Search Results (326)

This study experimentally investigated the effect of characteristic chamber length, $L^{\ast }$, on combustion efficiency and stability in CAMUI-type hybrid rockets using 70 wt% and 80 wt% hydrogen peroxide under non-catalytic spray-injection conditions. Combustion tests were conducted by systematically varying $L^{\ast }$ through changes in the nozzle throat diameter while maintaining the combustor volume constant. For both oxidizer concentrations, the characteristic exhaust velocity efficiency, ${\eta }_{c^{\ast }}$, increased with increasing $L^{\ast }$. The 70 wt% cases required a larger $L^{\ast }$ than the 80 wt% cases to achieve comparable efficiency, and flame blowoff occurred in the low-$L^{\ast }$ region. The normalized RMS pressure fluctuation was also larger for the 70 wt% cases, particularly in the low-$L^{\ast }$ region, indicating lower combustion stability. These results indicate that reducing the hydrogen peroxide concentration increases the $L^{\ast }$ required to maintain stable and efficient combustion. As a key outcome of this study, stable and efficient combustion of 70 wt% hydrogen peroxide was demonstrated without catalytic assistance when a sufficiently large $L^{\ast }$ was provided. These results demonstrate the capability of the CAMUI-type combustor to extend stable operation toward lower oxidizer concentrations and experimentally clarify the concentration-dependent $L^{\ast }$ requirement as a practical design guideline for catalyst-free hydrogen peroxide hybrid rockets. Full article

Red liquor combustion is a crucial step in the chemical recovery process in the pulp and paper industry and has two main functions: recovering MgO and SO₂ from magnesium bisulfite spent liquor and generating steam as a heat source for further usage. This research aims to analyze how different red liquor spraying characteristics affect combustion time, guiding recommendations for optimal spraying characteristics to achieve faster combustion using computational fluid dynamics (CFD). Red liquor combustion is simulated in the open-source environment OpenFOAM^®, employing Eulerian–Lagrangian coupling simulations, treating red liquor droplets as Lagrangian particles. One-step devolatilization and combustion kinetics are derived from performed non-isothermal thermogravimetric analyses (TGA) and implemented into the model. An industrial red liquor combustion vessel served as a reference case. Through virtual experiments, we explore the impact of spray angle (15° and 30°), droplet size (2 mm and 3 mm), and spray type (fullcone vs. hollowcone) on combustion time. The performed simulations indicate that the combustion time can be reduced by approximately 30% by reducing the characteristic particle diameter from 3 mm to 2 mm. Furthermore, hollowcone spraying revealed faster combustion times than fullcone spraying. The fastest combustion time was achieved with a characteristic particle size of 2 mm, a spraying angle of 30°, and using a hollowcone spray type. Full article

Liquid rocket engine injectors play a fundamental role in determining combustion efficiency, stability, and overall propulsion performance. This review paper provides a comprehensive analysis of liquid-injector technologies used in space propulsion systems, with emphasis on their historical evolution, atomization mechanisms, and cross-domain insights from aviation fuel injection systems. The study begins by examining the fundamental processes governing liquid jet breakup, including primary and secondary atomization, ligament formation, and droplet generation, together with the non-dimensional parameters that control these phenomena. The historical development of injector architectures -from early orifice-based and impinging designs to modern coaxial and pintle configurations—is then discussed in relation to increasing performance requirements and combustion stability challenges. A comparative perspective with aviation gas turbine injectors is introduced to highlight similarities in atomization physics and differences in operating conditions and design constraints. The paper also reviews experimental and numerical approaches used to characterize spray formation and injector performance. The results indicate that injector geometry and flow conditions strongly influence mixing efficiency, droplet size distribution, and combustion–acoustic coupling mechanisms. The study concludes that integrating cross-domain knowledge and modern design techniques is essential for advancing injector performance in next-generation propulsion systems. Full article

The engine system requirements for different engine cycles significantly influence the design of the mixing head. A literature review of fuel-injection technology for hydrogen and methane is presented. The literature review aimed to answer proposed questions specific to the liquid rocket engine fuel injector design. The current review methodology accounts for the engine system effect. Thus, a comprehensive literature review of the working principles of startup-staged-combustion-cycle engines based on original patents is provided. At the end of the review, the research gaps and suggestions for further work are summarised. At high mass flow rate and injection pressure in the supercritical regime (>50 MPa), experience is limited to the staged-combustion cycle developed in Russia and the US. It is necessary to consider a fluid-dynamic heat transfer coupling study for the multi-injection element design in the supercritical state. Cryogenic spray atomisation experiments need to be designed with research significance in mind. It is still needed to study how the similarity of the spray flow field to the combustion performance affects a liquid rocket engine problem. Moreover, scaling stoichiometric mixing theory needs to be expanded to different injector types, such as tricoaxial and pintle injectors, to validate the correlation between the non-reactive mixing length and flame length. Full article

Erosion–corrosion at elevated temperature represents a critical degradation mechanism in components exposed to particle-laden gaseous flows, such as industrial boilers and combustion systems. This study evaluates the combined erosion–corrosion behaviour of atmospheric plasma-sprayed (APS) coatings based on Al₂O₃/TiO₂ (97/3, 87/13, and 50/50 wt.%), TiO_2, and a hybrid Al₂O₃/NiCrAlY (90/10 wt.%) system. Coatings were characterised by scanning electron microscopy, X-ray diffraction, Vickers microhardness and porosity analysis, and subsequently tested under solid particle erosion and cyclic oxidation at 200 and 400 °C with impact angles of 30° and 90°. All coatings exhibited significantly higher hardness (446–597 HV) than the AISI 310 substrate (181 HV), together with distinct differences in porosity and interlamellar cohesion. Erosion rates decreased with increasing temperature for both impact angles; however, the synergistic contribution to total degradation increased, particularly under normal impact (90°). This behaviour indicates that thermochemical activation enhances the nonlinear interaction between mechanical damage and oxidation. Coatings with lower defect connectivity showed reduced synergistic effects, demonstrating that microstructural architecture governs the magnitude of combined degradation. The Al₂O₃/NiCrAlY system exhibited improved thermomechanical stability associated with the formation of protective Al- and Cr-rich oxides. Full article

Ammonia (NH₃) has emerged as a promising carbon-free fuel for next-generation green energy systems due to its high hydrogen density, ease of storage and transport, and compatibility with existing infrastructure. These attributes contrast with hydrogen, which presents major challenges related to storage, safety, and high-pressure handling. Thus, ammonia offers a more practical alternative for combustion-based applications. However, its low reactivity and complex vaporization behavior, particularly under flash-boiling conditions, pose challenges for accurate modeling. This study presents a comprehensive numerical investigation of liquid-ammonia spray behavior under a range of ambient pressures, encompassing both flash-boiling and non-flashing conditions. Simulations were conducted using the Lagrangian particle tracking method, coupled with various turbulence models (the renormalization group (RNG) family, k-ω family, $\varsigma -f$, V2F models) to evaluate their predictive performance. Validation against experimental data for liquid and vapor penetration demonstrated that the V2F model achieved the best overall balance between accuracy and computational efficiency. Under strong flash-boiling conditions (2 bar), rapid droplet breakup and notable cooling were observed, with droplet temperatures decreasing to approximately 235 K within a few millimeters of the nozzle. In contrast, the cooling effect was more moderate under non-flashing conditions at higher ambient pressures (10–15 bar). Although the current findings were based on numerical simulations, experimental studies are ongoing to validate and refine the modeling framework further. This work provided valuable insights into the coupled effects of turbulence, phase change, and thermal transport in superheated ammonia sprays. Future research will build upon these results by extending the model to NH₃/H₂ dual-fuel systems, refining turbulence-phase interaction models, and exploring the potential application of ammonia-based flash-boiling cooling systems for electric vehicle (EV) battery thermal management. Full article

Pintle injectors offer variable thrust capability and combustion stability advantages for liquid rocket engines. This study presents experimental and numerical investigation of spray characteristics for a liquid–liquid pintle injector using water as simulant. Ten cold flow tests covering total momentum ratio (TMR) from 0.36 to 2.76 captured spray angle variations from 26° to 80°. Computational fluid dynamics (CFD) simulations using Ansys Fluent 2025 R1 with the Volume of Fluid method and dispersed interface modeling showed good agreement with experimental spray angles for TMR > 0.74 (error < 8%), but demonstrated increasing discrepancy at lower TMR values (up to 62% error at TMR = 0.36). This deviation indicates limitations of steady-state RANS models in capturing unsteady, fuel-dominated flow regimes. The experimental dataset provides validation benchmarks for CFD modeling and contributes to injector design optimization for sounding rocket applications. Full article

Elastomeric ablative coatings are essential for protecting solid rocket motor (SRM) combustion chambers from extreme thermal and erosive environments, and their performance is governed by both material composition and processing strategy. This review examines the main elastomer systems used for SRM insulation, including ethylene propylene diene monomer (EPDM), nitrile butadiene rubber (NBR), hydroxyl-terminated polybutadiene (HTPB), polyurethane (PU), silicone-based compounds, and related hybrids, and discusses how their rheological behavior, cure kinetics, thermal stability, and ablation mechanisms affect manufacturability and in-service performance. A comprehensive assessment of coating technologies is presented, covering casting, molding, centrifugal forming, spraying, automated deposition, and emerging additive-manufacturing approaches for complex geometries. Emphasis is placed on processing parameters that control adhesion to metallic substrates, layer uniformity, defect formation, and thermomechanical integrity under high-heat-flux exposure. The review integrates current knowledge on how material choice, surface preparation, and application sequence collectively determine insulation efficiency under operational SRM conditions. Practical aspects such as scalability, compatibility with complex chamber architectures, and integration with quality-control tools are highlighted. By comparing the capabilities and limitations of different materials and technologies, the study identifies key development trends and outlines remaining challenges for improving the durability, structural robustness, and ablation resistance of next-generation elastomeric coatings for SRMs. Full article

Fly ash (FA), a major by-product of coal combustion, has long been regarded as a challenging industrial solid waste. Its inherent abundance of alkaline-earth oxides positioned it as a promising candidate for CO₂ sequestration through mineral carbonation. This study systematically investigated the effects of key operational parameters, including time, stirring rate, ultrasonic treatment, and solid-to-liquid ratio, on the leaching efficiency of calcium ions and subsequent CO₂ fixation. Ultrasonic treatment, a solid-to-liquid ratio of 1:7, a stirring speed of 600 rpm, and 7% monoethanolamine (MEA) collectively enhanced the calcium leaching efficiency (χ_e) to 16.7%, thereby supplying a substantial reservoir of calcium ions for CO₂ fixation. Additionally, the CO₂ injection into fly ash slurry and the slurry spraying into CO₂ gas were investigated to optimize reactor configurations. The latter method demonstrated superior performance, attaining a CO₂ fixation efficiency of 7.23%. This corresponds to a carbonation conversion efficiency (ηc) of approximately 44.5%, indicating that nearly half of the leached calcium ions were successfully converted into stable carbonates. Advanced characterization techniques (SEM-EDS, XRD, FTIR) confirmed the formation of stable carbonates and highlighted the role of additives in enhancing reactivity. The environmental benefit of this approach is addressing fly ash wastes and transforming fly ash into a CO₂ fixation material. These findings provided critical insights for calcium leaching and CO₂ fixation of fly ash. Full article

With the increasingly stringent mandatory emission regulations for engines and the continuous growth of energy consumption, reducing energy consumption and emission pollution has become an inevitable choice for engine development. Against this backdrop, biodiesel and boot-shaped injection rates have attracted widespread attention. However, research results on the combination of boot-shaped injection and biodiesel applied to engines have not yet been reported. In order to provide direction for the optimal matching of the combustion system parameters of biodiesel engines under saddle-shaped injection conditions, this paper achieves boot-shaped injection using a dual solenoid valve control strategy for ultra-high-pressure fuel injection devices, establishes a simulation model of biodiesel engines under saddle-shaped injection conditions using software and validates the model based on experiments. Subsequently, the model is used to study the influence of nozzle numbers, swirl ratio and bore-to-stroke ratio on the performance of biodiesel engines under saddle-shaped injection conditions. The results show that under saddle-shaped injection conditions, appropriately increasing the nozzle hole can refine the fuel spray, which is beneficial for fuel–air mixing and combustion in the cylinder. However, too many nozzle holes can lead to interference between adjacent fuel sprays. When the swirl ratio is large, air flow accelerates, and the oxygen concentration in the cylinder increases, which can effectively control soot formation. When the bore-to-stroke ratio is large, the fuel spray is farther away from the combustion chamber side wall, facilitating sufficient contact between fuel and air, resulting in better fuel–air mixing and effectively reducing soot formation. However, the cylinder temperature also increases, leading to higher NOx formation. Full article

To reveal the physical evolution of methanol spray under different environmental conditions and injection strategies, this study focuses on the atomization and evaporation behavior of low-pressure methanol spray. The coupled effects of temperature, pressure, and injection parameters are systematically investigated based on constant-volume combustion chamber experiments and three-dimensional CFD simulations. The formation, evolution, and interaction mechanisms of the liquid column core and cooling core are revealed. The results indicate that temperature is the dominant factor influencing methanol spray atomization. When the temperature increases from 255 K to 333 K, the spray penetration distance increases by approximately 70%, accompanied by a pronounced shortening of the liquid-core length and enhanced evaporation and air entrainment. Under low-temperature conditions, a stable liquid-core structure and a strong cooling core are formed, characterized by a high-density, long-axis morphology and an extensive low-temperature region, which suppress fuel–air mixing and ignition. Increasing the ambient pressure improves spray–air mixing but reduces penetration; at 255 K, increasing the ambient pressure from 0.05 MPa to 0.2 MPa increases the spray cone angle by approximately 10% while reducing the penetration distance by about 50%. Furthermore, optimizing the injection pressure or shortening the injection pulse width effectively enhances atomization performance: increasing the injection pressure from 0.4 MPa to 0.6 MPa and reducing the pulse width from 5 ms to 2 ms increases the penetration distance by approximately 30% and reduces the mean droplet diameter by about 20%. Full article

In the pursuit of cleaner and more efficient internal combustion engines, dual-fuel strategies combining diesel and hydrogen are gaining increasing attention. This study employs detailed computational fluid dynamics (CFD) simulations to investigate the behaviour of pilot diesel injections in dual-fuel diesel–hydrogen engines. The study aims to characterize spray formation, ignition delay and early combustion phenomena under various energy input levels. Two combustion models were evaluated to determine their performance under these specific conditions: Tabulated Well Mixed (TWM) and Representative Interactive Flamelet (RIF). After an initial numerical validation using dual-fuel constant-volume vessel experiments, the models are further validated using in-cylinder pressure measurements and high-speed natural combustion luminosity imaging acquired from a large-bore optical engine. Particular attention was given to ignition location due to its influence on subsequent hydrogen ignition. Results show that both combustion models reproduce the experimental behavior reasonably well at high energy input levels (EILs). At low EILs, the RIF model better captures the ignition delay; however, due to its single-flamelet formulation, it predicts an abrupt ignition of all available premixed charge in the computational domain once ignition conditions are reached in the mixture fraction space. Full article

The energy transition in the transportation sector makes hydrogen a promising candidate as a fuel for internal combustion engines; however, its tendency to knock limits its use to lean mixtures, resulting in a reduction in performance. In this context, water injection represents a technical solution capable of reducing both the risk of knocking and the pollutant emissions of nitrogen oxide (NOx). Although several studies have been published on the benefits of water injection, its capacity to suppress high-intensity knocking phenomena was never investigated and is not traceable in the scientific literature. On account of this lack, the authors of the present paper experimentally evaluate the effectiveness of port water injection in suppressing high-intensity knock phenomena and its potential in terms of nitrogen oxide emission reduction. Differently from previous works, a highly reactive fuel (PRF60) was adopted to reproduce, as closely as possible, the knocking tendency of hydrogen. The tests were carried out on a single-cylinder CFR engine, suitably modified to allow port water injection, operating with stoichiometric air–fuel mixture (λ = 1) and at low engine speed, which constitutes the most critical condition, since it allows for heavy knocking and is less favorable for injected water evaporation. Moreover, aiming to assess the effect of spray atomization, the tests were repeated using three different water injection pressure levels. The study presented, however, is confined to the effects of port water injection on knock suppression and NOx emission reduction, while no engine performance or efficiency variation were considered. The results showed that port water injection, with water addition up to 40% by mass with respect to fuel, enables an almost complete suppression of high-intensity knocking phenomena, along with a significant reduction in NOx emissions (up to −62%). Full article

This work presents a microstructural characterization methodology for Diamalloy 3001 metallic powders sprayed onto Inconel 718 substrates by flame combustion. Hence, two flame stoichiometric (acetylene/oxygen) rates and specified thermal spray distances were performed in order to study their effects on the developed microstructure of the sprayed coatings. The morphology and chemical composition of the developed coatings were evaluated with microscopy, and a comparison of microstructural quality was performed. The findings indicated that spray distance affected coating quality, which is composed of morphology-type lamellar with elongated features, while gravel-like morphologies related to semi-solid powder particles were observed. Moreover, X-ray diffraction analyses established that chemical content of phases rich in oxides increased proportionally with spray distance. Vickers hardness measures and three-point bending tests were correlated with the microstructure and spray distance. These characteristics show that cobalt-based coatings could be proposed for commercial applications requiring high mechanical resistance. Full article

To investigate the influence of injector recess depth on the combustion characteristics of air heaters, high-speed shadowgraph imaging technology combined with numerical simulation was employed. Targeting a tripropellant coaxial direct-flow single injector, three test cases with recess depths of 0 mm, 5 mm, and 10 mm were designed to systematically study the ignition process, flame propagation characteristics, quasi-steady combustion, and flow field evolution mechanisms. Experimental results indicate that the recessed structure can expand the liquid mist distribution range before ignition: the dimensionless spray width ratios of the 5 mm and 10 mm recess cases are increased by 57.5% and 64.9% respectively compared to the non-recessed case, with an obvious “saturation effect” observed. Injectors with recess exhibit the characteristic of “jet head priority ignition”, which shortens the ignition time and improves ignition efficiency. The 5 mm shallow recess case achieves the optimal combustion stability with the smallest chamber pressure fluctuation (±0.1 MPa). Although the 10 mm deep recess enhances near-field mixing and combustion intensity, it tends to induce flame oscillation and combustion instability. Simulation results verify the experimental observations: the recess depth regulates droplet atomization, component mixing, and combustion heat release processes by altering the recirculation zone range, velocity gradient, and gas–liquid momentum exchange efficiency. This research provides experimental and theoretical support for the structural optimization of injectors in combustion-type air heaters. Full article