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NASA NTRS1981

Low NOx Heavy Fuel Combustor Concept Program

The development of the technology required to operate an industrial gas turbine combustion system on minimally processed, heavy petroleum or residual fuels having high levels of fuel-bound nitrogen (FBN) while producing acceptable levels of exhaust emissions is discussed. Three combustor concepts were designed and fabricated. Three fuels were supplied for the combustor test demonstrations: a typical middle distillate fuel, a heavy residual fuel, and a synthetic coal-derived fuel. The primary concept was an air staged, variable-geometry combustor designed to produce low emissions from fuels having high levels of FBN. This combustor used a long residence time, fuel-rich primary combustion zone followed by a quick-quench air mixer to rapidly dilute the fuel rich products for the fuel-lean final burnout of the fuel. This combustor, called the rich quench lean (RQL) combustor, was extensively tested using each fuel over the entire power range of the model 570 K engine. Also, a series of parameteric tests was conducted to determine the combustor's sensitivity to rich-zone equivalence ratio, lean-zone equivalence ratio, rich-zone residence time, and overall system pressure drop. Minimum nitrogen oxide emissions were measured at 50 to 55 ppmv at maximum continuous power for all three fuels. Smoke was less than a 10 SAE smoke number.

Novick, A. S.↗

NASA NTRS1984

Preliminary investigation of a two-zone swirl flow combustor

The effect of full-annular swirling-flow on a flow-zone combustor design is investigated. Swirl flow angles of 25, 35, and 45 degrees were investigated in a combustor design envelope typical of those used in modern engines. The two-zone combustor had 24 pilot-zone fuel injectors and 24 main-fuel injectors located in the centerbody between the pilot and swirl passage. Combustor performance was determined at idle, and two parametric 589 K inlet temperature conditions. Combustor performance was highest with the 45 degree swirl vane design; at the idle condition, combustion efficiency was 99.5 percent. The 45 degree swirl vane also produced the lowest pattern factor of the three angles and showed a combustor lean blowout limit below a 0.001 fuel-air ratio. Combustor total pressure drop varied from a low of 4.6 percent for the 25 degree swirl to a high of 4.9 percent for the 45 degree swirl.

Biaglow, J. A.↗

NASA NTRS1984

Preliminary investigation of a two-zone swirl flow combustor

Biaglow, J. A.↗

NASA NTRS1993

Emission characteristics of a model gas turbine combustor at practical conditions

This paper reports on in situ and exit plane emissions measurements from a model gas turbine combustor at practical air preheat temperatures and pressures for a range of operating conditions. The model combustor chosen for the study features two rows of jets (primary and dilution) with four jets per row, and utilizes effusive air cooling holes on the liner wall. The combustor dome is equipped with a flat-vaned swirler with a vane angle of 60 deg. Data are obtained at combustor pressures ranging from 2 to 10 atmospheres, air preheat temperatures from 204 C to 427 C, and combustor reference velocities from 10.0 to 20.0 m/s. An overall equivalence ratio of 0.3 was constant for all conditions. Exit plane and in situ measurements are presented for HC, O2, CO2, CO, and NO(x). The results from exit plane NO(x) measurements illustrate that the model combustor is representative of current gas turbine combustors. The in situ data reveal effects of fuel/air and wall jet mixing on emission performance.

Drennan, S. A.↗

NASA NTRS1957

Preliminary investigation of the combustion of a 50 percent pentaborane - 50 percent JP-4 fuel blend in a turbojet combustor at simulated altitude conditions

A preliminary investigation was conducted to determine the combustion characteristics of a fuel composed of 50 percent pentaborane and 50 percent JP-4 (MIL-F-5624A) by weight in a turbojet combustor. A combustor designed to fit the housing of a J33-A-23 turbojet engine was selected for convenience. The fuel was evaluated at two engine conditions simulating altitudes of 40,000 and 57,000 feet, an engine speed of 85 percent of rated rpm, and a flight Mach number of 0.6. The pentaborane blend was initially evaluated in combustors developed for pure pentaborane and diborane reported in NACA RM E53B18 and RM E52L15. The performance of the blend was unsatisfactory in these combustors. A new combustor was then developed which provided combustor efficiencies measured from 91 to 101 percent as compared with efficiencies of 92 to 94 percent previously obtained for pentaborane at comparable conditions. Additional refinements of design details are needed to obtain lower oxide deposits and a more uniform outlet temperature profile; however, the combustor is believed to incorporate some of the design principles required to obtain satisfactory over-all performance with the fuel blend investigated.

FUELS - JP-4-*PENTABORANE↗

NASA NTRS1993

Combustor technology for future small gas turbine aircraft

Future engine cycles proposed for advanced small gas turbine engines will increase the severity of the operating conditions of the combustor. These cycles call for increased overall engine pressure ratios which increase combustor inlet pressure and temperature. Further, the temperature rise through the combustor and the corresponding exit temperature also increase. Future combustor technology needs for small gas turbine engines is described. New fuel injectors with large turndown ratios which produce uniform circumferential and radial temperature patterns will be required. Uniform burning will be of greater importance because hot gas temperatures will approach turbine material limits. The higher combustion temperatures and increased radiation at high pressures will put a greater heat load on the combustor liners. At the same time, less cooling air will be available as more of the air will be used for combustion. Thus, improved cooling concepts and/or materials requiring little or no direct cooling will be required. Although presently there are no requirements for emissions levels from small gas turbine engines, regulation is expected in the near future. This will require the development of low emission combustors. In particular, nitrogen oxides will increase substantially if new technologies limiting their formation are not evolved and implemented. For example, staged combustion employing lean, premixed/prevaporized, lean direct injection, or rich burn-quick quench-lean burn concepts could replace conventional single stage combustors.

Lyons, Valerie J.↗

NASA NTRS1991

Orbit transfer rocket engine technology program enhanced heat transfer combustor technology

In order to increase the performance of a high performance, advanced expander-cycle engine combustor, higher chamber pressures are required. In order to increase chamber pressure, more heat energy is required to be transferred to the combustor coolant circuit fluid which drives the turbomachinery. This requirement was fulfilled by increasing the area exposed to the hot-gas by using combustor ribs. A previous technology task conducted 2-d hot air and cold flow tests to determine an optimum rib height and configuration. In task C.5 a combustor calorimeter was fabricated with the optimum rib configuration, 0.040 in. high ribs, in order to determine their enhancing capability. A secondary objective was to determine the effects of mixture ratio changers on the enhancement during hot-fire testing. The program used the Rocketdyne Integrated Component Evaluator (ICE) reconfigured into a thrust chamber only mode. The test results were extrapolated to give a projected enhancement from the ribs for a 16 in. long cylindrical combustor at 15 Klb nominal thrust level. The hot-gas wall ribs resulted in a 58 percent increase in heat transfer. When projected to a full size 15K combustor, it becomes a 46 percent increase. The results of those tests, a comparison with previous 2-d results, the effects of mixture ratio and combustion gas flow on the ribs and the potential ramifications for expander cycle combustors are detailed.

Brown, William S.↗

NASA NTRS1994

The effect of incomplete fuel-air mixing on the lean blowout limit, lean stability limit and NO(x) emissions in lean premixed gas turbine combustors

Gas turbine engines for both land-based and aircraft propulsion applications are facing regulations on NOx emissions which cannot be met with current combustor technology. A number of alternative combustor strategies are being investigated which have the potential capability of achieving ultra-low NOx emissions, including lean premixed combustors, direct injection combustors, rich burn-quick quench-lean burn combustors and catalytic combustors. The research reported in this paper addresses the effect of incomplete fuel-air mixing on the lean limit performance and the NOx emissions characteristics of lean premixed combustors.

Shih, W.-P.↗

NASA NTRS2001

Experimental and Computational Study of Trapped Vortex Combustor Sector Rig with Tri-pass Diffuser

The Trapped Vortex Combustor (TVC) potentially offers numerous operational advantages over current production gas turbine engine combustors. These include lower weight, lower pollutant emissions, effective flame stabilization, high combustion efficiency, excellent high altitude relight capability, and operation in the lean burn or RQL (Rich burn/Quick mix/Lean burn) modes of combustion. The present work describes the operational principles of the TVC, and provides detailed performance data on a configuration featuring a tri-pass diffusion system. Performance data include EINOx (NO(sub x) emission index) results for various fuel-air ratios and combustor residence times, combustion efficiency as a function of combustor residence time, and combustor lean blow-out (LBO) performance. Computational fluid dynamics (CFD) simulations using liquid spray droplet evaporation and combustion modeling are performed and related to flow structures observed in photographs of the combustor. The CFD results are used to understand the aerodynamics and combustion features under different fueling conditions. Performance data acquired to date are favorable in comparison to conventional gas turbine combustors. Further testing over a wider range of fuel-air ratios, fuel flow splits, and pressure ratios is in progress to explore the TVC performance. In addition, alternate configurations for the upstream pressure feed, including bi-pass diffusion schemes, as well as variations on the fuel injection patterns, are currently in test and evaluation phases.

Hendricks, Robert C.↗

NASA NTRS2002

Measurement and Computation of Supersonic Flow in a Lobed Diffuser-Mixer for Trapped Vortex Combustors

The trapped vortex combustor (TVC) pioneered by Air Force Research Laboratories (AFRL) is under consideration as an alternative to conventional gas turbine combustors. The TVC has demonstrated excellent operational characteristics such as high combustion efficiency, low NO(x) emissions, effective flame stabilization, excellent high-altitude relight capability, and operation in the lean-burn or rich burn-quick quench-lean burn (RQL) modes of combustion. It also has excellent potential for lowering the engine combustor weight. This performance at low to moderate combustor mach numbers has stimulated interest in its ability to operate at higher combustion mach number, and for aerospace, this implies potentially higher flight mach numbers. To this end, a lobed diffuser-mixer that enhances the fuel-air mixing in the TVC combustor core was designed and evaluated, with special attention paid to the potential shock system entering the combustor core. For the present investigation, the lobed diffuser-mixer combustor rig is in a full annular configuration featuring sixfold symmetry among the lobes, symmetry within each lobe, and plain parallel, symmetric incident flow. During hardware cold-flow testing, significant discrepancies were found between computed and measured values for the pitot-probe-averaged static pressure profiles at the lobe exit plane. Computational fluid dynamics (CFD) simulations were initiated to determine whether the static pressure probe was causing high local flow-field disturbances in the supersonic flow exiting the diffuser-mixer and whether shock wave impingement on the pitot probe tip, pressure ports, or surface was the cause of the discrepancies. Simulations were performed with and without the pitot probe present in the modeling. A comparison of static pressure profiles without the probe showed that static pressure was off by nearly a factor of 2 over much of the radial profile, even when taking into account potential axial displacement of the probe by up to 0.25 in. (0.64 cm). Including the pitot probe in the CFD modeling and data interpretation lead to good agreement between measurement and prediction. Graphical inspection of the results showed that the shock waves impinging on the probe surface were highly nonuniform, with static pressure varying circumferentially among the pressure ports by over 10 percent in some cases. As part of the measurement methodology, such measurements should be routinely supplemented with CFD analyses that include the pitot probe as part of the flow-path geometry.

Brankovic, Andreja↗

NASA NTRS2004

Experimental and Computational Study of Trapped Vortex Combustor Sector Rig With Tri-Pass Diffuser

The Trapped Vortex Combustor (TVC) potentially offers numerous operational advantages over current production gas turbine engine combustors. These include lower weight, lower pollutant emissions, effective flame stabilization, high combustion efficiency, excellent high altitude relight capability, and operation in the lean burn or RQL modes of combustion. The present work describes the operational principles of the TVC, and extends diffuser velocities toward choked flow and provides system performance data. Performance data include EINOx results for various fuel-air ratios and combustor residence times, combustion efficiency as a function of combustor residence time, and combustor lean blow-out (LBO) performance. Computational fluid dynamics (CFD) simulations using liquid spray droplet evaporation and combustion modeling are performed and related to flow structures observed in photographs of the combustor. The CFD results are used to understand the aerodynamics and combustion features under different fueling conditions. Performance data acquired to date are favorable compared to conventional gas turbine combustors. Further testing over a wider range of fuel-air ratios, fuel flow splits, and pressure ratios is in progress to explore the TVC performance. In addition, alternate configurations for the upstream pressure feed, including bi-pass diffusion schemes, as well as variations on the fuel injection patterns, are currently in test and evaluation phases.

Hendricks, R. C.↗

NASA NTRS2002

Sector Tests of a Low-NO(sub x), Lean, Direct- Injection, Multipoint Integrated Module Combustor Concept Conducted

The low-emissions combustor development described is directed toward advanced high pressure aircraft gas-turbine applications. The emphasis of this research is to reduce nitrogen oxides (NOx) at high-power conditions and to maintain carbon monoxide and unburned hydrocarbons at their current low levels at low power conditions. Low-NOx combustors can be classified into rich-burn and lean-burn concepts. Lean-burn combustors can be further classified into lean-premixed-prevaporized (LPP) and lean direct injection (LDI) concepts. In both concepts, all the combustor air, except for liner cooling flow, enters through the combustor dome so that the combustion occurs at the lowest possible flame temperature. The LPP concept has been shown to have the lowest NOx emissions, but for advanced high-pressure-ratio engines, the possibility of autoignition or flashback precludes its use. LDI differs from LPP in that the fuel is injected directly into the flame zone, and thus, it does not have the potential for autoignition or flashback and should have greater stability. However, since it is not premixed and prevaporized, good atomization is necessary and the fuel must be mixed quickly and uniformly so that flame temperatures are low and NOx formation levels are comparable to those of LPP. The LDI concept described is a multipoint fuel injection/multiburning zone concept. Each of the multiple fuel injectors has an air swirler associated with it to provide quick mixing and a small recirculation zone for burning. The multipoint fuel injection provides quick, uniform mixing and the small multiburning zones provide for reduced burning residence time, resulting in low NOx formation. An integrated-module approach was used for the construction where chemically etched laminates, diffusion bonded together, combine the fuel injectors, air swirlers, and fuel manifold into a single element. The multipoint concept combustor was demonstrated in a 15 sector test. The configuration tested had 36 fuel injectors and fuel-air mixers that replaced two fuel injectors in a conventional dual-annular combustor. During tests, inlet temperatures were up to 870 K and inlet pressures were up to 5400 kPa. A correlation was developed that related the NOx emissions with the inlet temperature, inlet pressure, fuel-air ratio, and pressure drop. At low-power conditions, fuel staging was used so that high combustion efficiency was obtained with only one-fourth of the fuel injectors flowing. The test facility had optical access, and visual images showed the flame to be very short, approximately 25 mm long.

Tacina, Robert R.↗

NASA NTRS2003

Active Control of High-Frequency Combustor Instability Demonstrated

To reduce the environmental impact of aerospace propulsion systems, extensive research is being done in the development of lean-burning (low fuel-to-air ratio) combustors that can reduce emissions throughout the mission cycle. However, these lean-burning combustors have an increased susceptibility to thermoacoustic instabilities-high-pressure oscillations much like sound waves that can cause severe high-frequency vibrations in the combustor. These pressure waves can fatigue the combustor components and even the downstream turbine blades. This can significantly decrease the combustor and turbine safe operating life. Thus, suppression of the thermoacoustic combustor instabilities is an enabling technology for lean, low-emissions combustors. Under the Propulsion and Power Program, the NASA Glenn Research Center in partnership with Pratt & Whitney, United Technologies Research Center, and Georgia Institute of Technology is developing technologies for the active control of combustion instabilities.

DeLaat, John C.↗

NASA NTRS2003

Hydrogen Fuel Capability Added to Combustor Flametube Rig

Facility capabilities have been expanded at Test Cell 23, Research Combustor Lab (RCL23) at the NASA Glenn Research Center, with a new gaseous hydrogen fuel system. The purpose of this facility is to test a variety of fuel nozzle and flameholder hardware configurations for use in aircraft combustors. Previously, this facility only had jet fuel available to perform these various combustor flametube tests. The new hydrogen fuel system will support the testing and development of aircraft combustors with zero carbon dioxide (CO2) emissions. Research information generated from this test rig includes combustor emissions and performance data via gas sampling probes and emissions measuring equipment. The new gaseous hydrogen system is being supplied from a 70 000-standard-ft3 tube trailer at flow rates up to 0.05 lb/s (maximum). The hydrogen supply pressure is regulated, and the flow is controlled with a -in. remotely operated globe valve. Both a calibrated subsonic venturi and a coriolis mass flowmeter are used to measure flow. Safety concerns required the placement of all hydrogen connections within purge boxes, each of which contains a small nitrogen flow that is vented past a hydrogen detector. If any hydrogen leaks occur, the hydrogen detectors alert the operators and automatically safe the facility. Facility upgrades and modifications were also performed on other fluids systems, including the nitrogen gas, cooling water, and air systems. RCL23 can provide nonvitiated heated air to the research combustor, up to 350 psig at 1200 F and 3.0 lb/s. Significant modernization of the facility control systems and the data acquisition systems was completed. A flexible control architecture was installed that allows quick changes of research configurations. The labor-intensive hardware interface has been removed and changed to a software-based system. In addition, the operation of this facility has been greatly enhanced with new software programming and graphic operator interface stations. Glenn s RCL23 facility systems were successfully checked out in the spring of 2002, and hydrogen combustor research testing began in the summer of 2002.

Frankenfield, Bruce J.↗

NASA NTRS2008

Characterization and Simulation of the Thermoacoustic Instability Behavior of an Advanced, Low Emissions Combustor Prototype

Extensive research is being done toward the development of ultra-low-emissions combustors for aircraft gas turbine engines. However, these combustors have an increased susceptibility to thermoacoustic instabilities. This type of instability was recently observed in an advanced, low emissions combustor prototype installed in a NASA Glenn Research Center test stand. The instability produces pressure oscillations that grow with increasing fuel/air ratio, preventing full power operation. The instability behavior makes the combustor a potentially useful test bed for research into active control methods for combustion instability suppression. The instability behavior was characterized by operating the combustor at various pressures, temperatures, and fuel and air flows representative of operation within an aircraft gas turbine engine. Trends in instability behavior versus operating condition have been identified and documented, and possible explanations for the trends provided. A simulation developed at NASA Glenn captures the observed instability behavior. The physics-based simulation includes the relevant physical features of the combustor and test rig, employs a Sectored 1-D approach, includes simplified reaction equations, and provides time-accurate results. A computationally efficient method is used for area transitions, which decreases run times and allows the simulation to be used for parametric studies, including control method investigations. Simulation results show that the simulation exhibits a self-starting, self-sustained combustion instability and also replicates the experimentally observed instability trends versus operating condition. Future plans are to use the simulation to investigate active control strategies to suppress combustion instabilities and then to experimentally demonstrate active instability suppression with the low emissions combustor prototype, enabling full power, stable operation.

DeLaat, John C.↗

NASA NTRS2008

Characterization and Simulation of Thermoacoustic Instability in a Low Emissions Combustor Prototype

Extensive research is being done toward the development of ultra-low-emissions combustors for aircraft gas turbine engines. However, these combustors have an increased susceptibility to thermoacoustic instabilities. This type of instability was recently observed in an advanced, low emissions combustor prototype installed in a NASA Glenn Research Center test stand. The instability produces pressure oscillations that grow with increasing fuel/air ratio, preventing full power operation. The instability behavior makes the combustor a potentially useful test bed for research into active control methods for combustion instability suppression. The instability behavior was characterized by operating the combustor at various pressures, temperatures, and fuel and air flows representative of operation within an aircraft gas turbine engine. Trends in instability behavior vs. operating condition have been identified and documented. A simulation developed at NASA Glenn captures the observed instability behavior. The physics-based simulation includes the relevant physical features of the combustor and test rig, employs a Sectored 1-D approach, includes simplified reaction equations, and provides time-accurate results. A computationally efficient method is used for area transitions, which decreases run times and allows the simulation to be used for parametric studies, including control method investigations. Simulation results show that the simulation exhibits a self-starting, self-sustained combustion instability and also replicates the experimentally observed instability trends vs. operating condition. Future plans are to use the simulation to investigate active control strategies to suppress combustion instabilities and then to experimentally demonstrate active instability suppression with the low emissions combustor prototype, enabling full power, stable operation.

DeLaat, John C.↗

NASA NTRS2012

A Comparison of Combustor-Noise Models

The present status of combustor-noise prediction in the NASA Aircraft Noise Prediction Program (ANOPP)1 for current-generation (N) turbofan engines is summarized. Several semi-empirical models for turbofan combustor noise are discussed, including best methods for near-term updates to ANOPP. An alternate turbine-transmission factor2 will appear as a user selectable option in the combustor-noise module GECOR in the next release. The three-spectrum model proposed by Stone et al.3 for GE turbofan-engine combustor noise is discussed and compared with ANOPP predictions for several relevant cases. Based on the results presented herein and in their report,3 it is recommended that the application of this fully empirical combustor-noise prediction method be limited to situations involving only General-Electric turbofan engines. Long-term needs and challenges for the N+1 through N+3 time frame are discussed. Because the impact of other propulsion-noise sources continues to be reduced due to turbofan design trends, advances in noise-mitigation techniques, and expected aircraft configuration changes, the relative importance of core noise is expected to greatly increase in the future. The noise-source structure in the combustor, including the indirect one, and the effects of the propagation path through the engine and exhaust nozzle need to be better understood. In particular, the acoustic consequences of the expected trends toward smaller, highly efficient gas-generator cores and low-emission fuel-flexible combustors need to be fully investigated since future designs are quite likely to fall outside of the parameter space of existing (semi-empirical) prediction tools.

Hultgren, Lennart S.↗

NASA NTRS2012

Core Noise: Overview of Upcoming LDI Combustor Test

This presentation is a technical summary of and outlook for NASA-internal and NASA-sponsored external research on core (combustor and turbine) noise funded by the Fundamental Aeronautics Program Fixed Wing Project. The presentation covers: the emerging importance of core noise due to turbofan design trends and its relevance to the NASA N+3 noise-reduction goal; the core noise components and the rationale for the current emphasis on combustor noise; and the current and planned research activities in the combustor-noise area. Two NASA-sponsored research programs, with particular emphasis on indirect combustor noise, "Acoustic Database for Core Noise Sources", Honeywell Aerospace (NNC11TA40T) and "Measurement and Modeling of Entropic Noise Sources in a Single-Stage Low-Pressure Turbine", U. Illinois/U. Notre Dame (NNX11AI74A) are briefly described. Recent progress in the development of CMC-based acoustic liners for broadband noise reduction suitable for turbofan-core application is outlined. Combustor-design trends and the potential impacts on combustor acoustics are discussed. A NASA GRC developed nine-point lean-direct-injection (LDI) fuel injector is briefly described. The modification of an upcoming thermo-acoustic instability evaluation of the GRC injector in a combustor rig to also provide acoustic information relevant to community noise is presented. The NASA Fundamental Aeronautics Program has the principal objective of overcoming today's national challenges in air transportation. The reduction of aircraft noise is critical to enabling the anticipated large increase in future air traffic. The Quiet Performance Research Theme of the Fixed Wing Project aims to develop concepts and technologies to dramatically reduce the perceived community noise attributable to aircraft with minimal impact on weight and performance.

Hultgren, Lennart S.↗