Gel fuel potentially combines the advantages of solid fuel and liquid fuel due to its special rheological properties, which have essential impacts on the application of gel fuel in propulsion systems. In this paper, we study the rheological property of organic kerosene gel through a series of measurements on its viscosity as a function of the shear rate, temperature, and shear history. The measured datasets are then fitted with constitutive relationships between the viscosity and shear rate at three different levels: the power law shear-thinning model, the power law dependency on both the temperature and shear rate, and the thixotropic property. It is found that intense pre-shear could exhaust thixotropy and reduce viscosity of the kerosene gel. For the power law shear-thinning model, the consistency index increases with the gellant mass fraction, whereas the power law exponent remains constant. The dependence of viscosity on temperature could be well approximated by an empirical power law relationship. As for the thixotropic property of the kerosene gel, the fitted second-order kinetic model corresponds accurately to the viscosity at different shear rates and shear times. The constitutive models fitted in this work at different levels are consistent with each other and provide useful tools for further applications of organic kerosene gel fuel.

In general, rheological properties of gelled fuels change dramatically when temperature changes. In this work, we investigate flow and heat transfer of water-gel in a straight pipe and a tapered injector for non-isothermal conditions, which mimic the situations when gelled fuels are used in propulsion systems. The gel-fluid is modeled as a non-Newtonian fluid, where the viscosity depends on the shear rate and the temperature; a correlation fitted with experimental data is used. For the fully developed flow in a straight pipe with heating, the mean apparent viscosity at the cross section when the temperature is high is only 44% of the case with low temperature; this indicates that it is feasible to control the viscosity of gel fuel by proper thermal design of pipes. For the flow in the typical tapered injector, larger temperature gradients along the radial direction results in a more obvious plug flow; that is, when the fuel is heated the viscosity near the wall is significantly reduced, but the effect is not obvious in the area far away from the wall. Therefore, for the case of the tapered injector, as the temperature of the heating wall increases, the mean apparent viscosity at the outlet decreases first and increases then due to the high viscosity plug formed near the channel center, which encourages further proper design of the injector in future. Furthermore, the layer of low viscosity near the walls plays a role similar to lubrication, thus the supply pressure of the transport system is significantly reduced; the pressure drop for high temperature is only 62% of that of low temperature. It should be noticed that for a propellent system the heating source is almost free; therefore, by introducing a proper thermal design of the transport system, the viscosity of the gelled fuel can be greatly reduced, thus reducing the power input to the supply pressure at a lower cost.

Gelled fuels combine the main advantages of liquid fuels (throttle ability) and solid fuels (easy handling, etc.) due to their non-Newtonian characteristics. In this paper, we study the flow characteristics of water-hydroxypropylcellulose (HPC) gel in converging tubes and tapered injectors which mimic the flow and injection of kerosene gel in typical geometries of propulsion systems. The water-HPC gel is modeled as a non-linear fluid, where the shear viscosity is assumed to depend on the local shear rate and modeled by the Carreau–Yasuda model; the model parameters are fitted with our experimental measurements done by a rotational rheometer. The numerical simulations indicate that for the converging tubes, increasing the convergence angle, causes the mean apparent viscosity at tube exit to decrease while the mass flow rate reduces at a constant pressure drop. Therefore, there is a balance between the lowering of the pressure loss and reducing mean apparent viscosity. In the tapered injectors, the straight pipe after the converging part has a detrimental effect on the viscosity reduction.

For propulsion systems using gel fuels, reducing the gel fuel viscosity is essential for achieving better atomization and combustion. In this paper, we investigate the flow and heat transfer in a water-gel with a temperature and shear dependent viscosity. We consider several different channels, mimicking the transport of gelled fuels in propulsion systems, and we also look at corrugation, which is a way of enhancing fluid mixing and thus improving the heat transfer characteristics. The rheological parameters in the constitutive model of the gel are fitted with experimental data. The influence of different corrugation profiles, corrugation configuration parameters and the Reynolds number on the mean apparent viscosity and the pressure drop are investigated. It was found that the flow recirculation formed in the valley of the corrugations enhances the heat transfer and thus the temperature of the main flow. We also noticed an increase in the pressure drop due to the stronger viscous dissipation. Furthermore, it was observed that the sinusoidal corrugation can achieve lower viscosity with a lower pressure drop compared with triangular and trapezoidal corrugations. A shorter wavelength and a deeper wave amplitude of the corrugation seemed to be better for reducing the gel fuel viscosity, while we must consider the adverse consequence of increased pressure drop. A larger Reynolds number was helpful for both lowering the pressure drop and for reducing the viscosity. In addition, compared with a smooth straight pipe, a Y-shape corrugated channel with a constant inlet velocity reduced the mean apparent viscosity by 70.8%, and this value increased to 72.6% by further applying a pulsed inlet velocity, which can greatly enhance the gel fuel atomization and thus improve the combustion efficiency.