To investigate the influence of swirling air flow field on the spray characteristics and the droplet behaviors of the swirl cup airblast fuel injector, a single swirler cup and a double swirlers cup airblast injector were operated in a wide range of fuel mass flow rates (mf) and relative air pressure drops (ΔPa). Various laser based diagnostics, including planar Mie scattering, phase-Doppler particle analyzer, and high speed particle imaging velocimetry, were employed to provide the information of spray angle, droplet Sauter mean diameter (SMD), droplet velocity, and air flow velocity. The results show that the air flow field was characterized by central toroidal recirculation zone (CTRZ), the double swirlers cup airblast injector generated stronger CTRZ than single swirlers cup airblast injector. The spray characteristics and the droplet behaviors with different size classes were significantly affected by the air flow field. The larger droplets (25–100 μm) with higher initial momentum were likely to keep its velocity when passing through CTRZ, when the mf increased, more large fuel droplets could pass through the CTRZ and expanded to both sides, resulting an increase in a spray angle. On the other hand, smaller droplets (<25 μm) with lower initial momentum were trend to be enrolled by the CTRZ; therefore, the spray droplets at lower mf were confined in the CTRZ. These droplets trend to coalesce with each other resulting in an increase of SMD in this region.

In order to reduce NO_x emissions, modern gas turbines are often equipped with lean-burn combustion systems, where the high-velocity fuel-lean conditions that limit NO_x formation in combustors also inhibit the ability of ignition, high altitude relight, and lean combustion stability. To face these issues, internally staged scheme of fuel injection is proposed. Primary and main fuel staging enable fuel distribution control, and multi-injections of main fuel lead to a fast and efficient mixing. A fuel-staged low emission combustor in the framework of lean-burn combustion is developed in the present study, i.e., the central pilot stage for low power conditions is swirl-cup prefilming atomization, the main stage is jet-in-crossflow multi-injection, and a combination of primary and main stage injection is provided for higher power output conditions. In lean-burn combustors, the swirling main air naturally tends to entrain the pilot flame and quench it at low power conditions, which is adverse to the operability specifications, such as ignition, lean blow-out (LBO), and high-altitude relight. In order to investigate the effects of the main swirl angle on combustion performances, the ignition and LBO performances were evaluated in a single dome rectangular combustor. Furthermore, the spray patterns and flow field are characterized by kerosene-planar laser induced fluorescence and particle image velocimetry (PIV) to provide insight into spray and combustion performances. Flow–flow interactions between pilot and main air streams, spray–flow interactions between pilot spray and main air streams, and flame–flow interactions between pilot flame and main air streams are comprehensively analyzed. The entrainment of recirculating main air streams on pilot air streams enhances with the increase of main swirl angle, because of the upward motion and increasing width of main recirculation zone. A small part of droplets are entrained by the recirculating main air streams at periphery of combustor and a majority of droplets concentrate near the centerline of combustor, making that entrainment of recirculating main air streams on pilot spray and quenching effects of recirculating main air streams on pilot flame are slight, and the extinguishing effects can be ignored. The contributions of main swirl strength to improvement of ignition and LBO performances are due to enhancement of air/fuel mixing by strengthening turbulence level in pilot zone.

The swirl cup airblast fuel injector is widely used in modern low-emission gas turbine combustors. It is important to understand the underlying physics in the interaction between fuel spray and complex swirling airflow. The present study investigates a swirl cup airblast fuel injector's swirling flow and spray atomization characteristics. Various laser-based diagnostics, including planar Mie scattering, phase-Doppler particle analyzer, and high-speed particle imaging velocimetry, were employed for this purpose. The swirl cup airblast fuel injectors, featuring different outer swirler swirl numbers (0.8<SN<1.8) and inner–outer relative swirling directions, were investigated in an air Reynolds number ranging from 0.77 × 106 to 1.16 × 106 and a 2 kg/h constant kerosene mass flow rate. The results showed that, since the swirler relative direction showed a significant influence on the inner swirler induced central toroidal recirculation zone and outer swirler induced swirling jet zone, the interaction between spray and swirling airflow was changed. Therefore, spray angle, Sauter mean diameter, and droplet velocity were changed by the swirler relative direction. Moreover, the effect of swirl number on the spray characteristics was found to be different for co- and counter-direction swirler configurations.

This work focuses on optimizing the flame stability by matching the primary spray with swirling air streams in swirl cup which is used as pilot stage of a lean-burn fuel injector. Two configures of pressure-swirl atomizer for pilot spray have been investigated for their ignition and lean blowout (LBO) performances, the new designed pilot atomizer decrease fuel–air ratio ( f/ a) of the ignition limit by about 35%, and capability of LBO is greatly improved with decreasing fuel–air ratio from 0.015 to 0.005. Furthermore, in order to relate the pilot spray characteristics with the combustion performances, the performances of pilot pressure-swirl atomizer working both single and together with swirlers are carried out by optical spray diagnostics in a quiescent open air environment. Fuel planar laser induced fluorescence method for fuel distribution, particle image velocimetry method for velocity of droplets, and Fraunhofer diffraction technique for line-of-sight measurement of D₃₂ are used to visualize the spray. The interactions between pilot spray and pilot, main swirling air streams are analyzed. The relative pressure loss of swirling air streams larger than 3% is recommended for this type of spray facility to make sure high quality of atomization at ignition and near LBO conditions. Improvements of ignition and LBO performances by optimizing the pilot spray illustrate that matching pilot spray with swirling air streams is an effective method to improve capability of stable combustion in fuel-staged multi-injection combustors.

Flow field, atomization field characteristics, and liquid film breakup behaviors of a pre-filming air-blast atomizer are investigated using PIV (Particle Imaging Velocimetry), PLIF (Fuel Planar Laser Induced Fluorescence), and high-speed shadowgraph technique under different air mass rates (m_a), fuel mass rates (m_f), and fuel temperatures (T). The influence of structures constituting the pre-filming air-blast atomizer on the flow field organization and atomization field organization are investigated too. The results illustrate that air-blast atomizer structures have a great difference on the flow fields and atomization fields. Air-blast atomizer structures have great differences on the liquid film breakup processes too. Flow field structure and atomization structure are mainly determined by the swirler structure, whereas there are seldom influences of air mass rate and fuel mass rate on them. The results of the mechanisms of flow field organization and atomization field organization in this study can be used to support the design of new low-emission combustor.

This study was dedicated to introducing a new method for predicting the Sauter mean diameter (SMD) buildup in the swirl cup airblast fuel injector. There have been considerable difficulties with predicting SMD mainly because of complicated flow characteristics in a spray. Therefore, the backpropagation (BP) neural network-based machine learning was applied for the prediction of SMD as a function of geometry, condition parameters, and axial distance such as primary swirl number, secondary swirl number, venturi angle, mass flow rate of fuel, and relative air pressure. SMD was measured by a phase Doppler particle analyzer (PDPA). The results show that the prediction accuracy of the trained BP neural network was excellent with a coefficient of determination (R²) score of 0.9599, root mean square error (RMSE) score of 1.4613, and overall relative error within 20%. Through sensitivity analysis, the relative air pressure drop and primary swirl number were the largest and smallest factors affecting the value of SMD, respectively. Finally, the prediction accuracy of the BP neural network model is far greater than the current prediction correlations. Moreover, for the predicting target in the present study, the BP neural network shows the advantages of a simple structure and short running time compared with PSO-BP and GRNN. All these prove that the BP neural network is a novel and effective way to predict the SMD of droplets generated by a swirl cup airblast fuel injector.