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The Simulation, Development, and Testing of a Staged

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The Simulation, Development, and Testing of a Staged THE SIMULATION, DEVELOPMENT, AND TESTING OF A STAGED CATALYTIC MICROTUBE IGNITION SYSTEM By MATTHEW CHARLES DEANS Submitted in partial fulfillment of the requirements for the degree of Doctor of Philosophy Thesis Advisors: Dr. James T’ien & Dr. Steven J. Schneider Department of Mechanical and Aerospace Engineering CASE WESTERN RESERVE UNIVERSITY January, 2013 CASE WESTERN RESERVE UNIVERSITY SCHOOL OF GRADUATE STUDIES We hereby approve the dissertation of Matthew Charles Deans for the Doctor of Philosophy in Aerospace Engineering degree*. (signed) James T’ien (Chair of the Committee) Steven Schneider Paul Barnhart Yasuhiro Kamotani Donald Feke (date) 7/23/2012 *We also certify that written approval has been obtained for any proprietary material contained therein. i Dedication: I would like to dedicate this work to my fiancée, Leah. Thank you for being there through my stress and struggles and for supporting me even with your own sacrifices. I will always appreciate everything you’ve ever done for me! ii Table of Contents Contents Dedication: ..................................................................................................................................... ii List of Tables: ................................................................................................................................. 4 List of Figures: ............................................................................................................................... 5 Acknowledgements: .................................................................................................................... 14 List of Abbreviations: .................................................................................................................. 16 Abstract ......................................................................................................................................... 22 Part 1: Methane and Oxygen Catalytic Microtube ................................................................. 25 Chapter 1: Introduction ........................................................................................................... 25 1.1: Background .................................................................................................................. 25 1.2: Prior Work ..................................................................................................................... 29 Chapter 2: Experimental Methodology ................................................................................ 32 2.1 Facility ............................................................................................................................ 34 Chapter 3: PLUG Catalytic Computational Methodology .................................................. 36 3.1: PLUG Code .................................................................................................................. 36 3.2: Chemical Mechanisms ................................................................................................ 39 Chapter 4: Methane/Oxygen Experimental Results........................................................... 40 4.1: Integrated Staged Design – Testing of Catalyst Element Only ............................ 41 4.2: Integrated Staged Design – Testing of Staged Ignition of Augmenter Stages .. 80 4.3: Integrated Staged Design – Testing of the Ignition of Main Igniter Propellant Flows at Atmospheric Pressure ...................................................................................... 119 Chapter 5: Plug Experimental Simulation Results ........................................................... 136 5.1: Introduction ................................................................................................................. 136 5.2: Variation of Inlet Temperature at Low Power Limit .............................................. 139 5.3: Power Variation.......................................................................................................... 146 5.4: Mixture Variation ........................................................................................................ 150 5.5: Velocity Variation ....................................................................................................... 154 5.6: Pressure Variation ..................................................................................................... 157 Chapter 6: Conclusions ........................................................................................................ 161 1 6.1: Summary ..................................................................................................................... 161 6.2: Future Work ................................................................................................................ 163 Part 2: Simulation of Hydrogen and Oxygen Catalytic Microtube Using a Transient Code ..................................................................................................................................................... 164 Chapter 7: Introduction ......................................................................................................... 164 Chapter 8: Microcombustor Code Computational Methodology .................................... 167 8.1: Governing Equations ................................................................................................ 169 8.2: Chemical Mechanisms .............................................................................................. 172 8.3: Geometry .................................................................................................................... 172 Chapter 9: Hydrogen/Oxygen Microcombustor Simulation Results .............................. 176 9.1: Variation of Equivalence Ratio (Fixed T, V, P, and Power) ................................ 176 9.2: Variation of Equivalence Ratio (Fixed Choked Mass Flow and Power) ............ 185 9.3: Variation of Power ..................................................................................................... 188 9.4a: Variation of Individual Preheat Temperatures .................................................... 194 9.4b: Cumulative Variation of Preheat Temperature ................................................... 198 9.5a: Nominal Case .......................................................................................................... 199 9.5b: Time Dependency of Nominal Case..................................................................... 205 9.6: Variation of Equivalence Ratio around Nominal Point ......................................... 213 9.7: Variation of Cumulative Preheat Temperature Around Nominal ........................ 217 9.8: Variation of Pressure Around Nominal ................................................................... 220 9.9: Variation of Velocity Around Nominal ..................................................................... 224 9.10: Variation of Applied Power Around Nominal ....................................................... 227 9.11: Variation of Inner Diameter Around Nominal ...................................................... 230 9.12: Variation of Wall Thickness and Outer Diameter Around Nominal .................. 235 9.13: Variation of Unheated Length Around Nominal .................................................. 239 Chapter 10: Conclusions ...................................................................................................... 244 10.1: Summary .................................................................................................................. 244 10.2: Future Work.............................................................................................................. 246 Appendix A: Calibration and Error .......................................................................................... 248 Appendix B: Catalytic Tube Array ........................................................................................... 252 Appendix C: Single Tube Catalyst .......................................................................................... 269 C.1: Single Tube Catalyst .................................................................................................... 269 2 C.2: Single Tube Catalyst with Platinum Tube Extension ............................................... 282 Appendix D: Staged Design .................................................................................................... 298 D.1: Staged Design with Wishbone Catalyst – Catalyst Only ........................................ 298 D.2: Staged Design with Wishbone Catalyst – Catalyst and Primary Augmenter ...... 308 D.3: Staged Design – Catalyst, Primary, and Secondary Augmenter (Vertical) ......... 317 D.4: Staged Design – Catalyst, Primary, and Secondary Augmenter (Horizontal) ..... 324 Appendix E: Integrated Staged Design – All Flows at Altitude with Cryogens ................ 332 Appendix F: Design Equation Reference .............................................................................. 356 Bibliography ............................................................................................................................... 358 3 List of Tables: Table 1: Definitions of Equivalence and Mixture Ratio for Methane and Oxygen ............. 47 Table 2: Comparison of Exit Concentrations Between Original Simulations and Experimentally Matched PLUG Case .................................................................................... 144 Table
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