A new Trapped Vortex Combustor (TVC) concept has been studied for applications such as those in Unmanned Aerial Vehicles (UAVs) as it offers potential for superior flame stability and low pressure loss. Flame stability is ensured by a strong vortex in a physical cavity attached to the combustor wall, and low pressure loss is due to the absence of swirl. Earlier studies on a compact combustor concept showed that there are issues with ensuring stable combustion over a range of operating conditions. The present work focuses on experimental studies and numerical simulations to study the stability issues and performance optimization in this compact single-cavity TVC configuration. For performing numerical simulations, an accurate and yet computationally affordable Modified Eddy Dissipation Concept combustion model is built upon the KIVA-3V platform to account for turbulence-chemistry interactions. Detailed validation with a turbulent non-premixed CH4/H2/N2 flame from literature showed that the model is sufficiently accurate and the effect of various simulation strategies is assessed. Transient flame simulation capabilities are assessed by comparison with experimental data from an acoustically excited oscillatory H2-air diffusion flame reported in literature. Subsequent to successful validation of the model, studies on basic TVC flow oscillations are performed. Frequencies of flow oscillations are found to be independent of flow velocities and cavity length, but dependent on the cavity depth. Cavity injection and combustion individually affect the magnitude of flow oscillations but do not significantly alter the resonant frequencies. Reacting flow experiments and flow visualization studies in an existing experimental TVC rig with optical access and variable cavity L/D ratio show that TVC flame stability depends strongly on the cavity air velocity. A detailed set of numerical simulations also confirms this and helps to identify three basic modes of TVC flame stabilization. A clockwise cavity vortex stabilized flame is formed at low cavity air velocities relative to the mainstream, while a strong anticlockwise cavity vortex is formed at high cavity air velocities and low L/Ds. At intermediate conditions, the cavity vortex structure is found to be in a transition state which leads to large scale flame instabilities and flame blow-out. For solving the flame instability problem, a novel strategy of incorporating a flow guide vane is proposed to establish the advantageous anticlockwise vortex without the use of cavity air. Experimental results with the modified configuration are quite encouraging for TVC flame stability at laboratory conditions, while numerical results show good stability even at extreme operating conditions. Further design optimization studies are performed in a multi-parameter space using detailed simulations. From the results, a strategy of using inclined struts in the main flow path along with the flow guide vane seems most promising. This configuration is tested experimentally and results pertaining to pressure drop, pattern factor and flame stability are found to be satisfactory.

Trapped Vortex Combustor (TVC) is a relatively new concept for potential use in gas turbine engines addressing ever increasing demands of high efficiency, low emissions, low pressure drop, and improved pattern factor. This concept holds promise for future because of its inherent advantages over conventional swirl-stabilized combustors. The main difference between TVC and a conventional gas turbine combustor is in the way combustion is stabilized. In conventional combustors, flame is stabilized because of formation of toroidal flow pattern in the primary zone due to interaction between incoming swirling air and fuel flow. On the other hand, in TVC, there is a physical cavity in the wall of combustor with continuous injection of air and fuel leading to stable and sustained combustion. Past work related to TVC has focussed on use of two cavities in the combustor liner. In the present study, a single cavity combustor concept is evaluated through simulation and experiments for applications requiring compact combustors such as Unmanned Aerial Vehicles (UAVs) and cruise missiles. In the present work, numerical simulations were initially performed on a planar, rectangular single-cavity geometry to assess sensitivity of various parameters and to design a single-cavity TVC test rig. A water-cooled, modular, atmospheric pressure TVC test rig is designed and fabricated for reacting and non-reacting flow experiments. The unique features of this rig consist of a continuously variable length-to-depth ratio (L/D) of the cavity and optical access through quartz plates provided on three sides for visualization. Flame stabilization in the single cavity TVC was successfully achieved with methane as fuel, and the range of flow conditions for stable operation were identified. From these, a few cases were selected for detailed experimentation. Reacting flow experiments for the selected cases indicated that reducing L/D ratio and increasing cavity-air velocity favour stable combustion. The pressure drop across the single-cavity TVC is observed to be lower as compared to conventional combustors. Temperatures are measured at the exit using thermocouples and corrected for radiative losses. Species concentrations are measured at the exit using an exhaust gas analyzer. The combustion efficiency is observed to be around 98-99% and the pattern factor is observed to be in the range of 0.08 to 0.13. High-speed imaging made possible by the optical access indicates that the overall combustion is fairly steady, and there is no major vortex shedding downstream. This enabled steady-state simulations to be performed for the selected cases. Insight from simulations has highlighted the importance of air and fuel injection strategies in the cavity. From a mixing and combustion efficiency standpoint, it is desirable to have a cavity vortex that is anti-clockwise. However, the natural tendency for flow over a cavity is to form a vortex that is clockwise. The tendency to blow-out at higher inlet flow velocities is thought to be because of these two opposing effects. This interaction helps improve mixing, however leads to poor flame stability unless cavity-air velocity is strong enough to support a strong anti-clockwise vortex in the cavity. This basic understating of cavity flow dynamics can be used for further design improvements in future to improve flame stability at higher inlet flow velocities and eventually lead to the development of a practical combustor.

In the present work, two phase reacting flow in a single cavity Trapped Vortex Combustor (TVC) is studied at atmospheric conditions. KIVA-3V, numerical program for simulating three dimensional compressible reacting flows with sprays using Lagrangian-Drop Eulerian-fluid procedure is used. The stochastic discrete droplet model is used for simulating the liquid spray. In each computational cell, it is assumed that the volume occupied by the liquid phase is very small. But this assumption of very low liquid volume fraction in a computational cell is violated in the region close to the injection nozzle. This introduces grid dependence in predictions of liquid phase in the region close to the nozzle in droplet collision algorithm, and in momentum coupling between the liquid and the gas phase. Improvements are identified to reduce grid dependence of these algorithms and corresponding changes are made in the standard KIVA-3V models. Pressure swirl injector which produces hollow cone spray is used in the current study along with kerosene as the liquid fuel. Modifications needed for modelling pressure swirl atomiser are implemented. The Taylor Analogy Breakup (TAB) model, the standard model for predicting secondary breakup is improved with modifications required for low pressure injectors. The pressure swirl injector model along with the improvements is validated using experimental data for kerosene spray from the literature. Simulations of two phase reacting flow in a single cavity TVC are performed and the temperature distribution within the combustor is studied. In order to identify an optimum configuration with liquid fuel combustion, the following parameters related to fuel and air such as cavity fuel injection location, cavity air injection location, Sauter Mean Diameter (SMD) of injected fuel droplets, velocity of the fuel injected are studied in detail in order to understand the effect of these parameters on combustion characteristics of a single cavity TVC.