An investigation of high pressure COIL performance improvement methods using CFD

Computational fluid dynamics (CFD) solutions of the full Navier-Stokes equations along with finite-rate chemical kinetics, are used to numerically simulate the reacting in-bore flowfield for a 120mm ram accelerator projectile propulsion system. Various unsteady flow phenomena are investigated, including projectile starting, obturator discard, and high-velocity unstarting. These simulations illustrate the importance of obturator discard dynamics in achieving a successful starting of the ram acceleration process. However, once started, high projectile velocities can induce an unstart if the combustion wave precedes the projectile under certain conditions. In addition, a CFD code validation case is presented for low pressure, steady flow, hydrogen/oxygen combustion around a wedge as compared to Schlieren/PLIF data from Stanford. Introduction Experimental testing and gasdynamic modeling of the ram acceleration technique for in-bore projectile propulsion has been investigated at the U.S. Army Research Laboratory (ARL) under the Hybrid Inbore RAM (HIRAM) propulsion program. This research program seeks to provide a highly efficient method of achieving hypervelocity (> 3 km/s) projectile gun-launch for use in high speed impact testing applications. The ARL ram accelerator system used a 120-mm (bore diameter) tube which was modeled after the 38-mm system at the University of Washington. Numerical solutions of the Navier-Stokes equations have been obtained at the ARL via computational fluid dynamics (CFD) codes for non-reacting and reacting, two-and three-dimensional flows. These codes are being used to investigate the complex gas dynamic physics of ram accelerator projectile propulsion. A variety of CFD techniques have been brought to bear on this problem, including models for chemically frozen (non-reacting) gas, finite-rate global and multiple step chemical kinetics, and equilibrium chemical processes. Accurate numerical simulation of hydrocarbon-based reacting flow creates a very great demand on computational resources since the number of intermediate species and the number of kinetic steps for typical hydrocarbon fuels are prohibitively large. Global reaction mechanisms based on up to thirty-two steps have therefore been investigated for use in preliminary design studies. Within several hours on supercomputers, viscous and chemically reacting gas dynamic simulations are used to assess the influence of projectile velocity, tube fill pressure and mixture composition, and projectile geometry on species consumption, tube wall pressure and projectile thrust. These studies are being used to seek optimum performance for the 120-mm ram accelerator with minimal gun firings. In particular, significant advances in CFD * Aerospace Engineer, Ballistics &; Weapons Concepts Division. Associate Fellow AIAA. This paper is declared a work of the U.S. Government and is not subject to copyright protection in the United States. • modeling for ram acceleration have been made at the ARE. Recently, ARL CFD models have been modified to simulate the unsteady coupling between the launch gun and the ram accelerator. In the Army experimental gun, projectile transition from the conventional (solid propellant) launcher to the accelerator was made through a transition/vent section. This section decouples the launch gun movement from the accelerator and vents combustion gases from the conventional launcher. Redesign of the ram accelerator for Navy applications has required that the ram accelerator operate without the vent section. The removal of the vent section requires that the CFD code be linked to an interior ballistics (IB) simulation of the launch gun in order to supply the pressure behind the obturator. The IB code must be able to adjust to the pressure on the forward face of the obturator, supplied from the CFD code simulating ram combustion. Simulation of ventless ram acceleration has been accomplished. Reacting Flow Model The chemically reacting hypervelocity flow field around a body is numerically simulated using a computer code based on computational fluid dynamics. The ARL-NSRG2 code solves the 2D/axisymmetric, unsteady, real-gas Navier-Stokes equations including equations for chemical kinetics and diffusion. These partial differential equations are cast in conservation form and converted to algebraic equations using a finite-volume formulation. The conservation law form of the equations assures that the end states of regions of discontinuity (e.g., shocks, flames and deflagrations) are physically correct even when smeared over a few computational cells. Solution takes place on a mesh of nodes distributed in a zonal fashion around the projectile and throughout the flow field such that sharp geometric corners and other details are accurately represented. The Navier-Stokes equations for 2D/axisymmetric reacting and unsteady flow are written in the following conservation form with variables nondimensionalized in a conventional fashion. dU dF_ dG_ fat

CAPTools - An interactive toolkit for mapping CFD codes onto parallel architectures

In a reactor severe accident, molten jet breakup and solidification are important behaviors after large pours of molten material fall into the coolant in-vessel or ex-vessel. However, heat and mass transfer processes inside melt during jet breakup have not been studied sufficiently. Existing research on jet fragmentation is relatively macroscopic, and the micro interface condensation details are not well studied. In this paper, a two-dimensional multiphase computational fluid dynamics (CFD) code with the Volume of Fluid (VOF) method and solidification model is applied to simulate molten jet breakup with surface solidification. The VOF model is used to capture the interface, study the details, and add the influence of solidification. Solidification and instability can be seen at the interface. In order to simulate melt solidification, an energy equation is modeled using an enthalpy-based formulation, and viscosity variation during phase change is taken into account. The comparative results between the CFD code and jet breakup experiments show that melt jet front position histories, breakup length, and breakup time are in good agreement with the experiments. The simulation results show that crust formation of the jet surface suppresses surface instability and jet breakup behavior. As the interfacial temperature decreases, the droplet cumulative mass fraction decreases, and the solidified metal proportion increases. The simulation results by the CFD code with the solidification model are valuable and important for understanding the molten jet breakup mechanism.

This paper describes the work done to achieve high parallel performance for an unstructured, unsteady turbomachinery computational fluid dynamics (CFD) code. The aim of the work described here is to be able to scale problems to the thousands of processors that current and future machine architectures will provide. The CFD code is in design use in industry and is also used as a research tool at a number of universities. High parallel scalability has been achieved for a range of turbomachinery test cases, from steady-state hexahedral mesh cases to fully unsteady unstructured mesh cases. This has been achieved by a combination of code modification and consideration of the parallel partitioning strategy and resulting load balancing. A sliding plane option is necessary to run fully unsteady multistage turbomachinery test cases and this has been implemented within the CFD code. Sample CFD calculations of a full turbine including parts of the internal air system are presented.

Thermal-hydraulic analysis of the TRADE spallation target

A computational fluid dynamics (CFD) code, developed at Argonne national laboratory to simulate turbulent mixing, combustion reaction, radiation heat transfer, and pollutant kinetics of combustion flow, has been used to study various melting furnaces. The code employs an integral approach to incorporate a lumped combustion reaction model in the flow calculation and a separate hybrid technique to perform pollutant kinetics calculations. The CFD code has been validated with experimental data collected from industrial furnaces and then used for a parametric study of various furnace geometries and operation conditions. The furnace configuration greatly effected the flow property distribution as well as the combustion efficiency. The air injection velocity effected the flow penetration and the species mixing. The injection angle also significantly effected the species mixing. And finally, the equivalence ratio effected the temperature and pollutant concentrations. The study demonstrates that CFD can be a useful tool for analyzing the flow field of the combustion space in industrial furnaces.

Generation-IV SuperCritical Water-cooled Reactors (SCWRs) are expected to have high thermal efficiencies within the range of 45–50% owing to the reactor’s high pressures and outlet temperatures. The behavior of supercritical water however, is not well understood and most of the methods available to predict the effects of the heat transfer phenomena within the pseudocritical region are based on empirical one-directional correlations which do not capture the multi-dimensional effects and do not provide accurate results in regions such as the deteriorated heat transfer regime. Computational Fluid Dynamics (CFD) is a numerical approach to model fluids in multidimensional space using the Navier-Stokes equations and databases of fluid properties to arrive at a full simulation of a fluid dynamics and heat transfer system. In this work, the CFD code, FLUENT-12, is used with associated software such as Gambit and NIST REFPROP to predict the Heat Transfer Coefficients at the wall and corresponding wall temperature profiles inside vertical bare tubes with SuperCritical Water (SCW) as the cooling medium. The numerical results are compared with experimental data and 1-D models represented by existing empirical correlations. Analysis of the individual heat-transfer regimes is conducted using an axisymmetric 2-D model of tubes of various lengths and composed of different nodalizations along the heated length. Wall temperatures and heat transfer coefficients were analyzed to select the best model for each region (below, at and above the pseudocritical region). Two turbulent models were used in the process: k-ε and k-ω, with variations in the sub-model parameters such as viscous heating, thermal effects, and low-Reynolds number correction. Results of the analysis show a fit of ±10% for the wall temperatures using the SST k-ω model in the deteriorated heat transfer regime and less than ±5% for the normal heat transfer regime. The accuracy of the model is higher than any empirical correlation tested in the mentioned regimes, and provides additional information about the multidimensional effects between the bulk-fluid and wall temperatures.

Auxiliary power units (APUs) are gas turbine engines that provide high-pressure air and electrical power to aircraft systems. They provide primary power while the aircraft is parked on the ramp, starting services for the main engines, and backup power while the aircraft is in flight. Many APUs employ inlet systems which include a “pop-up” door that allow for the capture of freestream ram pressure during flight. This results in increased inlet recovery and a corresponding improvement in the performance of the APU. This APU door, when open, is exposed to airflow instability inherent in the aircraft boundary layer in the aft section of the fuselage, where APUs are typically housed. Additionally, the pop-up nature of the inlet door produces a large region of separated airflow off of the back side of the door. Systematic vortex shedding is frequently a major component of this separated region. As new APU doors are made with less rigid material to save weight, a need to better understand the unsteady aerodynamic excitations of the flow field around the door has arisen, as these new doors may be more susceptible to vibration during flight. Recent advances in Computational Fluid Dynamics (CFD) meshing tools and transient modeling have enabled a CFD study to be performed which will investigate this time-dependent phenomenon. As transient CFD analysis is still a relatively new field for commercial CFD codes, a calibration was needed to verify the accuracy of the CFD predictions and to form any calibration correction terms. Honeywell Aerospace owns a Boeing 757 flight test vehicle which is normally used to flight test propulsion engines. However, this aircraft also includes a pop-up APU inlet door that is similar to most other APU inlet door styles. This APU door was instrumented using high response pressure transducers placed on the forward and aft sides of the inlet door as well as upstream of the door to measure upstream instability. The aircraft was flown at a variety of flight conditions and APU operating points and the transient data was recorded. After the completion of the flight test, a CFD model was constructed of the B757 flight test vehicle. Because aerodynamic instability can be generated anywhere on the aircraft, the entire airframe from nose to tail was modeled. The APU inlet door geometry was also created, meshed and added to the CFD model. This CFD model was run in a transient mode to simulate the exact same flight conditions and APU operating points as were tested during the flight test. Dynamic results in the time and frequency domains predicted by the CFD analyses were compared to flight test data and correlation and calibration factors were derived.

Accurate prediction of bubble behavior in large diameter pipes is crucial for evaluating the performance of safety systems, steam generators, and heat exchangers in nuclear systems. Bubble behavior in large diameter pipes under two-phase flow significantly differs from that in small pipes. With the increasing use of computational fluid dynamics (CFD) codes, predicting interfacial area concentration (IAC) is critical for understanding multi-dimensional bubble behavior. This study developed a two-group local bubble size model for bubbly, slug, and churn flows under adiabatic conditions. The model includes correlations for void fraction and bubble sizes of two groups, which were implemented into CFD codes and validated against experimental data from large diameter pipes with low-pressure air–water flow. Results show the model's prediction accuracy surpasses existing correlations. The developed correlations are applicable across a range of flow conditions covering pipe diameters in the range 0.05–0.152 m, pressures from atmospheric to 300 kPa, superficial liquid velocities from 0.25 m/s to 2.85 m/s, and superficial gas velocities from 0.04 m/s to 5.48 m/s. The model is expected to enhance the prediction capabilities of CFD codes for the adiabatic two-group two-phase flows in the large diameter pipes.

Three-dimensional numerical simulation of pressure drop and liquid holdup for high-pressure trickle-bed reactor

The Use of Computational Fluid Dynamic Code for Modelling Spray from a Mistblower

Transitional flow has a significant impact on vehicles operating at supersonic and hypersonic speeds. An economic way to simulate this problem is to use computational fluid dynamics (CFD) codes. However, not all CFD codes can solve transitional flows. This paper examines the ability of the Spalart–Allmaras one-equation BCM (SA-BCM) transitional model to solve hypersonic transitional flow, implemented in the open-source CFD code Eilmer. Its performance is validated via existing wind tunnel data. Eight different hypersonic flow conditions are applied. A flat plate model is built for the numerical tests. The results indicate that the existing SA-BCM model is sensitive to the freestream turbulence intensity and the grid size. It is not accurate in all the test cases, though the transitional length can be matched by tuning the freestream intensity. This is likely due to the intermittency term of the SA-BCM model not being appropriately calibrated for high-velocity flow, though if the model can be recalibrated it may be able to solve the general high-velocity flows. Although the current SA-BCM model is only accurate under certain flow conditions after one calibration process, it remains attractive to CFD applications. As a one-equation model, the SA-BCM model runs much faster than multiple-equation flow models.

Modelling aerosol number distributions from a vehicle exhaust with an aerosol CFD model

Simulation of some fluid phenomena associated with Generation IV reactors requires the capability of modeling mixing in two- or three-dimensional flow. At the same time, the flow condition of interest is often transient and depends upon boundary conditions dictated by the system behavior as a whole. Computational fluid dynamics (CFD) is an ideal tool for simulating mixing and three-dimensional flow in system components, whereas a system analysis tool is ideal for modeling the entire system. This paper presents the reasoning which has led to coupled CFD and systems analysis code software to analyze the behavior of advanced reactor fluid system behavior. In addition, the kinds of scenarios where this capability is important are identified. The important role of a coupled CFD/systems analysis code tool in the overall calculation scheme for a Very High Temperature Reactor is described. The manner in which coupled systems analysis and CFD codes will be used to evaluate the mixing behavior in a plenum for transient boundary conditions is described. The calculation methodology forms the basis for future coupled calculations that will examine the behavior of such systems at a spectrum of conditions, including transient accident conditions, that define the operational and accident envelope of the subject system. The methodology and analysis techniques demonstrated herein are a key technology that in part forms the backbone of the advanced techniques employed in the evaluation of advanced designs and their operational characteristics for the Generation IV advanced reactor systems.

The Method of Manufactured Solutions is used to perform order of accuracy code verification tests on some features of a hypersonic computational fluid dynamics (CFD) code and a material response code. The CFD verification tests include results for a two species gas mixture in thermal nonequilibrium, and the material response results are for an anisotropic material. After verifying the two codes separately, a verification test is performed with the codes loosely coupled so that the material response code provides updated boundary conditions to the CFD code. In the cases tested, the observed order of accuracy of the CFD code is less than the theoretical order. The tests of the material response code, however, show the expected order of accuracy.