The highly competitive gas turbine industry has been motivated by consumer demands for higher power-to-weight ratios, increased thermal efficiencies, and reliability while maintaining affordability. In its continual quest, the industry must continually try to raise the turbine inlet temperature, which according to the well-known Brayton cycle is key to higher engine efficiencies. The desire for increased turbine inlet temperatures creates an extremely harsh environment for the combustor liner in addition to the components downstream of the combustor. Shear layers between the dilution jets and the mainstream, as well as combustor liner film-cooling interactions create a complex mean flow field within the combustor, which is not easy to model. A completely uniform temperature and velocity profile at the combustor exit is desirable from the standpoint of reducing the secondary flows in the turbine. However, this seldom occurs due to a lack of thorough mixing within the combustor. Poor mixing results in non-uniformities, such as hot streaks, and allow non-combusted fuel to exit the combustor. This investigation developed a database documenting the thermal and flow characteristics within a combustor simulator representative of the flowfield within a gas turbine aero-engine. Three- and two-component laser Doppler velocimeter measurements were completed to quantify the flow and turbulence fields, while a thermocouple rake was used to quantify the thermal fields. The measured results show very high turbulence levels due to the dilution flow injection. Directly downstream of the dilution jets, an increased thickness in the film-cooling was noted with a fairly non-homogeneous temperature field across the combustor width. A highly turbulent shear layer was found at the leading edge of the dilution jets. Measurements also showed that a relatively extensive recirculation region existed downstream of the dilution jets. Despite the lack of film-cooling injection at the trailing edge of the dilution hole, there existed coolant flow indicative of a horse-shoe vortex wrapping around the jet. As a result of the dilution jet interaction with the mainstream flow, kidney-shaped thermal fields and counter-rotating vortices developed. These vortices serve to enhance combustor mixing. / Master of Science

Acoustic Transfer Functions Derived from Finite Element Modeling for Thermoacoustic Stability Predictions of Gas Turbine Engines Design and prediction of thermoacoustic instabilities is a major challenge in aerospace propulsion and the operation of power generating gas turbine engines. This is a complex problem in which multiple physical systems couple together. Traditionally, thermoacoustic models can be reduced to dominant physics which depend only on flame dynamics and acoustics. This is the general approach adopted in this research. The primary objective of this thesis is to describe how to obtain acoustic transfer functions using finite element modeling. These acoustic transfer functions can be coupled with flame transfer functions and other dynamics to predict the thermoacoustic stability of gas turbine engines. Results of this research effort can go beyond the prediction of instability and potentially can be used as a tool in the design stage. Consequently, through the use of these modeling tools, better gas turbine engine designs can be developed, enabling expanded operating conditions and efficiencies. This thesis presents the finite element (FE) methodology used to develop the acoustic transfer functions of the Combustion System Dynamics Laboratory (CSDL) gaseous combustor to support modeling and prediction of thermoacoustic instabilities. In this research, several different areas of the acoustic modeling were addressed to develop a representative acoustics model of the hot CSDL gaseous combustor. The first area was the development and validation of the cold acoustic finite element model. A large part of this development entailed finding simple but accurate means for representing complex geometries and boundary conditions. The cold-acoustic model of the laboratory combustor was refined and validated with the experimental data taken on the combustion rig. The second stage of the research involved incorporating the flame into the FE model and has been referred to in this thesis as hot-acoustic modeling. The hot-acoustic model also required the investigation and characterization of the flame as an acoustic source. The detailed mathematical development for the full reacting acoustic wave equation was investigated and simplified sufficiently to identify the appropriate source term for the flame. It was determined that the flame could be represented in the finite element formulation as a volumetric acceleration, provided that the flame region is small compared to acoustic wavelengths. For premixed gas turbine combustor flames, this approximation of a small flame region is generally a reasonable assumption. Both the high temperature effects and the flame as an acoustic source were implemented to obtain a final hot-acoustic FE model. This model was compared to experimental data where the heat release of the flame was measured along with the acoustic quantities of pressure and velocity. Using these measurements, the hot-acoustic FE model was validated and found to correlate with the experimental data very well. The thesis concludes with a discussion of how these techniques can be utilized in large industrial-size combustors. Insights into stability are also discussed. A conclusion is then presented with the key results from this research and some suggestions for future work. / Master of Science

To advance the design of hypersonic vehicles, high-fidelity multi-physics CFD is used to characterize 3-D scramjet flow-fields in two novel streamline traced configurations. The two inlets, Jaws and Scoop, are analyzed and compared to a traditional rectangular inlet used as a baseline for on/off-design conditions. The flight trajectory conditions selected are Mach 6 and a dynamic pressure of 1,500 psf (71.82 kPa). Analysis of these hypersonic inlets is performed to investigate distortion effects downstream with multiple single cavity combustors acting as flame holders, and several fuel injection strategies. The best integrated scramjet inlet/combustor design is identified. The flow physics is investigated and the integrated performance impact of the two innovative scramjet inlet designs is quantified. Frozen and finite rate chemistry is simulated with 13 gaseous species and 20 reactions for an Ethylene/air finite-rate chemical model. In addition, URANS and LES modeling are compared to explore overall flow structure and to contrast individual numerical methods. The flow distortion in Jaws and Scoop is similar to some of the distortion in the traditional rectangular inlet, despite design differences. The baseline and Jaws performance attributes are stronger than Scoop, but Jaws accomplishes this while eradicating the cowl lip interaction, and lessening the total drag and spillage penalties. The innovative inlets work best on-design, whereas for off-design, the traditional inlet is best. Early pressure losses and flow distortions in the isolator aid the mixing of air and fuel, and improve the overall efficiency of the system. Although the trends observed with and without chemical reactions are similar, the former yields roughly 10% higher mixing efficiency and upstream reactions are present. These show a significant impact on downstream development. Unsteadiness in the combustor increases the mixing efficiency, varying the flame anchoring and combustion pressure effects upstream of the step.

This thesis investigates the use of the Stagnation-Point Reverse-Flow (SPRF) combustor geometry for burning low-grade solid fuels that are attractive for specific industrial applications because of their low cost and on-site availability. These fuels are in general, hard to burn, either because of high moisture and impurity-content, e.g. biomass, or their low-volatiles content, e.g., petroleum-coke. This results in various challenges to the combustor designer, for example reduced flame stability and poor combustion efficiency. Conventional solutions include preheating the incoming flow as well as co-firing with high-grade fuels. The SPRF combustor geometry has been chosen because it was demonstrated to operate stably on standard gaseous and liquid-fuels corresponding to ultra fuel-lean conditions and power densities at atmospheric-pressure around 20-25 MW/m3. Previous studies on the SPRF combustor have proven that the unique, reverse flow-geometry allows entrainment of near-adiabatic products into the incoming reactants, thereby enhancing the reactivity of the mixture. Further, the presence of the stagnation-end created a region of low mean velocities and high levels of unsteadiness and mixing-rates that supported the reaction-zones. In this study, we examine the performance of the SPRF geometry on a specific low grade solid fuel, petroleum coke. There are three main goals of this thesis. The first goal is the design of a SPRF combustor to operate on solid-fuels based on a design-scaling methodology, as well as demonstration of successful operation corresponding to a baseline condition. The second goal involves understanding the mode of operation of the SPRF combustor on solid-fuels based on visualization studies. The third goal of this thesis is developing and using reduced-order models to better understand and predict the ignition and quasi-steady burning behavior of dispersed-phase particles in the SPRF combustor. The SPRF combustor has been demonstrated to operate stably on pure-oxygen and a slurry made from water and petroleum-coke, both at the baseline conditions (125 kW, 18 g/s, ~25 µm particles) and higher power-densities and powder sizes. For an overall combustor length less than a meter, combustion is not complete (global combustion efficiency less than 70%). Luminance imaging results indicate the incoming reactant jet ignites and exhibits intense burning at the mid-combustor region, around 15 jet diameters downstream of the inlet, most likely due to enhanced mixing as a result of the highly unsteady velocity field. This roughly corresponds to the location of the reaction zones in the previous SPRF combustors operating on gas and liquid fuels. Planar laser visualization of the reacting flow-field using particle-scattering reveals that ignition of a significant amount of the reactants occurs only after the incoming jet has broken into reactant packets. Post-ignition, these burning packets burn out slowly as they reverse direction and exit the combustor on either side of the central injector. This is unlike the behavior in liquid and gas-fueled operation where the incoming reactants burned across a highly corrugated, thin-flame front. Based on these findings, as well as the results of previous SPRF studies, an idealized model of combustor operation based on a plug flow reactor has been developed. The predictions suggest that fuel-conversion efficiency is enhanced by the combustor operating pressure and lowered by the heat-losses. Overall, this effort has shown the SPRF geometry is a promising compact-combustor concept for self-sustained operation on low-grade solid-fuels for typical high-pressure applications such as direct steam-generation. Based on these findings, it is recommended that future designs for the specific application previously mentioned have a shorter base-combustor with lower heat-losses and a longer steam-generation section for injection of water.

Heat management is an essential part of combustor design, as operating temperatures within the combustor generally exceed safe working temperatures of the materials employed in its construction. Two principal methods used to manage this heat are impingement and film cooling. Impingement heat transfer refers to jets of impinging fluid delivered by orifices integrated into internal structures in order to remove undesired heat. This mode of heat transfer has a relatively high effectiveness, making it an attractive method of heat management. As such, a considerable number of studies have been done on the subject providing a substantial body of useful knowledge. However, there are innovative cooling configurations being used in gas turbines which generate compressibility and temperature ratio effects on heat transfer which are currently unexplored. Presented here are data showing that these effects have a significant impact on heat transfer and new correlations are presented to account for temperature ratio and Mach number effects for a range of conditions. These findings are significant and can be applied to impinging flows in other areas of a gas turbine engine such as turbine blades and vanes. Film cooling refers to the injection of coolant onto a surface through an array of sharply angled holes. This is done in a manner that allows the coolant to remain close to the surface where it provides an insulating layer between the hot gas freestream and the cooler surface. In order to improve turbine efficiency, research efforts in film cooling are directed at reducing film cooling flow without decreasing turbine inlet temperatures. Both impingement cooling and film cooling are heavily utilized in combustor liners. Frequently, cooling air first impinges against the back side of the liner, then the spent impingement fluid passes through film cooling holes. This arrangement combines the convective heat transfer of the impinging jets convection as the coolant passes through the film cooling holes and the benefits that come from having a thin film of cool air between the combustor wall and the combustion products. In order to improve the understanding of internal cooling in gas turbine engines, the influence of previously unexplored physical parameters such as compressible flow effects and temperature ratio in impingement flows and variable blowing ratio in a film cooling array must be examined. Prior to this work, there existed in the available literature only an extremely limited exploration of compressibility effects in impingement heat transfer and the results of separately examining the effects of Mach number and Reynolds number. The film cooling literature provides no information for a full array of film cooling holes along a contraction at high blowing ratios. Exploring these effects and conditions adds to the body of available data and allows the validation of numerical predictions.

Reverse-flow combustors have been used in heavy land-based gas turbines for many decades. A sheath is typically installed to provide cooling at an expense of large pressure losses, through small jet impingement cooling and strong forced convention channel flow. With the modern advancement in metallurgy and thermal-barrier coating technologies, it may become possible to remove this sheath to recover the pressure losses without melting the combustor chamber. However, without the sheath, the flow inside the dump diffuser may exert nonuniform cooling on the combustion chamber. Therefore, the objective of this project is to investigate the flow pattern, pressure drop, and heat transfer in the dump-diffuser reverse-flow combustor with and without sheath to determine if the sheath could be removed. The investigation was conducted through both experimental and computational simulation. The results show that 3.3% pressure losses could be recovered and the highest wall temperature will increase 18% without the sheath.

<p>In modern gas turbines parts of combustion chamber and turbine section are under heavy heat load, for example, the rotor inlet temperature is far higher than the melting point of the rotor blade material. These high temperatures causes thermal stresses in the material, therefore it is very important to cool the components for safe operation and to achieve desired component life. But on the other hand the cooling reduces the turbine efficiency, for that reason it is vital to understand and optimize the cooling technique.</p><p>In this project Thermochromic Liquid Crystals (TLCs) are used to measure distribution of heat transfer coefficient over a scaled up combustor liner section. TLCs change their color with the variation of temperature in a particular temperature range. The color-temperature change relation of a TLC is sharp and precise; therefore TLCs are used to measure surface temperature by painting the TLC over a test surface. This method is called Liquid Crystal Thermography (LCT). LCT is getting popular in industry due to its high-resolution results, repeatability and ease of use.</p><p>Test model in present study consists of two plates, target plate and impingement plate. Cooling of the target plate is achieved by impingement of air coming through holes in the impingement plate. The downstream surface of the impingement plate is then cooled by cross flow and re-impingement of the coolant air.</p><p>Heat transfer on the target plate is not uniform; areas under the jet which are called stagnation points have high heat transfer as compare to the areas away from the center of jet. It is almost the same situation for the impingement plate but the location of stagnation point is different. A transient technique is used to measure this non-uniform heat transfer distribution. It is assumed that the plates are semi-infinitely thick and there is no lateral heat transfer in the plates. To fulfill the assumptions a calculated time limit is followed and the test plates are made of Plexiglas which has very low thermal conductivity.</p><p>The transient technique requires a step-change in the mainstream temperature of the test section. However, in practical a delayed increase in mainstream temperature is attained. This issue is dealt by applying Duhamel’s theorem on the step-change heat transfer equation. MATLAB is used to get the Hue data of the recorded video frames and calculate the time taken for each pixel to reach a predefined surface temperature. Having all temperatures and time values the heat transfer equation is iteratively solved to get the value of heat transfer coefficient of each and every pixel of the test surface.</p><p>In total fifteen tests are conducted with different Reynolds number and different jet-to-target plate distances. It is concluded that for both the target and impingement plates, a high Reynolds number provides better overall heat transfer and increase in jet-to-target distance</p><p>decreases the overall heat transfer.</p>

A numerical analysis was conducted to study the effects of geometrically scaling scramjet inlet-combustor isolators. Three-dimensional fully viscous numerical simulation of the flow inside constant area rectangular ducts, with a downstream back pressure condition, was analyzed using the SolidWorks Flow Simulation software. The baseline, or 1X, isolator configuration has a 1” x 2.67” cross section and 20” length. This baseline configuration was scaled up based on the 1X configuration mass flow to 10X and 100X configurations, with ten and one hundred times the mass flow rate, respectively. The isolator aspect ratio of 2.67 was held constant for all configurations. To provide for code validation, the Flow Simulation program was first used to analyze a converging-diverging channel and a wind tunnel nozzle. The channel case was compared with analytical theory and showed good agreement. The nozzle case was compared with AFRL experimental data and showed good agreement with the entrance and exit conditions (Pi0= 40 psia, Ti0= 530ºR, Pe= 18.86 psia, Te= 456ºR, respectively). While the boundary layer thickness remained constant, the boundary layer thickness with respect to the isolator height decreased as the scale increased. For all the isolator simulations, a shock train was expected to form inside the duct. However, the flow simulation failed to generate this flow pattern, due to improper sizing of the isolator and combustor for a 3-D model or having a low pressure ratio of 2.38. Instead, a single normal shock wave was established at the same relative location within the length of each duct, approximately 80% of the duct length from the isolator entrance. The shape of the shock changed as the scale increased from a normal shock wave, to a bifurcated shock wave, and to a normal shock train, respectively for the 1X, 10X, and 100X models.

This thesis explores the effects of operating parameters on the location and shape of lifted flames in a Low Swirl Burner (LSB). In addition, it details the development and analysis of a CH PLIF imaging system for visualizing flames in lean combustion systems. The LSB is studied at atmospheric pressure using LDV and CH PLIF. CH* chemiluminescence is used for high pressure flame imaging. A four-level model of the fluorescing CH system is developed to predict the signal intensity in hydrocarbon flames. Results from imaging an atmospheric pressure laminar flame are used to validate the behavior of the signal intensity as predicted by the model. The results show that the fluorescence signal is greatly reduced at high pressure due to the decreased number of CH molecules and the increased collisional quenching rate. This restricts the use of this technique to increasingly narrow equivalence ratio ranges at high pressures. The limitation is somewhat alleviated by increasing the preheat temperature of the reactant mixture. The signal levels from high hydrogen-content syngas mixtures doped with methane are found to be high enough to make CH PLIF a feasible diagnostic to study such flames. Finally, the model predicts that signal levels are unlikely to be significantly affected by the presence of strain in the flow field, as long as the flames are not close to extinction. The results from the LSB flame investigation reveal that combustor provides reasonably robust flame stabilization at low and moderate values of combustor pressure and reference velocities. However, at very high velocities and pressures, the balance between the reactant velocity and the turbulent flame speed shifts in favor of the former resulting in the flame moving downstream. The extent of this movement is small, but indicates a tendency towards blow off at higher pressures and velocities that may be encountered in real world gas turbine applications. There is an increased tendency of relatively fuel-rich flames to behave like attached flames at high pressure. These results raise interesting questions about turbulent combustion at high pressure as well as provide usable data to gas turbine combustor designers by highlighting potential problems.

In modern gas turbines parts of combustion chamber and turbine section are under heavy heat load, for example, the rotor inlet temperature is far higher than the melting point of the rotor blade material. These high temperatures causes thermal stresses in the material, therefore it is very important to cool the components for safe operation and to achieve desired component life. But on the other hand the cooling reduces the turbine efficiency, for that reason it is vital to understand and optimize the cooling technique. In this project Thermochromic Liquid Crystals (TLCs) are used to measure distribution of heat transfer coefficient over a scaled up combustor liner section. TLCs change their color with the variation of temperature in a particular temperature range. The color-temperature change relation of a TLC is sharp and precise; therefore TLCs are used to measure surface temperature by painting the TLC over a test surface. This method is called Liquid Crystal Thermography (LCT). LCT is getting popular in industry due to its high-resolution results, repeatability and ease of use. Test model in present study consists of two plates, target plate and impingement plate. Cooling of the target plate is achieved by impingement of air coming through holes in the impingement plate. The downstream surface of the impingement plate is then cooled by cross flow and re-impingement of the coolant air. Heat transfer on the target plate is not uniform; areas under the jet which are called stagnation points have high heat transfer as compare to the areas away from the center of jet. It is almost the same situation for the impingement plate but the location of stagnation point is different. A transient technique is used to measure this non-uniform heat transfer distribution. It is assumed that the plates are semi-infinitely thick and there is no lateral heat transfer in the plates. To fulfill the assumptions a calculated time limit is followed and the test plates are made of Plexiglas which has very low thermal conductivity. The transient technique requires a step-change in the mainstream temperature of the test section. However, in practical a delayed increase in mainstream temperature is attained. This issue is dealt by applying Duhamel’s theorem on the step-change heat transfer equation. MATLAB is used to get the Hue data of the recorded video frames and calculate the time taken for each pixel to reach a predefined surface temperature. Having all temperatures and time values the heat transfer equation is iteratively solved to get the value of heat transfer coefficient of each and every pixel of the test surface. In total fifteen tests are conducted with different Reynolds number and different jet-to-target plate distances. It is concluded that for both the target and impingement plates, a high Reynolds number provides better overall heat transfer and increase in jet-to-target distance decreases the overall heat transfer.