode surfaces, with higher porosity reducing gas coverage, and its not strictly dependent on the electrode geometry. However, the electrode’s base geometry significantly affects gas accumulation at the separator gap, independent of porosity. A foam electrode geometry resulted in the lowest gas coverage of all electrodes with a median volumetric gas coverage of 11%, but at the cost of a 70% reduction in active area compared with the largest surface area electrode, while gyroid electrodes showed the best trade-off between gas coverage, particularly at the separator surface, and electrochemically active area. In conclusion, the results highlight the need for holistic electrode design strategies.

Alkaline↗
DOE OSTI2024

High- and Mid-Fidelity Modeling Comparison for a Floating Marine Turbine System

There is a lack of suitable numerical tools, particularly open-source tools, that can be used for designing and optimizing marine turbine systems. The National Renewable Energy Laboratory has added features to their widely used mid-fidelity wind turbine modeling code, OpenFAST, to enable modeling of axial-flow marine turbines. This necessitated the addition of several physical effects relevant to marine turbines that are neglected for wind turbines. These include buoyancy, added mass and inertial loads, wave-current superposition, and changes to the coordinate systems. This updated version of OpenFAST allows for the modeling of both fixed and floating marine turbines at a speed comparable to real time. While efficient for large sets of load cases and design studies, mid-fidelity codes make simplifying assumptions that may impact their accuracy. High-fidelity computational fluid dynamics (CFD) simulations can capture more flow effects with fewer assumptions and provide detailed body pressure mapping and flow-field information. It is important to compare predictions between mid-fidelity and high-fidelity codes, both to verify the models and to understand the limitations. A floating marine turbine system was modeled both with OpenFAST and with the commercial CFD code STAR-CCM+. The CFD model used a three-dimensional unsteady Reynolds-averaged Navier-Stokes solver for a volume-of-fluid numerical wave and current tank. The blade-resolved simulations used the sliding-interface technique for the spinning rotor and an overset grid to accommodate the rigid-body motion of the floating system. The mooring system was modeled with a custom coupling of the CFD solver with the open-source code MoorDyn. This improves upon the existing quasi-static catenary solver in STAR-CCM+, which lacks seabed contact or line-to-line connections. Simulation results for a floating marine turbine are compared between OpenFAST and CFD, highlighting the capabilities of the mid-fidelity code and identifying the areas where a high-fidelity approach is needed.

CFD↗
NASA NTRS1991

RIPPLE - A new model for incompressible flows with free surfaces

A new free surface flow model, RIPPLE, is summarized. RIPPLE obtains finite difference solutions for incompressible flow problems having strong surface tension forces at free surfaces of arbitrarily complex topology. The key innovation is the continuum surface force model which represents surface tension as a (strongly) localized volume force. Other features include a higher-order momentum advection model, a volume-of-fluid free surface treatment, and an efficient two-step projection solution method. RIPPLE's unique capabilities are illustrated with two example problems: low-gravity jet-induced tank flow, and the collision and coalescence of two cylindrical rods.

Kothe, D. B.↗
NASA NTRS1992

A numerical model for atomization-spray coupling in liquid rocket thrust chambers

The physical process of atomization is an important consideration in the stable operation of liquid rocket engines. Many spray combustion computational fluid dynamics (CFD) codes do not include an atomization sub-model but assume arbitrary drop size distributions, drop initial locations, and velocities. A method of coupling an atomization model with the spray model in a REFLEQS CFD code is presented. This method is based on a jet-embedding technique in which the equations governing the liquid jet core are solved separately using the surrounding gas phase conditions. The droplet initial conditions are calculated using a stability analysis appropriate for the atomization regime of liquid jet break-up. This novel coupling model is used to analyze the SSME fuel preburner single injector flow. Results of the diffusion flame characteristics in a single injection element will be presented. The effect of relative velocity, mixture ratio and droplet initial conditions will be shown. The predictions of present atomization model is compared with that of the widely used CICM correlation. The results are also compared with the predictions of volume-of-fluid method.

M. G. Giridharan↗
NASA NTRS1992

A numerical model for coupling between atomization and spray dynamics in liquid rocket thrust chambers

This paper describes a novel method of coupling the atomization and spray combustion processes encountered in coaxial injection elements of liquid rocket engine thrust chambers. This method is based on the Jet-Embedding technique in which the liquid jet core equations and the gas phase equations are solved separately. The liquid and gas phase solutions, however, are coupled through the boundary conditions at the interface between the phases. The computational grid for the gas phase calculations are adapted to the shape of the liquid jet core. The axial variation of droplet sizes are calculated using a stability analysis appropriate for the atomization regime of liquid jet breakup. The predictions of this method have been validated with experimental data on low speed water jets. Using this method, calculations are performed for the SSME fuel preburner single injector flow field. The results obtained are in good agreement with the predictions of the volume-of-fluid method.

Giridharan, M. G.↗
NASA NTRS1993

Adaptation of the Advanced Spray Combustion Code to Cavitating Flow Problems

A very important consideration in turbopump design is the prediction and prevention of cavitation. Thus far conventional CFD codes have not been generally applicable to the treatment of cavitating flows. Taking advantage of its two-phase capability, the Advanced Spray Combustion Code is being modified to handle flows with transient as well as steady-state cavitation bubbles. The volume-of-fluid approach incorporated into the code is extended and augmented with a liquid phase energy equation and a simple evaporation model. The strategy adopted also successfully deals with the cavity closure issue. Simple test cases will be presented and remaining technical challenges will be discussed.

Liang, Pak-Yan↗
NASA NTRS2001

CFD Simulation of Liquid Rocket Engine Injectors

Detailed design issues associated with liquid rocket engine injectors and combustion chamber operation require CFD methodology which simulates highly three-dimensional, turbulent, vaporizing, and combusting flows. The primary utility of such simulations involves predicting multi-dimensional effects caused by specific injector configurations. SECA, Inc. and Engineering Sciences, Inc. have been developing appropriate computational methodology for NASA/MSFC for the past decade. CFD tools and computers have improved dramatically during this time period; however, the physical submodels used in these analyses must still remain relatively simple in order to produce useful results. Simulations of clustered coaxial and impinger injector elements for hydrogen and hydrocarbon fuels, which account for real fluid properties, is the immediate goal of this research. The spray combustion codes are based on the FDNS CFD code' and are structured to represent homogeneous and heterogeneous spray combustion. The homogeneous spray model treats the flow as a continuum of multi-phase, multicomponent fluids which move without thermal or velocity lags between the phases. Two heterogeneous models were developed: (1) a volume-of-fluid (VOF) model which represents the liquid core of coaxial or impinger jets and their atomization and vaporization, and (2) a Blob model which represents the injected streams as a cloud of droplets the size of the injector orifice which subsequently exhibit particle interaction, vaporization, and combustion. All of these spray models are computationally intensive, but this is unavoidable to accurately account for the complex physics and combustion which is to be predicted, Work is currently in progress to parallelize these codes to improve their computational efficiency. These spray combustion codes were used to simulate the three test cases which are the subject of the 2nd International Workshop on-Rocket Combustion Modeling. Such test cases are considered by these investigators to be very valuable for code validation because combustion kinetics, turbulence models and atomization models based on low pressure experiments of hydrogen air combustion do not adequately verify analytical or CFD submodels which are necessary to simulate rocket engine combustion. We wish to emphasize that the simulations which we prepared for this meeting are meant to test the accuracy of the approximations used in our general purpose spray combustion models, rather than represent a definitive analysis of each of the experiments which were conducted. Our goal is to accurately predict local temperatures and mixture ratios in rocket engines; hence predicting individual experiments is used only for code validation. To replace the conventional JANNAF standard axisymmetric finite-rate (TDK) computer code 2 for performance prediction with CFD cases, such codes must posses two features. Firstly, they must be as easy to use and of comparable run times for conventional performance predictions. Secondly, they must provide more detailed predictions of the flowfields near the injector face. Specifically, they must accurately predict the convective mixing of injected liquid propellants in terms of the injector element configurations.

Farmer, Richard↗
NASA NTRS2016

Validation of High-Resolution CFD Method for Slosh Damping Extraction of Baffled Tanks

Determination of slosh damping is a very challenging task as there is no analytical solution. The damping physics involve the vorticity dissipation which requires the full solution of the nonlinear Navier-Stokes equations. As a result, previous investigations and knowledge were mainly carried out by extensive experimental studies. A Volume-Of-Fluid (VOF) based CFD program developed at NASA MSFC was applied to extract slosh damping in a baffled tank from the first principle. First, experimental data using water with subscale smooth wall tank were used as the baseline validation. CFD simulation was demonstrated to be capable of accurately predicting natural frequency and very low damping value from the smooth wall tank at different fill levels. The damping due to a ring baffle at different liquid fill levels from barrel section and into the upper dome was then investigated to understand the slosh damping physics due to the presence of a ring baffle. Based on this study, the Root-Mean-Square error of our CFD simulation in estimating slosh damping was less than 4.8%, and the maximum error was less than 8.5%. Scalability of subscale baffled tank test using water was investigated using the validated CFD tool, and it was found that unlike the smooth wall case, slosh damping with baffle is almost independent of the working fluid and it is reasonable to apply water test data to the full scale LOX tank when the damping from baffle is dominant. On the other hand, for the smooth wall, the damping value must be scaled according to the Reynolds number. Comparison of experimental data, CFD, with the classical and modified Miles equations for upper dome was made, and the limitations of these semi-empirical equations were identified.

Yang, H. Q.↗
NASA NTRS2016

Validation of High-Resolution CFD Method for Slosh Damping Extraction of Baffled Cryogenic Propellant Tanks

Propellant slosh is a potential source of disturbance critical to the stability of space vehicles. The slosh dynamics are typically represented by a mechanical model of a spring-mass-damper. This mechanical model is then included in the equation of motion of the entire vehicle for Guidance, Navigation and Control analysis. A Volume-Of-Fluid (VOF) based Computational Fluid Dynamics (CFD) program developed at MSFC was applied to extract slosh damping in the baffled tank from the first principle. First the experimental data using water with sub-scale smooth wall tank were used as the baseline validation. It is demonstrated that CFD can indeed accurately predict low damping values from the smooth wall at different fill levels. The damping due to a ring baffles at different depths from the free surface was then simulated, and fairly good agreement with experimental measurement was observed. Comparison with an empirical correlation of Miles equation is also made.

Yang, H. Q.↗
NASA NTRSDate not supplied

CFD Modeling of Phase Change and Pressure Drop during Violent Sloshing of Cryogenic Fluid in a Small-Scale Tank

This paper presents the development of a two-phase CFD model that is used to study sloshing of a cryogenic fluid (LN2) undergoing phase change generated by lateral acceleration and its effects on the ensuing heat and mass transfer and pressure drop in a small-scale tank. In this model the interface is captured using the volume-of-fluid (VOF) method [1]. Kinetic-theory based Schrage relation [2] is used for calculating phase change mass transfer at the liquid-vapor interface. Computational results are compared to the data provided by a non-isothermal sloshing experiment with phase change conducted by the University of Tokyo and JAXA in 2018 using liquid Nitrogen in a transparent tank. The effect of different thicknesses of a liquid temperature stratification layer created at the interface on the pressure drop during sloshing was studied experimentally. CFD results for interface movement and tank pressure are presented and compared in this paper to experimental data for the cases with the smallest and largest liquid temperature stratification thickness.

phase change↗
NASA NTRSDate not supplied

Validation of CFD Model Prediction of Flow Boiling Regime Transitions during LN2 Line Chilldown

Propellant storage and transfer during future long-duration missions will involve fuel depot operations in which a donor depot tank is used to fill a receiver spacecraft tank with a cryogenic propellant. Prior to the on-Orbit filling operation both the receiver tank and the transfer line must be cooled. The line chilldown process involves transition between boiling regimes in microgravity that will be quite different from their 1g ground-based counterparts. Since the cryogenic propellant itself will be used to perform the chilldown process, the time constants to cool the wall and the amount of fuel that will be used become important design considerations. In this light, the focus of the present work is to understand the flow boiling characteristics of a cryogenic fluid, namely, liquid nitrogen, during the chill-down of a transfer line using CFD modelling and simulations. The cryogenic chill-down process involves different flow boiling regimes: film boiling, transition boiling and nucleate boiling. The prediction of transition between these regimes in a CFD framework is new and challenging. The present work addresses this challenge by employing a volume-of-fluid (VOF) based methodology with Lee phase change model to predict the film boiling regime of the chill-down process in ANSYS Fluent®. The transition and nucleate boiling regimes are predicted by incorporating a sub-grid model developed by Craft Tech that accounts for bubble nucleation, growth, shedding frequency, and departure diameter. The sub-grid model is implemented into Fluent via a user-defined function for wall-fluid heat flux calculations. The sub-grid model is similar in formulation to the well-known Rensselaer Polytechnic Institute (RPI) boiling model. The model constants are tested for different operating conditions and designated values are reported. The CFD model is validated against published experimental data for liquid nitrogen chill-down of a heated stainless-steel pipe in 1g. Predicted results showing good agreement of wall temperature, rewetting temperature, and transition between film and nucleate boiling with the experimental measurements are presented and discussed.

Boiling regimes↗
NASA NTRSDate not supplied

Modeling Autogenous Pressurization and Draining of a Cryogenic Storage Tank in Normal Gravity

A two-phase CFD model for autogenous pressurization and draining of a cryogenic storage tank is presented using both the Sharp Interface and Volume-Of-Fluid (VOF) approaches for capturing the front and the associated interfacial heat, mass and momentum transfer between the liquid and vapor regions. Both models are validated against data provided by the Cryogenic Propellant Storage and Transfer (CPST) Engineering Development Unit (EDU) experiment. The results of the autogenous pressurization are presented first, focusing on the phase change and turbulence effects on the tank pressure and temperature predictions. Both the Sharp Interface (SI-CFD) and VOF (VOF-CFD) multiphase models predict tank pressure during pressurization within 3% of the measured values. The sensitivity of key physical and numerical parameters of the problem are tested using the Sharp Interface model. Effects of the accommodation coefficient (AC), and the computational grid structure are studied. The second part of this paper is devoted to validating the SI-VOF model, with an enhanced capability of moving the liquid-vapor interface, against the draining segment of the EDU experiment. The VOF-CFD model was also used to simulate tank draining and its results were compared with the results of the Sharp Interface model with the moving interface. Both models predict tank pressure during draining within 3.5% of the measured values. Pressure decrease rate is underpredicted by both models during the first 100 seconds of draining but matches the experimental rate for the rest of the simulation.

Computational Fluid Dynamics↗
NASA NTRSDate not supplied

Modeling Autogenous Pressurization and Draining of a Cryogenic Storage Tank in Normal Gravity

A two-phase CFD model for autogenous pressurization and draining of a cryogenic storage tank is presented using both the Sharp Interface and Volume-Of-Fluid (VOF) approaches for capturing the front and the associated interfacial heat, mass and momentum transfer between the liquid and vapor regions. Both models are validated against data provided by the Cryogenic Propellant Storage and Transfer (CPST) Engineering Development Unit (EDU) experiment1. The results of the autogenous pressurization are presented first, focusing on the phase change and turbulence effects on the tank pressure and temperature predictions. Both the Sharp Interface (SI-CFD) and VOF (VOF-CFD) multiphase models predict tank pressure during pressurization within 3% of the measured values. The sensitivity of key physical and numerical parameters of the problem are tested using the Sharp Interface model. Effects of the accommodation coefficient (AC), and the computational grid structure are studied. The second part of this paper is devoted to validating the SI-VOF model, with an enhanced capability of moving the liquid-vapor interface, against the draining segment of the EDU experiment. The VOF-CFD model was also used to simulate tank draining and its results were compared with the results of the Sharp Interface model with the moving interface. Both models predict tank pressure during draining within 3.5% of the measured values. Pressure decrease rate is underpredicted by both models during the first 100 seconds of draining but matches the experimental rate for the rest of the simulation.

Computational Fluid Dynamics↗
NASA NTRSDate not supplied

Predictions of Line Chilldown Boiling Regime Transitions by a Coupled CFD-Sub-Grid Boiling Model Validated against 1G LN2 Experiments

Propellant storage and transfer during future long-duration missions will involve fuel depot operations in which a donor depot tank is used to fill a receiver spacecraft tank with a cryogenic propellant. Prior to the on-Orbit filling operation both the receiver tank and the transfer line must be cooled. The line chilldown process involves transition between boiling regimes in microgravity that will be quite different from their 1g ground-based counterparts. Since the cryogenic propellant itself will be used to perform the chilldown process, the time constants to cool the wall and the amount of fuel that will be used become important design considerations. In this light, the focus of the present work is to capture the flow boiling characteristics of a cryogenic fluid, namely, liquid nitrogen, during the chill-down of a transfer line using CFD modelling and simulations. The cryogenic chill-down process involves different flow boiling regimes: film boiling, transition boiling and nucleate boiling. The prediction of transition between these regimes in a CFD framework is new and challenging. The present work addresses this challenge by employing a volume-of-fluid (VOF) based methodology with Lee phase change model to predict the film boiling regime of the chill-down process in ANSYS Fluent®. The transition and nucleate boiling regimes are predicted by incorporating a sub-grid model that accounts for bubble nucleation, growth, shedding frequency, and departure diameter. The sub-grid model is implemented into Fluent via a user-defined function for wall-fluid heat flux calculations. The sub-grid model is similar in formulation to the well-known Rensselaer Polytechnic Institute (RPI) boiling model. The CFD model is validated against published experimental data for liquid nitrogen chill-down of a heated stainless-steel pipe in 1g. Predicted results shows good agreement of wall temperature, rewetting temperature, and transition between film and nucleate boiling with the experimental measurements for several different LN2 flowrates in the vertical orientation. The strengths and weaknesses of this modeling approach are presented and discussed.

Cryogenic Fluid Management↗