Back to the Future: Revisiting Nonpremixed Designs for Fuel Flexible (H2/NH3/CH4), Low NOx Combustion
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Shivam J. Patel↗
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Theoretical and Experimental Investigations of Ignition, Combustion and Expansion Processes of Hypergolic Liquid Fuel Combinations at Gas Temperatures up to 3000 K
The ignition, combustion, and expansion characteristics of hypergolic liquid propellant mixtures in small rocket engines are studied theoretically and experimentally. It is shown by using the Bray approximation procedure that the reaction H + OH + M = H2O + M (where M is the molecular mass of the gas mixture) has a strong effect on the combustion efficiency. Increases in recombination energies ranging from 30 to 65% were obtained when the rate of this reaction was increased by a factor of 10 in gas mixtures containing 90% oxygen. The effect of aluminum additions and various injection techniques on the combustion process is investigated.
Schulz, Harry↗
Three-dimensional computations of transverse hydrogen jet combustion in a supersonic airstream
A computational fluid dynamics (CFD) code is being developed to compute the mixing and combustion of hydrogen fuel in the turbulent flow fields of supersonic combustion ramjets (scramjet). The code solves the three-dimensional Reynolds time-averaged complete Navier-Stokes equations including transport equations for a four species, two reaction, global finite rate chemistry model. The code was applied to the case of transverse injection of hydrogen from a sonic circular orifice into a supersonic airstream. The equations were numerically integrated using MacCormack's explicit method, and the algebraic eddy viscosity model of Baldwin-Lomax was used to model the turbulence. In the species transport and energy equations, diffusion coefficients based on Fick's Law and an assumption of unit Lewis number were applied. Computed features of the three-dimensional flow field are depicted by static pressure, static temperature, mass fraction of species, and velocity vectors. For engineering interest, mixing and combustion parameters were examined to assess the effect of injector diameter, injected fuel pressure, fuel-air ratio, and spacing of fuel injectors. The objective of the present paper is to demonstrate the capability of the present three-dimensional spatially elliptic, CFD code for turbulent, reacting flow. Application of the code to specific supersonic combustion configurations is planned.
Uenishi, K.↗
System Modeling and Diagnostics for Liquefying-Fuel Hybrid Rockets
A Hybrid Combustion Facility (HCF) was recently built at NASA Ames Research Center to study the combustion properties of a new fuel formulation that burns approximately three times faster than conventional hybrid fuels. Researchers at Ames working in the area of Integrated Vehicle Health Management recognized a good opportunity to apply IVHM techniques to a candidate technology for next generation launch systems. Five tools were selected to examine various IVHM techniques for the HCF. Three of the tools, TEAMS (Testability Engineering and Maintenance System), L2 (Livingstone2), and RODON, are model-based reasoning (or diagnostic) systems. Two other tools in this study, ICS (Interval Constraint Simulator) and IMS (Inductive Monitoring System) do not attempt to isolate the cause of the failure but may be used for fault detection. Models of varying scope and completeness were created, both qualitative and quantitative. In each of the models, the structure and behavior of the physical system are captured. In the qualitative models, the temporal aspects of the system behavior and the abstraction of sensor data are handled outside of the model and require the development of additional code. In the quantitative model, less extensive processing code is also necessary. Examples of fault diagnoses are given.
Poll, Scott↗
Self-Aligned Focusing Schlieren and OH Planar Laser-Induced Fluorescence Flow Visualization in a Dual-Mode Scramjet
Ahigh-speed self-aligned focusing schlieren (SAFS) system was used to visualize density gradients in and around the cavity flameholder of the combustor section of the University of Virginia Supersonic Combustion Facility (UVASCF). Images with this system were acquired at a framing rate of 110 kHz with no fuel injection, with fuel injection but no flame, and for fuel injection with combustion corresponding to a global equivalence ratio of 𝜙 = 0.18. Images with an air throttle in operation to modify the shock train location with fuel injection and with flame were also acquired. Simultaneous OH planar laser-induced fluorescence (PLIF) images were also acquired at a framing rate of 20 Hz. Results obtained with both visualization techniques are compared to one another to highlight how SAFS can complement more advanced flow visualization techniques and resolve dynamic behavior that may not otherwise be captured. Both proper orthogonal decomposition (POD) and dynamic mode decomposition (DMD) analysis techniques are applied to the SAFS image sequences to identify coherent periodic structures for the runs with fuel injection and combustion.
Brett F Bathel↗
Effect of degree of fuel vaporization upon emissions for a premixed partially vaporized combustion system
An experimental and analytical study of the combustion of partially vaporized fuel-air mixtures was performed to assess the impact of the degree of fuel vaporization upon emissions for a premixing-prevaporizing flametube combustor. Data collected in this study showed near linear increases in nitric oxide emissions with decreasing vaporization at equivalence ratios of 0.6. For equivalence ratios of 0.72, the degree of vaporization had very little impact on nitric oxide emissions. A simple mechanism which accounts for the combustion of liquid droplets in partially vaporized mixtures was found to agree with the measured results with fair accuracy with respect to both trends and magnitudes.
Cooper, L. P.↗
Longitudinal mode combustion instabilities of a high-pressure fuel-rich LOX/RP-1 preburner
During the hot-fire testing of a high-pressure fuel-rich LOX/RP-1 preburner, longitudinal mode combustion instabilities were observed. The experimental data showing how the instability varied with the chamber pressure, mixture ratio, chamber length and turbulence ring are given. Technical rationales are given for the test-to-test hardware configuration changes that eventually led to the stable result.
Fang, J. J.↗
Longitudinal mode combustion instabilities of a high-pressure fuel-rich LOX/RP-1 preburner
During the hot-fire testing of a high-pressure fuel-rich LOX/RP-1 preburner, longitudinal mode combustion instabilities were observed. This paper presents the experimental data showing how the instability varied with the chamber pressure, mixture ratio, chamber length and turbulence ring. Technical rationales are given for the test-to-test hardware configuration changes that eventually led to the stable result.
Fang, J. J.↗
Control of Thermo-Acoustics Instabilities: The Multi-Scale Extended Kalman Approach
"Multi-Scale Extended Kalman" (MSEK) is a novel model-based control approach recently found to be effective for suppressing combustion instabilities in gas turbines. A control law formulated in this approach for fuel modulation demonstrated steady suppression of a high-frequency combustion instability (less than 500Hz) in a liquid-fuel combustion test rig under engine-realistic conditions. To make-up for severe transport-delays on control effect, the MSEK controller combines a wavelet -like Multi-Scale analysis and an Extended Kalman Observer to predict the thermo-acoustic states of combustion pressure perturbations. The commanded fuel modulation is composed of a damper action based on the predicted states, and a tones suppression action based on the Multi-Scale estimation of thermal excitations and other transient disturbances. The controller performs automatic adjustments of the gain and phase of these actions to minimize the Time-Scale Averaged Variances of the pressures inside the combustion zone and upstream of the injector. The successful demonstration of Active Combustion Control with this MSEK controller completed an important NASA milestone for the current research in advanced combustion technologies.
Le, Dzu K.↗
Plasma torch for ignition, flameholding and enhancement of combustion in high speed flows
Preheating of fuel and injection into a plasma torch plume fro adjacent the plasma torch plume provides for only ignition with reduced delay but improved fuel-air mixing and fuel atomization as well as combustion reaction enhancement. Heat exchange also reduced erosion of the anode of the plasma torch. Fuel mixing atomization, fuel mixture distribution enhancement and combustion reaction enhancement are improved by unsteady plasma torch energization, integral formation of the heat exchanger, fuel injection nozzle and plasma torch anode in a more compact, low-profile arrangement which is not intrusive on a highspeed air flow with which the invention is particularly effective and further enhanced by use of nitrogen as a feedstock material and inclusion of high pressure gases in the fuel to cause effervescence during injection.
O'Brien, Walter F.↗
Autoignition of hydrogen injected transverse to a supersonic airstream
A parametric study of autoignition characteristics of transverse fuel injector patterns for a hydrogen-fueled, supersonic-combustion ramjet was conducted in direct-connect tests over a range of simulated hypersonic flight conditions. Autoignition limits, defined directly by visual observations and indirectly by measured wall pressure and temperature, are compared with a semi-empirical ignition limit model which accounts for first order effects on autoignition. It is shown that to initiate combustion in the immediate region of the fuel injector, ignition must occur in the separation region ahead of the fuel jet. Autoignition within this separation zone exhibits strong dependence on flow pressure and temperature, injector diameter, local boundary layer energy thickness, wall temperature, and on fluid dynamic interactions with adjacent downstream facing steps (such as inlet isolation steps). Secondary effects are also discussed. The empirical model is used to define limits of test temperature, pressure, and scale required for autoignition in a current subscale engine test program.
Mcclinton, C. R.↗
Overview of thermal barrier coatings in diesel engines
An understanding of delamination mechanisms in thermal barrier coatings has been developed for diesel engine applications through rig tests, structural analysis modeling, nondestructive evaluation, and engine evaluation of various thermal barrier coatings. This knowledge has resulted in improved thermal barrier coatings which survive abusive cyclic fatigue tests in high output diesel engines. Although much conflicting literature now exists regarding the impact of thermal barrier coatings on engine performance and fuel consumption, the changes in fuel consumption appear to be less than a few percent and can be negative for state-of-the-art diesel engines. The ability of the thermal barrier coating to improve fuel economy tends to be dependent on a number of factors including the fuel injection system, combustion chamber design, and the initial engine fuel economy. Limited investigations on state-of-the-art diesel engines have indicated that the surface connected porosity and coating surface roughness may influence engine fuel economy. Current research efforts on thermal barrier coatings are primarily directed at reducing in-cylinder heat rejection, thermal fatigue protection of underlying metal surfaces and a possible reduction in diesel engine emissions. Significant efforts are still required to improve the plasma spray processing capability and the economics for complex geometry diesel engine components.
Yonushonis, Thomas M.↗
Pressure Effects on Combustion of Methanol and Methanol-Docecanol Droplets
The objective of this research is to improve understanding of the combustion of binary fuel mixtures in the vicinity of the critical point. Fiber-supported single droplets and two-droplet arrays of methanol and of mixtures of methanol and 1-dodecanol, initially 0.9 mm in diameter, were burned in room-temperature air at pressures from 0.1 MPa to 9.0 MPa in the NASA Lewis 2.2-second drop tower. The work is a continuation of a collaborative Japan-US research effort designed to increase knowledge of high-pressure combustion of fuel sprays, relevant to application in propulsive and power-production devices such as Diesel engines. Some previous publications from this cooperative program may be cited. All of the previous experiments concerned alkanes and alkane mixtures. The new research reported here addresses alcohols and alcohol mixtures, to ascertain the degree to which previous results for alkanes extend to alcohols. There have been many previous experimental studies of methanol droplet combustion and a few of alcohol mixtures, but not at the high pressures of interest here. There is some experimental information on methanol droplet combustion at elevated pressure but none on the alcohol mixtures extending to critical pressures, as in the present study.
Okai, K.↗
Corrosion Prevention in Copper Combustion Chamber Liners of Liquid Oxygen/Methane Booster Engines
Prior research conducted by United Technologies Research Center and Rockwell International Rocketdyne Division encountered severe copper corrosion while flowing hydrocarbon fuels through copper cooling tubes. These experimental results have very important implications for the development of low-cost, regeneratively cooled, oxygen/hydrocarbon bipropellant booster engines. Aerojet TechSystems undertook a program sponsored by NASA/Lewis Research Center in 1986 with two objectives: (1) to define the corrosive interaction process that occurs between hydrocarbon fuels and copper combustion chamber liner materials, using both static and dynamic test methods, and (2) to identify and demonstrate protective measures against this corrosive process. The results of the first program task demonstrated that the most damaging corrosive process was caused by trace amounts of sulfur-containing impurities in the hydrocarbon fuel which react with the copper chamber liner material to form cuprous sulfide (Cu2S), as reported in Paper No. AlAA 88-3215. Experiments were conducted which demonstrated this corrosive process with Mil-Spec RP-1, propane, and methane fuels in contact with OFHC, NASA-Z, and ZrCu coppers. The preliminary results of the second program task demonstrated that electrodeposited gold and platinum coatings held promise of preventing corrosion of copper chamber liners by methane contaminated with sulfur-containing impurities, as reported in Paper No. AIAA 89-2738. Experiments were conducted which demonstrated greatly reduced corrosion of copper by hydrogen sulfide (H2S) and methyl mercaptan (CH3SH) as measured impurities in methane. This paper presents the concluding, confirmatory results from the second program task. The efficacy of a protective gold coating on NASA-Z copper cooling channel walls was conclusively demonstrated. Tests were conducted in the Aerojet Carbothermal Test Facility which provide realistic simulations of booster engine cooling channel conditions such as temperature, pressure, flow velocity, and heat flux. Dynamic test series were performed with methane containing 5 and 10 ppm (by volume) hydrogen sulfide. Gold-plated and unplated copper alloy specimens were evaluated. The tests demonstrated that gold coatings were effective in preventing corrosion of the copper. Posttest metallographic examinations of the unplated specimens showed severe corrosion as a result of reaction with the sulfur containing contaminant in the fuel. In contrast, posttest metallographic examination of the gold-coated specimens showed no corrosion under similar operating conditions. The findings from metallurgical and chemical analyses of the copper specimens, chemical analysis of the methane, and description of all test conditions are provided. Conclusions are reached as to the efficacy of the plating methods and the effectiveness of the metal coatings in the prevention of corrosion in hydrocarbon-fueled booster engine combustion chamber liners.
S D Rosenberg↗
Experimental investigation of fuel evaporation in the vaporizing elements of combustion chambers
A description is given of the experimental apparatus and the methods used in the investigation of the degree of fuel (kerosene) evaporation in two types of vaporizing elements in combustion chambers. The results are presented as dependences of the degree of fuel evaporation on the factors which characterize the functioning of the vaporizing elements: the air surplus coefficient, the velocity of flow and temperature of the air at the entrance to the vaporizing element and the temperature of the wall of the vaporizing element.
Vezhba, I.↗
Low Emission Hydrogen Combustors for Gas Turbines Using Lean Direct Injection
One of the key technology challenges for the use of hydrogen in gas turbine engines is the performance of the combustion system, in particular the fuel injectors. To investigate the combustion performance of gaseous hydrogen fuel injectors flame tube combustor experiments were performed. Tests were conducted to measure the nitrogen oxide (NOx) emissions and combustion performance at inlet conditions of 600 to 1000 deg F, 60 to 200 pounds per square inch absolute (psia), and equivalence ratios up to 0.48. All the injectors were based on Lean Direct Injection (LDI) technology with multiple injection points and quick mixing. One challenge to hydrogen based premixing combustion systems is flashback since hydrogen has a reaction rate over seven times that of Jet-A. To reduce the risk, design mixing times were kept short and velocities high to minimize flashback. Five fuel injector designs were tested in 2.5 and 3.5-in. diameter flame tubes with non-vitiated heated air and gaseous hydrogen. Data is presented on measurements of NOx emissions and combustion efficiency for the hydrogen injectors at 1.0, 3.125, and 5.375 in. from the injector face. Results show that for some configurations, NOx emissions are comparable to that of state of the art Jet-A LDI combustor concepts.
Marek, C. John↗
Low-Emission Hydrogen Combustors for Gas Turbines Using Lean Direct Injection
One of the key technology challenges for the use of hydrogen in gas turbine engines is the performance of the combustion system, in particular the fuel injectors. To investigate the combustion performance of gaseous hydrogen fuel injectors flame tube combustor experiments were performed. Tests were conducted to measure the nitrogen oxide (NO(x)) emissions and combustion performance at inlet conditions of 588 to 811 K, 0.4 to 1.4 MPa, and equivalence ratios up to 0.48. All the injectors were based on Lean Direct Injection (LDI) technology with multiple injection points and quick mixing. One challenge to hydrogen-based premixing combustion systems is flashback since hydrogen has a reaction rate over 7 times that of Jet-A. To reduce the risk, design mixing times were kept short and velocities high to minimize flashback. Five fuel injector designs were tested in 6.35- and 8.9-cm-diameter flame tubes with non-vitiated heated air and gaseous hydrogen. Data is presented on measurements of NO(x) emissions and combustion efficiency for the hydrogen injectors at 2.540, 7.937, and 13.652 cm from the injector face. Results show that for some configurations, NO(x) emissions are comparable to that of state of the art Jet-A LDI combustor concepts.
Marek, C. John↗
Computer program for obtaining thermodynamic and transport properties of air and products of combustion of ASTM-A-1 fuel and air
A computer program for determining desired thermodynamic and transport property values by means of a three-dimensional (pressure, fuel-air ratio, and either enthalpy or temperature) interpolation routine was developed. The program calculates temperature (or enthalpy), molecular weight, viscosity, specific heat at constant pressure, thermal conductivity, isentropic exponent (equal to the specific heat ratio at conditions where gases do not react), Prandtl number, and entropy for air and a combustion gas mixture of ASTM-A-1 fuel and air over fuel-air ratios from zero to stoichiometric, pressures from 1 to 40 atm, and temperatures from 250 to 2800 K.
Hippensteele, S. A.↗