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The dimensions of the energy situation are discussed in relation to air travel. Energy conservation, fuel consumption, and combustion efficiency are examined, as well as the proposal for subsonic aircraft using hydrogen fuel.
A brief testing program was undertaken to determine if spontaneous ignition and stable combustion could be obtained in a jet engine afterburning operating with an inlet temperature of 1240 K and a pressure of 1 atmosphere with ASTM Jet-A fuel. Spontaneous ignition with 100-percent combustion efficiency and stable burning was obtained using water-cooled fuel spraybars as flameholders.
Tests were conducted to determine the performance of a hydrogen burner used to produce a test gas that simulates air entering a scramjet combustor at various flight conditions. The test gas simulates air in that it duplicates the total temperature, total pressure, and the volume fraction of oxygen of air at flight conditions. The main objective of the tests was to determine the performance of the burner as a function of the effective exhaust port area. The conclusions were: (1) pressure oscillations of the chugging type were reduced in amplitude to plus or minus 2 percent of the mean pressure level by proper sizing of hydrogen, oxygen, and air injector flow areas; (2) combustion efficiency remained essentially constant as the exhaust port area was increased by a factor of 3.4; (3) the mean total temperature determined from integrating the exit radial gas property profiles was within plus or minus 5 percent of the theoretical bulk total temperature; (4) the measured exit total temperature profile had a local peak temperature more than 30 percent greater than the theoretical bulk total temperature; and (5) measured heat transfer to the burner liner was 75 percent of that predicted by theory based on a flat radial temperature profile.
A full-scale annular swirl can combustor equipped with diffuser bleed capability was tested at low fuel-air ratio, burning natural gas fuel. Test results show that, by drawing off a small amount of air on the inner or outer diffuser wall, the radial profile of combustor exit temperature could be changed from a strongly tip biased, to a strongly hub biased shape. Furthermore, combustor total pressure loss could be reduced by about one third by using a total bleed rate equal to 6 percent of diffuser inlet flow. At simulated engine idle conditions combustion efficiency was increased from 64 percent to nearly 100 percent by using 3 percent outer wall bleed. Combustor blowout performance was also improved significantly by using this diffuser bleed scheme.
Measurement techniques used during nine years of intensive research in supersonic combustion are presented. The tests employed a number of combustor and injector configurations, which were directly connected to a Mach 3.2 supersonic nozzle, and both gaseous hydrogen and storable liquid fuels. Nominal plenum conditions for the arc-heated air were 3000 to 4500 R and 30 atm. Measurements included wall surface pressures, wall temperatures, heat flux, skin friction, instream cone-static and pitot pressures, and gas samples. Measurement and analysis techniques have been developed for determining total enthalpy of an airstream containing NO concentrations in excess of equilibrium using the two-throat technique, bulk combustion efficiency using steam calorimetry, radial gradients of fluid properties in the combustor exit plane using a stream tube method, and wall shear from measurements of heat transfer in a reacting supersonic flow using Reynolds analogy.
A test program was conducted with an augmentor which employed swirling flow as a means of promoting rapid flame propagation. The program evaluated the effect of augmentor length, swirl intensity, fuel zoning and Mach number on augmentor performance. Combustion efficiencies near 100% were demonstrated over most of the operating range which extended from an equivalence ratio of 0.2 to over 1.0. The tests were conducted at an inlet temperature of 649 C (1200 F) and at a pressure of 2 atmospheres. The augmentor total pressure losses were typical of current state of the art augmentors.
A simple, semi-empirical performance correlation/prediction technique applicable to gaseous and liquid propellant rocket engines is presented. Excellent correlations were attained for over 100 test firings by adjusting the computation of the gaseous mixing of an unreactive, coaxial jet using a correlation factor, F, which resulted in prediction of the experimental combustion efficiency for each firing. Static pressure, mean velocity and turbulence intensity in the developing region of non-reactive coaxial jets, typical of those of coaxial injector elements were determined. Detailed profiles were obtained at twelve axial locations (extending from the nozzle exit for a distance of five diameters) downstream from a single element of the Bell Aerospace H2/O2 19-element coaxial injector. These data are compared with analytical predictions made using both eddy viscosity and turbulence kinetic energy mixing models and available computer codes. Comparisons were disappointing, demonstrating the necessity of developing improved turbulence models and computational techniques before detailed predictions of practical coaxial free jet flows are attempted.
A test program was undertaken to determine if variable combustor geometry could be used to reduce exhaust emissions of a low-pressure-ratio jet engine operating at ground idle conditions. Three techniques for varying combustor geometry were simulated. Other techniques evaluated were radial fuel staging and the use of preheated fuel. When simulated variable combustor geometry was employed with radial fuel staging, combustion efficiency at a fuel-air ratio of 0.01 was increased from 77 to 95 percent, and exhaust emissions of unburned hydrocarbons and carbon monoxide were significantly reduced.
Flow measurements were performed on each of six swirl-can combustor module designs under simulated combustor operating conditions to find the design which exhibited a small recirculation zone, intense air mixing, and good fuel distribution in its wake. Conditions that are favorable for producing low oxides of nitrogen emissions and high combustion efficiency were investigated. The recirculation zone, the turbulence intensity and the fuel distribution pattern are obtained in the wake region of the center module of a three module array. The most promising swirl-can module design incorporates two air swirlers which discharge air in opposite directions (contraswirl), mixes the fuel and air upstream of the inner swirler, and has a flow area blockage of 64.3% for the three module array.
Improved designs of swirl-can combustor modules were tested using seven-module arrays in a combustor. The combustor was operated over a pressure range of 69 to 207 N/sq cm, a fuel-air ratio range of 0.015 to 0.046, at a constant inlet air temperature of 733 K, and at reference velocities of 23.9 and 30.6 m/sec. The three designs tested performed with high combustion efficiency at all conditions tested and exhibited oxides of nitrogen emissions substantially lower than that of conventional gas turbine combustors. A correlating parameter used to extrapolate oxides of nitrogen emissions to full power or takeoff conditions for large commercial turbofan engines predicts oxides of nitrogen emissions somewhat higher than those specified in the 1979 government emissions standards.
The performance of a single-can JT8D combustor was investigated with a number of fuels exhibiting wide variations in chemical composition and volatility. Performance parameters investigated were combustion efficiency, emissions of CO, unburned hydrocarbons and NOx, as well as liner temperatures and smoke. At the simulated idle condition no significant differences in performance were observed. At cruise, liner temperatures and smoke increased sharply with decreasing hydrogen content of the fuel. No significant differences were observed in the performance of an oil-shale derived JP-5 and a petroleum-based Jet A fuel except for emissions of NOx which were higher with the oil-shale JP-5. The difference is attributed to the higher concentration of fuel-bound nitrogen in the oil-shale JP-5.
Attention is given to a semiempirical correlation technique based on the rational assumption that the turbulent mixing of reactants is the rate controlling process in combustors employing diffusion flames. Questions of performance computation are considered along with the flow conditions. Predictions of combustion efficiency are obtained with the aid of a standard finite-difference computational technique.-
An analytical investigation is presented of mixing and reacting hydrogen jets injected from multiple orifices transverse and parallel to a supersonic airstream. The COMOC computer program, based upon a finite-element solution algorithm, was developed to solve the governing equations for three-dimensional, turbulent, reacting, boundary-region, and confined flow fields. The computational results provide a three-dimensional description of the velocity, temperature, and species-concentration fields downstream of hydrogen injection. Detailed comparisons between cold-flow data and results of the computational analysis have established validity of the turbulent-mixing model based on the elementary mixing-length hypothesis. A method is established to initiate computations for reacting flow fields based upon cold-flow correlations and the appropriate experimental parameters of Mach number, injector spacing, and pressure ratio. Key analytical observations on mixing and combustion efficiency for reacting flows are presented and discussed.
A test rig program was conducted with the objective of evaluating and minimizing the exhaust emissions, in particular NO sub x, of three advanced aircraft combustor concepts at a simulated, high altitude cruise condition. The three combustor designs, all members of the lean reaction, premixed family, are the Jet Induced Circulation (JIC) combustor, the Vortex Air Blast (VAB) combustor, and a catalytic combustor. They were rig tested in the form of reverse flow can combustors in the 0.127 m. (5.0 in.) size range. Various configuration modifications were applied to each of the initial JIC and VAB combustor model designs in an effort to reduce the emissions levels. The VAB combustor demonstrated a NO sub x level of 1.1 gm NO2/kg fuel with essentially 100% combustion efficiency at the simulated cruise combustor condition of 50.7 N/sq cm (5 atm), 833 K (1500 R) inlet pressure and temperature respectively and 1778 K (3200 R) outlet temperature on Jet-A1 fuel. Early tests on the catalytic combustor were unsuccessful due to a catalyst deposition problem and were discontinued in favor of the JIC and VAB tests. In addition emissions data were obtained on the JIC and VAB combustors at low combustor inlet pressure and temperatures that indicate the potential performance at engine off-design conditions.
Experiments were conducted to determine the effectiveness of several premixing prevaporizing gas turbine combustor designs in reducing formation of oxides of nitrogen at the supersonic cruise condition. An atomized spray from a single injector mounted on the axis of the mixer tube produced a high initial concentration of fuel near the axis and only moderate premixed conditions entering the combustor. A fuel spray produced by 12 flush-mounted normal injection orifices in the mixer tube wall produced a good initial despersion of fuel and resulted in nearly complete premixing. Oxides of nitrogen emission levels of the order of 0.2 g NO2/kg fuel were obtained at 99 percent combustion efficiency at an equivalence ratio of 0.4. Overall total pressure drop was less than 3 percent through the 1-meter combustor module.
Emissions of nitrogen oxides, carbon monoxide, and unburned hydrocarbons were measured in a burner where liquid Jet A fuel was sprayed into the heated air stream and vaporized upstream of a perforated plate flameholder. The burner was tested at inlet air temperatures at 640, 800, and 833 K, an inlet pressure of 5.6 X 100,000 N/m squared, a reference velocity of 25 m/sec, and equivalence ratios from lean blowout to 0.7. Nitrogen oxide levels of below 1.0 g NO2/kg fuel were obtained at combustion efficiencies greater than 99 percent. The measured emission levels for the liquid fuel agreed well with previously reported premixed gaseous propane data and agreed with well stirred reactor predictions. Autoignition of the premixed fuel air mixture was a problem at inlet temperatures above 650 K with 104 msec premixing time.
The following six highly energy intensive industries were studied as targets of energy conservation opportunity: food and kindred products, paper and allied products, chemicals and allied products, petroleum and coal products, stone, glass and clay products, and primary manufacturing. After studying conservation actions within each industry the actions were grouped under three broad categories: increased combustion efficiency, process improvement, and good housekeeping. Some of the results were: (1) approximately 2.18 quads could be saved in 1980 and 2.57 quads in 1985 by installing cogenerative facilities in 50% of the industries, (2) regenerative air-preheaters could result in a 10-15% increase in furnace efficiency representing a 15-25% fuel savings (2.3 to 3.9 quads in 1980 and 2.7 to 4.5 quads in 1985), (3) several major industries have potential for energy savings by recycling-aluminum (0.2 quads), steel (1 quad), glass (0.006 quads), paper and cement (0.08 quads).
A test program has been conducted with an augmentor that employed swirling flow as a means of promoting rapid flame propagation. The program measured the trajectory and dispersion of JP-5-type kerosene sprayed into a strongly swirling flowfield. Using the data obtained, a set of sprayrings was designed and evaluated in the augmentor at conditions simulating those typical of augmented turbojet engines. At the inlet test temperature of 649 C the swirling flowfield had no effect on the radial position of the fuel spray. The augmentor demonstrated combustion efficiencies greater than 95% over most of the operating range, which extended from an equivalence ratio of 0.2 to over 1.0.