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This is a lecture given at the Combustion Institute Summer School held at UC Irvine in August 2023. Part one provides a primer on aircraft combustors and combustion emissions in turbofan engines. Part two provides a history of NASA-sponsored research to improve emissions and plans for future research.
This paper presents experimental results for a low-NOxaero gas turbine combustor, in particular, a third-generationswirl-venturi lean direct injection (SV-LDI-3) combustor conceptcalled V4. The purpose of testing was three-fold. First,to evaluate the combustor against the 80% NOx reduction goalset by NASA’s AATT project. Second, to compare V4 to a previousSV-LDI-3 combustor concept called V3, especially at lowpower conditions. Third, to examine the accuracy of a type ofcorrelation equation frequently used by engine systems analysisgroups to estimate NOx emissions. All three testing goals weremet. For the first testing goal, with an estimated NOx reductionof 85%-90%, SV-LDI-3 V4 surpassed the AATT goal. For thesecond goal, however, V4 did not perform better than V3 at lowpower conditions. For the third goal, it was found that a majorassumption of the correlation equations — a simple dependenceon combustor inlet pressure — did not hold.
An overview is provided of a parametric study conducted to study the effect of liner cooling airflow rates on NOx emissions of a seven-element lean-direct injection (LDI) module with radial airflow main swirlers. The goal of the CFD study was to determine the increase in cooling flow rate at which the NOx emissions would exceed 20% of the predicted emissions with zero liner cooling flow. The Open version of the National Combustion Code (OpenNCC) was used to perform two-phase reacting flow computations with a new LDI injection module design with radial airflow swirlers instead of axial airflow swirlers. CFD analysis with OpenNCC predicted a 20% increase in EINOx emissions was reached when the liner cooling airflow rate was increased to 15% of the baseline combustor airflow rate. The liner cooling flow rate was predicted to have a non-linear effect on increase in overall EINOx of the seven element LDI injection module.
Film injection from discrete holes in a smooth, flat plate was studied for two configurations: (1) spanwise injection through a four hole staggered array; and (2) compound angle injection through a 49 hole staggered array. The ratio of boundary layer thicknesses to hole diameter and the Reynolds number were typical of gas turbine film cooling applications. Streaklines showing the motion of the injected air were obtained by photographing small, neutrally buoyant, helium-filled soap bubbles that followed the flow field.
Performance tests of short length, gas turbine combustors with atomized or vaporized fuel injection
Film cooling injection is widely applied in the thermal design of turbomachinery, as it contributes to achieve higher operating temperature conditions of modern gas turbines, and to meet the requirements for reliability and life cycles. It is a significant part of the high-pressure turbine system. The film cooling injection, however, interacts with the main flow and is susceptible to have an influence on the aerodynamic performance of the cooled components, and through that may cause a penalty on the overall efficiency of the gas turbine. The main reasons are the loss of total pressure resulting from mixing the cooling air with mainstream and the reduction of the gas stagnation temperature at the exit of the combustion chamber to a lower value at the exit of nozzle guide vane. In addition, the impact of the injected air on the evolution of the trace species of the hot gas is not yet quite clear. This work computationally investigates the film cooling influence on post-combustor trace chemistry, as trace species in aircraft exhaust affect climate and ozone.
Because of one engine inoperative requirements, together with hot-gas reingestion and hot day, high altitude takeoff situations, power augmentation for multiengine rotorcraft has always been of critical interest. However, power augmentation using overtemperature at the turbine inlet will shorten turbine life unless a method of limiting thermal and mechanical stresses is found. A possible solution involves allowing the turbine inlet temperature to rise to augment power while injecting water into the turbine cooling air to limit hot-section metal temperatures. An experimental water injection device was installed in an engine and successfully tested. Although concern for unprotected subcomponents in the engine hot section prevented demonstration of the technique's maximum potential, it was still possible to demonstrate increases in power while maintaining nearly constant turbine rotor blade temperature.
Because of one engine inoperative requirements, together with hot-gas reingestion and hot day, high altitude takeoff situations, power augmentation for multiengine rotorcraft has always been of critical interest. However, power augmentation using overtemperature at the turbine inlet will shorten turbine life unless a method of limiting thermal and mechanical stresses is found. A possible solution involves allowing the turbine inlet temperature to rise to augment power while injecting water into the turbine cooling air to limit hot-section metal temperatures. An experimental water injection device was installed in an engine and successfully tested. Although concern for unprotected subcomponents in the engine hot section prevented demonstration of the technique's maximum potential, it was still possible to demonstrate increases in power while maintaining nearly constant turbine rotor blade temperature.
Performance of a multipoint, lean direct injection (MP-LDI) strategy for low emission aero-propulsion systems has been tested in a Jet-A fueled, lean flame tube combustion rig. Operating conditions for the series of tests included inlet air temperatures between 672 and 828 K, pressures between 1034 and 1379 kPa and total equivalence ratios between 0.41 and 0.45, resulting in equilibrium flame temperatures approaching 1800 K. Ranges of operation were selected to represent the spectrum of subsonic and supersonic flight conditions projected for the next-generation of commercial aircraft. This document reports laser-based measurements of in situ fuel velocities and fuel drop sizes for the NASA 9-point LDI hardware arranged in a 3 3 square grid configuration. Data obtained represent a region of the flame tube combustor with optical access that extends 38.1-mm downstream of the fuel injection site. All data were obtained within reacting flows, without particle seeding. Two diagnostic methods were employed to evaluate the resulting flow path. Three-component velocity fields have been captured using phase Doppler interferometry (PDI), and two-component velocity distributions using planar particle image velocimetry (PIV). Data from these techniques have also offered insight into fuel drop size and distribution, fuel injector spray angle and pattern, turbulence intensity, degree of vaporization and extent of reaction. This research serves to characterize operation of the baseline NASA 9- point LDI strategy for potential use in future gas-turbine combustor applications. An additional motive is the compilation of a comprehensive database to facilitate understanding of combustor fuel injector aerodynamics and fuel vaporization processes, which in turn may be used to validate computational fluid dynamics codes, such as the National Combustor Code (NCC), among others.
An algorithm is presented for calculating both the quantity of compressor bleed flow required to cool the turbine and the decrease in turbine efficiency caused by the injection of cooling air into the gas stream. The algorithm, which is intended for an axial flow, air routine in a properly written thermodynamic cycle code. Ten different cooling configurations are available for each row of cooled airfoils in the turbine. Results from the algorithm are substantiated by comparison with flows predicted by major engine manufacturers for given bulk metal temperatures and given cooling configurations. A list of definitions for the terms in the subroutine is presented.
Aircraft compressors can suffer debilitating consequences as a result of rotating stall and surge events caused by inlet distortions. This is particularly true of aircraft during takeoff, when the compressor is operating at peak performance close to the surge line. Significant research has been conducted by the NASA Glenn Research Center in the area of compressor stability enhancement through active and passive control methods. Most recently, an experiment was conducted at the Wright Patterson Air Force Base Research Laboratory on a two-stage fan with inlet guide vanes and inlet distortion. In this joint Small Business Innovation Research effort between Scientific Systems and Glenn, control of rotating stall was demonstrated in a multistage transonic fan. This twostage fan with inlet guide vanes was tested under clean and distorted inlet conditions. The compressor was also configured with a circumferential distortion screen capable of 180 of distortion and with 14 high-velocity injectors upstream of the first rotor. Twelve of these injectors could oscillate up to frequencies of 450 Hz. The additional two injectors were located next to each other and were used in concert with each other as a single, on/off, high-authority actuator. In a first test of injection in this multistage environment, 12 of the valves were opened 50 percent of their full stroke to assess steady injection through the compressor. This baseline injection is shown in the compressor characteristic of the following figure, and stall margin improvements are tracked from this baseline condition. The compressor was then tested with clean inlet conditions using 12 injectors and active control. Pressure disturbances were tracked before rotating stall, and a constant gain control scheme reduced the stalling mass flow by 10.8 percent over the baseline. With the distortion screen present in the inlet, a pole-zero cancellation control scheme was used to achieve a 6.4-percent decrease in stalling mass flow. These improvements also are shown in the figure. In a final experiment, actively controlled, high-frequency injection from the 12 valves was used in conjunction with the high-authority actuators. In this test, the stalling mass flow of the compressor was reduced by 27 percent as indicated in the graph. These results were obtained by injecting less than 2 percent of the total compressor throughflow into the rotor tip region via 14 injection ports. These results mark the first successful demonstration of actively controlled air injection as a stall-control strategy for multistage compressors operating at speeds typical of an actual gas turbine engine. A goal of continuing research is to determine the combination of air-injection parameters and control strategies that are most effective in providing stall control for both clean and distorted inlet flow conditions for multistage environments. Other goals include the demonstration of stall control at many locations along the core compressor and development and application of active stall control strategies that will be integral flightworthy components of onboard engine hardware.
Because of one-engine-inoperative (OEI) requirements, together with hot-gas reingestion and hot-day, high-altitude take-off situations, power augmentation for multiengine rotorcraft has always been of critical interest. However, power augmentation by using overtemperature at the turbine inlet will shorten turbine life unless a method of limiting thermal and mechanical stress is found. A possible solution involves allowing the turbine inlet temperature to rise to augment power while injecting water into the turbine cooling air to limit hot-section metal temperatures. An experimental water injection device was installed in an engine and successfully tested. Although concern for unprotected subcomponents in the engine hot section prevented demonstration of the technique's maximum potential, it was still possible to demonstrate increases in power while maintaining nearly constant turbine rotor blade temperature.
Rocket engines and high-power new generations of gas-turbine jet engines and diesel engines oftentimes involve the injection of one or more reactants at subcritical temperatures into combustor environments at high pressures, and more particularly at pressures higher than those corresponding to the critical points of the individual components of the mixture, which typically range from 13 to 50 bars for most propellants. This class of trajectories in the thermodynamic space has been traditionally referred to as transcritical. However, the fundamental understanding of fuel atomization, vaporization, mixing, and combustion processes at such high pressures remains elusive. In particular, whereas fuel sprays are relatively well characterized at normal pressures, analyses of dispersion of fuel in high-pressure combustors are hindered by the limited experimental diagnostics and theoretical formulations available. The description of the thermodynamics of hydrocarbon-fueled mixtures employed in chemical propulsion systems is complex and involves mixing-induced phenomena, including an elevation of the critical point whereby the coexistence region of the mixture extends up to pressures much larger than the critical pressures of the individual components. As a result, interfaces subject to surface-tension forces may persist in multicomponent systems despite the high pressures, and may give rise to unexpected spray-like atomization dynamics that are otherwise absent in monocomponent systems above their critical point. In this article, the current understanding of this phenomenon is reviewed within the context of propulsion systems fueled by heavy hydrocarbons. Emphasis is made on analytical descriptions at mesoscopic scales of interest for computational fluid dynamics. In particular, a set of modifications of the constitutive laws in the Navier–Stokes equations for multicomponent flows, supplemented with a high-pressure equation of state and appropriate redefinitions of the thermodynamic potentials, are introduced in this work based on an extended version of the diffuse-interface theory of van der Waals. The resulting formulation involves revisited forms of the stress tensor and transport fluxes of heat and species, and enables a description of the mesoscopic volumetric effects induced by transcritical interfaces consistently with the thermodynamic phase diagram of the mixture at high pressures. Additionally, applications of the theory are illustrated in canonical problems, including dodecane/nitrogen transcritical interfaces in non-isothermal systems. The results indicate that a transcritical interface is formed between the propellant streams that persists downstream of the injection orifice over distances of the same order as the characteristic thermal-entrance length of the fuel stream. The transcritical interface vanishes at an edge that gives rise to a fully supercritical mixing layer.
In this work, a large-scale symmetric canonical axial turbine squealer tip model is developed, which allows for the investigation of incoming gas path flow interaction with coolant flow injected into the squealer cavity. The model is developed to investigate Reynolds numbers on the order of one million for their applicability to novel supercritical CO2 cycles.
The effect of fuel injection technique on the performance of an advanced reverse flow combustor liner constructed of Lamilloy (a multilaminate transpiration type material) was determined. Performance and emission levels are documented over a range of simulated flight conditions using simplex pressure atomizing, spill return, and splash cone airblast injectors. A parametric evaluation of the effect of increased combustor loading with each of the fuel injector types is obtained.
The effect of fuel injection technique on the performance of an advanced reverse flow combustor liner constructed of Lamilloy (a multilaminate transpiration type material) was determined. Performance and emission levels are documented over a range of simulated flight conditions using simplex pressure atomizing, spill return, and splash cone airblast injectors. A parametric evaluation of the effect of increased combustor loading with each of the fuel injector types is obtained.
Mixing of gaseous jets in a cross-flow has significant applications in engineering, one example of which is the dilution zone of a gas turbine combustor. Despite years of study, the design of jet injection in combustors is largely based on practical experience. A series of experiments was undertaken to delineate the optimal mixer orifice geometry. A cross-flow to core-flow momentum-flux ratio of 40 and a mass flow ratio of 2.5 were selected as representative of an advanced design. An experimental test matrix was designed around three variables: the number of orifices, the orifice aspect ratio (long-to-short dimension), and the orifice angle. A regression analysis was performed on the data to arrive at an interpolating equation that predicted the mixing performance of orifice geometry combinations within the range of the test matrix parameters. Results indicate that mixture uniformity is a non-linear function of the number of orifices, the orifice aspect ratio, and the orifice angle. Optimum mixing occurs when the asymptotic mean jet trajectories are in the range of 0.35 less than r/R less than 0.5 (where r = 0 is at the mixer wall) at z/R = 1.0. At the optimum number of orifices, the difference between shallow-angled slots with large aspect ratios and round holes is minimal and either approach will lead to good mixing performance. At the optimum number of orifices, it appears possible to have two local optimums where one corresponds to an aspect ratio of 1.0 and the other to a high aspect ratio.
A mixer assembly for a gas turbine engine is provided, including a main mixer with fuel injection holes located between at least one radial swirler and at least one axial swirler, wherein the fuel injected into the main mixer is atomized and dispersed by the air flowing through the radial swirler and the axial swirler.