Advanced Physics Modeling for Gas Turbine Particulate Ingestion

CRAFT Tech has developed a Reactive Solids Tool which can be interfaced with modern high-fidelity Computational Fluid Dynamics (CFD) codes to predict silicate particle (e.g., sand) behavior in high temperature combustor environments, and the potential for deposition of solid and molten particulate on gas turbine internal surfaces. A series of Phase II tasks is proposed to further mature the Reactive Solids Tool to account for slag buildup on the gas flow path and heat transfer to the substrate wall by adapting the computational mesh to track the deposit accumulation, account for the change in target mechanical properties as slag forms on the substrate wall, enhance the capability to accurately model the turbulent dispersion of entrained particles, and account for effects of target surface temperature on particle deposition. This effort utilizes state-of-the-art knowledge of the material, chemical, morphological, and rheological response of sand/ash in high-temperature environments along with a companion experimental program performed at the Ohio State University Turbine Aerothermodynamics Laboratory to develop algorithms accounting for time varying silicate material properties, state, and adhesion characteristics, and provide additional test data on molten silicate particle deposition to facilitate a comprehensive validation program. At the end of the Phase II effort, the Reactive Solids CFD Tool will provide a capability to perform time-resolved Reynolds-Average Navier Stokes and Large Eddy Simulation CFD predictions for passage of solid particles of reactive sand and dust through the flow path of gas turbine engines and assess the potential for accumulation of solid particulate and molten deposits on locations throughout the engine, and their effect on engine performance and integrity. This computational capability will also allow assessment of the effectiveness of alternate design concepts to mitigate particle ingestion effects on Gas Turbine performance. Advanced features of implemented in this STTR effort will provide significantly increased fidelity in the simulation results, making the CRAFT Tech Reactive Solids Tool the most advanced silicate particle deposition modeling software commercially available to support the Navy’s mission.