Modeling of underexpanded hydrogen jets through square and rectangular slot nozzles

The development and revision of safety codes and standards for hydrogen infrastructure requires a solid scientific basis, including studies of unignited releases from high pressure systems for various scenarios. Most hydrogen releases are modeled as axisymmetric jets, but real leaks are more likely to be non-axisymmetric jets issuing from high aspect ratio cracks or slots. In the present study, underexpanded hydrogen jets from square and rectangular nozzles with aspect ratios of 1–16 were numerically modeled for stagnation pressures up to 20 MPa. The near and far flow fields were modeled separately using two sequential computational domains to accurately and efficiently capture the flow characteristics. The numerical models were first validated with experimental data from a previous experimental study and literature data. The mass fraction and velocity distributions show that the centerline decay rates increase as the nozzle aspect ratio increases, but this increase is dependent on the pressure. This means that the canonical decay law of round turbulent jets and plumes no longer applies to the slot nozzle jets for high pressures. The radial profiles collapse onto a Gaussian curve in the major axis plane, but neither collapse, nor are they Gaussian in the minor axis plane with peaks away from the jet centerline. Different shock patterns were identified along the major and minor axes and the axis switching phenomenon seen in the literature was also reproduced. The axis switching resulted in significantly wider flattened concentration distributions compared with the axisymmetric jet which may require consideration during safety analyses for non-circular nozzles. A scaling factor taking both the nozzle shape and pressure effects into account was then developed to better scale the centerline decay rates for jets from both the square and rectangular nozzles. The present study demonstrates that the nozzle shape effects on the jet spreading should not be overlooked and proper scaling factors are required to collapse the data and calculate decay rates.     

Numerical study of the near-field of highly underexpanded turbulent gas jets

For safety issues related to the storage of gases (e.g. hydrogen) under high pressure, it is necessary to determine how the gas is released in the case of failure. In particular, there exist limited quantitative information on the near-field properties of gas jets, which are important for establishing proper decay laws in the far-field. Simulations of the near-field of highly underexpanded (high pressure) gas jets have been performed using Finite-Volume solver of the CAST3M code and validated using several sources available in the literature. The numerical model solves the 3D Compressible Multi-Component Navier–Stokes equations directly without relying on the compressibility-corrected turbulence models. It provides sufficiently fair mean predictions both in the case of one-component air–air and two-component helium-air releases. Possible initial conditions for the far-field simulations are suggested in terms of distance from the source, as well as the turbulence characteristics and gas-dynamic parameters at this location. In addition, these results are used to evaluate several notional nozzle concepts in order to determine the one physically consistent.     

Measurements of concentration decays in underexpanded jets through rectangular slot nozzles

Previously studies of hydrogen releases have focused on hydrogen jets through round nozzles, but leaks are more likely to result in jets through slots. In this study, the concentration decays along the jet centerline were measured for underexpanded jets from rectangular slot nozzles with aspect ratios (AR) of 1–12.6 for storage pressures up to 3.7 MPa. The mass fractions along the jet centerlines decay inversely with distance from the nozzle as with axisymmetric jets but with a faster decay rate. All the data collapses onto a single curve when normalized by the proper factor of the downstream location, except for the jets from square nozzles (AR1). The decay rates for jets from rectangular nozzles with AR greater than unity are significantly larger than for the jets from square nozzles. The jets from square nozzles behave somewhat like the circular jets from circular nozzles due to the symmetric geometry, so the decay rate is closer to that of circular jets relative to the jets from the other rectangular nozzles. This database will be useful for model validations for the modeling of jets from rectangular nozzles.     

Self-similar characteristics of underexpanded,cryogenic hydrogen and methane jets

Underexpanded, cryogenic hydrogen and methane jets were measured using laser Raman scattering diagnostic. The jets were released from 1 mm to 1.25 mm orifices for the stagnation pressure ranges of 2–6 bar and temperature ranges of 37–46 K (hydrogen) and 112–189 K (methane). Raman signals are inherently small, thus a denoising algorithm was developed to substantially reduce the noise hindering the statistical analysis of the data. The time-averaged concentration and temperature data were plotted to show a hyperbolic decay law along the jet centerline and a Gaussian distribution in the radial direction. The concentration fluctuations of the cryogenic jets are similar to those of warm jets, the centerline RMS mass fraction decays similarly to the mean mass fraction, and the highest radial concentration fluctuations appear in the shear layer. Thus, the self-similar characteristics of the cryogenic jets are comparable with room-temperature jets for the present test conditions.     

Computational study of horizontal subsonic free jets of hydrogen: Validation and classical similarity analysis

Computational fluid dynamic simulations were performed using the commercial program Fluent in order to study the hydrogen concentration decay along the centerline of free horizontal subsonic jets. The hydrogen jets were assumed to be steady and turbulent. To explore the buoyancy effect on the hydrogen dispersion processes, the Froude numbers were varied from 250 to 1000. Zero gravity jets were also simulated and analyzed in order to determine the jet momentum dominated limit. Classical similarity analysis was performed and our results were compared to the results of vertical axisymmetric free jets from the literature.     

Simplified partitioning model to simulate high pressure under-expanded jet flows impinging vertical obstacles

Various reduced-order models have been developed to quickly model high pressure underexpanded jets. One example is the two-layer partitioning model which was developed to model underexpanded jets, but it has not been evaluated for high pressure jets with obstacles in the jet flow region. This research describes an improved two-layer partitioning model based on the Abel-Noble equation of state that is applied here to model horizontal jet flows impacting a vertical obstacle with validations against high pressure gas experiments, full CFD simulations and a revised notional nozzle model based on the Abel-Noble equation of state. The improved two-layer partitioning model accurately predicts the gas concentrations on the obstacle for a 15 MPa underexpanded jet while consuming much less computational resources and time compared with the full CFD simulation.     

Numerical investigation of the flammable extent of semi-confined hydrogen and methane jets

The effect of surfaces on the extent of high pressure horizontal unignited jets of hydrogen and methane is studied using computer fluid dynamics simulations performed with FLACS Hydrogen. Results for constant flow rate through a 6.35 mm diameter pressure relief Device (PRD) orifice from 100 barg, 250 barg, 400 barg, 550 barg and 700 barg compressed gas systems are presented for both horizontal hydrogen and methane jets. To quantify the effect of a horizontal surface on the jet, the jet exit is positioned at various heights above the ground ranging from 0.1 m to 10 m. Free jet simulations are performed for comparison purposes. Also, for cross-validation purposes, a number of cases for 100 barg releases were simulated using proprietary models developed for hydrogen within commercial CFD software PHOENICS. It is found that the presence of a surface and its proximity to the jet centreline result in a pronounced increase in the extent of the flammable cloud compared to a free jet.     

Release and dispersion modeling of cryogenic under-expanded hydrogen jets

In the present work performed within the framework of the SUSANA EC-project, we address the release and dispersion modeling of hydrogen stored at cryogenic temperatures and high pressures. Due to the high storage pressures the resulting jets are under-expanded. Due to the low temperatures the choked conditions can be two-phase. For the release modeling the homogeneous equilibrium model (HEM) was used combined with NIST equation of state for hydrogen. For the dispersion modeling the 3d CFD methodology was used combined with a) a notional nozzle approach to bridge the expansion to atmospheric pressure region that exists near the nozzle, b) the ideal gas assumption for hydrogen and air and c) the standard (buoyancy included) k–ε turbulence model. Predicted release choked mass fluxes are compared against 37 experiments from literature. Predicted steady state hydrogen concentrations along the jet axis are compared against five dispersion experiments from literature as well as the Chen and Rodi correlation and the behavior of the proposed release and dispersion modeling approaches is assessed.     

Plane hydrogen jets

This study is focused on understanding the structure and behaviour of hydrogen under-expanded jets from plane nozzles and their differences with circular nozzle jets. Results of numerical simulations of hydrogen highly under-expanded jets from a storage vessel at pressure 40 MPa through a circular nozzle and two plane nozzles with aspect ratios 5.0 and 12.8 respectively, all of the same cross-section area, are presented. Two stages approach is applied to simulate under-expanded unignited jets and jet fires. At the first stage, the high Mach number flow in a near field to the nozzle is simulated by compressible flow solver. At the second stage, incompressible flow solver is applied to simulated either unignited or combusting jets in the far from the nozzle field with “inner” boundary conditions taken from the first stage. The structure and behaviour of hydrogen plane highly under-expanded jets is scrutinised, including the switch-of-axis phenomenon when the exiting jet expands in the vicinity of the nozzle only in the direction of the minor nozzle axis while it contracts in the major axis direction. Simulations demonstrated that plane jets may provide faster concentration decay compared to axisymmetric jets with the same mass flow rate due to the difference in air entrainment. The concentration decay rate is shown to be a function of the plane nozzle aspect ratio. The eddy break-up model is applied to simulate under-expanded hydrogen jet fires from the equipment at pressure of 40 MPa. The circular and plane nozzle jet fire simulations are validated against experiments by Mogi and Horiguchi (2009). The simulations are in a good agreement with the experiment.     

Ignitability and mixing of underexpanded hydrogen jets

Reliable methods are needed to predict ignition boundaries that result from compressed hydrogen bulk storage leaks without complex modeling. To support the development of these methods, a new high-pressure stagnation chamber has been integrated into Sandia National Laboratories’ Turbulent Combustion Laboratory so that relevant compressed gas release scenarios can be replicated. For the present study, a jet with a 10:1 pressure ratio issuing from a small 0.75 mm radius nozzle has been examined. Jet exit shock structure was imaged by Schlieren photography, while quantitative Planar Laser Rayleigh Scatter imaging was used to measure instantaneous hydrogen mole fractions downstream of the Mach disk. Measured concentration statistics and ignitable boundary predictions compared favorably to analytic reconstructions of downstream jet dispersion behavior. Model results were produced from subsonic jet dispersion models and by invoking self-similarity jet scaling arguments with length scaling by experimentally measured effective source radii. Similar far field reconstructions that relied on various notional nozzle models to account for complex jet exit shock phenomena failed to satisfactorily predict the experimental findings. These results indicate further notional nozzle refinement is needed to improve the prediction fidelity. Moreover, further investigation is required to understand the effect of different pressure ratios on measured virtual origins used in the jet dispersion model.     

Surface effects on flammable extent of hydrogen and methane jets

Studies on the effect of surfaces on the extent of the flammable cloud of high-pressure horizontal and vertical jets of hydrogen and methane are performed using CFD numerical simulations. For the horizontal jets, two scenarios pertaining to the location of the surface are studied: horizontal surface (the ground), and vertical surface (side wall). For a constant flow rate release, the extent of the flammable cloud is determined as a function of time. Effects of the proximity of the surface on the flammable extent along the axis of the jet and its impact on the maximum extent of the flammable cloud is explored and compared for both hydrogen and methane. The results are also compared to the predictions of the Birch correlations for flammable extents. It is found that the presence of a surface and its proximity to the jet centerline result in a pronounced increase in the extent of the flammable cloud compared to a free jet.     

Experimental investigation on the microscopic characteristics of underexpanded transient hydrogen jets

The microscopic characteristics of hydrogen jet affect the concentration distribution and gas-air mixing of high-pressure gas jets for a hydrogen engine. In this study, the schlieren method was used to record the hydrogen jet for an outward-opening injector. The results showed that the jet asymmetricity was large in the initial stage of the jet development, then decreased rapidly as the jet developed, and finally entered a stable range of 13%–38% when the valve fully opened. The increase of the ambient pressure was beneficial to reduce the fluctuation range of the asymmetricity. The steady S of an outward-opening injector (S = 0.7 ± 0.03) is larger than that of a single-hole injector (S = 0.25 ± 0.05). The increase in injection pressure and the decrease in ambient pressure caused S to decrease to 1 faster. The steady Γ of an outward-opening injector was experimentally determined, and the value (Γ = 0.98 ± 0.1) was smaller than that of a single-hole injector. According to the transient Γ, the injection process can be divided into the developing phase and the self-similar phase. Γ increased rapidly with time and then stabilized after the injector valve reached its maximum lift position. The gas concentration distribution was uneven along the axial direction. The mole fraction decreased with the increase in axial penetration, and entered a stable range of 0.27–0.37 when axial penetration was greater than 20 mm. The average equivalent ratio was large at the beginning of injection under different pressure ratios, and then decreased and finally stabilized in the range of 1.4–5.     

Comparison of two-layer model for hydrogen and helium jets with notional nozzle model predictions and experimental data for pressures up to 35 MPa

A two-layer, reduced order model of high pressure hydrogen jets was developed which includes partitioning of the flow between the central core jet region leading to the Mach disk and the supersonic slip region around the core. The flow after the Mach disk is subsonic while the flow around the Mach disk is supersonic with a significant amount of entrained air. This flow structure significantly affects the hydrogen concentration profiles downstream. The predictions of this model are compared to previous experimental data for high pressure hydrogen jets up to 20 MPa and to notional nozzle models and CFD models for pressures up to 35 MPa using ideal gas properties. The results show that this reduced order model gives better predictions of the mole fraction distributions than previous models for highly underexpanded jets. The predicted locations of the 4% lower flammability limit also show that the two-layer model much more accurately predicts the measured locations than the notional nozzle models. The comparisons also show that the CFD model always underpredicts the measured mole fraction concentrations.     

Large eddy simulation of highly turbulent under-expanded hydrogen and methane jets for gaseous-fuelled internal combustion engines

Burning hydrogen in conventional internal combustion (IC) engines is associated with zero carbon-based tailpipe exhaust emissions. In order to obtain high volumetric efficiency and eliminate abnormal combustion modes such as preignition and backfire, in-cylinder direct injection (DI) of hydrogen is considered preferable for a future generation of hydrogen IC engines. However, hydrogen's low density requires high injection pressures for fast hydrogen penetration and sufficient in-cylinder mixing. Such pressures lead to chocked flow conditions during the injection process which result in the formation of turbulent under-expanded hydrogen jets. In this context, fundamental understanding of the under-expansion process and turbulent mixing just after the nozzle exit is necessary for the successful design of an efficient hydrogen injection system and associated injection strategies. The current study used large eddy simulation (LES) to investigate the characteristics of hydrogen under-expanded jets with different nozzle pressure ratios (NPR), namely 8.5, 10, 30 and 70. A test case of methane injection with NPR = 8.5 was also simulated for direct comparison with the hydrogen jetting under the same NPR. The near-nozzle shock structure, the geometry of the Mach disk and reflected shock angle, as well as the turbulent shear layer were all captured in very good agreement with data available in the literature. Direct comparison between hydrogen and methane fuelling showed that the ratio of the specific heats had a noticeable effect on the near-nozzle shock structure and dimensions of the Mach disk. It was observed that with methane, mixing did not occur before the Mach disk, whereas with hydrogen high levels of momentum exchange and mixing appeared at the boundary of the intercepting shock. This was believed to be the effect of the high turbulence fluctuations at the nozzle exit of the hydrogen jet which triggered Gortler vortices. Generally, the primary mixing was observed to occur after the location of the Mach disk and particularly close to the jet boundaries where large-scale turbulence played a dominant role. It was also found that NPR had significant effect on the mixture's local fuel richness. Finally, it was noted that applying higher injection pressure did not essentially increase the penetration length of the hydrogen jets and that there could be an optimum NPR that would introduce more enhanced mixing whilst delivering sufficient fuel in less time. Such an optimum NPR could be in the region of 100 based on the geometry and observations of the current study.     

Analysis of jet flames and unignited jets from unintended releases of hydrogen

A combined experimental and modeling program is being carried out at Sandia National Laboratories to characterize and predict the behavior of unintended hydrogen releases. In the case where the hydrogen leak remains unignited, knowledge of the concentration field and flammability envelope is an issue of importance in determining consequence distances for the safe use of hydrogen. In the case where a high-pressure leak of hydrogen is ignited, a classic turbulent jet flame forms. Knowledge of the flame length and thermal radiation heat flux distribution is important to safety. Depending on the effective diameter of the leak and the tank source pressure, free jet flames can be extensive in length and pose significant radiation and impingement hazard, resulting in consequence distances that are unacceptably large. One possible mitigation strategy to potentially reduce the exposure to jet flames is to incorporate barriers around hydrogen storage equipment. The reasoning is that walls will reduce the extent of unacceptable consequences due to jet releases resulting from accidents involving high-pressure equipment. While reducing the jet extent, the walls may introduce other hazards if not configured properly. The goal of this work is to provide guidance on configuration and placement of these walls to minimize overall hazards using a quantitative risk assessment approach. The program includes detailed CFD calculations of jet flames and unignited jets to predict how hydrogen leaks and jet flames interact with barriers, complemented by an experimental validation program that considers the interaction of jet flames and unignited jets with barriers.     

Experimental investigation of nozzle aspect ratio effects on underexpanded hydrogen jet release characteristics

Most experimental investigations of underexpanded hydrogen jets have been limited to circular nozzles in an attempt to better understand the fundamental jet-exit flow physics and model this behaviour with pseudo source models. However, realistic compressed storage leak exit geometries are not always expected to be circular. In the present study, jet dispersion characteristics from rectangular slot nozzles with aspect ratios from 2 to 8 were investigated and compared with an equivalent circular nozzle. Schlieren imaging was used to observe the jet-exit shock structure while quantitative Planar Laser Rayleigh Scattering was used to measure downstream dispersion characteristics. These results provide physical insight and much needed model validation data for model development.     

Injection of multi hydrogen jets within cavity flameholder at supersonic flow

Efficient distribution of hydrogen gas inside the supersonic chamber is the main challenge for the increasing the performance of the supersonic vehicles. In this study, the new injection arrangements of the multi hydrogen jets within the cavity flameholder are comprehensively studied at a supersonic free stream. In order to investigate the effect of multi jets within a cavity flameholder, a three-dimensional model is developed and computational technique is used to simulate the flow and mixing zone inside this region. The influence of important parameters such as the pressure of jet and free stream Mach number is investigated to illustrate the flow pattern and evaluate the mixing rate in the supersonic combustion chamber. Obtained results show that the rise of the total pressure of hydrogen jet enlarges the ignition zone within the cavity. Furthermore, the increase of free stream Mach number limited the mixing rate and jet interaction. Our findings confirm that fuel jet with PR = 0.5 significantly enhances the performance of the cavity flameholder inside the scramjet.     

Experimental study of ignited unsteady hydrogen jets into air

In order to simulate an accidental hydrogen release from the low pressure pipe system of a hydrogen vehicle a systematic study on the nature of transient hydrogen jets into air and their combustion behaviour was performed at the FZK hydrogen test site HYKA. Horizontal unsteady hydrogen jets with an amount of hydrogen up to 60 STP dm³ and initial pressures of 5 and 16 bar have been investigated. The hydrogen jets were ignited with different ignition times and positions. The experiments provide new experimental data on pressure loads and heat releases resulting from the deflagration of hydrogen-air clouds formed by unsteady turbulent hydrogen jets released into a free environment. It is shown that the maximum pressure loads occur for ignition in a narrow position and time window. The possible hazard potential arising from an ignited free transient hydrogen jet is described.     

Effect of dual micro fuel jets on mixing performance of hydrogen in cavity flameholder at supersonic flow

In this article, numerical simulations were done to study the influence of the various hydrogen injections on the mixing rate in the cavity flameholder of the scramjet. This study tried to present the main effective parameters on the flow feature and distribution of the hydrogen jet within a cavity in supersonic free stream domain. In order to simulate the cavity flameholder with micro air/fuel jets, a three-dimensional model is chosen and computational fluid dynamic approach is used for the simulations. The effect of significant parameters is studied by using the Reynolds-averaged Navier–Stokes equations with Menter's Shear Stress Transport (SST) turbulence model. The effect of horizontal and vertical fuel injection is comprehensively studied. Moreover, the characteristics of the mixing in various free stream velocities (M = 1.2, 2.2 and 3.2) are examined and the effects of micro air jet on the size of ignition domain for preserving flame holder are investigated. Results show that the increase of free stream Mach number significantly enhances the mixing of horizontal fuel injection in the cavity. The obtained results reveal that the injection of micro air jets enhances the mixing rate in low Mach number (M = 1.2). Our findings also show that vertical hydrogen injection considerably increases the mixing zone within the cavity and the mixing rate significantly improves by rising free stream velocity.     

Computational study of the multi hydrogen jets in presence of the upstream step in a Ma=4 supersonic flow

The injection of the hydrogen is the main noteworthy stage for the advance of the supersonic engine. In our computational study, the incidence of the step condition in the upstream of the hydrogen multi-jet is investigated for the augmentation of the fuel distribution in downside of the fuel jets at Mach = 4. To perform our research, a 3-dimensional computational domain is taken to unveil the primary flow organization of the hydrogen jets and its interactions with the freestream for the advance of fuel mixing. This work comprehensively examined the impression of the jet pressure on the mixing value and flow structure. Besides, the three-dimensional outcome of the step on the pattern of the four multi-jets is compared with the single equivalent jet. According to our results, the existence of step improves the fuel mixing efficiency up to 30% close to of early jets. Our findings reveal that increasing the step height from 0.5 to 2 mm enhances the fuel mixing more than 15%.