Combustion Design

Considerations
EGR 4347
Analysis and Design of Propulsion
Systems

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
COMBUSTOR DESI GN GOALS ARE DEFI NED
BY THE ENGI NE OPERATI NG
REQUI REMENTS
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
CRITICAL DESIGN PARAMETERS
Equivalence ratio,
Combustor loading parameter, CLP
Space heat release rate, SR
Reference velocity, V
ref
Main burner dome height, H
d
Main burner length/dome height ratio, L
mb
/H
d
Passage velocity, V
pass
Number and spacing of fuel injectors
Pattern factor correlation parameters, PF
Profile factor correlation parameter, P
f
DEFI NI TI ON OF TERMS
PATTERN FACTOR
SYSTEM PRESSURE DROP
LINER PRESSURE DROP
(T
EXIT
)
MAX
- (T
EXIT
)
AVE
(T
EXIT
)
AVE
- (T
INLET
)
AVE
PF =
(P
INLET
)
TOTAL
- (P
EXIT
)
TOTAL
(P
INLET
)
TOTAL
DPS =
(P
INLET
)
STATIC
- (P
EXIT
)
STATIC
(P
INLET
)
STATIC
DP =
COMBUSTI ON 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.)
2C
8
H
18
+ 25(O
2
+ 79/21 N
2
) 16 CO
2
+ 18H
2
O + 25(79/21)N
2
f
stoich
=
EQUIVALENCE RATIO,
2 96 18
25 32
79
21
28
0 0664
( )
( )
.
+
+
=
| =
f
f
stoich
ENGI NE OPERATI ON AFFECTS I NGNI TI ON
AND LEAN STABI LI TY
IGNITION
ENVELOPE
A
L
T
I
T
U
D
E

MACH NO.
DECELERATION
SCHEDULE
OPERATIONAL
ENVELOPE
STABLE
FLAMEOUT
ENGINE SPEED
F
U
E
L

F
L
O
W

COMBUSTI ON PROCESS
PROBLEM: want low | (<1); can easily by 0.5
SOLUTION: locally rich mixture thats burned then diluted and
cooled to acceptable T
t4
PROBLEM: want stationary flame within a moving flow
SOLUTION: Recirculating region at front of combustor, or flame
holders in AB
2
0.1
0.2
0.4
0.6
1.0
4
6
10
50
100 150
200
250
T (C)
Flammable
vapor
Spontaneous
ignition
Flammable
mist
Flash point
Rich flammability limit
E
q
u
i
v
a
l
e
n
c
e

R
a
t
i
o
,

|
Lean
flam
m
ability
lim
it
COMBUSTI ON PROCESS
(I gnition)
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
Ignition Delay
P T
const
t
ign
1
, exp
|
.
|

\
|

COMBUSTI ON 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
CLP
|
Stable
Unstable
Unstable
( ) Vol P
m
CLP
n

COMBUSTI ON PROCESS
(Stability - CLP)
Gives an estimate of combustor length
L V t
ref res
=
=

t ref res
A t
m
3

2"
L
A
ref
V
ave
= V
ref
m
L: distance required for combustion to be completed
A
ref
: cross-sectional area normal to airflow

t3
: approximate density of air entering combustor

t t
P
c
3 3
1

t P
res t
n

3
COMBUSTI ON PROCESS
(Stability - CLP)
Eq. 10-31:
( )
L
P
T
A
A
t
t
t ref
res
c
c

3
1
4
4

Design of new combustor based on old designs (Table 10-5)

F100: L = 18.5 in
D = 25 in
P
t3
= 366 psia
T
t4max
= 3025 R
Known Similar Reference
( )
(

=

c
c
t
r
t
n r
T
P
Const L

1
where
4
3
New Design
( )
n
t
t
t
P
T
P
const L
c
c

=
3
4
1
3

Note: this equation needs to be corrected

in your book
Thus: the length of main burners
varies with pressure and temperature
COMBUSTI ON PROCESS
(Total Pressure Loss)
Heat interaction (Rayleigh Loss) + Friction/Drag (Fanno Loss)
q = c
pe
T
te
- c
pi
T
ti
Drag V C A
i i D
=
1
2
2

q
D
i
e
V
i

T
ti
V
e

T
te
Cont: V V
Mom: P
V
g
P
V
g
V C
Energy: q=c T - c T
i i e e
i
i i
2
c
e
e e
2
c
i i
2
D
pe te pi ti



=
+ = + +
1
2
COMBUSTI ON PROCESS
(Total Pressure Loss)
Solution to these
3 equations:
exit, e 4
inlet, i 3
Equations 10-35 thru
10-38 on page 823
( )
{ }
( )
( )
1.
T
T
q c T
c T
2. =
M 1
1
M
1+ M 1 C
T
T
3. M
2
1- 2 1- 2 1
4.
P
P
1+ M 1
C
2
1 M
5.
P
P
P
P
1
1
M
1
1
M
1
t4
t3
p3 t3
p4 t3
3 3
2
3
3
2
4 3 3
2
D
t4
t3
4
2
4 4
4
3
3 3
2
D
4 4
2
t4
t3
4
3
4
4
2
3
3
2
=
+
+

`
)

=
+ +
=

+
=
+

`
)
+

`
)
<

u
u
u u

2
2
2
2
1
1
4
4
3
3

COMBUSTI ON PROCESS
(Total Pressure Loss)
0 0.05 0.1 0.15 0.2 0.25 0.3
0.75
0.80
0.85
0.90
0.95
1.00 1.0
0.80
0.6
0.4
0.2
0.0
M
i
or M
3
M
e
or M
4
P / P
or
P / P
te ti
t4 t3
COMBUSTOR DI FFUSER
(Total Pressure Loss)
smooth-wall
diffuser
step (dump)
diffuser
1
2
3
Smooth-Wall Dump
( )
( )
P
P
M
A
A
M
t
t
2
1
1
2
1
2
2
1
2
1
1
2
1 1
1
1
2
=

`
)
+

|
\

|
.
|

P
P
M
A
A
A
A
t
t
3
2
2
2
2
3
2
2
3
6
2
1 1 =
|
\

|
.
|
+
|
\

|
.
|

(
(

exp

A
1
A
2
A
3

Set by Compressor Blade Height
COMBUSTOR DESI GN I TERATI ON
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
A
ref
A
comb
V
ref
V
comb
~ 30 ft/s
A
pass
V
pass
~ 150 ft/s
A
ref
= A
pass
+ A
comb

ref t
a
ref
A
m
V
3
3

=
r
i

r
o

H = r
o
- r
i

Main Burner Height, H
Main Burner Areas, Heights, and Velocities
r
m

m
ref
r
A
H
-
~
t 2
COMBUSTOR DESI GN I TERATI ON
Assume the following typical combustor geometry
Primary Combustor Volume, 3.5 ft
3
( A
comb
*L
comb
)
Combustor Reference Area, A
ref
= t(r
t
2
- r
h
2
) = 5 ft
2

Dome Height, H = r
t
- r
h
= 7 in
Total Combustor Volume, Vol = 7.0 ft
3
A
ref
A
comb
V
ref
Primary Volume
Combustor Volume
(includes Primary)
H = r
t
-r
h
r
h
r
t
L
mb
= L
diff
+ L
comb
~
COMBUSTOR DESI GN I TERATI ON
Can calculate from performance data the following:
Combustor Efficiency, q
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, V
ref

Review literature to determine acceptable values for the
above parameters then adjust the design choices
such as Volumes, Areas, and Height.
COMBUSTOR EFFICIENCY
(reaction rate parameter)

{ } ( )
03 . 1 " " 03 . 1 " "
03 . 1 / ln 2 382 10
5
.
3
75 . 1
3
3
> < +
= =

| |
| u
when when
b where x
m
H e A P
b
T
ref t
t
COMBUSTOR STABILITY (CLP)
( ) Vol P
m
CLP
n

SPACE HEAT RELASE (SR) and
REFERENCE VELOCITY (V
ref
)
AB t
PR AB
Vol P
h f m
SR
) (
3600

=
ref t
ref
A
m
V
3
3
.

=
Primary Comb
Zone
m
3a
*50%
m
3a
*50%
Passage
m
3a
|
local
= |/50%
L
mb
= L
diff
+ L
comb

4
3
t
r
t
mb
T
P
L

= const
Main Burner Lengths and Mass Flow Rates
L
mb

L
diff

L
comb

L
diff
= L
sm
+L
dump

3a
3b
3c
Vol
mb
= 0.8L
mb
*A
ref

Vol
comb
= L
comb
*A
comb

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
Afterburners
Components:
Diffuser
Spray Ring
Flame Holder
Cooling Liner
Screech Liner
Variable Throat Nozzle
Afterburners - Components
Cooling Liner
Zone 2 fuel spray ring
Zone 3 fuel spray ring
Zone 4 fuel spray ring
Flame holder Splitter cone
Fan flow
Core flow
Zone 1 fuel
spray ring
Zone 2 fuel
spray ring
Diffuser cone
Linear louvered
Linear perforated
Station 6 Station 7
Diffuser Combustion Section
Afterburners - Components
Diffuser
Spray Ring
Flame Holder
Recirculating Zone
W
H
V
2
d
L
Mixing Zone
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
Spray Ring - I njection, Atomization,
Vaporization, & I gnition
Injection: core stream first (high temp)
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
spray
ring
Ignition: spark or arc igniter
pilot burner
Flame Holder - Flame Stabilization
Two main types
V-gutter Flame Holders
Pilot burners
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
Recirculating Zone
W
d
L
Mixing Zone
V
2
Flame Holder
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
M
Alt
Screech Regime
Rumble
Variable Nozzle
MFP - applied at Nozzle throat, M
8
= 1
A
m T
P MFP M
t
t
8
8 8
8 8
=

( )
Single Flameholder Design
d
L
W
H
D
max
= 35 in
1, i
V
2
V
1
e
Inlet Conditions (Typical)
P
t1
= 40 psia
1
= 1.33
T
t1
=1750 R
m = 200 lb
m
/s
Flameholder Geometry (Choice)
half angle, o = 30 deg
d = 3.5 in
|
local
= 0.8
Exit Conditions (Typical)
T
te
= 3800 R
2
= 1.3
f
AB
= 0.035
Design Calculations
1. Find M
1
2. Check for flame stability for |
local
= 0.8
MFP M
m T
P A
t
t
( )

1
1 1
1 1
=
|
.
|

\
|

+
=
2
1
1
1
1
2
1
1 M
T
T
t

) 1 (
2
1
1
1
1
1
1
2
1
1

|
.
|

\
|

+
=

M
P
P
t
Eq. 10-53 and Fig 10-89
Characteristic ignition time, t
c
t
k
P T
c
ref ref
ref
=
( )
.
|
2 5
t
k
PT
t P T
PT
c
c ref
ref
ref
= =
( )
.
.
.
|
2 5
2 5
2 5
Design Calculations (contd)
2. Flame stability (contd)
eq 10-51:
t
L
V
c
c

2
want something in terms of V
1c
, H, and t
c
, where V
1c

is the maximum entrance velocity for a stable flame
54 10
2
1
2
1 1

|
.
|

\
|
|
.
|

\
|
|
|
.
|

\
|
= =
|
.
|

\
|
eq
H
W
W
L
V
V
W
W
V
L
H
V
H
t V
c
c
Blowout
c c
V
V
W
H
1
2
,
are functions of flameholder blockage
ratio, B = d/H - see Table 10-7
L
W
~ 4
Solve for V
1c
above and compare to
V M RTg
c 1 1 1 1
=
If V
1c
> V
1
, the flame will not blow out
Design Calculations (contd)
3. Total Pressure Drop (t
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: C
D
& T
te
/T
ti
- T
te
/T
ti
is given from calculations (Perf)
- C
D
is estimated using equation 10-57
2
1
2
|
|
.
|

\
|
~
V
V
B C
D
- Use equations 10-35 thru 10-38 to determine
pressure ratio due to Rayleigh & Fanno losses
Design Calculations (contd)
4. Total Afterburner Length - Based on Fig 10-92
5. Space Heat Release Rate, SR
AB t
PR AB
Vol P
h f m
SR
) (
3600

=
Vol = (total length x AB cross-sectional area)
Desired value near 8 x 10
6
Btu/(hr ft
3
atm)
Combustion Chemistry
- General Fuel-to-Air Stoichiometric Equation
2 2 2 2 2
2 4
76 . 3
2 2 4
76 . 3
2 4
N
z y
x O H
y
xCO N
z y
x O
z y
x O H C
z y x
|
.
|

\
|
+ + + |
.
|

\
|
+ + |
.
|

\
|
+ +
| | 16 . 28 76 . 3 32
2 4
16 1 12
- +
|
.
|

\
|
+
+ +
= =
z y
x
z y x
m
m
f
air
fuel
stoich
- Simple Approximation for Heating Value of the Fuel
(Hill and Peterson, p. 221)
m
PR
H
n
m
C
H
C
H
h
n
m
C n Hydrocarbo for
01 . 12
008 . 1
where
lb
BTU
in 800 , 15 900 , 15
-
-
=
|
.
|

\
|
- + =
Combustion Chemistry
Fuel
JP
4
(CH
2.02
)
Propane (C
3
H
8
)
Methane (CH
4
)

Liquid Hydrogen
Heating Value (Btu/lb
m
)
18,400
1

19,944
2

21,518
2


51,593
2

(Equation not Valid)
1
EGTP, pg 827
2
Standard Handbook for Mechanical Engineers, pg 4-29, table 4.1.6
Estimate (Btu/lb
m
)
18,579
19,436
21,203

Combustion Chemistry
- Non-Reacting Mixtures-
mass:
Mole Number :
Mass Fraction:
Mole Fraction:
Mass:
Gas Constant:
m m
N N
mf mf mf
N
N
m N M m M
R
R
M
m i
i
k
m i
i
k
i i
i
k
i
i
k
i
i
m
i
i
k
i i i m i
i
k
i
m
u
m
=
= =
= =
= =
=
=
=
= =
=
=

1
1
1 1
1
1
1
1
,
,
;
_ _
_
Basic Equations Applied Equations
( )( )
1
7
7
6
6
5
5
4
4
3
3
2
2 1 0
mole m
mole
1
1

/lb lb 946186 . 0 - 97 . 28
R) (Btu/lb 9857117 . 1

(
(

=
+
- +
=
+ + +
+ + + + =
-

=
pm
m
pprod pair
pm
p
C
R
f
C f C
C
T A T A T A
T A T A T A T A A C
f
R

-Coefficients for C
p
equation given in
Table 2-4 (pg 106) Mattingly
-Variation in properties given in
Figures 6-1 and 6-2
Combustion Chemistry
- Variation with Temp-
versus Temp for JP-4
1.24
1.26
1.28
1.3
1.32
1.34
1.36
1.38
1.4
1.42
0 500 1000 1500 2000 2500 3000 3500 4000 4500
Temp (R)

f = 0
f = 0.02
f = 0.04
f = 0.06
f = 0.0676
C
p
versus Temp for JP-4
0.22
0.24
0.26
0.28
0.3
0.32
0.34
0.36
0 500 1000 1500 2000 2500 3000 3500 4000 4500
Temp (R)
C
p

(
B
t
u
/
l
b
m
R
)
f = 0
f = 0.02
f = 0.04
f = 0.06
f = 0.0676
Design Example
For the information given on the 1st slide, find the following:

1. M
1
and V
1

2. V
1c
(check stability)
3. Pressure ratio due to Rayleigh and Fanno losses
4. AB length
5. SR

COMBUSTI ON PROCESS
(Total Pressure Loss)
Example: What is the pressure ratio across the
burner for the following conditions:
1. T
t4
/T
t3
= 3.0 and C
D
= 0 (No Drag)

2. T
t4
/T
t3
= 1 and C
D
= 2.0 (No q)

3. T
t4
/T
t3
= 3.0 and C
D
= 2.0 (Both Drag and q)
P
t4
/P
t3
COMBUSTOR DI FFUSER
(Total Pressure Loss)
Station 1 to 2 (smooth-wall, sm)
Station 2 to 3 (Dump)
1
2
Given: q = 0.9, A
1
/A
3
= 0.20
M
1
= 0.5
Pick: A
1
/A
2
= ________
Find: P
t2
/P
t1
= __________ (Use Eq 9.17b)
M
2
= _______ (Use MFP)
L
sm
/H
sm
= ___________ (Use Fig 9.8)
2
3
Calc: A
2
/A
3
= ________
Find: P
t3
/P
t2
= __________ (Use Eq 9.18)
M
3
= ___________ (Use MFP)
L
sm
H
sm
Set by Compressor Blade Height
Overall Pressure Ratio of Diffuser, P
t3
/P
t1
: _________
H
D
L H
D D
~