Exploring STAR-CCM+ Capabilities, Enhancements and Practices for Aerospace Combustion. Niveditha Krishnamoorthy CD-adapco

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1 Exploring STAR-CCM+ Capabilities, Enhancements and Practices for Aerospace Combustion Niveditha Krishnamoorthy CD-adapco

2 Outline Overview of modeling capability Applications, Practices and Enhancements Gas Turbines Rocket Nozzles Scramjets Summary

3 Overview (1) Density and Pressure- based flow solvers Incompressible through hypersonic flow regimes Full range of turbulence models RANS, LES and DES Multi-physics Combustion CHT Fluid-Structure Interaction Aeroacoustics

4 Overview (2) Combustion and Emissions Modeling Models for different flame types: Premixed, non-premixed and partially premixed Multi-component liquids, solids and gases Homogeneous and Heterogeneous chemistry Global, tabulated chemistry, reduced/detailed chemistry Emission models for Soot, and Nox Soot Nox Two equation semi-empirical model Method of moments Fuel Prompt Thermal Mass Fraction of CO (LES run)

5 Overview (3) Participating Media Radiation Model Radiative Transport Equation (RTE) solved using the Discrete Ordinates Method (DOM) S2 to S16 Quadratures available Properties of the medium: Gray Thermal Radiation User defined Weighted Sum of Gray Gases Multiband Thermal Radiation Properties in wavelength bands Particle Radiation Scattering: isotropic, gray Absorption: gray

6 Application, Practices and Enhancements Gas Turbine Combustors

7 Gas Turbine Combustor System Level Emissions Fuel Flexibility, Flame Stability Thermo-acoustic Instability Mechanical Durability Cost UHC Soot Nox CO Flame shape Flame location Flash-back/ blow-off Gaseous/liquid Fuels Liner temperature Component temperature Fluid Dynamics Flow and mixing Swirlers Bluff bodies Combustion Chemistry Fuel formulation Operating conditions Chemical kinetics Thermodynamics Heat Transfer Conduction Convection Radiation Unit Level

8 Combustion Chemistry: Models Liquid Droplet Combustion Droplet Evaporation Quasi-steady User defined Droplet Break-up Primary atomization Linear Instability Sheet Atomization (LISA) Secondary break-up Kelvin Helmholtz-Rayleigh Taylor (KHRT) Taylor Analogy (TAB) Stochastic Break-up (SSD) Droplet Wall-impingement Bai-Gosman Satoh Collision Detection Model No Time Counter (NTC) O Rourke Two-way Coupling Turbulence Dispersion Random Walk Technique

9 Gas Phase Combustion Modeling Global Chemistry Global multi-step reactions can be calibrated for specific operating conditions Calibration carried out using HEEDs and DARS-Basic [ Freely propagating Flame] 5 Step Mechanism Sample Reaction: C + D E + F Calibration to match flame speed Reaction Rate: ω = Ae E A/RT C n D m Variables we can vary A : Pre-exponential Factor n, m : FORD (forward reaction rate exponents) Blue = Literature Red = uncalibrated Green = Calibrated Purple = Hand Calibrated

10 Gas Phase Combustion enhancements Tabulated Chemistry Presumed Probability Distribution Models (PPDF Flamelet) Update PPDF Species once per time step without affecting results Can delete species not needed for post-processing: affects table size and look-up times Vectorial table retrieval and more efficient table interpolation Flamelet Generated Manifold (FGM) Flexible definition of progress variable Transports progress variable and its variance. Better representation of state-space than the traditional progress variable model Inclusion of heat loss effects in the table always ensures species and enthalpy are consistent

11 Performance Improvements: Large Cases (LES) Flow Solver improvements in v9.04 Case 1 Case 2 Combustion solver improvements in v9.02 (40-50% speedup) Flow and Lagrangian solver improvements in v9.04 (20-25% speedup from v9.02) Case 1 Case 2

12 Heat Transfer Accurate temperature distributions are required for emission predictions and to assess component life Heat transfer in solid components requires adequate description of Conduction Convection Radiation Liners can either be modelled as shells (1-D heat conduction) or with 3-D heat conduction

13 General Meshing Procedure for CHT Import CAD Single or multiple injectors Liners can have all details like dilution holes, effusion holes All solid components can be included: splash plate, dome etc. Repair the CAD to get a closed geometry Extract fluid domain and all the solid components from the closed CAD Refine prism layer mesher for CHT components such that Y+ is close to 1

14 Meshing Need to ensure there are no intersecting parts or gaps between components Fully conformal mesh possible Quality of mesh can be checked by running mesh diagnostic report Checks for: Face Validity Cell quality Volume change statistics Cell and boundary skewness angle 1:1 matching Conformal mesh

15 Other useful settings Lagrangian update can be done once every time-step Dynamic load balancing for Lagrangian spray helps with speed up Update species and radiation once per time-step (for LES runs)

16 Application, Practices and Enhancements Rocket Nozzles

17 Application Areas Combustion Chamber Multicomponent Droplet combustion Real Gas Equation of State Equilibrium and finite rate chemistry models Nozzle Flow/Plume Study Coupled Solver Equilibrium or finite rate chemistry Heat Transfer (CHT) Base heating Film Cooling

18 Combustion with Real Gas Model Fuel: Methane at K Oxidizer: Oxygen at K Solver: 3D, Steady, k-omega SST Redlick Kwong EOS, Coupled Implicit with solution driver and convergence accelerator (CCA) Non-premixed, non-adiabatic PPDF

19 Reacting Nozzle Flow Coupled Implicit, Axisymmetric Steady, SST K-Omega turbulence Detailed chemistry: 11 species DARS-CFD Approximation options: In-situ Adaptive Tabulation Populates source terms as the simulation progresses for subsequent look-up Speeds computational time once the table is populated Equilibrium Time-Scale Quick approximate solution for detailed chemistry calculations Assumes chemical composition relaxes to local equilibrium composition at time-scale determined by flow and chemistry

20 Inert Stream model for PPDF Combustion One stream or part of one-stream is inert, its reactivity neglected Sole effect of inert stream is to dilute reacting products Transport equation solved for corresponding mixture fractions Species mass fractions computed as linear combination from inert stream and reacting streams Yi=Zinert*Yi_inert+(1-Zinert)*Yi_reaction Faster table generation and interpolation. Smaller table size

21 Application, Practices and Enhancements Scramjets

22 High Speed Reacting Flows Density-based Solver Coupled, implicit formulation with AMG acceleration TVD reconstruction AUSM+ or Roe inviscid flux schemes MUSCL + Venkata limiter Advanced initialization and convergence control Real gas models Redlich Kwong Soave-Redlich Kwong Modified Soave-Redlich Kwong Peng Robinson EBU, PPDF combustion models

23 Advanced Initialization and Convergence Control Advanced Initialization Grid sequencing option Fully implicit newton-type solution algorithm Controllable number of coarse levels Continuity Convergence Accelerator (CCA) Used for high speed flows where convergence for mass flow is slow Solves pressure correction equation using density based Riemann Flux discretization Overall and individual cell mass imbalances are minimized at each iteration Option available for Coupled Implicit Solver.

24 Supersonic Combustion H2 Fueled NASA SCHOLA direct-connect Scramjet engine Validate against experiment and NASA VULCAN code Mesh: 1.4M Hex-dominant 10 Prism Layers Solver: Density based solver Steady,k-w SST, AUSM+FVS Non-adiabatic PPDF

25 Supersonic Combustion (2)

26 Combustion Modeling in Scramjets Global Chemistry Single or multi-step Variants of eddy break-up model Standard Hybrid Combined time-scale Kinetics only Tabulated Chemistry PPDF Equilibrium Detailed Chemistry DARS-CFD stiff chemistry solver Use Equilibrium Time-Scale approximation for initial guess Then switch to finite rate chemistry Laminar flame concept Eddy dissipation concept Dual Mode Scramjet

27 General Tips for Scramjets Meshing Utilize extruded (directed) mesh as much as possible in long, non-complex, ductwork (isolator, combustor, etc.) Use directional reordering of mesh in streamwise direction Coupled Flow and Energy Coupled inviscid flux scheme: AUSM+ Coupled Energy: Enable Enthalpy Formulation Boundary Conditions Specify fuel inlets as mass flow. Ramp flow rate over 1000 iterations Pressure outlets can have a small area of extrusion w/ free slip wall

28 Solver Settings for Scramjets Coupled Implicit CFL = 5.0 Ramp CFL from 0.1 over first 300 iterations AMG Linear Solver Max Cycles = 10 V-Cycle: Pre-Sweeps = 1 Post-Sweeps = 3 Max. Levels = 50 Grid Sequencing Initialization 10 Levels, iter./level, Tolerance = 0.005, CFL = 5.0 Expert Driver CFL Ramp:End Iteration = 250 Min. Explicit Relaxation = 0.35 Max. Explicit Relaxation = 0.75 Target AMG Cycles = 6 Continuity Convergence Accelerator URF = 0.6 (Ramp from 0.03 over first 100 iterations) Enhanced Mass-Imbalance Calculations Enabled AMG Solver Convergence Tolerance = 0.05, V-Cycle: 1 Pre-Sweep, 1 Post-Sweep, Max levels = 50

29 Summary Multi-physics simulations involving high speed flows, reactions and heat transfer possible using STAR-CCM+ Continued efforts on making the code faster for complex flows Best practices established for: Meshing Physics set-up Solver settings Initial and boundary condition specifications In each area of application across industry sectors

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