The electrospray: Fundamentals and combustion applications

Liquid fuel dispersion in practical systems is typically achieved by spraying the fuel into a polydisperse distribution of droplets evaporating and burning in a turbulent gaseous environment. In view of the nearly unsurmountable difficulties of this two-phase flow, it would be useful to use an experimental arrangement that allow a systematic study of spray evolution and burning in configurations of gradually increasing levels of complexity, starting from laminar sprays to fully turbulent ones. An Electrostatic Spray (ES) of charged droplets lends itself to this type of combustion experiments under well-defined conditions and can be used to synthesize gradually more complex spray environments. In its simplest configuration, a liquid is fed into a small metal tube maintained at several kilovolts relative to a ground electrode few centimeters away. Under the action of the electric field, the liquid meniscus at the outlet of the capillary takes a conical shape, with a thin jet emerging from the cone tip. This jet breaks up farther downstream into a fine spray of charged droplets. Several advantages distinguish the electrospray from alternative atomization techniques: the self-dispersion property of the spray due to coulombic repulsion; the absence of droplet coalescence; the potential control of the trajectories of charged droplets by suitable disposition of electrostatic fields; and the decoupling of atomization, which is strictly electrostatic, from gas flow processes. Furthermore, as recently shown in our laboratory, the electrospray can produce quasi-monodisperse droplets over a very broad size range (1-100 microns). The ultimate objective of this research project is to study the formation and burning of electrosprays of liquid fuels first in laminar regimes and then in turbulent ones. Combustion will eventually be investigated in conditions of three-dimensional droplet-droplet interaction, for which experimental studies have been limited to either qualitative observations in sprays or more quantitative observations on simplified systems consisting of a small number of droplets or droplet arrays. The compactness and potential controllability of this spray generaiton system makes it appealing for studies to be undertaken in the next two years on electrospray combustion in reduced-gravity environments such as those achievable at NASA microgravity test facilities

An Experimental and Theoretical Study of Radiative Extinction of Diffusion Flames

In a recent paper on 'Observations of candle flames under various atmospheres in microgravity' by Ross et al., it was found that for the same atmosphere, the burning rate per unit wick surface area and the flame temperature were considerably reduced in microgravity as compared with normal gravity. Also, the flame (spherical in microgravity) was much thicker and further removed from the wick. It thus appears that the flame becomes 'weaker' in microgravity due to the absence of buoyancy generated flow which serves to transport the oxidizer to the combustion zone and remove the hot combustion products from it. The buoyant flow, which may be characterized by the strain rate, assists the diffusion process to execute these essential functions for the survival of the flame. Thus, the diffusion flame is 'weak' at very low strain rates and as the strain rate increases the flame is initially 'strengthened' and eventually it may be 'blown out'. The computed flammability boundaries of T'ien show that such a reversal in material flammability occurs at strain rates around 5 sec. At very low or zero strain rates, flame radiation is expected to considerably affect this 'weak' diffusion flame because: (1) the concentration of combustion products which participate in gas radiation is high in the flame zone; and (2) low strain rates provide sufficient residence time for substantial amounts of soot to form which is usually responsible for a major portion of the radiative heat loss. We anticipate that flame radiation will eventually extinguish this flame. Thus, the objective of this project is to perform an experimental and theoretical investigation of radiation-induced extinction of diffusion flames under microgravity conditions. This is important for spacecraft fire safety

Droplet combustion at reduced gravity

The current work involves theoretical analyses of the effects identified, experiments in the NASA Lewis drop towers performed in the middeck areas of the Space Shuttle. In addition, there is laboratory work associated with the design of the flight apparatus. Calculations have shown that some of the test-matrix data can be obtained in drop towers, and some are achievable only in the space experiments. The apparatus consists of a droplet dispensing device (syringes), a droplet positioning device (opposing, retractable, hollow needles), a droplet ignition device (two matched pairs of retractable spark electrodes), gas and liquid handling systems, a data acquisition system (mainly giving motion-picture records of the combustion in two orthogonal views, one with backlighting for droplet resolution), and associated electronics

Radiant extinction of gaseous diffusion flames

The absence of buoyancy-induced flows in microgravity significantly alters the fundamentals of many combustion processes. Substantial differences between normal-gravity and microgravity flames have been reported during droplet combustion, flame spread over solids, candle flames, and others. These differences are more basic than just in the visible flame shape. Longer residence time and higher concentration of combustion products create a thermochemical environment which changes the flame chemistry. Processes such as flame radiation, that are often ignored under normal gravity, become very important and sometimes even controlling. This is particularly true for conditions at extinction of a microgravity diffusion flame. Under normal-gravity, the buoyant flow, which may be characterized by the strain rate, assists the diffusion process to transport the fuel and oxidizer to the combustion zone and remove the hot combustion products from it. These are essential functions for the survival of the flame which needs fuel and oxidizer. Thus, as the strain rate is increased, the diffusion flame which is 'weak' (reduced burning rate per unit flame area) at low strain rates is initially 'strengthened' and eventually it may be 'blown-out'. Most of the previous research on diffusion flame extinction has been conducted at the high strain rate 'blow-off' limit. The literature substantially lacks information on low strain rate, radiation-induced, extinction of diffusion flames. At the low strain rates encountered in microgravity, flame radiation is enhanced due to: (1) build-up of combustion products in the flame zone which increases the gas radiation, and (2) low strain rates provide sufficient residence time for substantial amounts of soot to form which further increases the flame radiation. It is expected that this radiative heat loss will extinguish the already 'weak' diffusion flame under certain conditions. Identifying these conditions (ambient atmosphere, fuel flow rate, fuel type, etc.) is important for spacecraft fire safety. Thus, the objective is to experimentally and theoretically investigate the radiation-induced extinction of diffusion flames in microgravity and determine the effect of flame radiation on the 'weak' microgravity diffusion flame

Spray combustion at normal and reduced gravity in counterflow and co-flow configurations

Liquid fuel dispersion in practical systems is typically achieved by spraying the fuel into a polydisperse distribution of droplets evaporating and burning in a turbulent gaseous environment In view of the nearly insurmountable difficulties of this two-phase flow, a systematic study of spray evaporation and burning in configurations of gradually increasing levels of complexity, starting from laminar sprays to fully turbulent ones, would be useful. A few years ago we proposed to use an electrostatic spray of charged droplets for this type of combustion experiments under well-defined conditions. In the simplest configuration, a liquid is fed into a small metal tube maintained at several kilovolts relative to a ground electrode few centimeters away. Under the action of the electric field, the liquid meniscus at the outlet of the capillary takes a conical shape, with a thin jet emerging from the cone tip (cone-jet mode). This jet breaks up farther downstream into a spray of charged droplets - the so-called ElectroSpray (ES). Several advantages distinguish the electrospray from alternative atomization techniques: (1) it can produce quasi-monodisperse droplets over a phenomenal size range; (2) the atomization, that is strictly electrostatic, is decoupled from gas flow processes, which provides some flexibility in the selection and control of the experimental conditions; (3) the Coulombic repulsion of homopolarly charged droplets induces spray self-dispersion and prevents droplet coalescence; (4) the ES provides the opportunity of studying regimes of slip between droplets and host gas without compromising the control of the spray properties; and (5) the compactness and potential controllability of this spray generation system makes it appealing for studies in reduced-gravity environments aimed at isolating the spray behavior from natural convection complications. With these premises, in March 1991 we initiated a series of experiments under NASA sponsorship (NAG3-1259 and 1688) in which the ES was used as a research tool to examine spray combustion in counter-flow and co-flow spray diffusion flames, as summarized below. The ultimate objective of this investigation is to examine the formation and burning of sprays of liquid fuels, at both normal and reduced gravity, first in laminar regimes and then in turbulent ones

Unsteady Diffusion Flames: Ignition, Travel, and Burnout (SUBCORE Project: Simplified Unsteady Burning of Contained Reactants)

An experimental apparatus for the examination of a planar, virtually strain-rate-free diffusion flame in microgravity has been designed and fabricated. Such a diffusion flame is characterized by relatively large spatial scale and high symmetry (to facilitate probing), and by relatively long fluid-residence time (to facilitate investigation of rates associated with sooting phenomena). Within the squat rectangular apparatus, with impervious, noncatalytic isothermal walls of stainless steel, a thin metallic splitter plate subdivides the contents into half-volumes. One half-volume initially contains fuel vapor diluted with an inert gas, and the other, oxidizer diluted with another inert gas-so that the two domains have equal pressure, density, and temperature. As the separator is removed, by translation in its own plane, through a tightly fitting slit in one side wall, a line ignitor in the opposite side wall initiates a triple-flame propagation across the narrow layer of combustible mixture formed near midheight in the chamber. The planar diffusion flame so emplaced is quickly disrupted in earth gravity. In microgravity, the planar flame persists, and travels ultimately into the half-volume containing the stoichiometrically deficient reactant; the flame eventually becomes extinguished owing to reactant depletion and heat loss to the walls

Direct Numerical Simulation of Non-Premixed Flame Extinction Phenomena

Non-premixed flame extinction phenomena are relevant in a variety of com- busting environments, including but hardly limited to diesel engines, pool fires, and fire suppression scenarios. These disparate phenomena are controlled by various parameters that contain information on flame stretch, heat losses, composition of the fuel and oxidizer supply streams, etc. Direct Numerical Simulation (DNS) is used in the present study to provide fundamental insight on diffusion flame extinction under non-adiabatic combustion conditions. The list of DNS configurations include: (C1) counterflow laminar flames with soot formation and thermal radiation transport; (C2) coflow turbulent flames with soot formation and thermal radiation transport; (C3) counterflow laminar and turbulent flames interacting with a mist-like water spray. Configurations C1 and C2 use single-step chemistry while configuration C3 uses detailed chemistry (all cases correspond to ethylene-air combustion). Configuration C1 is also treated using large Activation Energy Asymptotics (AEA). The AEA analysis is based on a classical formulation that is extended to include thermal radiation transport with both emission and absorption effects; the analysis also includes soot dynamics. The AEA analysis provides a flame extinction criterion in the form of a critical Damköhler number criterion. The DNS results are used to test the validity of this flame extinction criterion. In configuration C1, the flame extinction occurs as a result of flame stretch or radiative cooling; a variation of configuration C1 is considered in which the oxidizer stream contains a variable amount of soot mass. In configuration C1, flame weakening occurs as a result of radiative cooling; this effect is magnified by artificially increasing the mean Planck soot absorption coefficient. In configuration C3, flame extinction occurs as a result of flame stretch and evaporative cooling. In all studied cases, the critical Damkohler number criterion successfully predicts transition to extinction; this result supports the unifying concept of a flame Damköhler number Da and the idea that different extinction phenomena may be described by a single critical value of Da

Aerodynamic, unsteady, kinetic and heat loss effects on the dynamics and structure of weakly-burning flames

The first objective of the program is to introduce the meritorious counterflow methodology in microgravity in order to quantify the steady and unsteady characteristics of weakly-burning premixed and diffusion flames for a wide variety of conditions including elevated pressures. Subsequently, through detailed modeling and comparisons with the experimental data, to provide physical insight into the elementary mechanisms controlling the flame response. The configuration offers good control over the parameters of interest and can be modelled closely. The knowledge which will be gained from the counterflow flames will be subsequently used to analyze near-limit phenomena related to other configurations by conducting detailed numerical simulations including multidimensional ones. Among the problems to be analyzed are the downward and upward propagation of near-limit flames in tubes and phenomena observed in spherical and cylindrical geometries

An Experimental and Theoretical Study of Radiative Extinction of Diffusion Flames

The objective of this research was to experimentally and theoretically investigate the radiation-induced extinction of gaseous diffusion flames in microgravity. The microgravity conditions were required because radiation-induced extinction is generally not possible in 1-g but is highly likely in microgravity. In 1-g, the flame-generated particulates (e.g. soot) and gaseous combustion products that are responsible for flame radiation, are swept away from the high temperature reaction zone by the buoyancy-induced flow and a steady state is developed. In microgravity, however, the absence of buoyancy-induced flow which transports the fuel and the oxidizer to the combustion zone and removes the hot combustion products from it enhances the flame radiation due to: (1) transient build-up of the combustion products in the flame zone which increases the gas radiation, and (2) longer residence time makes conditions appropriate for substantial amounts of soot to form which is usually responsible for most of the radiative heat loss. Numerical calculations conducted during the course of this work show that even non-radiative flames continue to become "weaker" (diminished burning rate per unit flame area) due to reduced rates of convective and diffusive transport. Thus, it was anticipated that radiative heat loss may eventually extinguish the already "weak" microgravity diffusion flame. While this hypothesis appears convincing and our numerical calculations support it, experiments for a long enough microgravity time could not be conducted during the course of this research to provide an experimental proof. Space shuttle experiments on candle flames show that in an infinite ambient atmosphere, the hemispherical candle flame in microgravity will burn indefinitely. It was hoped that radiative extinction can be experimentally shown by the aerodynamically stabilized gaseous diffusion flames where the fuel supply rate was externally controlled. While substantial progress toward this goal was made during this project, identifying the experimental conditions for which radiative extinction occurs for various fuels requires further study. Details concerning this research which are discussed in published articles are included in the appendices

Simulation of Non-premixed Ethylene-air Crossflow Jet Flame

Computational fluid dynamics tool has been employed in the past to determine and analyze efficiency or performance in combustion engines and for combustion analysis. This paper represents a systematic investigation on the best model predicts the temperature and soot production in coflow jet flame, by applying various RANS turbulent model, soot models and radiation models in presence or absence of gravity. It also applies this model predicted in crossflow jet flame and investigates the velocity ratio (ratio of the velocity of fuel jet to the velocity of air stream) variation effect on temperature and soot production. ANSYS-Fluent CFD software tool was utilized for this study. For the co-flow jet result, one-step soot model, SST turbulent model and Rosseland radiation model with gravity was in a reasonable agreement with the Coppalle and Joyeux [50] experimental data that it was compared with. The crossflow jet was simulated with the best model predicted in the coflow, and variation of velocity ratio of fuel jet and air stream was investigated. The results showed that increase in velocity of fuel jet increased temperature and soot volume fraction, which is as a result of an increase in heat released in the reaction zone when fuel concentration increases (velocity of fuel increases) and leading to significant increase in soot production as temperature increases. It was also observed that as the fuel jet velocity/concentration increases, its maximum temperature and soot volume fraction, get further away from the proximity of jet inlet. The effect of mixing of fuel and air streams was also analyzed