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 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

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, L mb/Hd
Passage velocity, Vpass
Number and spacing of fuel injectors
Pattern factor correlation parameters, PF
Profile factor correlation parameter, P f

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 =
(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
fstoich =

2(96 18)
0.0664
25(32 79 21 28)

EQUIVALENCE RATIO,

ff
stoich

ENGINE OPERATION AFFECTS INGNITION

AND LEAN STABILITY

IGNITION
ENVELOPE

FUEL FLOW

ALTITUDE

OPERATIONAL
ENVELOPE
DECELERATION
SCHEDULE

STABLE

FLAMEOUT

MACH NO.

ENGINE SPEED

COMBUSTION PROCESS
10
6
E q u iv a le n c e R a tio ,

4
2
1 .0

R ic h fl a m m a b il i t y l im i t
F la m m a b le
m is t

F la m m a b le
vapor

S p o n ta n e o u s
ig n it io n

0 .6
0 .4
0 .2
0 .1

F la s h p o i n t
50

100

150

200

T (C )

250

PROBLEM: want low (<1); can easily by 0.5

SOLUTION: locally rich mixture thats 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
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
1
const
tign exp
Ignition Delay
,
P
T

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
CLP

m
P n Vol

Unstable

Stable
Unstable
CLP

COMBUSTION PROCESS
(Stability - CLP)
Gives an estimate of combustor length
L Vref t res

t 3A ref t res

Aref

2"

Vave = Vref

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

t res Pt3 n

COMBUSTION PROCESS
(Stability - CLP)

Eq. 10-31: L

Pt 3

Tt 4

A4
t res
A ref

Note: this equation needs to be corrected

in your book

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

Known Similar Reference
F100: L = 18.5 in
D = 25 in
Pt3 = 366 psia
Tt4max = 3025 R
c 1
L const

Pt 3
Tt 4

Pt3n

New Design
Pt3r
L Const
Tt 4

where r n

c 1
c

Thus: the length of main burners

varies with pressure and temperature

COMBUSTION PROCESS
(Total Pressure Loss)
Heat interaction (Rayleigh Loss) + Friction/Drag (Fanno Loss)
1
2
Drag

V
q = cpeTte - cpiTti
i i CDA
2
Vi
Tti

D
i

Ve
Tte
e

Cont: Vi i Vee
i Vi2
eVe2 1
Mom: Pi
Pe
i Vi2CD
gc
gc
2
Energy: q = c peTte - c pi Tti

COMBUSTION PROCESS
(Total Pressure Loss)
Solution to these
3 equations:
exit, e 4
inlet, i 3
Equations 10-35 thru
10-38 on page 823

Tt4 q c p3Tt3
1.

Tt3
c p4 Tt3
1 2
3 M 32 1 3
M3
2

Tt4
2. =
2
4 1 + 3 M 32 1 CD Tt3

3. M 42
P
4. 4
P3

5.

2
1 - 2 4 1 - 2 4 1

1 + 3 M 32 1

CD

1 4 M 42

4
4 1 2 4 1
M4

3
3 1 2 3 1
M3

Pt4 P4

Pt3 P3

COMBUSTION PROCESS
(Total Pressure Loss)

Pte / Pti
or
Pt4 / Pt3

1 .0 0

1 .0

0 .9 5

0 .8 0

0 .9 0

0 .6

0 .8 5

0 .4

0 .8 0

0 .2

0 .7 5

0 .0
0

0 .0 5

0 .1

0 .1 5

0 .2

Mi or M3

0 .2 5

0 .3

Me or M4

COMBUSTOR DIFFUSER
(Total Pressure Loss)
3
Set by Compressor Blade Height
2
1
A2

A1

A3

smooth-wall
diffuser
step (dump)
diffuser

Smooth-Wall

2
2

A1
M1 1 1
A 2
Pt 2
2

Pt1
1 1 M 2 1
1

Pt 3
2
exp M 2
Pt 2
2

Dump
A2
1

A3

A
1 2
A3

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

Main Burner Areas, Heights, and Velocities

rm

V ref
A re f
A com b
V c o m b ~ 3 0 ft /s

ro

A pass
V p a s s ~ 1 5 0 ft /s

ri

Main Burner Height, H

Aref = Apass + Acomb

m 3a
Vref
t 3 Aref

H = ro - ri
Aref
H
2 rm

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
H = rt-rh

V re f
A com b

A re f

Primary Volume
Combustor Volume
(includes Primary)

rh

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.

COMBUSTOR EFFICIENCY
(reaction rate parameter)

1.75
t3

Tt 3
b

Aref e H
.

x 10 5

m3
"" when 1.03

where b 382 2 ln / 1.03

"" when 1.03

COMBUSTOR STABILITY (CLP)

CLP

P Vol
n

SPACE HEAT RELASE (SR) and

REFERENCE VELOCITY (Vref)
f AB hPR 3600
m
SR
Pt (Vol ) AB
.

Vref

m3

t 3 Aref

Main Burner Lengths and Mass Flow Rates

Lcomb

Ldiff = Lsm +Ldump

Ldiff

lo c a l = /5 0 %
m 3 a*50 %
P r im a r y C o m b
Zone

3b

m 3a

3c

m 3 a*50 %

Passage

3a

Lmb

Lmb = Ldiff + Lcomb

Pt3r
Lmb const
Tt 4

Volmb = 0.8Lmb*Aref
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

Afterburners
Components:
Diffuser
Spray Ring
Flame Holder
Cooling Liner
Screech Liner
Variable Throat Nozzle

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
Cooling Liner

Core flow

Zone 2 fuel Zone 1 fuel

spray ring spray ring

Diffuser cone
Linear perforated
Linear louvered

Station 6

Station 7

Afterburners - Components

Spray Ring
Diffuser

Flame Holder

V2

Recirculating Zone

H
W

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 - 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

Flame Holder - Flame Stabilization

Two main types
V-gutter Flame Holders
Pilot burners

V2
d

Recirculating Zone

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

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
M

Variable Nozzle
MFP - applied at Nozzle throat, M8 = 1

m
8 Tt 8
A8
Pt 8MFP( M8 )

Single Flameholder Design

Dmax= 35 in
V1

V2
L

1, i
Inlet Conditions (Typical)
Pt1 = 40 psia
= 1.33
Tt1 =1750 R
m = 200 lbm/s
Exit Conditions (Typical)
Tte = 3800 R
2 = 1.3
fAB = 0.035

e
Flameholder Geometry (Choice)
half angle, = 30 deg
d = 3.5 in
local = 0.8

Design Calculations
1. Find M1

m
1 Tt1
MFP ( M1 )
Pt1A1

2. Check for flame stability for local = 0.8

T1

Tt1
1 1 2
1
M1
2

P1

Eq. 10-53 and Fig 10-89

Characteristic ignition time, tc
tc

k ()
PT

2.5

Pt1

1 2
M1
1 1
2

t c ref

2.5
t c ref Pref Tref

PT 2.5

( 1 1)

k ()
2.5
Pref Tref

Design Calculations (contd)

2. Flame stability (contd)

eq 10-51:

L
tc
V2c

want something in terms of V1c, H, and tc, where V1c

is the maximum entrance velocity for a stable flame
V1c tc

Blowout

V1 W
,
V2 H

V1c L W V1 L

H V2c W V2 W

eq 10 54

are functions of flameholder blockage

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

Design Calculations (contd)

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
V
C D B 2
V1

- 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

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)

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

f stoich

m fuel
mair

12 x 1y 16 z
y z

x 32 3.76 28.16
4 2

- Simple Approximation for Heating Value of the Fuel

(Hill and Peterson, p. 221)
H
in BTU lb
m
C

hPR 15,900 15,800

where

H 1.008 m

for Hydrocarbon C n H m
C 12.01 n

Combustion Chemistry
Fuel
JP4 (CH2.02)
Propane (C3H8)
Methane (CH4)
Liquid Hydrogen

Heating Value (Btu/lbm) Estimate (Btu/lbm)

18,4001
19,9442
21,5182

18,579
19,436
21,203

51,5932
(Equation not Valid)

EGTP, pg 827
2
Standard Handbook for Mechanical Engineers, pg 4-29, table 4.1.6
1

Combustion Chemistry
- Non-Reacting MixturesBasic Equations

Applied Equations

mass: mm mi
i 1

Mole Number : N m N i

C p A0 A1T A2T 2 A3T 3 A4T 4

i 1

Mass Fraction: mfi mfi ,

i 1

Mole Fraction: i

1.9857117 (Btu/lbmole R)
28.97 - f 0.946186 lbm /lbmole

Ni
,
Nm

A5T 5 A6T 6 A7T 7

mfi 1

i 1

i 1

i 1

C pm

C pair f C pprod
1 f

R
1 m
C pm

Mass: mi N i M i ; m m i M i
i 1

Gas Constant: R m

Ru
Mm

-Coefficients for Cp 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

Cp versus Temp for JP-4

1.42

0.36

f=0
f = 0.02
f = 0.04
f = 0.06
f = 0.0676

1.4

0.34

1.38
1.36

0.3

1.34

Cp (Btu/lbmR)

0.32

1.32

0.28

1.3

f=0
f = 0.02
f = 0.04
f = 0.06
f = 0.0676

0.26
0.24

1.28
1.26

0.22

1.24
0

500

1000

1500

2000

2500

Temp (R)

3000

3500

4000

4500

500

1000

1500

2000

2500

Temp (R)

3000

3500

4000

4500

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

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)

COMBUSTOR DIFFUSER
(Total Pressure Loss)
Set by Compressor Blade Height
Station 1 to 2 (smooth-wall, sm)
Given:

= 0.9, A1/A3 = 0.20

M1 = 0.5

Pick:

A1/A2 = ________

Find:

Pt2/Pt1 = __________ (Use Eq 9.17b)

1
Hsm
Lsm

M2 = _______ (Use MFP)

3

Lsm/Hsm = ___________ (Use Fig 9.8)

Station 2 to 3 (Dump)
Calc:

A2/A3 = ________

Find:

Pt3/Pt2 = __________ (Use Eq 9.18)

HD

M3 = ___________ (Use MFP)

Overall Pressure Ratio of Diffuser, Pt3/Pt1: _________

LD HD