Mist or aerosol explosions present a serious hazard to process industries. Heat transfer fluids are widely used in the chemical process industry, are flammable above their flash points, and can cause aerosol explosions. Though the possibility of aerosol explosions has been widely documented, knowledge about their explosive potential is limited. Studying the formation of such aerosols by emulating leaks in process equipment will help define a source term for aerosol dispersions and aid in characterizing their explosion hazards. Analysis of the problem of aerosol explosions reveals three major steps: source term calculations, dispersion modeling, and explosion analysis. The explosion analysis, consisting of ignition and combustion, is largely affected by the droplet size distribution of the dispersed aerosol. The droplet size distribution of the dispersed aerosol is a function of the droplet size distribution of the aerosol formed from the leak. Existing methods of dealing with the problem of aerosol explosions are limited to enhancing the dispersion to prevent flammable concentrations and use of explosion suppression mechanisms. Insufficient data and theory on the flammability limits of aerosols renders such method speculative at best. Preventing the formation of aerosol upon leaking will provide an inherently safer solution to the problem. The research involves the non-intrusive measurement of heat transfer fluid aerosol sprays using a Malvern Diffraction Particle Analyzer. The aerosol is generated by plain orifice atomization to simulate the formation and dispersion of heat transfer fluid aerosols through leaks in process equipment. Predictive correlations relating aerosol droplet sizes to bulk liquid pressures, temperatures, thermal and fluid properties, leak sizes, and ambient conditions are presented. These correlations will be used to predict the conditions under which leaks will result in the formation of aerosols and will ultimately help in estimating the explosion hazards of heat transfer fluid aerosols. Heat transfer fluid selection can be based on liquids that are less likely to form aerosols. Design criteria also can incorporate the data to arrive at operating conditions that are less likely to produce aerosols. The goal is to provide information that will reduce the hazards of aerosol explosions thereby improving safety in process industries.

L’optimisation des chambres de combustion est généralement réalisée à l'aide d’outils desimulation numérique. Lorsque le carburant est injecté sous forme liquide, la qualité des simulationsdépend en partie de la définition des conditions aux limites imposées pour cette phase à proximité del'injecteur (diamètre, vitesse et flux volumique des gouttes, vitesse de glissement entre phases). Cesconditions aux limites sont généralement définies à partir d'une analyse expérimentale dans desconditions réalistes d’injection, qui fait appel, dans le meilleur des cas, à l’utilisation del’Anémogranulomètre Phase Doppler (PDA). Cependant, cette technique ponctuelle est coûteuse entemps pour une caractérisation globale de l’injecteur et fournit une mesure des flux volumiques avecdes limitations. Il est également difficile d’accéder à des grandeurs telles que la vitesse de la phasegazeuse en présence des gouttes. Pour répondre à cette problématique, il paraît judicieux de mettre enœuvre des techniques de diagnostic optique spatialement résolues. Cette étude consiste à développer des techniques optiques de champ couplant des approches basées sur la diffusion de Mie, sur l'émission fluorescente des gouttes ou de traceurs et utilisant des algorithmes de type PIV, pour caractériser de manière simultanée et quantitative la granulométrie, la vitesse et le flux volumique de la phase dispersée, ainsi que la vitesse de la phase continue dans les brouillards de gouttes au sein d’une configuration réaliste de foyer aéronautique. Une attentionparticulière est portée à l'étude de la précision de la mesure. Ainsi, des comparaisons sont effectuéesavec des bases de données complètes obtenues à l’aide du PDA. L'analyse de ces résultats estconfrontée aux modèles de l'optique physique régissant les phénomènes de fluorescence et dediffusion de la lumière par des particules à l’aide de simulations. Cette démarche nous permetd'interpréter efficacement les résultats obtenus par imagerie directe et de définir les paramètresd'acquisition et de traitement assurant une précision optimale des mesures. / The optimization of combustion chambers is generally carried out using numerical simulation tools.When fuel is injected in liquid form, the simulation quality depends on the boundary conditionsimposed to this phase close to the injector (diameter, velocity and volume flux of the droplets, slipvelocity between phases). These boundary conditions are usually set from an experimental analysisunder realistic conditions of injection, which in the best case uses Phase Doppler Anemo-granulometry(PDA). However, this point measurement technique is time consuming for an overall injectorcharacterization and provides a measurement of the volume flux with some limitations. It is alsodifficult to access variables such as the velocity of the gas phase in the presence of droplets. Toaddress this problem, it seems appropriate to implement spatially resolved optical diagnostictechniques. This study consists in the development of optical field techniques which combine approaches based onMie scattering, fluorescent emission from droplets or tracers and use PIV algorithms to characterizesimultaneously and quantitatively size, velocity and volume flux of the dispersed phase, and velocityof the continuous phase in droplet sprays in a realistic configuration of aeronautical injector. Aparticular attention is given to the study of the measurement accuracy. Thus, comparisons are carriedout with complete databases obtained with the PDA. The analysis of these results is faced withphysical optics models governing phenomena of fluorescence and light scattering by particles usingsimulations. This approach allows us to effectively interpret the results obtained by direct imaging anddefine acquisition and processing parameters ensuring optimum accuracy.

The phenomenon of spray in crossflow is of relevance in gas turbine combustor development. The current work focuses on spray in crossflow rather than liquid jet in crossflow from the standpoint of enhancing fuel dispersion and mixing. Specifically, the first part of the work involves study of spray structure, droplet sizing, and velocimetry for sprays of water and ethanol in a crossflow under ambient conditions. Laser-based diagnostic techniques such as Particle/Droplet Image Analysis (PDIA) and Particle Tracking Velocimetry (PTV) are utilized. Using spray structure images, trajectory equations are derived by multi-variable regression. It is found that the spray trajectory depends only on the two-phase momentum ratio and is independent of other flow parameters. A generalized correlation for the spray trajectory is proposed incorporating the liquid surface tension, which is found to be effective for our data, with water and ethanol, as well as data on Jet-A from the literature for a wide variety of operating conditions. An interesting phenomenon of spatial bifurcation of the spray is observed at low Gas-to-Liquid ratios (GLRs). The reason for this phenomenon is attributed to the co-existence of large and highly deformed ligaments along with much smaller droplets at low GLR conditions. The smaller droplets lose their vertical momentum rapidly leading to lower penetration, whereas the larger ligaments/droplets penetrate much more due to their larger momentum leading to a spatial separation of the two streams. The second part of the study focuses on evaporating sprays in preheated crossflow. Experiments are conducted using ethanol, decane, Jet-A1 fuel, and a two-component surrogate for Jet-A1 fuel. The crossflow air is heated up to 418 K and the effect of evaporation is studied on spray trajectory and droplet sizes. Measured droplet sizes and velocities at two successive locations are used to estimate droplet evaporation lifetimes. Evaporation constant for the d2 law derived from the droplet lifetimes represents the first-ever data for the above-mentioned liquids under forced convective conditions. This data can be used to validate multi-component droplet evaporation models. The last part of the study focuses on Large Eddy Simulations (LES) of the spray in crossflow. The near-nozzle spray structure is investigated experimentally to obtain droplet size and velocity distributions that are used as inputs to the computational model. For the spray in crossflow under ambient conditions, trajectory and droplet sizes at different locations are compared with experimental results. While the predicted trajectory is found to be in good agreement with data, the predicted droplet sizes are larger than the measured values. This is attributed to the implicit assumption in the secondary breakup model that the droplets are spherical, whereas the experimental data in the near-nozzle region clearly shows presence of mostly ligaments and non-spherical droplets, especially for the low GLR cases. A modified breakup model is found to lead to improved agreement in droplet sizes between predictions and measurements. Overall, the experiments and computations have provided significant insight into spray in crossflow phenomenon, and have yielded useful results in terms of validated spray trajectory correlations, droplet evaporation lifetimes under forced convective conditions, and a methodology for simulation of airblast sprays.