Solid Propellant Engineering
Solid propellant engineering, binder curing reactions, ATS engine development, pintle nozzle thrust vector control, and low pressure combustion
COMBUSTION↗
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Search indexed NASA NTRS and DOE OSTI research on propulsion, heat transfer, battery materials and energy systems. Follow report and document links to the original sources.
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Longitudinal Mode Aeroengine Combustion Instability: Model and Experiment
Combustion instabilities in gas turbine engines are most frequently encountered during the late phases of engine development, at which point they are difficult and expensive to fix. The ability to replicate an engine-traceable combustion instability in a laboratory-scale experiment offers the opportunity to economically diagnose the problem more completely (to determine the root cause), and to investigate solutions to the problem, such as active control. The development and validation of active combustion instability control requires that the casual dynamic processes be reproduced in experimental test facilities which can be used as a test bed for control system evaluation. This paper discusses the process through which a laboratory-scale experiment and be designed to replicate an instability observed in a developmental engine. The scaling process used physically-based analyses to preserve the relevant geometric, acoustic, and thermo-fluid features, ensuring that results achieved in the single-nozzle experiment will be scalable to the engine.
Cohen, J. M.↗
Reduction of nitric oxide emissions from a combustor
A turbojet combustor and method for controlling nitric oxide emissions by employing successive combustion zones is described. After combustion of an initial portion of the fuel in a primary combustion zone, the combustion products of the primary zone are combined with the remaining portion of fuel and additional plenum air and burned in a secondary combustion zone under conditions that result in low nitric oxide emissions. Low nitric oxide emissions are achieved by a novel turbojet combustor arrangement which provides flame stability by allowing stable combustion to be accompanied by low nitric oxide emissions resulting from controlled fuel-lean combustion (ignited by the emission products from the primary zone) in a secondary combustion zone at a lower combustion temperature resulting in low emission of nitric oxide.
Craig, R. A.↗
Ignition and combustion characteristics of metallized propellants
Research designed to develop detailed knowledge of the secondary atomization and ignition characteristics of aluminum slurry propellants was started. These processes are studied because they are the controlling factors limiting the combustion efficiency of aluminum slurry propellants in rocket applications. A burner and spray rig system allowing the study of individual slurry droplets having diameters from about 10 to 100 microns was designed and fabricated. The burner generates a near uniform high temperature environment from the merging of 72 small laminar diffusion flames above a honeycomb matrix. This design permits essentially adiabatic operation over a wide range of stoichiometries without danger of flashback. A single particle sizing system and velocimeter also were designed and assembled. Light scattered from a focused laser beam is related to the particle (droplet) size, while the particle velocity is determined by its transit time through the focal volume. Light from the combustion of aluminum is also sensed to determine if ignition was achieved. These size and velocity measurements will allow the determination of disruption and ignition times as functions of drop sizes and ambient conditions.
Turns, S. R.↗
An analysis of combustion studies in shock expansion tunnels and reflected shock tunnels
The effect of initial nonequilibrium dissociated air constituents on the combustion of hydrogen in high-speed flows for a simulated Mach 17 flight condition was investigated by analyzing the results of comparative combustion experiments performed in a reflected shock tunnel test gas and in a shock expansion tunnel test gas. The results were analyzed and interpreted with a one-dimensional quasi-three-stream combustor code that includes finite rate combustion chemistry. The results of this study indicate that the combustion process is kinetically controlled in the experiments in both tunnels and the presence of the nonequilibrium partially dissociated oxygen in the reflected shock tunnel enhances the combustion. Methods of compensating for the effect of dissociated oxygen are discussed.
Jachimowski, Casimir J.↗
Advanced Engine and Fuel Technologies Annual Progress Report (FY2019)
On behalf of the Vehicle Technologies Office of the U.S. Department of Energy, we are pleased to introduce the Fiscal Year (FY) 2019 Annual Progress Report for the Advanced Engine and Fuel Technologies Program. In support of the Vehicle Technology Office’s goal for future U.S. economic growth, the Program focuses on early-stage research and development to improve understanding of combustion processes, fuel properties, and emissions control technologies, generating knowledge and insight necessary for industry to cost-effectively develop the next generation of engines and fuels. One of the most promising and cost-effective approaches to improving the fuel economy of the U.S. vehicle fleet is to introduce the next generation of higher-efficiency, very-low-emission combustion engines that meet future federal emissions regulations into the passenger and commercial vehicle markets. Advanced fuel formulations that can incorporate non-petroleum-based blending agents could further enhance engine efficiency, reduce greenhouse gas emissions, and provide fuel diversification. Also, innovations in combustion, fuels, emissions control, air control, turbomachinery, and energy recovery could potentially increase fuel economy considerably compared to today’s vehicles. The expected national economic, environmental, and energy security benefits from these next-generation engines and fuels would be significant inasmuch as the majority of vehicles sold over the next several decades will still include an engine. The Program has set the following goals for passenger and commercial vehicle fuel economy improvements. By 2030, increase light-duty engine efficiency to demonstrate 35% improvement in passenger vehicle fuel economy (25% improvement from engine efficiency and 10% from fuel co-optimization) relative to a 2015 baseline vehicle, while meeting the U.S. Environmental Protection Agency Tier 3 Emission and Fuel Standards. By 2030, improve heavy-duty engine efficiency by 35% relative to a 2009 baseline vehicle and identify cost-effective high-performance fuels that can further increase efficiency up to an additional 4%, while meeting prevailing U.S. Environmental Protection Agency emissions standards. The Program utilized advanced combustion processes to increase engine efficiency, resulting in a modeled passenger vehicle fuel economy improvement of 19.4% (over a Model Year 2015 baseline) in FY 2019. This report highlights progress achieved by the Advanced Engine and Fuel Technologies Program during FY 2019. The nature, current focus, and recent progress of the Program are described together with summaries of National Laboratory, industry, and university projects that provide an overview of the exciting work being conducted to address critical technical barriers and challenges to commercializing the next generation of higher-efficiency engine, emissions control, and fuel technologies for passenger and commercial vehicles.
33 ADVANCED PROPULSION SYSTEMS↗
Digital temperature and velocity control of mach 0.3 atmospheric pressure durability testing burner rigs in long time, unattended cyclic testing
Hardware and software were developed to implement the hybrid digital control of two Jet A-1 fueled Mach 0.3 burners from startup to completion of a preset number of hot corrosion flame durability cycle tests of materials at 1652 F. This was accomplished by use of a basic language programmable microcomputer and data aquisition and control unit connected together by the IEEE-488 Bus. The absolute specimen temperature was controlled to + or - 3 F by use of digital adjustment of the fuel flow using a P-I-D (Proportional-Integral-Derivative) control algorithm. The specimen temperature was within + or - 2 F of the set point more than 90 percent of the time. Pressure control was achieved by digital adjustment of the combustion air flow using a proportional control algorithm. The burner pressure was controlled at 1.0 + or - 0.02 psig. Logic schemes were incorporated into the system to protect the test specimen from abnormal test conditions in the event of a hardware of software malfunction.
Deadmore, D. L.↗
Heavy-Duty Mixed-Controlled Compression Ignition: Fuel Effects and Ducted Fuel Injection.
This project is focused on developing advanced combustion strategies for mixing-controlled compression ignition (MCCI, i.e., diesel-cycle) engines that are synergistic with renewable and/or unconventional fuels in a manner that enhances domestic energy security, economic competitiveness, and environmental quality. During this reporting period, the two focus areas were ducted fuel injection (DFI) and surrogate diesel fuels.
33 ADVANCED PROPULSION SYSTEMS↗
Burn coal cleanly in a fluidized bed - The key is in the controls
The fluidized-bed combustion (FBC) process produces few sulfur emissions, and can burn wood, municipal solid waste as well as every kind of coal available in the U.S. The presurized, coal-burning fluidized-bed reactor at NASA's Lewis Research Center is described, together with a discussion of the operating results. The FBC system at Lewis, having a completely instrumented reactor, is used to test turbine blade alloys for future power plant applications. With the same type of coal and limestone used in the first testing phase covering 136 hours, it was found that all NOx values were below the EPA standard of 0.7 lb/MBtu, whereas the maximum observed level of SO2 was above the EPA standard of 1.3 lb/MBtu, but with the average SO2 level, however, only 0.63 lb/MBtu. Unburned hydrocarbon and CO levels were very low, indicating combustion efficiencies of close to 99% in almost all tests. Testing is now underway using high temperature cyclones and gas turbine to eliminate erosion and corrosion effects which were observed after the initial tests on the turbine and blades.
Kobak, J. A.↗
An extended supersonic combustion model for the dynamic analysis of hypersonic vehicles
The development of an advanced dynamic model for aeroelastic hypersonic vehicles powered by air breathing engines requires an adequate engine model. This report provides a discussion of some of the more important features of supersonic combustion and their relevance to the analysis and design of supersonic ramjet engines. Of particular interest are those aspects of combustion that impact the control of the process. Furthermore, the report summarizes efforts to enhance the aeropropulsive/aeroelastic dynamic model developed at the Aerospace Research Center of Arizona State University by focusing on combustion and improved modeling of this flow. The expanded supersonic combustor model described here has the capability to model the effects of friction, area change, and mass addition, in addition to the heat addition process. A comparison is made of the results from four cases: (1) heat addition only; (2) heat addition plus friction; (3) heat addition, friction, and area reduction, and (4) heat addition, friction, area reduction, and mass addition. The relative impact of these effects on the Mach number, static temperature, and static pressure distributions within the combustor are then shown. Finally, the effects of frozen versus equilibrium flow conditions within the exhaust plume is discussed.
Bossard, J. A.↗
Verification of diesel spray ignition phenomenon in dual-fuel diesel-piloted premixed natural gas engine
Dual-fuel (DF) engines, in which premixed natural gas and air in an open-type combustion chamber is ignited by diesel-fuel pilot sprays, have been more popular for marine use than pre-chamber spark ignition (PCSI) engines because of their superior durability. However, control of ignition and combustion in DF engines is more difficult than in PCSI engines. In this context, here we focus on the ignition stability of n-heptane pilot-fuel jets injected into a compressed premixed charge of natural gas and air at low-load conditions. To aid understanding of the experimental data, chemical-kinetics simulations were carried out in a simplified engine-environment that provided insight into the chemical effects of methane (CH4) on pilot-fuel ignition. The simulations reveal that CH4 has an effect on both stages of n-heptane autoignition: the small, first-stage, cool-flame-type, low-temperature ignition (LTI) and the larger, second-stage, high-temperature ignition (HTI). As the ratio of pilot-fuel to CH4 entrained into the spray decreases, the initial oxidization of CH4 consumes the OH radicals produced by pilot-fuel decomposition during LTI, thereby inhibiting its progression to HTI. Using imaging diagnostics, the spatial and temporal progression of LTI and HTI in DF combustion are measured in a heavy-duty optical engine, and the imaging data are analyzed to understand the cause of severe fluctuations in ignition timing and combustion completeness at low-load conditions. Images of cool-flame and hydroxyl radical (OH*) chemiluminescence serve as indicators of LTI and HTI, respectively. The cycle-to-cycle and spatial variation in ignition extracted from the imaging data are used as key metrics of comparison. The imaging data indicate that the local concentration of the pilot-fuel and the richness of the surrounding natural-gas air mixture are important for LTI and HTI, but in different ways. In particular, higher injection pressures and shorter injection durations increase the mixing rate, leading to lower concentrations of pilot-fuel more quickly, which can inhibit HTI even as LTI remains relatively robust. Decreasing the injection pressure from 80 MPa to 40 MPa and increasing the injection duration from 500 µs to 760 µs maintained constant pilot-fuel mass, while promoting robust transition from LTI to HTI by effectively slowing the mixing rate. This allows enough residence time for the OH radicals, produced by the two-stage ignition chemistry of the pilot-fuel, to accelerate the transition from LTI to HTI before being consumed by CH4 oxidation. Thus from a practical perspective, for a premixed natural gas fuel–air equivalence-ratio, it is possible to improve the “stability” of the combustion process by solely manipulating the pilot-fuel injection parameters while maintaining constant mass of injected pilot-fuel. This allows for tailoring mixing trajectories to offset changes in fuel ignition chemistry, so as to promote a robust transition from LTI to HTI by changing the balance between the local concentration of the pilot-fuel and richness of the premixed natural gas and air. This could prove to be a valuable tool for combustion design to improve fuel efficiency or reduce noise or perhaps even reduce heat-transfer losses by locating early combustion away from in-cylinder walls.
42 ENGINEERING↗
Fiber-Supported Droplet Combustion Experiment-2
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).
Colantonio, Renato O.↗
Nonlinear combustion instability in liquid propellant rocket motors
Fluid dynamic model and diffusion-controlled flame analysis data on nonlinear combustion instability in liquid propellant rocket engines
Burstein, S. Z.↗
Nitrogen evolution, NO X formation and reduction in pressurized oxy coal combustion
Oxy-combustion is one of the most prominent solutions for reducing CO 2 emissions from coal-fired power plants using carbon-capture-and-utilization technology. However, when compared to air combustion at atmospheric pressure, oxy-combustion is very expensive, owing to the significant efficiency penalties associated with air separation, flue gas recirculation (FGR), treatment, compression, and storage or transit of CO 2 . In comparison, pressurized oxy-combustion (POC) is more efficient as it recovers a significant amount of heat energy from the flue gas moistures. Nevertheless, CO 2 derived from pressurized oxy coal combustion has impurities, e.g., acid gases (NO X and SO X ) that can corrode the plant equipment, transport lines as well as deteriorating effect on the environment. Fortunately, in pressurized combustion systems, both NO X and SO X can be scrubbed by a single-column direct contact cooler (DCC), but this requires a minimum ratio of NO X to SO X at the inlet to be efficiently removed. Therefore, NOx is one of the important hindering parameters in commercializing the pressurized oxy-combustion. Although NOx evolution during oxy-coal combustion has been explored extensively at 1 atm, higher pressure studies are rare. Much still needs to be done to better understand the NO X mechanism and the effects of different parameters on NO X emissions under these conditions. Here, this paper reviews the published literature on nitrogen evolution, NO X formation and reduction in pressurized oxy-coal combustion. At higher pressures, the NO X from fuel-bound nitrogen is generated through volatiles, tar and char, all of which are discussed. Where literature is not available, the effect of pressure on NOx evolution in different stages of coal combustion is predicted through CHEMKIN simulation. Homogeneous and heterogeneous pathways of NO X formation and their destruction in pressurized oxy-coal combustion are evaluated. Additionally, the effect of pressure on a few mature and commercialized NOx abatement methods is explored. In the last, the future perspective and recommendation are given. This review will aid in the provision of basic knowledge about NOx evolution and control in pressurized fuel combustion, as well as the identification of new research areas to pursue.
01 COAL, LIGNITE, AND PEAT↗
Smoke Point in Co-flow Experiment
The Smoke Point In Co-flow Experiment (SPICE) determines the point at which gas-jet flames (similar to a butane-lighter flame) begin to emit soot (dark carbonaceous particulate formed inside the flame) in microgravity. Studying a soot emitting flame is important in understanding the ability of fires to spread and in control of soot in practical combustion systems space. Previous experiments show that soot dominates the heat emitted from flames in normal gravity and microgravity fires. Control of this heat emission is critical for prevention of the spread of fires on Earth and in space for the design of efficient combustion systems (jet engines and power generation boilers). The onset of soot emission from small gas jet flames (similar to a butane-lighter flame) will be studied to provide a database that can be used to assess the interaction between fuel chemistry and flow conditions on soot formation. These results will be used to support combustion theories and to assess fire behavior in microgravity. The Smoke Point In Co-flow Experiment (SPICE) will lead to a o improved design of practical combustors through improved control of soot formation; o improved understanding of and ability to predict heat release, soot production and emission in microgravity fires; o improved flammability criteria for selection of materials for use in the next generation of spacecraft. The Smoke Point In Co-flow Experiment (SPICE) will continue the study of fundamental phenomena related to understanding the mechanisms controlling the stability and extinction of jet diffusion flames begun with the Laminar Soot Processes (LSP) on STS-94. SPICE will stabilize an enclosed laminar flame in a co-flowing oxidizer, measure the overall flame shape to validate the theoretical and numerical predictions, measure the flame stabilization heights, and measure the temperature field to verify flame structure predictions. SPICE will determine the laminar smoke point properties of non-buoyant jet diffusion flames (i.e., the properties of the largest laminar jet diffusion flames that do not emit soot) for several fuels under different nozzle diameter/co-flow velocity configurations. Luminous flame shape measurements would also be made to verify models of the flame shapes under co-flow conditions. The smoke point is a simple measurement that has been found useful to study the influence of flow and fuel properties on the sooting propensity of flames. This information would help support current understanding of soot processes in laminar flames and by analogy in turbulent flames of practical interest.
Urban, David L.↗
Hybrid propulsion based on fluid-controlled solid gas generators
The use of fuel-rich solid (gas generator-type) propellants for hybrid propulsion affords some design and utilization efficiency advantages. Both forward and aft liquid injection control concepts are evaluated from the operational standpoints of ballistics, throttling, stability and extinguishment. Steady-state and non-steady ballistics analyses are employed for this evaluation. Stability of solid motor operation is enhanced by fluid injection with adequate injector pressure drop. Efficient throttling and reliable extinguishment are attained through a combination of solid propellant combustion tailoring, grain design, control valves and sensors. Initial results from a laboratory-scale slab combustor, combining a gas generator propellant with gaseous oxygen injection, are also presented.
Cohen, Norman S.↗
Co-optimization of fuel properties, combustion system geometry, and injection strategy for conventional diesel fuel
Here, studies have shown that fuel properties can impact an engine’s operation in several ways, including ignition delay, sooting tendency, mixture formation, and combustion temperature. In mixing-controlled compression ignition (MCCI) engines, the fuel system design and piston bowl geometry significantly affect combustion performance and emissions. Based on current information, it is difficult to draw conclusions about fuel property effects and sensitivities. The central fuel hypothesis approach used in the US Department of Energy Co-Optima program has worked well for spark ignition fuels: identifying critical fuel property ranges is sufficient to screen fuel blends that are expected to maximize efficiency and reduce pollutant emissions. However, for MCCI-relevant fuels, the information gained from past studies is not sufficient to build such a merit function or to allow for performing a similar screening of fuel blends. It is hypothesized that a co-optimization of a fuel’s physical and chemical properties, combustion system geometry, and injection strategy could leverage synergies between the effects of the fuel properties and geometries, resulting in improved performance over state-of-the-art. A machine learning–assisted unconstrained global optimization algorithm was used to explore a design space comprising 23 independent variables. The results show that physical property effects were minimal even for large variations in fuel properties, and the only interaction effect that was observed was the effect of varied fuel density parameters on fuel/air mixture formation. Nevertheless, these interactions were not sufficient in magnitude to significantly affect optimization results. Therefore, analysis of the results suggests that fuel physical properties cannot be leveraged in a co-optimization context to increase engine efficiency.
33 ADVANCED PROPULSION SYSTEMS↗
Advanced Engine and Fuel Technologies FY2020 Annual Progress Report
In support of the Vehicle Technology Office’s goal for future U.S. economic growth, the Advanced Engine and Fuel Technologies Program focuses early-stage research and development on improving the understanding of combustion processes, fuel properties, and emissions control technologies, generating knowledge and insight necessary for industry to develop the next generation of engines and fuels for the efficient, cost-effective, and secure transportation of people and goods across America.
33 ADVANCED PROPULSION SYSTEMS↗