Fatigue cracking of an aircraft engine labyrinth seal occurred during pre-flight factory testing. Testing in a static rig revealed that the seal could be aeroelastically excited by the labyrinth leakage air flow. An earlier analytical model used for stability analysis was extended to account for the effect of acoustic natural frequency on the aeroelastic stability. The new model predicted that the ratio of acoustic and mechanical natural frequencies was of vital importance in determining if the nature of the pressure fluctuations within the labyrinth seal teeth provided either positive or negative aerodynamic damping to the seal. The analytical results were verified by further rig testing and also by correlation with test results for several other seals tested as part of a labyrinth seal technology program. A mechanical friction damper sleeve was designed to suppress the aeroelastic instability. The damper sleeve was tested in a rotating rig to evaluate its damping characteristics. The aircraft engine was qualified with the newly designed damper which has demonstrated its effectiveness for eight years of service and half a million hours of operation without incident.
Hydrogen micromix combustion is a promising concept to reduce the environmental impact of both aero and land-based gas turbines by delivering carbon-free and ultra-low-NOx combustion without the risk of autoignition or flashback. The ENABLEH2 project aims to demonstrate the feasibility of such a switch to hydrogen for civil aviation, within which the micromix combustion, as a key enabling technology, will be matured to TRL3. The micromix combustor comprises thousands of small diffusion flames for which air and fuel are mixed in a cross-flow pattern. This technology is based on the idea of minimizing the scale of mixing to maximize mixing intensity. The high-reactivity and wide flammability limits of hydrogen in a micromix combustor can produce short and low-temperature small diffusion flames in lean overall equivalence ratios. For hydrogen-air mixtures there is a need to further characterise the physical importance and calibration process of the laminar Schmidt (Sc), Lewis (Le) and Prandtl (Pr) and turbulent Schmidt (Sc) numbers. In addition, there is limited numerical and experimental data about flame characteristics and emissions of hydrogen micromix combustor at high pressure and temperature conditions. In this paper, the CFD software STAR-CCM+ was used with the FGM (Kinetic Rate) combustion model to simulate and calibrate hydrogen micromix flames. The research was divided into two parts. In the first part, the values of laminar Schmidt, Lewis and Prandtl numbers for H2 and air, non-reactive, flow mixtures were estimated as 0.22, 0.3 and 0.75 from correlations obtained in the literature. The typical Borghi diagram has been modified to represent this type of diffusion flame, since the assumption of Sc = Le = Pr = 1 can not be applied to hydrogen micromix flames and it is only for premixed flames. This diagram characterizes flame regime based on Damköhler (Da), Karlovitz (Ka) and turbulent Reynolds (Ret) numbers that were calculated from preliminary CFD simulations. In the second part, the value of laminar Schmidt number was set as constant while laminar Lewis and Prandtl numbers were obtained from the flamelet tables. A Turbulent Schmidt number was then obtained by comparing RANS and LES simulations of a single injector. If Sct > 0.2, the predicted NOx production of RANS simulations approaches that of LES; while Sct < 0.2 provides similar overall flame structure between RANS and LES. It is concluded that, for the current simulations, Sct = 0.2 is a good compromise between flame structure and emissions prediction. Flame characteristics and NOx emissions given by Thickened Flame and FGM Kinetic Rate models in a single injector geometry were also compared.
In this article, a preliminary design framework containing a detailed design methodology is developed for modern low emissions aero combustors. The inter-related design elements involving flow distribution, combustor sizing, heat transfer and cooling, emission and performance are coupled in the design process. The physics-based and numerical methods are provided in detail, in addition to empirical or semi-empirical methods. Feasibility assessment on the developed work is presented via case studies. The proposed combustor sizing methodology produces feasible combustor dimensions against the public-domain low emissions combustors. The results produced by the physics-based method show a reasonable agreement with experimental data to represent NOx emissions at key engine power conditions. The developed emission prediction method shows the potential to assess current and future technologies. A two-dimensional global prediction on liner wall temperature distribution for different cooling systems is reasonably captured by the developed finite difference method. It can be of use in the rapid identification of design solutions and initiating the optimisation of the design variables. The altitude relight efficiency predicted shows that the method could be used to provide an indicative assessment of combustor altitude relight capability at the preliminary design phase. The methodology is applied and shows that it enables the automatic design process for the development of a conceptual lean staged low emissions combustor. The design evaluation is then performed. A sensitivity analysis is carried out to assess the design uncertainties. The optimisation of the air distribution and cooling geometrical parameters addresses the trade-off between the NOx emissions and liner wall cooling, which demonstrates that the developed work has potential to identify and solve the design challenges at the early stages of the design process.
The development of gas turbine combustors is expected to consider the effects of radiation heat transfer in modeling. However, this is not always the case in many studies that neglect this for adiabatic conditions. The effect of radiation is substantiated here, concerning the impact on the performance, mainly the emissions. Also, the fuel–air unmixedness (mixing quality) influenced by the combustor design and operational settings has been investigated with regard to the emissions. The work was conducted with a Mitsubishi-type dry low NOx combustor developed and validated against experimental data. This 3D computational fluid dynamics study was implemented using Reynolds-averaged Navier Stokes simulation and the radiative transfer equation model. It shows that NO, CO, and combustor outlet temperature reduce when the radiative effect is considered. The reductions are 17.6% and below 1% for the others, respectively. Thus, indicating a significant effect on NO. For unmixedness across the combustor in a non-reacting simulation, the mixing quality shows a direct relationship with the turbulence kinetic energy (TKE) in the reacting case. The most significant improvements in unmixedness are shown around the main burner. Also, the baseload shows better mixing, higher TKE, and lower emissions (particularly NO) at the combustor outlet, compared to part-load.
Liquid hydrogen is considered a technically feasible fuel for all gas turbine applications including propulsion systems [1]. However, the exceptional combustion properties of hydrogen will make fundamental changes to gas turbine combustion systems essential. Micromixing, with a novel cross-flow fuel-injection feature and a large plurality of injection holes offers miniaturised diffusive combustion without the risk of auto-ignition or flashback. A detailed analytical study has been performed to explore combustion behaviour of hydrogen in the micro-diffusion combustor concept. The aims are to investigate a broad range of analytical tools and sensitivities related to hydrogen micromix combustion numerical modelling. Comparative studies based on a number of RANS and LES simulations were carried out to down-select suitable numerical models for species transport, turbulence, chemistry and thermochemistry. Simulation results were found to be particularly sensitive to the species diffusion effects. The study was then extended to identify proper thermal boundary conditions capable of replicating experimental work. A thorough discussion of the findings is provided. The study has generated a novel micromix-injector geometry promising to yield ultra-low NOx emissions. This paper sheds light on the difficulties encountered in modelling the combustion of a gaseous fuel (hydrogen) in a novel micro-diffusion combustion chamber and suggests effective approaches to overcome them. It also identifies additional benefits related to hydrogen as a fuel.
Hydrogen has been proposed as an alternative fuel to meet long term emissions and sustainability targets, however due to the characteristics of hydrogen significant modifications to the combustion system are required. The micromix concept utilises a large number of miniaturised diffusion flames to improve mixing, removing the potential for local stoichiometric pockets, flash-back and autoignition. No publicly available studies have yet investigated the thermoacoustic stability of these combustion systems, however due to similarities with lean-premixed combustors which have suffered significant thermoacoustic issues, this risk should not be neglected. Two approaches have been investigated for estimating flame response to acoustic excitations of a single hydrogen micromix injector element. The first uses analytical expressions for the flame transfer function with constants obtained from RANS CFD while the second determines the flame transfer function directly using unsteady LES CFD. Results show the typical form of the flame transfer function but suggest micromix combustors may be more susceptible to higher frequency instabilities than conventional combustion systems. Additionally, the flame transfer function estimated using RANS CFD is broadly similar to that of the LES approach, therefore this may be suitable for use as a preliminary design tool due to its relatively low computational expense.
Hydrogen micromix combustion is a promising concept to reduce the environmental impact of both aero and land-based gas turbines by delivering carbon-free and ultra-low-NOx combustion without the risk of autoignition or flashback. As a part of the ENABLEH2 project, the current study focuses on the influence of design parameters on the micromix hydrogen combustion injectors. This study provides deeper insights into the design space of a hydrogen micromix injection system via numerical simulations. The key geometrical design parameters of the micromix combustion system are the sizing of the air gates and the hydrogen injector orifices together with the offset distance between air gate and hydrogen injection, the mixing distance and the injector to injector spacing. This paper first presents results of the numerical simulation of four designs, down selected from a series of combinations of the key design parameters, including cases with low and high momentum flux ratio, weak and strong flame-flame interaction. It was discovered that the hydrogen/air mixing characteristics, and flame to flame interactions, are the main factors influencing the combustor gas temperature distributions, flame lengths and the corresponding NOx production. The current study then focused on the effect of air gate geometry on the mixing characteristics, flame shape and temperature distribution. The momentum flux ratio was kept constant throughout this investigation by keeping the air gate area constant. Variations of the original baseline air gate design were studied, followed by a study of various novel air gate geometries, including circular, semi-circular and elliptical shapes. It is concluded that NOx production is influenced by a number of factors including jet penetration flame interactions and air gate shape and that there is a “Sweet Spot” that results in the lowest practicable NOx production. Flatter and wider air gate shapes tend to yield the lowest temperature and consequently the lowest NOx. Reduced interaction between flames also tends to reduce NOx and by manipulating hydrogen penetration, there is the potential to further reduce the NOx production.
Fatigue cracking of an aircraft engine labyrinth seal occurred during pre-flight factory testing. Testing in a static rig revealed that the seal could be aeroelastically excited by the labyrinth leakage air flow. An earlier analytical model used for stability analysis was extended to account for the effect of acoustic natural frequency on the aeroelastic stability. The new model predicted that the ratio of acoustic and mechanical natural frequencies was of vital importance in determining if the nature of the pressure fluctuations within the labyrinth seal teeth provided either positive or negative aerodynamic damping to the seal. The analytical results were verified by further rig testing and also by correlation with test results for several other seals tested as part of a labyrinth seal technology program. A mechanical friction damper sleeve was designed to suppress the aeroelastic instability. The damper sleeve was tested in a rotating rig to evaluate its damping characteristics. The aircraft engine was qualified with the newly designed damper which has demonstrated its effectiveness for eight years of service and half a million hours of operation without incident.
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