Project 3, CEA Exercise

• This Programing Assignment is due on Beginning of Final Exam Period

-- 11:30 AM MDT, Wednesday May 3.

• We are going to build a chemistry table for an AP-composite rocket

Propellant, and investigate the effects due to increasing metallization
of the grain.

• Look at important effects on flame temperature, molecular weights, and

C* (infinitely expanded nozzle)

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MAE 5450 - Propulsion Systems
 Download and Build CEA Code
• Down Load the CEAGUI from the NASA Glenn Research center Web site
- Recommend you use the windows GIU as it seems to be bug free …
- Linix code has a bunch of compile errors that need to be fixed
- Special Setup Procedure for MAC User ..
http://www.neng.usu.edu/classes/mae/6530/propulsion_systems/section7/ceagui_FAQ_g77MacPC.pdf

• See … http://www.grc.nasa.gov/WWW/CEAWeb/ceaRequestForm.htm
1)Update your comuter’s Java Runtime Environment, Reboot Computer
• Java SE Runtime Environment 8 Downloads

Works for most of you

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MAE 5450 - Propulsion Systems
 Download and Build CEA Code (2)
• FCEA2.exe … built code for PC processor
• Download all three(3) .zip files and save into the installation directory

• Extract (unzip) the CEAgui JAR file (CEAgui-jar.zip)

• Extract (unzip)the CEA+ Fortran Package (CEA+Fortran.zip) for CEA files
• Extract (unzip) the CEAexec Package (CEAexec-win.zip)
• You must have the 6! Unzipped files installed in the installation directory

à 1) CEAgui.jar, 2) thermo.lib, 3) trans.lib, 4) b1b2b3.exe, 5) syntax.exe, and 6) FCEA2.exe in the installation

directory.)

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MAE 5450 - Propulsion Systems
 Download and Build CEA Code (3)
• Directory Structure

JAVA GUI Interface

Command Line (DOS) Interface

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MAE 5450 - Propulsion Systems
 Project Background
Need at
Least 15%
minimum
total HTPB
binder by mass
for “cake” to
stick together

M HTPB Adiabatic Flame Temperature of AP/HTPB/Al

0.150 ≤ Composite Propellant as function of Mass

MAE 5450(- Propulsion

+ M HTPB )
M Al + M APSystems 5
 Project Background (2)
• Investigate Mixture effects

O/F

Plot T0,g ,C* for both Chamber & Throat vs O/F for increasing aluminization levels
• Using equilibrium properties at Throat, plot data for various mixture ratios
and determine optimal operating mixture ratio (based on C*) .. Assume T0 is
constant through out motoe
• Based on flow properties from nozzle throat …
Update AMW L-700 model for “Best case” Formulation Properties
Assume that St. Roberts burn /erosive burn/Bates
Grain parameters are same as previously used 6
MAE 5450 - Propulsion Systems
 Project Overview
• Set up input file to run as “Rocket” Problem with a combustion pressure
of 3000 kPa (30 bars)

• Look AP Composite propellant with Mixture ratio of AP/HTPB/AL

• Run code in “equilibrium”, with “infinite” combustor contraction ratio

• Use results for molecular weight(Mw), ratio of specific heats (g), and
combustion temperature to calculate and C*
1) Based on Chamber, g, Mw.etc.
2) Based on Throat (*), g, Mw. etc.

…. Assume that T0chamber = T0*

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MAE 5450 - Propulsion Systems
 Project Overview (2)

• Apply what we learn to AMW-L700 Motor Analysis

.. Look at both Cylindrical Port with both erosive burn and Bates grain ..
Compare original and “improved” propellant” formulation (be sure to re-
evaluate the propellant density based on formulation) Using new g, Rg,
Mw, T0 ….......

Compare time history plots of

chamber pressure
thrust
regression rate

Calculate and compare …

total impulse .. effective Isp’s

… assume that Saint Robert’s burn parameters (a, n} and the erosion
parameters (k, Mcrit) remain unchanged for new propellant
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MAE 5450 - Propulsion Systems
 Project Overview (3)

• Using equilibrium combustor properties from CEA

• Based on Equilibrium flow “Frozen” at nozzle throat …

Compare to project 2 solution including erosive burn model for cylindrical grain
and /Bates grain model
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MAE 5450 - Propulsion Systems
 Equilibrium Properties at
Chamber and Throat (example)
CHAMBER THROAT

P0/Pstatic 1.0000 1.7428 Assume P0, T0 constant

P, BAR 31.000 17.787
T, K 2925.58 2744.19 throughout motor
RHO, KG/CU M 3.65500 2.2555 0
H, KJ/KG 0.00000 -454.46 Calculate C* based on local
U, KJ/KG
G, KJ/KG
-848.15
-26683.
-1243.08
9 -25484.0 g (throat), Mw (throat) , T0 (chamber)
S, KJ/(KG)(K) 9.1209 9.1209

MW, (1/n) 28.680 28.932

(dLV/dLP)t -1.01044 -1.00776
(dLV/dLT)p 1.2400 1.1912
Cp, KJ/(KG)(K) 3.1727 2.9098
GAMMAs 1.1495 1.1526
SON VEL,M/SEC 987.4 953.4
MACH NUMBER 0.000 1.000

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MAE 5450 - Propulsion Systems
 Chamber Pressure Ballistic Equation
Show that when “shifting equilibrium” from chamber to throat
and then properties frozen at throat is used … the chamber
pressure equation for solid motor must be modified as …
Rg = Ru/Mw

*, Mw* -> properties at throat

Rg -> based on molecular weight at chamber conditions, Mw
P0, T0 Chamber stagnation Pressure, temperature
Use modified chamber pressure ballistic
equation in your follow-on analysis
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MAE 5450 - Propulsion Systems
 Characteristic Velocity, C*
• The characteristic velocity is a figure
of thermo-chemical merit for a particular
propellant and may be considered to be
Indicative of the combustion efficiency.

*
*
*
*
*

• Lower Molecular Weight Propellants Produce Higher C*

• For this calculation based value on g, M at the nozzle throat …
w

MAE 5450 - Propulsion Systems

 Mass Fraction Relationships
⎧
⎪ M NH ClO ⎫
⎪
⎪
⎪ ⎪
⎪
⎪ O/ F≡ 4 4
⎪
⎪
⎪ M HTPB + M AL ⎪
⎪
⎪
⎪ ⎪
⎪
Relate O F to (%)NH ClO →⎪
⎨ ⎪
⎬
4 4 ⎪
⎪ ⎪
⎪
⎪ ⎛ M NH ClO ⎞⎟ ⎪
⎪ ⎜⎜ ⎟⎟ ⎪
⎪
⎪ ( % ) ≡ 100%× ⎜
4 4

⎜⎜⎝ M NH ClO + M HTPB + M AL ⎟⎟⎠

⎪
⎪
⎪
⎪
NH 4ClO4
⎪
⎪
⎪
⎩ 4 4
⎪
⎭

⎛ ⎞⎟
⎜⎜ ⎟⎟ ⎛ ⎞⎟
⎛ ⎞⎟ ⎜⎜ ⎟⎟ ⎜
⎜⎜ ⎟⎟
⎜⎜
→ (%)NH ClO = 100%×⎜
M NH ClO
⎟
⎟⎟ = 100%×⎜⎜ ⎜ 1 ⎟ ⎜ 1 ⎟⎟ = 100%×⎛⎜ O / F ⎞⎟⎟
4 4
⎟⎟ = 100%×⎜ ⎜⎜
4 4 ⎜⎜⎝ M NH ClO + M HTPB + M AL ⎟⎠ ⎜ M HTPB + M AL ⎟⎟ ⎜⎜ 1 ⎟⎟⎟ ⎝ O / F +1⎟⎟⎠
4 4 ⎜⎜1+ ⎟⎟ ⎜⎜⎝1+ ⎟⎟
⎜⎝ M NH ClO ⎟⎠ O / F ⎠
4 4

(%)NH ClO
4 4

Inverse → O / F = 100%
(%)NH ClO
1− 4 4

100%

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MAE 5450 - Propulsion Systems
 Mass Fraction Relationships (2)
…i.e. Mass Constraint Rsolid on terms of O/F and fal
M NH ClO + M AL
Rsolid ≡ 4 4
M AL M AL M AL
M NH ClO + M HTPB + M AL +1 +1 +1
4 4
M NH ClO (O / F )⋅( M HTPB + M AL ) (O / F )⋅( M HTPB + M AL )
M AL → Rsolid = 4 4
=
f Al ≡ M AL + M HTPB M AL + M HTPB 1
M HTPB + M AL +1 +1 +1
M NH ClO (O / F )⋅( M HTPB + M AL ) (O / F )
M NH ClO = (O / F ) ⋅( M HTPB + M AL )
4 4

4 4

M AL M AL
+1 + (O / F )
(O / F )⋅( M HTPB + M AL ) (O / F ) ( M HTPB + M AL ) f Al + (O / F )
Rsolid = ⋅ = =
1
+1 (O / F ) (O / F ) +1 (O / F ) +1
(O / F )

Rsolid − f Al
Inverse → (O / F ) =
1− Rsolid
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MAE 5450 - Propulsion Systems
 Mass Fraction Relationships (3)
…Summary

⎛ M NH ClO ⎞⎟
⎜⎜ ⎟⎟
(%)NH ClO
4 4
= 100%×⎜ 4 4

⎜⎜⎝ M NH ClO + M HTPB + M AL ⎟⎟⎠

Mass Constraint
4 4

M NH ClO
(O / F ) = 4 4
(O / F ) + f Al
( M HTPB + M AL ) →
Rsolid =
(O / F ) +1
M NH ClO + M AL
Rsolid ≡ Rsolid − f Al
(O / F ) =
4 4

M NH ClO + M HTPB + M AL
4 4 1− Rsolid
M AL
f Al ≡
M HTPB + M AL

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MAE 5450 - Propulsion Systems
 Mass Fraction Relationships (4)
…i.e. Mass Constraint on terms of O/F and fal
⎛ M Al + M AP ⎞⎟
⎜⎜ ⎟⎟ − f Al
⎜⎜⎝ M + M Al + M AP ⎟⎠ (0.85)− f Al
O / FMax = HTPB
=
⎛
⎜ M Al + M AP ⎞⎟ 1−(0.85)
1−⎜⎜ ⎟⎟
⎜⎝ M +M +M
HTPB Al AP ⎠
⎟

M Al + M AP
Required .... ≤ 0.85
M HTPB + M Al + M AP

M Al M Al f Al
f Al = =
M HTPB + M Al M HTPB 1− f Al
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MAE 5450 - Propulsion Systems
 Mass Fraction Relationships (3)
…e.g. look at à fAl = 0.2 @ O/F = 5
M AL f Al ⎛ M NH ClO ⎞⎟
0.2 ⎜⎜ ⎟⎟ < 0.85
= = = 0.25 → Required → Rsolid =⎜ 4 4

M HTPB f Al −1 0.8 ⎜⎜⎝ M NH ClO + M HTPB + M AL ⎟⎟⎠

4 4

Too High of Al Fraction!

(O / F ) + f Al (5) + 0.2 5.2
Rsolid = = = = 0.86667 > 85% ..... NO GOOD! .. Must Lower O/F or f Al
(O / F ) +1 (5) +1 6

… look at à fAl = 0.15 @ O/F = 4.5

M AL f Al ⎛ M NH ClO ⎞⎟
0.15 ⎜⎜ ⎟⎟ < 0.85
= = = 0.1765 → Required → Rsolid =⎜ 4 4

M HTPB f Al −1 0.85 ⎜⎜⎝ M NH ClO + M HTPB + M AL ⎟⎟⎠

4 4

(O / F ) + f Al (4.5) + 0.15
Rsolid = = = 0.8455 < 85% ..... Just BARELY!
(O / F ) +1 (4.5) +1
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MAE 5450 - Propulsion Systems
 AP Composite Propellant
Key Physical Properties
• AP chemical formula, NH4 Cl O4 Fine white powder used
as propellant oxidizer

Ammonium perchlorate crystals decompose

ρ NH 4ClO4 = 1.950 g
before melting

cm 3 When AP is mixed with a fuel (like a Al

M w NH ClO = 117.49 kg/kg−mol powder) or polymeric binder (like HTPB) it
4 4 can generate considerable het release and
MAE 5450 - Propulsion Systems allows self-sustained combustion once lit 18
 AP Composite Propellant -- Key
Physical Properties
• Powdered Elemental Al, micron-scale

(molecular weight) kg / kg − mol

ΔH f0 = 0 KJ /mol

Al Powder acts both as a fuel

and combustion catalyst

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MAE 5450 - Propulsion Systems
 Key Physical Properties, cont’d (2)
• HTPB -- (ARCO R-45TM, polymerization ~ 50)
• Full Chemical Formula

OH -

- OH

• Butadiene C4H6, with n-50 degree of polymerization with hydroxyl termination

(hydroxyl makes polymerized rubber more hydrophobic)

(C4H6)50 OH2 à Molecular Weight ~ 2766 kg/kg-mol

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MAE 5450 - Propulsion Systems
 Key Physical Properties (3)
• “Reduced” Chemical Formula w Broken
Polymer Bonds
C4H6 (butadiene gas) (C4 H6 )⋅(OH ) 0.4
0.04
O2 H2 TARs
• Main “fuel” for Molecular Weight ~ 54.68 kg/kg-mol
combustion reaction
ρ HTPB = 0.930 g
cm 3

ΔH f ~ 23.99 KJ / g−mol = 23.99×103 KJ /kg−mol

0
• Enthalpy of Formation Accounts for Energy Required to
Break Polymer Chains

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MAE 5450 - Propulsion Systems
 Key Physical Properties (4)
• HTPB Properties
not listed in CEA
tables
• Insert HTPB
Properties
Here (Not in CEA
tables)

• CEA calculates
mass properties
based on entered
chemical formula

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MAE 5450 - Propulsion Systems
 Key Physical Properties (5)
• Other Important Physical Properties ρ HTPB = 0.930 g
cm 3
Need to calculate your propellant density for
ρ NH 4ClO4 = 1.950
“best mixture” g
cm 3

ρ Al Powder = 2700 kg
m3

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MAE 5450 - Propulsion Systems
 Key Physical Properties (6)
• Other Important Physical Properties ρ HTPB = 0.930 g
cm 3

ρ NH 4ClO4 = 1.950 g
cm 3

ρ Al Powder = 2700 kg
m3

1
ρ propellant =
⎛% ⎞⎟ ⎛
⎜⎜ NH4ClO4 ⎟ ⎜ % Al ⎞⎟ ⎛⎜ % HTPB ⎞⎟
⎜ 100% ⎟⎟ ⎜⎜ ⎟⎟ ⎜
⎜
⎟⎟
⎜⎝ ⎟⎠ ⎝100% ⎟⎠ ⎝ 100% ⎟⎠
+ +
ρ propellant ρ NH ClO ρ HTPB
4 4
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MAE 5450 - Propulsion Systems
 CEA Input File ….. Example < file >.inp

problem o/f=1,1.5,2,2.5,3,3.5,4,4.5,5,5.5,6,6.5,7.,7.5,8,9,
rocket equilibrium frozen nfz=1 tcest,k=3000
p,bar=30,
react
oxid=NH4CLO4(I) wt=100 t,k=298
fuel=AL(cr) wt=25 t,k=298
fuel=HTPB wt=75 t,k=298
h,kj/mol=23.99 C 4 H 6 O 0.04 H 0.04
output
plot p t rho m cp gam end

Setup file by default written to < file > input when

Code is saved using > “save as”
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MAE 5450 - Propulsion Systems