Combustion Design
Considerations
EGR 4347
Analysis and Design of Propulsion
Systems
1
PROPERTIES OF COMBUSTION CHAMBERS
• Complete combustion
• Low total pressure loss
• Stability of combustion process
• Proper temperature distribution at the exit with no “hot
spots”
• Short length and small cross section
• Freedom from flameout
• Relightability
• Operation over a wide range of mass flow rates,
pressure and temperatures
2
COMBUSTOR DESIGN GOALS ARE DEFINED
BY THE ENGINE OPERATING
REQUIREMENTS
• LEAN BLOW OUT FUEL-AIR RATIO
• IGNITION FUEL-AIR RATIO
• PATTERN FACTOR
• RADIAL PROFILE FACTOR
• PRESSURE DROP (SYSTEM AND LINER)
• COMBUSTION EFFICIENCY
• MAXIMUM WALL TEMPERATURE
• SMOKE AND GASEOUS EMISSIONS
3
CRITICAL DESIGN PARAMETERS
• Equivalence ratio,
• Combustor loading parameter, CLP
• Space heat release rate, SR
• Reference velocity, Vref
• Main burner dome height, Hd
• Main burner length/dome height ratio, Lmb/Hd
• Passage velocity, Vpass
• Number and spacing of fuel injectors
• Pattern factor correlation parameters, PF
• Profile factor correlation parameter, Pf
4
DEFINITION OF TERMS
• PATTERN FACTOR
(TEXIT)MAX - (TEXIT)AVE
PF =
(TEXIT)AVE - (TINLET)AVE
• SYSTEM PRESSURE DROP
(PINLET)TOTAL - (PEXIT)TOTAL
DPS =
(PINLET)TOTAL
• LINER PRESSURE DROP
(PINLET)STATIC - (PEXIT)STATIC
DP = 5
(PINLET)STATIC
COMBUSTION PROCESS
• REACTION RATE - f(Temp, Press)
– T & P high fast reaction rate
– limited by rate at which fuel is vaporized
• FUEL/AIR RATIO (OCTANE e.g.)
– 2C8H18 + 25(O2 + 79/21 N2) 16 CO2 + 18H2O + 25(79/21)N2
2(96 18)
0.0664
– fstoich = 25(32 79 21 28)
ff
• EQUIVALENCE RATIO, stoich
6
ENGINE OPERATION AFFECTS INGNITION
AND LEAN STABILITY
OPERATIONAL
ENVELOPE
ALTITUDE
DECELERATION
FUEL FLOW
SCHEDULE
IGNITION STABLE
ENVELOPE
FLAMEOUT
MACH NO. ENGINE SPEED
7
COMBUSTION PROCESS
10
6
4 R ich flam m ability lim it
E qu ivalen ce R atio,
2
F la m m a b le
m ist F la m m a b le S p o n ta n e o u s
1.0 va p o r ig n itio n
0.6
0.4 L ea n f la m m
a b ilit y lim it
0.2 Flash p oin t
0.1
50 10 0 15 0 20 0 250
T (C )
• PROBLEM: want low (<1); can easily by 0.5
SOLUTION: locally rich mixture that’s burned then diluted and
cooled to acceptable Tt4
• PROBLEM: want stationary flame within a moving flow
SOLUTION: Recirculating region at front of combustor, or “flame 8
holders” in AB
COMBUSTION PROCESS
(Ignition)
• Requires fuel/air mixture be within flammability
limits
• Sufficient residence time
• Ignition source in vicinity of combustible mixture
– If mixture is below Spontaneous Ignition
Temperature (SIT), an ignition source is
required to bring temp up to SIT (Spark Plug)
– Ignition energy - fig 10-68
const 1
– Ignition Delay tign exp ,
T P 9
COMBUSTION PROCESS
(Stability)
• Ability of the combustion process to sustain itself
• PROBLEMS: Too lean or too rich
– Temp & reaction rates drop below that required to heat
and vaporize the fuel/air mixture
• CLP (Combustion Loading Parameter)
– Indication of stability based on mass flow, pressure (n
= 1.8 for typical fuels), and combustor volume
Unstable
m
CLP
P n Vol Stable
Unstable
10
CLP
COMBUSTION PROCESS
(Stability - CLP)
• Gives an estimate of combustor length
L Vref t res
t 3A ref t res
L
m Aref
2"
Vave = Vref
m
L: distance required for combustion to be completed
Aref: cross-sectional area normal to airflow 1
t3: approximate density of air entering combustor t 3 Pt 3
c
t res Pt3 n
11
COMBUSTION PROCESS
(Stability - CLP)
c 1
Pt 3 c
A4
Eq. 10-31: L t res Note: this equation needs to be corrected
Tt 4 A ref in your book
Design of “new” combustor based on “old” designs (Table 10-5)
Known Similar Reference New Design
F100: L = 18.5 in
Pt3r
D = 25 in L Const
Tt 4
Pt3 = 366 psia
c 1
Tt4max = 3025 R where r n
c
c 1
c
Pt 3
L const Pt3n Thus: the length of main burners
Tt 4 12
varies with pressure and temperature
COMBUSTION PROCESS
(Total Pressure Loss)
• Heat interaction (Rayleigh Loss) + Friction/Drag (Fanno Loss)
1 2
q = cpeTte - cpiTti Drag i i CDA
V
2
Vi D Ve
Tti Tte
i e
q
Cont: Vi i Vee
i Vi2 eVe2 1
Mom: Pi Pe i Vi2CD
gc gc 2
13
Energy: q = c peTte - c pi Tti
COMBUSTION PROCESS
(Total Pressure Loss)
Tt4 q c p3Tt3
• Solution to these 1.
Tt3
c p4 Tt3
3 equations: 1 2
3 M 32 1 3 M3
exit, e 4 2. = 2 Tt4
2
inlet, i 3 4 1 + 3 M 32 1 CD Tt3
• Equations 10-35 thru 3. M 42
2
10-38 on page 823 1 - 2 4 1 - 2 4 1
P
4. 4
1 + 3 M 32 1
CD
2
P3 1 4 M 42
4
1 4 1 2 4 1
M4
Pt4 P4 2
5. 3 1
Pt3 P3
1 3 1 M 2 3 1
3 14
2
COMBUSTION PROCESS
(Total Pressure Loss)
1 .0 0 1 .0
0 .9 5 0 .8 0
Pte / Pti 0 .9 0 0 .6
or Me or M4
0 .8 5 0 .4
Pt4 / Pt3
0 .8 0 0 .2
0 .7 5 0 .0
0 0 .0 5 0 .1 0 .1 5 0 .2 0 .2 5 0 .3
Mi or M3
15
COMBUSTOR DIFFUSER
(Total Pressure Loss)
3
Set by Compressor Blade Height
2
1
A1 A2 A3
smooth-wall
diffuser
step (dump)
diffuser
Smooth-Wall Dump
2 2
A1
M1 1 1 A 2 2 6
Pt 2 2 Pt 3 A A
1
2
exp M 2 1 2
1 2
Pt1 Pt 2 2 A A 3
1 1 M 2 1 3
2 1 16
COMBUSTOR DESIGN ITERATION
• Estimate the combustor geometry
– Check Combustion Stability (at all flight conditions)
– Determine Combustion Efficiency (at all flight
conditions)
– Calculate Space Rate Heat Release (at all flight
conditions)
– Determine Combustor Reference Velocity (at all flight
conditions)
• NEXT: Modify design based on the above
calculations and typical/target values
17
Main Burner Areas, Heights, and Velocities
V ref rm
A ref
A comb
ro V comb ~ 30 ft/s
A pass
ri V pass~ 150 ft/s
Main Burner Height, H
m 3a H = ro - ri
Aref = Apass + Acomb Vref Aref
t 3 Aref H
2 r18m
COMBUSTOR DESIGN ITERATION
• Assume the following “typical” combustor geometry
– Primary Combustor Volume, 3.5 ft3 ( Acomb*Lcomb)
– Combustor Reference Area, Aref = (rt2 - rh2) = 5 ft2
– Dome Height, H = rt - rh = 7 in
– Total Combustor Volume, Vol = 7.0 ft3
rt
V ref
H = rt-rh
A ref
Acomb
Primary Volume
Combustor Volume
rh
(includes Primary)
19
Lmb = Ldiff + Lcomb
COMBUSTOR DESIGN ITERATION
• Can calculate from performance data the following:
– Combustor Efficiency, b
– Check Stability by plotting CLP vs
– Calculate Space Rate or Space Heat Release Rate -- measure of
intensity of energy release
– Calculate the Reference Velocity, Vref
• Review literature to determine acceptable values for
the above parameters then adjust the design choices
such as Volumes, Areas, and Height. 20
COMBUSTOR EFFICIENCY
(reaction rate parameter)
Tt 3
1.75
P Aref e H
b
where b 382 2 ln / 1.03
t3
.
x 10 5
m3 21
"" when 1.03 "" when 1.03
COMBUSTOR STABILITY (CLP)
m
CLP
n
P Vol 22
SPACE HEAT RELASE (SR) and
REFERENCE VELOCITY (Vref)
f AB hPR 3600
m
SR
Pt (Vol ) AB
.
m3
Vref
t 3 Aref
23
Main Burner Lengths and Mass Flow Rates
Ldiff = Lsm +Ldump Lcomb
Ldiff
local = /50%
m 3a*50%
Primary Com b
Zone
3c Passage
3b
m 3a *50%
m 3a
3a
Lmb
Pt3r Volmb = 0.8Lmb*Aref
Lmb = Ldiff + Lcomb Lmb const
Tt 4 24
Volcomb = Lcomb*Acomb
Afterburner Design Requirements
*Large temperature rise
*Low dry loss (non-AB thrust)
*Wide temperature modulation (throttle)
*High combustion efficiency
*Short length; light weight
*Altitude light-off capability
*No acoustic combustion instabilities
*Long life, low cost, easy repair
25
Afterburners
Components:
• Diffuser
• Spray Ring
• Flame Holder
• Cooling Liner
• Screech Liner
• Variable Throat Nozzle
26
Afterburners - Components
Diffuser Combustion Section
Zone 4 fuel spray ring
Zone 3 fuel spray ring
Zone 2 fuel spray ring
Fan flow Splitter cone Flame holder
Core flow Cooling Liner
Zone 2 fuel Zone 1 fuel Diffuser cone
spray ring spray ring Linear perforated
Linear louvered
Station 6 Station 7
27
Afterburners - Components
Spray Ring
Flame Holder
V2
Diffuser H
d Recirculating Zone
W
L
Mixing Zone
28
Diffuser
• Balance between low total pressure loss
during combustion (loss Mach no) and
AB cross-sectional area (no larger than
largest diameter upstream)
• Short diffuser to reduce AB length with low
total pressure loss
• Analysis - same as combustor diffuser
29
Spray Ring - Injection, Atomization,
Vaporization, & Ignition
• Injection: core stream first (high temp)
spray
ring
Fuel is injected
perpendicular to air stream &
ripped into micron-sized droplets (atomized).
Fuel is vaporized then ignited prior to
being trapped in downstream flameholder
• Ignition: spark or arc igniter
pilot burner 30
Flame Holder - Flame Stabilization
V2
• Two main types d
– V-gutter Flame Holders Recirculating Zone
W
– Pilot burners L
Flame Holder
Mixing Zone
• Bluff body that generates a low-speed mixing
region just downstream of fuel injection
– high local equivalence ratio (~ 1)
– 2 zones: 1) Mixing - turbulent flow with very high shear
sharp temp gradients and vigorous chemical reactions;
2) Recirculating - strong recirculation, low reaction rates
and temps very near stoiciometric 31
Cooling and Screech Liner
• Cooling
– Isolates the very high temperatures from outer casing. In F119
all the fan air is used to cool the AB and Nozzle during
AB operation.
• Screech
– Attenuates high frequency oscillations associated with
combustion instability (high heat release rates)
– 200-20000 Hz,high heat loading & vibratory stresses
Rumble
Alt
Screech Regime
32
M
Variable Nozzle
• MFP - applied at Nozzle throat, M8 = 1
m
8 Tt 8
A8
Pt 8MFP( M8 )
33
Single Flameholder Design
Dmax= 35 in
d V2
V1 W H
L
1, i e
Inlet Conditions (Typical) Flameholder Geometry (Choice)
Pt1 = 40 psia = 1.33 half angle, = 30 deg
Tt1 =1750 R d = 3.5 in
m = 200 lbm/s local = 0.8
Exit Conditions (Typical)
Tte = 3800 R 2 = 1.3
fAB = 0.035 34
Design Calculations
m
1 Tt1
1. Find M1 MFP( M1 )
Pt1A1
2. Check for flame stability for local = 0.8
Tt1 Pt1
T1 P1
1 1 2 1 1 2
1
( 1 1)
1 M1 1 M1
2 2
Eq. 10-53 and Fig 10-89
k ()
Characteristic ignition time, tc t c ref 2.5
Pref Tref
2.5
k () t c ref Pref Tref
tc 2.5
PT PT 2.5
35
Design Calculations (cont’d)
L
2. Flame stability (cont’d) eq 10-51: tc
V2c
want something in terms of V1c, H, and tc, where V1c
is the maximum entrance velocity for a stable flame
V1c tc V1c L W V1 L W
eq 10 54
H Blowout H V2c W V2 W H
V1 W are functions of flameholder blockage
,
V2 H ratio, B = d/H - see Table 10-7
L
4
W
Solve for V1c above and compare to V1 M1 1RT1g c
If V1c > V1, the flame will not blow out 36
Design Calculations (cont’d)
3. Total Pressure Drop (AB) - Target Values: Fig 10-90
Diffuser: combination of smooth wall & dump
- same approach as main combustor diffuser
using equations 10-42a&b and 10-43
Rayleigh + Fanno: CD & Tte/Tti
- Tte/Tti is given from calculations (Perf)
- CD is estimated using equation 10-57
2
V
C D B 2
V1
- Use equations 10-35 thru 10-38 to determine
pressure ratio due to Rayleigh & Fanno losses
37
Design Calculations (cont’d)
4. Total Afterburner Length - Based on Fig 10-92
5. Space Heat Release Rate, SR
f AB hPR 3600
m
SR
Pt (Vol ) AB
Vol = (total length x AB cross-sectional area)
Desired value near 8 x 106 Btu/(hr ft3 atm)
38
Combustion Chemistry
- General Fuel-to-Air Stoichiometric Equation
y z y z y y z
C x H y Oz x O2 3.76 x N 2 xCO2 H 2O 3.76 x N 2
4 2 4 2 2 4 2
m fuel 12 x 1y 16 z
f stoich
mair y z
x 32 3.76 28.16
4 2
- Simple Approximation for Heating Value of the Fuel
(Hill and Peterson, p. 221)
H
hPR 15,900 15,800 in BTU
C lb m
H 1.008 m
where for Hydrocarbon C n H m
C 12.01 n
39
Combustion Chemistry
Fuel Heating Value (Btu/lbm) Estimate (Btu/lbm)
JP4 (CH2.02) 18,4001 18,579
Propane (C3H8) 19,9442 19,436
Methane (CH4) 21,5182 21,203
Liquid Hydrogen 51,5932
(Equation not Valid)
1
EGTP, pg 827
2
Standard Handbook for Mechanical Engineers, pg 4-29, table 4.1.6
40
Combustion Chemistry
- Non-Reacting Mixtures-
Basic Equations Applied Equations
k
mass: m m mi
i 1
1.9857117 (Btu/lbmole R)
R
k 28.97 - f 0.946186lbm /lb mole
Mole Number : N m N i C p A0 A1T A2T 2 A3T 3 A4T 4
i 1
A5T 5 A6T 6 A7T 7
k k
C pair f C pprod
Mass Fraction: mfi mfi , mfi 1 C pm
i 1 i 1 1 f
1
k R
Ni 1 m
Mole Fraction: i , i 1 C pm
Nm i 1
k
Mass: mi N i M i ; m m i M i
i 1
-Coefficients for Cp equation given in
Ru Table 2-4 (pg 106) Mattingly
Gas Constant: R m
Mm
-Variation in properties given in
Figures 6-1 and 6-2 41
Combustion Chemistry
- Variation with Temp-
Cp versus Temp for JP-4 versus Temp for JP-4
0.36 1.42
f=0
1.4 f = 0.02
0.34 f = 0.04
1.38 f = 0.06
f = 0.0676
0.32
1.36
Cp (Btu/lbmR)
0.3 1.34
0.28 1.32
1.3
0.26 f=0
f = 0.02 1.28
f = 0.04
0.24 f = 0.06 1.26
f = 0.0676
0.22 1.24
0 500 1000 1500 2000 2500 3000 3500 4000 4500 0 500 1000 1500 2000 2500 3000 3500 4000 4500
Temp (R) Temp (R)
42
Design Example
For the information given on the 1st slide, find the following:
1. M1 and V1
2. V1c (check stability)
3. Pressure ratio due to Rayleigh and Fanno losses
4. AB length
5. SR
43
COMBUSTION PROCESS
(Total Pressure Loss)
Example: What is the pressure ratio across the
burner for the following conditions:
Pt4/Pt3
1. Tt4/Tt3 = 3.0 and CD = 0 (No Drag)
2. Tt4/Tt3 = 1 and CD = 2.0 (No q)
3. Tt4/Tt3 = 3.0 and CD = 2.0 (Both Drag and q)
44
COMBUSTOR DIFFUSER
(Total Pressure Loss)
Station 1 to 2 (smooth-wall, sm) Set by Compressor Blade Height
2
1
Given: = 0.9, A1/A3 = 0.20
Hsm
M1 = 0.5
Pick: A1/A2 = ________
Lsm
Find: Pt2/Pt1 = __________ (Use Eq 9.17b)
M2 = _______ (Use MFP)
3
Lsm/Hsm = ___________ (Use Fig 9.8)
Station 2 to 3 (Dump)
Calc: A2/A3 = ________ 2 HD
Find: Pt3/Pt2 = __________ (Use Eq 9.18)
M3 = ___________ (Use MFP) LD HD
45
Overall Pressure Ratio of Diffuser, Pt3/Pt1: _________
