Effects of Co - and Counter-Swirl On The Droplet CH

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Effects of co- and counter-swirl on the droplet characteristics in a spray ﬂame
Article in Chemical Engineering and Processing · November 2008

DOI: 10.1016/j.cep.2007.11.017
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Available online at www.sciencedirect.com
Chemical Engineering and Processing xxx (2008) xxx–xxx
Effects of co- and counter-swirl on the droplet characteristics

in a spray flame
R. Hadef a,∗ , B. Lenze b
aBP 297, Institut de Génie Mécanique, Université Larbi Ben M’Hidi, 04000 Oum El Bouaghi, Algeria
b Engler-Bunte-Institut, Lehrstuhl für Verbrennungstechnik, Universität Karlsruhe (TH), Kaiserstreet 12, 76128 Karlsruhe, Germany
Received 2 May 2007; received in revised form 29 November 2007; accepted 30 November 2007
Abstract
This paper reports measurements of droplet characteristics and flow field in a spray flame with inner and outer swirling air streams. The spatial
distribution of droplet characteristics produced by the burner’s airblast atomizer was measured using dual-phase Doppler anemometry (PDA). The
spray flame was operated near the lean blow-out limit at two flow conditions: co-swirling (flow rotation in the same direction) and counter-swirling
(flow rotation in opposite directions). In both cases, the flame exhibited a U-shaped form and was marked by a large central recirculation zone.
Based on the measurements of the droplet velocity components, differences between both configurations appeared for the counter-rotational setup
mainly in the near burner region, where the decrease of total swirl causes deeper penetration of the droplets from the inner duct into the combustion
chamber, resulting in a much more homogeneous distribution than the other one. The droplet size in terms of the Sauter mean diameter (SMD)
shows little variation in the change of the direction swirl condition. Application of counter-swirl results in more turbulent droplet motion.
© 2008 Published by Elsevier B.V.
Keywords: Spray; Phase Doppler anemometry; Swirl; Flame; Airblast
1. Introduction atomization characteristics, low liquid pressure requirements

and potential for achieving significant reductions in soot for-
Combustion of liquid fuel is encountered in many applica- mation and exhaust smoke [4]. In this atomizer the fuel supply
tions such as gas turbines and diesel engines, industrial furnaces is sandwiched between two swirling air streams.
and liquid-fuelled rocket engines. Swirl flows are widely used The effect of the swirl combinations on spray character-
in these applications. Because of performance requirements istics has been studied by several researchers. Through their
and their effect on the design of these devices, there is a experimental work, Aigner and Wittig [5] were able to show
considerable interest in identifying optimal swirl, geometri- that with a proper selection of swirl elements, particularly
cal conditions and the details of the fuel injector to achieve with counter-swirl, the effectiveness of shear stresses on the
specific practical goals. Numerous experiments in swirling atomization edge can be increased, resulting in a finer atom-
reacting flows have been carried out and have established the ization. Chin et.al. [6] explored the effect of the air swirling
general characteristics of swirl flows. They revealed the impor- orientation on the Sauter mean diameter (SMD) experimen-
tant influence of swirl on decreasing emissions by offering tally, and show that the least efficient atomizer configuration
a means to control the stability and intensity of the com- is that of two counter-rotating air streams to atomize the liquid
bustion as well as the size and shape of the flame region sheet. Moreover, the lowest SMD values were achieved when
[1–3]. the inner air stream was co-swirling and the outer air stream
Most aero-engine and gas turbine applications in service was counter-swirling with respect to the fuel swirling orienta-
today use a prefilming airblast atomizer because of its good tion. However, they used the atomization model proposed by
Dombrowski and Johns [7] for two-dimensional liquid sheets.
On the other hand, the application of counter-swirling stream
∗ Corresponding author. is better at stabilizing the flame than the co-swirling stream
E-mail address: rhadef@rocketmail.com (R. Hadef). [8–10]. Time-resolved measurements of temperature fluctu-
0255-2701/$ – see front matter © 2008 Published by Elsevier B.V.

doi:10.1016/j.cep.2007.11.017
Please cite this article in press as: R. Hadef, B. Lenze, Effects of co- and counter-swirl on the droplet characteristics in a spray flame, Chem.
Eng. Process. (2008), doi:10.1016/j.cep.2007.11.017
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2 R. Hadef, B. Lenze / Chemical Engineering and Processing xxx (2008) xxx–xxx
ations and subsequent calculated thermal micro-time scales

within an unconfined premixed flame in a double-swirl con-
figuration indicate a stronger radial exchange in case of the
co-swirling burner comparing to the counter-swirling one [11].
Three-dimensional laser dual-velocimetry measurements within
an isothermal flow of an airblast atomizer nozzle showed that
the flow field of the counter-swirl arrangement, compared to that
of the co-swirl configuration, exhibits a marked increase of the
mass flow recirculated in the internal recirculation zone and a
reduction of its length in the axial direction [12]. Following this
work, several studies [13–17] continued to investigate the effects
of the gas swirling orientation on the spray dispersion pattern of
prefilming airblast atomizers. However, the mechanism of the
spray dispersion in such atomizer configurations has not still
completely understood and thus further research is necessary.
Therefore, the present research focuses on investigating
how the swirl configuration (co- and counter-swirling) keep-
ing all other parameters fixed, affects the spray dispersion in
the present geometry. Measurements of droplets characteris-
tics were obtained non-intrusively using the dual-phase Doppler
anemometry (PDA) technique. Data are presented for the mean
droplet size, velocity components, number density and axial
volume flux of fuel droplets within the spray flame.
2. Experimental setup
2.1. Atomizer
The experiments were carried out using an atmospheric air-

blast nozzle in a cylindrical combustion chamber with optical
access for laser diagnostics. A sketch of the experimental com-
bustion burner under investigation is given in Fig. 1a. The nozzle
consisted of a modular arrangement of two radial swirl gener-
ators, an atomizer lip which separates the two air streams from Fig. 1. (a) Presentation of the burner. (b) Double-swirler-Fuel atomization
each other within the nozzle, and an air diffuser with a throat assembly. (c) Optical arrangement of a dual-mode phase Doppler system.
diameter of D0 = 25 mm.
The liquid fuel was pressurized to 8 bar and injected by a sim- dimension; it determines mean drop size in the fuel spray and
plex atomizer, which spread a thin wavy film onto the prefilming has direct impact on combustion efficiency, pollutant emissions
surface, interfacing the inner flow. This fuel film was transported and combustion instability [4]. Theory predicts, and experiment
by shear forces to the atomization edge. Upon arriving at the pre- confirms, that the mean drop size is roughly proportional to the
filmer lip, the liquid exited the airblast atomizer as an annular square root of the sheet thickness [4].
sheet which was then subjected to high-speed swirling inner
and outer air streams. The liquid sheet–air interaction gener- 2.2. Operating conditions
ally produces waves that become unstable and disintegrate into
fragments (Fig. 1b). Under favourable conditions the oscilla- Co- and counter-swirling nozzles were created by replacing
tions are amplified, these fragments become ligaments and, in the secondary swirl generator by one which offers the same
turn, break-down into droplets by the shearing effect of the high- amount of swirl, but in the opposite direction. The design of
speed swirling air streams on both sides. This process is referred the nozzle fitting allows the mass flow rate and the preheat
to as primary atomization and involves the action of pressure, temperature of primary and secondary airflow to be adjusted
aerodynamic, centrifugal, surface tension forces, and internal independently of each other. The fuel, liquid kerosene, was fed
effects such as turbulence and those arising from velocity pro- through an atomizer located on the burner centreline. The spray
file relaxation. The droplets were then transported and mixed was ignited by a high voltage spark and the flame was confined in
with air by the swirl, and delivered to the primary zone of the a cylindrical combustion chamber (i.d. 10 cm). Limitation of the
combustion chamber. The presence of the atomizing air leads main reaction zone was provided by an orifice with 40% diame-
to shorter break-up length [18] and enhances liquid–air mixing ter reduction placed at the exit of the combustion chamber. The
[19]. It is well known that the initial thickness of the discharged entire burner was fixed and the optical setup was mounted on a
annular liquid sheet as it leaves the atomizer is the most critical three-axis stepper motor traverse system.
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R. Hadef, B. Lenze / Chemical Engineering and Processing xxx (2008) xxx–xxx 3
The air stream through the nozzle was electrically preheated

up to 200 ◦ C and split between the inner circular passage and the
outer annular canal. The splitting of the air stream is character-
ized by the parameter μ, defined as the ratio of the inner air mass
flow to the outer one: μ = Ṁin /Ṁout . For the current study, the
value of μ was 0.6. The total mass flow rates of air and kerosene
were ṀA = 85.17 kg/h and ṀF = 2.5 kg/h, respectively. This
corresponds to a thermal load of 30 kW and an air-to-fuel ratio
λ = 2.5 which is very close to the lean blow-out limit, measured
experimentally as λ = 2.7 [20]. The Reynolds number is cal-
culated as the product of the axial average air velocity at the
nozzle exit and the throat diameter of the diffuser divided by the
kinematic viscosity of air and yields approximately 46,200.
The swirl strength is characterized by the outlet swirl number Fig. 3. Spatial distribution of droplets number con centration [droplets/cm3 ].
S0 , defined as the ratio of angular to axial momentum flux in the
nozzle divided by the outside nozzle radius R0 as given by:
R0
ρ(Ū W̄r + u w r)r dr
S0 = 0 R 2
R0 0 0 ρ(Ū 2 + u )r dr
where ρ is the fluid density, r is the radial coordinate, U and W are
the axial and tangential velocity components respectively, and
u and w are their velocity fluctuations. The value of S0 should
be calculated from measured values of velocity profiles. Due
to the lack of detailed velocity measurements, the theoretical
swirl number Sth calculated from only the geometrical data of
the swirl generator is used since it is approximately equal to S0
[21]. In the present work it is of the inner airflow Sth,in = 0.46
and of the outer airflow Sth,out = 1.0 in the case of the co-swirl
and Sth,out = 0.85 at the counter-swirl. The value of resulting total
swirl number is Sth,out = 0.80 for the co-swirl configuration and
Sth,total = −0.40 for the counter-swirl configuration.
2.3. Measurement technique
Measurements of droplet size and velocity were conducted

using a commercial DANTEC dual-PDA system. The system
combines a conventional and a planar particle dynamics analyzer
(Fig. 1c) and was developed to improve measurement accuracy
of mass flux and concentration [22]. Due to its higher reso-
lution, the size measurement was performed using the phase
difference of the conventional PDA. The planar PDA is used
to resolve the 2π ambiguity and for validation. The latter is
based on comparison of the droplet diameters measured by
the planar and conventional PDA. As both configurations are
Fig. 4. Radial and axial droplet size distribution for both swirl configurations
Fig. 2. Flame form (a) and streamlines (b). () co-swirl (䊉) counter-swirl.
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affected differently by the slit effect, the trajectory effect, and measurement volume was approximately 53 ␮m in diameter and
non-spherical droplets, erroneous measurements are rejected 2 mm in length. Due to the lens on the receiving probe a por-
[23]. tion of approximately 200 ␮m is cut out of the measurement
The system used an argon-ion laser (INNOVA 70) operat- volume. The light scattered by the droplets was transmitted by
ing at an output power of 200 mW. The laser beam was steered optical fibers to photodetectors, where the light signals were
into the fiber drive which separates the beam into two beams converted into electronic signals. They were further processed
of equal intensity. The beams are subsequently directed into by a real-time signal analyzer and the data were collected by
single-mode fibers, which steer the light to the transmitter. One an acquisition board installed in a personal computer. The mea-
beam of each colour was frequency-shifted by 40 MHz by using surements include size, velocity components number density
a Bragg cell for the purpose of direction recognition of the and turbulent kinetic energy of the droplets as well as the liq-
velocities. The polarization direction was adjusted to be per- uid volume flux. For each measurement location, 5000 samples
pendicular to the scattering plane. In the present experiment, are recorded to allow a determination of the mean properties
two components of the velocity were measured simultaneously with low statistically error. No measurement was made when
with two beam pairs with wavelengths of 514.5 and 488 nm, the data rate was below 5 Hz. In addition, measurements below
respectively. A 30◦ off-axis forward scattering configuration an axial height of 11 mm were not possible due to optical access
with a 400 mm focal length receiving lens was selected. The restrictions.
Fig. 5. (a) Axial droplets mean velocity distribution at both swirl configurations ( ) 10–20 ␮m ( ) 30–40 ␮m ( ) total droplets. (b) Radial droplets mean velocity
distribution at both swirl configurations ( ) 10–20 ␮m ( ) 30–40 ␮m ( ) total droplets. (c) Tangential droplets mean velocity distribution at both swirl configurations
( ) 10–20 ␮m ( ) 30–40 ␮m ( ) total droplets.
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Fig. 5. (Continued )
3. Results 3.2. Droplet characteristics
3.1. Flame shape The spatial distribution of droplet number concentration (pro-
portional to the droplet number density) is shown in Fig. 3. It
Fig. 2a displays a photograph of the investigated flame. The shows that the counter-swirl combinations of the swirler pair
flame is U-shaped due to a low value of the parameter μ, i.e. the (inner and outer swirlers) result in a larger droplet popula-
airflow is mainly provided through the outer duct with strong tion in the inner region of the spray than the corresponding
swirl. Fig. 2b shows pseudo-streamlines in the z–r plane based co-swirl case. The counter-swirl case also tends to introduce
on the mean axial and radial velocity components for a stable droplets into the inner region of the spray, especially in the
flame. The flow field is in the form of a one-celled great toroidal downstream region close to z = 15 mm, compared to the co-swirl
vortex caused by the adverse pressure gradient induced by the one.
swirl and occupying the entire burner volume. Exhaust gas prop- The droplet size of interest in combustion flows is the
agates radially outwards, setting up a wall jet at the enclosure. Sauter mean diameter, which represents the ratio of the
Rounding and smoothing of wall surfaces enhance the formation total volume to the total surface area of the spray droplets.
of wall jets. This recirculation zone primarily aids in flame sta- Radial and axial distributions of the SMD values for both
bilization by providing an aerodynamic blockage and reducing configurations on four measurement planes are shown in
gas velocities necessary to stabilize a flame. It also transports hot Fig. 4.
and chemically active combustion species from the downstream For both cases, the largest droplets are measured roughly
region of the flame to the root of the flame. in the wake of the atomizer lip, due to poor secondary atom-
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Fig. 5. (Continued )
ization. With increasing radial distance, as well as near the lower than in the co-swirl configuration, particularly down-
combustor exit, a considerable increase in droplet diameter is stream of the atomizer edge. This is due the high shear forces
observed. Only large droplets, due to their high inertia, are exerted by the two opposing airstreams on the liquid film
able to penetrate the region of hot recirculating combustion which support efficient atomization, in addition to the very
gases, so that a growth of relative concentration of droplets with rapid decay of the air swirl component that reduces the chances
0 < SMD < 50 ␮m within the radial range from 0 < r < 10 mm is of droplet coalescence. On the other hand, since the growth
observed. As will be shown later on, this maximum matches rate of disturbances on the liquid–air interface (which gov-
regions of very low liquid volume flux. Due to the swirling erns the characteristics of the resulting spray) is higher in the
motion of the gas flow and to resulting centrifugal forces, larger co-inner/counter-outer air stream combination [25], it likely pro-
droplets are separated from the smaller ones and cause a con- duces the finest spray. This behaviour is consistent with the
siderable increase in droplet size at larger radii. Due to their earlier measurements [6]. Also, when the swirl orientation is
larger surface to volume ratio, very small droplets evaporate reversed, the change of annular liquid sheet velocity profile at
faster, resulting in a less pronounced dependence of SMD on the atomizer exit contributed to this distinction as it has been
local measurement position with increasing axial distance from reported in the recent theoretical analyses and experimental val-
the atomizer. This trend agrees well with the previous result idations [26–32].
obtained at elevated pressure [24] where the qualitative sheet Smaller droplets vaporize faster than larger droplets, result-
stability behaviour is similar to that at atmospheric pressure ing in faster fuel vapour mixing with air, which induces
[25]. However, the most noticeable result is that the SMD of full vaporization of the spray at the burner exit plane (Due
the droplets in the counter-swirl configuration is found to be to lack of droplets, measurements were not made above
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an axial height of 35 mm in the counter-swirling config-

uration).
In the present study, size-dependent droplet behaviour was
investigated to increase the understanding of the spray dispersion
characteristics mentioned above. In the following, the results
for the droplet velocity components in two different size classes
(10–20 and 30–40 ␮m) are also presented (Fig. 5). For conve-
nience, they are called 15 and 35 ␮m size classes, or simply
the smaller and the larger droplet classes, respectively. The flow
field of the droplets is described in Fig. 5 through the mean
velocity in axial, radial and tangential directions denoted by
U, V, and W, respectively, as well as by their turbulent kinetic
energy, k.
Generally, all profiles of the mean axial velocity show the typ-
ical behaviour of jets, i.e., a linear increase with radial distance
in the centre region to reach a maximum value, followed by a
decrease in the outer periphery of the spray. As the flow diverges
downstream, this maximum decreases. Compared to the co-swirl
configuration the flow field of the counter-swirl arrangement, the
droplet mean axial velocity component is higher in the centre of
the burner. This observation is more pronounced for the smaller
droplets because these follow the gas flow more closely. Pre-
vious measurements have shown a moderately higher velocity
downstream of the nozzle exit region [33]. On the other hand, the
larger droplets move in to this region more slowly, leading to a
longer residence time in the combustion zone and consequently
a more rapid vaporization.
Examination of the droplet mean radial velocity component
confirms the large spreading of the jet in the radial direction
for this configuration and the inward motion of the droplets just
downstream of the nozzle opening within the central recircula-
tion zone within the radial range from 0 < r < 10 mm up to their
complete evaporation, i.e. at z = 30 mm.
The radial profiles of the mean tangential velocity component
for the droplets emanating from the inner duct of the atom-
izer are identical, since the geometry of the primary swirler
is kept constant in both cases. The radial profiles of tangen- Fig. 6. Radial and axial distribution of the droplets turbulent kinetic energy ()
tial velocity caused by the outer swirler are expected to be of Co-swirl (䊉) Counter-swirl.
the same shape, but have opposite sign. With growing axial
distance, the tangential mean velocity decreases substantially trifugal force that drives the flow to move outwards in the radial
in the central region, without any change in the periphery of direction; the stronger outward radial flow transports the turbu-
the spray for the co-swirl configuration. Further downstream, lent kinetic energy in the radial direction towards the wall faster;
the effect of inlet conditions vanishes and the profile becomes finally, turbulence near the wall is dissipated quickly by the wall
uniform with a complete disappearance in the counter-rotating viscous friction. The production of turbulence near the walls is
swirl. The non-zero values recorded near the axis arise from not significant since the velocity and the velocity gradient near
some instability of the central recirculation zone whose centre the wall are low.
moves slowly around the axis [34] as suggested by the higher However, the most noticeable finding is that the droplets
turbulent kinetic energy values measured on the axis, visible in generally exhibit more significant turbulent motion in the
Fig. 6. counter-swirl case than in the co-swirl case. This improves the
The turbulent kinetic energy radial profiles (Fig. 6) show sim- air-fuel mixing which results in a uniform temperature distri-
ilar behaviour for both cases. They are characterized a high peak bution following combustion without significant temperature
in the centre region of the inlet combustion chamber due to the gradient, therefore reducing the formation of local hot spots
production of turbulence is the shear layer caused by the strong where the thermal formation of harmful oxides of nitrogen (NOx )
recirculation zone where turbulence eddies are highly energetic (exponentially dependent on the temperature) can be severe
and anisotropic. Farther downstream, the turbulence level begins [35,36]. On the other hand, it has been analytically demonstrate
to decay owing to the combination effect of swirling motion and that the ratio of NOx produced to the total mass of fuel droplets
the wall friction. Firstly, the swirling motion generates a cen- burned is an increasing function of the droplet size (i.e., finer
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4. Conclusions
The behaviour of droplets in a spray flame formed by two

swirling annular jets has been studied using the dual-phase PDA
technique. Two swirl configurations, co- and counter-swirling,
were compared in the same operating conditions.
The counter-swirl configuration is characterized by a higher
population of droplets near the burner axis. This observation is
likely responsible for the good flame stability [33].
The results indicate that atomization is finer and more spa-
tially dispersed in the counter-swirl configuration. The first
effect is due to the break-up phenomena of the liquid liga-
ments exiting the lip atomizer, and the second results from the
high additional turbulence level generated in this configuration,
Fig. 7. Spatial distribution of Sauter mean diameter and vector velocity of the
total droplets. leading to enhanced fuel–air mixing.
This advantage leads to easier ignition, a wider burning range,
sprays produce less NOx ) [37]. This finding has been confirmed and lower pollutant emissions, which helps in improving com-
experimentally [38–41] and an excellent review has been written bustion efficiency.
on this subject by Sirignano [42].
Fig. 7 displays a flow field of droplets as a vector plot overlaid Acknowledgements
on the SMD and the axial liquid flux. Every vector represents the
sum of the local axial and radial mean velocity components at The authors gratefully acknowledge the financial support of
all measured positions. This figure clearly shows a radial expan- the BMBF for funding during the KEROMIX program and of
sion of droplets to the wall for both configurations. The impact the DAAD for the award of a fellowship to R. Hadef.
of counter-rotating swirl is twofold. Firstly, it causes a more
pronounced presence of the droplets in the inner central zone. References
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Effects of Co - and Counter-Swirl On The Droplet CH

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Effects of co- and counter-swirl on the droplet characteristics in a spray ﬂame

Article in Chemical Engineering and Processing · November 2008

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Chemical Engineering and Processing xxx (2008) xxx–xxx

Effects of co- and counter-swirl on the droplet characteristics

Keywords: Spray; Phase Doppler anemometry; Swirl; Flame; Airblast

1. Introduction atomization characteristics, low liquid pressure requirements

0255-2701/$ – see front matter © 2008 Published by Elsevier B.V.

ations and subsequent calculated thermal micro-time scales

The experiments were carried out using an atmospheric air-

The air stream through the nozzle was electrically preheated

2.3. Measurement technique

Measurements of droplet size and velocity were conducted

3. Results 3.2. Droplet characteristics

an axial height of 35 mm in the counter-swirling config-

The behaviour of droplets in a spray flame formed by two

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