RPA: Tool for Rocket Propulsion Analysis

Thermal Analysis of Thrust Chambers

Alexander Ponomarenko
[email protected]
http://www.propulsion-analysis.com
July 2012 (v.3)

Abstract
RPA (Rocket Propulsion Analysis) is a multi-platform analysis tool intended for use in
conceptual and preliminary design of rocket engines.
This article describes a numerical model of thermal analysis of cooled combustion chambers
and nozzles, implemented as a Thermal Analysis Module for RPA.

1
Contents
Nomenclature........................................................................................................................................3
Introduction...........................................................................................................................................4
Numerical Model...................................................................................................................................4
Gas-Side Heat Transfer.....................................................................................................................4
Ievlev's Method............................................................................................................................4
Bartz Method...............................................................................................................................7
Boundary Layer Cooling..............................................................................................................8
Film Cooling................................................................................................................................8
Gaseous Film...........................................................................................................................8
Liquid Film............................................................................................................................10
Radiation Heat Transfer.............................................................................................................11
Thrust Chamber Outer Cooling......................................................................................................13
Radiation Cooling......................................................................................................................13
Regenerative Cooling.................................................................................................................14
Pressure Drop in Cooling Passages.......................................................................................16
Coaxial-Shell Thrust Chamber Design.................................................................................17
Channel-Wall Thrust Chamber Design.................................................................................17
Tubular-Wall Thrust Chamber Design..................................................................................18
Thermal Barrier Coating Layer......................................................................................................18
Loss in Specific Impulse.................................................................................................................19
Computer Program RPA .....................................................................................................................21
Graphical User Interface.................................................................................................................21
Input Data...................................................................................................................................21
Output Data................................................................................................................................21
Verification.....................................................................................................................................22
SSME 40k..................................................................................................................................23
Aestus.........................................................................................................................................24
Future Work ........................................................................................................................................25
Conclusion...........................................................................................................................................25
References...........................................................................................................................................26

2
Nomenclature
τ viscosity stress

q heat flux
αT heat transfer coefficient

Re Reynolds number

Pr Prandtl number
μ , μt laminar and turbulent coefficient of viscosity

A area, m2

p pressure, Pa

T temperature, K

w velocity, m/s

 density, kg/m3

V volume, m3

ṁ mass flow rate

λw thermal conductivity

Is specific impulse, m/s

c∗ characteristic exhaust velocity, m/s

CF thrust coefficient
ξf friction loss coefficient
φf performance correction factor for the friction loss

Further symbols will be introduced and explained in the text.

3
Introduction
Thermal analysis is an essential part in the design of rocket engines. The rapid and accurate
estimation of cooling effectiveness is required if new vehicle propulsion concepts are to be
evaluated in a timely and cost effective manner. The used tools should allow the analysis of
different types of cooling methods, including radiation, convective and film cooling.

Numerical model described in this article and implemented in RPA enables the thermal
analysis of rocket engine thrust chambers with accuracy sufficient for conceptual and
preliminary design studies, as well as for rapid evaluation of different variants of cooled thrust
chambers and its verification in detailed design phase.

Numerical Model

Gas-Side Heat Transfer

The thermodynamic and transport properties of the combustion gases are evaluated using the
chemical equilibrium composition module of the RPA [9].

Ievlev's Method
Ievlev obtained the gas-side heat flux calculation method from integral boundary layer
equations and semi-empirical heat transfer relations. The detailed description of the method
as well as derivation of relations can be found in [1].

Figure 1: Definition sketch for flow in boundary layer

Assuming that there is no chemical reaction in the boundary layer, the governing equations
for boundary layer in axisymmetric channel (see figure 1) are given as follows:

the continuity equation:

∂ (r ρ w ) + ∂ (r ρw ) = 0
x y
∂x ∂y

the momentum equation:

4
 ∂ wx ∂ wy dp 1
ρ wx + ρwy = − + ∂ ( r τ)
∂x ∂y dx r ∂ y

the energy equation:

0 0
∂I ∂I 1
ρ wx + ρ wy = − ∂ (r q)
∂x ∂y r ∂y

where

∂ wx λ+λ t ∂ I 0
τ=(μ+μt ) and q= .
∂y cp ∂ y

Integrating these equations yield:

d dw
(ρx w2∞ δ ** R)+ ∞ (ρ∞ w∞ δ* R)=τ w R
dx dx

d 0 **
[ρ w ( I −I ) δ R]=q w R
dx x ∞ ∞ w T

where
∞
ρ wx
*
δ =∫
0
r
R
1−(ρ∞ w∞
dy )
ρ wxr w
( )
∞
δ**=∫ 1− x dy
0 ρ∞ w ∞ R w∞
∞
ρ w x r I 0∞ −I 0
T =∫
δ** dy
0 ρ∞ w ∞ R I 0∞ −I w

Introducing new variables:

ρ w δ
**
ρ w δ
** ρ0∞ wmax Dt
Re = x μ∞x
**
; Re = x μ∞x T
**
; Re0=
T
μ 0∞

and
τw qw
α= 2 ; αT =
ρx w ∞ ρx w∞ ( I 0∞ −I ∞ )

as well as

Re
** Re**
T
z= α zT= α
T

and making some generalizations from empirical data, Ievlev obtained the following

5
correlations:
0.54

( )
1−β2
zT
= 1.769
2
1−β +β 1−0.08696 2
(
1− T̄ w +0.1β2 ) 1.1
z 1−T̄ w +0.1β 2

̄l 1 1
Re0 ρ x μ0∞ 1−γ 0 d ̄l
1 ∫ 0 μx
1− γ
zT= ̄
D (I −I ) β + const
1
ρ
∞ w
cos θ 1.2
l
( I 0∞ −I w )
1− γ 1−γ ∞
(1−γ) D
̄ 0

0.089 Pr −0.56 2 0.9225

αT =
( ) (
z
zT
1−0.21
1−Pr β
Pr 4 /3 1−T̄ w ) 1.3

(307.8+54.8 log ( 19.5

Pr
)) Pr 2 0.45
z 0.08
−650

α=0.03327z−0.224 +3.966⋅10−4 1.4

q w = αT ρx w ∞ ( I 0∞−I w ) 1.5
2
 w =  x w∞ 1.6

where

=w /w max , w max= √2 γ( RT )0∞ /γ−1

T w =T w /T e , T e=R T 0∞ / R1500 , R1500 - gas constant of reaction products at T =1500 K

D
̄ =D /Dt =2R / Dt , l=l/ D t
−0.823 −0.177
p 1+ T̄ w β 3+T̄ w 9β2
2
ρx
=
ρ0∞ p 0c 2 ( −
4 ) ( 4
−
16 )
−0.7
μ 0∞ 1+T̄ w β2
(
μx ≈ 2 − 4 )
Using these relations, the heat flux is calculated as follows:

1. Subdivide the thrust chamber into several stations (see figure 2).

2. Assign the wall temperature to each station (when calculation chamber cooling, use
the results from the previous iteration).

3. Using chemical equilibrium composition module of the RPA [9], calculate the hot gas
properties at each station.

4. Using relations 1.1 and 1.2, calculate values of z and z T at each station.

6
 5. From equation 1.3, calculate the heat transfer coefficient αT .

6. From equation 1.5, calculate the heat flux q .

7. Calculate the viscosity stress τ , using equations 1.4 and 1.6.

The following approach is used to calculate the value of I ∞0 −I w (as described in [2]):

T ∞0 >1500 K and T w <1500 K :

– I ∞0 is calculated as a stagnation enthalpy in combustion chamber

– I w is calculated as an enthalpy of reaction products at the temperature T w , but

with composition that corresponds to the temperature 1500 K.

T ∞ >1500 K and T w >1500 K :

0

– I ∞0 is calculated as a stagnation enthalpy in combustion chamber

– I w is calculated as an enthalpy of reaction products at the temperature T w .

Bartz Method
The basic correlation for gas-side heat transfer is given by

q w = αT (T e −T w )

where

[ 1+Pr 0.33 ( γ−1

2 )

]
2
M
0
T e=T c
γ−1
1+(
2 )
2
M

For the heat transfer coefficient, the following correlation is used [3]:

[ ( ) ( ) ]( )
0 0.2 0 0 0.8 0.1 0.9
0.026 (μ ∞ ) c p∞ pc Dt At
αT = σ
D0.2
t ( Pr 0∞)0.6 c* R A

The correction factor σ can be calculated as follows:

−0.68

[ ] [
−0.12
1 Tw
σ= 0
2 Tc
1+
γ−1 2 1
2
M +
2 ( ) 1+
γ−1 2
2
M ]

7
Boundary Layer Cooling
The analysis method for estimation of boundary layer cooling effectiveness is developed
under the following assumptions:

– the large-scale distribution of mixture composition and the gas properties in the shear
flow are conserved along the nozzle;

– the convective heat flux to the wall is completely defined by the heat transfer between
the wall and the layer next to the wall

– the layer next to the wall is transparent for the radiation heat transfer

To calculate the convective heat flux from the cooler surface layer, the Ievlev's correlation for
similar conditions is used:

q(1) S (1)
=
q(2) S (2)

where

 I 0∞ −I w  T 0.425
e  0.15
1000
S= 0.425
R1500 T e T w  3T e T w 0.15
0.595

Using these correlation, the heat flux is calculated as follows:

(1)
1. Calculate the heat flux q to the wall from the core flow (that is, without taking into
account the presence of the cooler surface layer)

2. Calculate the value S (1) for the gas in the flow core

3. For the known mixture composition within the surface layer, calculate the parameters
of the gas in this layer, using the chemical equilibrium composition module of the RPA
[9]

4. Calculate the value S (2) for the gas in the surface layer
(2)
5. Calculate the corrected heat flux as q (2)=q (1) S
S (1)

Film Cooling

Gaseous Film
After injecting into the thrust chamber, the gaseous coolant is mixing with existing surface
layer and producing the layer with new mixture composition.

Correlations for the turbulent mixing are developed from [1] and given by

8
 0 0
(r i )s = k ss (r i)s + k sf (r i)f (i=0. .. NS)
0 0
(r i )f = k fs (r i )s + k ff (r i)f (i=0. .. NS)
0 0
m
̄s ξ , k =m̄f ξ
k ss =
m
̄s
1−
2( ) sf
m
̄s 2
0 0
m
̄f ξ , k =m̄s ξ
k ff =
m
̄f
1− (
2 ) fs
m
̄f 2

m
̄ s= m
0
̄ s 1− ( ξ2 )+ m̄ ξ2 0
f

0ξ ξ
m
̄ f =m
̄ s +m
2
0
̄ f 1−
2 ( )
2

=1−e−M x

m
̄s
M =K t
m
̄f

2
x = x / H s

where

superscript “0” denotes the initial parameters of the surface layer and the film at the location
of injection

subscripts “s” and “f” denote the parameters of the surface layer and the film
correspondingly

NS – total number of species in the surface layer and the film (the initial composition of the
coolant may differ from the initial composition of the surface layer)

r i – mass ratio of the species i in the mixture

ṁs , f – relative mass flow rate

m
 s, f =
ṁ

ṁ f – mass flow rate of the coolant in the film

ṁ s – mass flow rate of the gas in the surface layer

ṁ – total mass flow rate in the chamber

9
 x – distance from the location of the film injection

H s – thickness of the surface layer

K t =(0.05 ... 0.20)⋅10−2 – coefficient that reflects the intensity of the turbulent mixing

The mixture composition of the surface layer after mixing with gaseous film is determined via
a space-marching technique starting from the location of coolant injection ( ξ=0 ) to the
location where the coolant is completely mixed with the surface layer ( ξ=1 ).

The estimation of the cooling effectiveness at each station can be performed using Ievlev's
correlation for similar conditions, as described in the previous section.

Liquid Film
When injected into the thrust chamber, the liquid coolant transformation goes through 3
phases:

– Heating

Assuming that the thin liquid coolant film is transparent for the radiation heat transfer,
the only component of the total heat flux reaching the wall is the radiation heat flux,
whereas the convective component heats the liquid coolant. The convective heat
transfer from the liquid coolant to the wall may be neglected.

The heating equation is given by

2 π R qTwf

d T f= dx
η ṁf c̄f

where

d T f – increase in temperature of the coolant

 – coefficient that reflects the stability of the Figure 2: Film stability coefficient [1]
liquid film and depends on Reynolds number
calculated from the parameters of the liquid film (see figure 2)

ṁ f
Re f = – Reynolds number calculated from the parameters of the liquid film
2 R f
T
q w – convective heat flux to the liquid coolant film at the coolant temperature T f
f

ṁ f – mass flow rate of the coolant in the film

 f – viscosity of the coolant

c f – average specific heat of the coolant



R , dx – size parameters of the chamber (see figure 1)

10
 The heating of the film coolant is determined via a space-marching technique starting
from the location of coolant injection to the location where the coolant is heated up to
the temperature of vaporization or decomposition.

– Vaporization

After heating up to vaporization/decomposition temperature, the part or all liquid in the

film is vaporized. Similar to the heating, the convective heat transfer from the liquid
coolant to the wall may be neglected.

The vaporization rate of the coolant is given by equation

2 π R qTw vap

d ṁf = dx
Q vap

where

d ṁ f – rate of the coolant vaporization/decomposition

ṁ f – mass flow rate of the coolant in the film

q Tw – convective heat flux to the liquid coolant film at the coolant vaporization
vap

temperature T vap

R , dx – size parameters of the chamber (see figure 1)

Qvap – coolant heat of vaporization or decomposition

The vaporization or decomposition of the film coolant is determined via a space-

marching technique starting from the location where the coolant reaches the
temperature of vaporization or decomposition, to the location where the whole coolant
is completely vaporized or decomposed.

– Mixing with surface layer

The gaseous products of vaporization/decomposition are mixing with existing surface

layer, producing the layer with new mixture composition. The mixing itself and the
estimation of the boundary layer cooling effectiveness can be performed as described
in two previous sections.

Radiation Heat Transfer

For given hot gas temperature T ∞ and wall temperature T w , the basic correlation for the
radiation heat transfer (under some assumptions mentioned in [1]) is given by

q r=εe σ ( εTr T 4∞ − εTr T 4w )

∞ w

where

11
 σ=5.670373×10−8 W /(m2 K 4 ) – Stefan–Boltzmann constant;

εe =εw /[1−(1−εw )( 1−εTr )] – effective emissivity coefficient of the wall;

w

w – emissivity coefficient of the wall material (see Table 1 for typical values of some
materials);

εTr ∞
– emissivity coefficient of the reaction products at temperature T ∞
Tw
εr – emissivity coefficient of the reaction products at temperature T w

Emissivity coefficients of reaction products at specific temperature T can be estimated as

follows [2]:
0
R Δ ω i, j
εTr =∑ ∑ β j [1−exp(−〈 K i , j 〉 p j L)] 4 −4
j i σ T 10

where

j – molecule, i – radiation strip (see the table 2)

α 3000 3000
〈K 〉=
Δω T
ω2
3.742(ω /1000)3⋅10−3
R =∫ 0
Δω dω
ω exp (1.44 ω /T )−1
1

δ=1 : ω1 =ω0−Δ ω /2 ; ω 2=ω0+Δ ω /2

δ=0 : ω1=ω0 −(Δ ω−Δ ω s ); ω 2=ω0 +Δ ω s

Δ ω=Δ ω s (1−δ)+a(1+δ)(T /1000)0.5

βH2O =1.09 , β j != H2O=1.00

4 V [cm], where V and F – the volume and surface area of combustion chamber.
L=0.9
F

p j is partial pressure of species j, [bar].

Table 1. Emissivity coefficients of some materials [4]

Material Surface temperature Tw, K Emissivity coefficient
Aluminum, oxidized 450 – 850 0.11 – 0.19
Copper alloy (bronze), 320 0.1
polished
Copper alloy (bronze), rough 320 – 420 0.55

12
Copper alloy (brass), oxidized 450 – 850 0.61 – 0.59
Copper, oxidized 450 – 850 0.57 – 0.87
Nickel, oxidized 450 – 850 0.37 – 0.48
Niobium 450 – 650 0.17
1250 – 1850 0.20
Stainless steel 750 0.35
Steel, oxidized 450 – 850 0.8
Steel, heavily oxidized 750 0.98
Chrom-Nickel alloy 400 – 1300 0.64 – 0.76

Table 2. Data for calculation of emissivity coefficients of reaction products [2]

Thrust Chamber Outer Cooling

Radiation Cooling
The general steady-state heat transfer equation for the cooled thrust chamber can be
expressed as follows:

T wg T wg λw T
q w +q r = (T −T ) = εwc σ T 4wc = q rcwc

t w wg wc

13
where
T T
q w and q r – convective and radiation heat flux to the inner surface of the wall at the
wg wg

temperature T wg ;

q Trc
wc
– radiation heat flux from the outer surface of the wall at the temperature T wc ;

T wg – temperature on the inner surface of the wall;

T wc – temperature on the outer surface of the wall;

−8 2 4
σ=5.670373×10 W /(m K ) – Stefan–Boltzmann constant;

εwc – emissivity coefficient of the wall material (see Table 1 for typical values of some
materials);
λ w – thermal conductivity of the wall at the temperature T =0.5(T wg +T wc ) ;

t w – thickness of the wall.

The steady-state heat transfer at each chamber/nozzle station is solved iteratively and
finishes when both T wg and T wc are found such that the heat flux to the inner surface of the
wall (q Tw +qTr ) is equal to the heat flux from the outer surface q Trc .
wg wg wc

Regenerative Cooling
For the numerical procedure, the thrust chamber is subdivided into a number of stations along
the longitudinal direction L, as shown in figure 3.

Figure 3: A thrust chamber subdivided

into a number of stations

The temperature distribution within the wall is determined via an space-marching technique
starting from station 0 to the last station n. The program marches axially from one station to
another. At each station, the following set of equations is used to determine the temperature
of the thrust chamber wall:

q Tw q Tr  Aw = ṁc 
c c T out in
c −T c 
wg wg

2  R qTw qTr 
wg wg

d Tc = dx
ṁc cc

14
 T wg T wg λ̄ w
q w +q r = (T −T )
t w wg wc
T wg T wg T wc
q w +q r = αc (T wc−T c ) = qwc

λc
α c = Nu
de

Tc
Nu = 0.021 Rec Pr c 0.64+0.36
0.8 0.4
( T wc ) (for kerosene) [2]

0.57
Tc
Nu = 0.033 Re0.8 0.4
c Pr c
( ) T wc
(for liquid hydrogen) [2]

0.1
Tc
Nu = 0.0185 Re0.8 0.4
c Pr c
( )
T wc
(for methane) [2]

Nu = 0.023 Re0.8 0.4

c Pr c (for other coolants) [1]

where

q Tw and q Tr – convective and radiation heat flux to the inner surface of the wall at the
wg wg

temperature T wg

T wg – gas-side wall temperature

T wc – coolant-side wall temperature

λ̄ w – thermal conductivity of the chamber wall at the temperature T =0.5(T wg +T wc)

t w – thickness of the chamber wall

T c – coolant temperature

T inc – initial temperature of the coolant as it enters the station

T out
c – final temperature of the coolant as it leaves the station

cc – average coolant specific heat

ṁ – coolant mass flow rate

Aw – wall surface area

de – equivalent diameter of the cooling passage

The calculation of the temperature distribution is performed iteratively as follows:

15
 1. Subdivide the thrust chamber into several stations (see figure 3).

2. On the first iteration step i=0 , assign the initial gas-side temperatures T iwg=0  at
each station.

3. At each station, calculate the gas-side heat flux (convective and radiation) for given
(i)
T wg ; in order to improve the execution speed of the program, the Ievlev's correlation
for similar conditions can be used on the follow-up iteration steps i0 (see section
Boundary Layer Cooling).

4. At each station, calculate the coolant heating and coolant exit temperature for known
input temperature (the direction of space-marching depends on the coolant flow
direction).

5. Calculate the coolant-side heat transfer coefficient α c .

6. From known heat flux and coolant-side heat transfer coefficient, calculate new values
of the coolant-side temperature T (i+1)
wc and the gas-side temperature T (i+1)
wg .

∣T (i) (i+1)
wg −T wg ∣
7. Calculate the convergence criteria as δ= (i )
< 0.05 T (i)
wg .
T wg

When the present iteration step is completed, comparison is made between the results of the
present step and that of the previous one to see if the convergence criteria has been met. If it
is not met at least at one station, the calculation starts again. The process continues until the
convergence is achieved at all stations.

Pressure Drop in Cooling Passages

The cooling passage can be treated as a hydraulic conduit and the pressure drop calculated
accordingly, as follows [7]:

l w2
Δ p=λ ρ
de 2

where

λ – friction loss coefficient, a function of the Reynolds number and of cooling passage
conditions such as geometric shape, surface smoothness etc.

l – length of the cooling passage

d e =4 A /Π – equivalent average diameter of the cooling passage

ρ – average density of the coolant

w=ṁ/ρ A – coolant flow velocity

ṁ – coolant total mass flow rate

16
 A – average total cross-section area of the cooling passages (that is the sum of the cross-
sections of all passages at specific station)

Π – average total perimeter of the cooling passages (that is the sum of the perimeters of
all passages at specific station)

Friction loss coefficient is estimated as follows [4], [7]:

64
– for laminar flows (Re ≤ 2320): λ= ε
Re f

0.3164
– for turbulent flows (2320 < Re < 105): λ= εf
√4 Re
0.221
– (
for turbulent flows (Re > 105): λ= 0.0032+
Re0.237)εf

Coefficient εf depends on geometric shape of the coolant passages and is given in the
sections below.

Coaxial-Shell Thrust Chamber Design

Regenerative cooling in coaxial-shell thrust chambers can be performed directly as described
in the previous sections.

Coefficient for calculation of the pressure drop is given as: εf =1.5 [4]

Channel-Wall Thrust Chamber Design

Regenerative cooling in channel-wall thrust chambers can be performed as described in
previous sections with following deviations [4]:
λc
α c = ηr Nu
de

a 2b th
 f= 
a a 

ξ=
√ 2 αc δ b
λw δ

where

 f – coefficient, introduced to reflect the increase in surface area of the cooling passages
(fin effect)

a , b ,  – width and height of the channel and thickness of the fin correspondingly
α c – coolant-side heat transfer coefficient

17
 w – thermal conductivity of the wall and fins

Coefficient εf depends on the shape of the single channel and can be estimated from the
figure 5.

Figure 4: Channel-wall thrust chamber schematic Figure 5: Form factor for channel-wall design [6]

Tubular-Wall Thrust Chamber Design

Regenerative cooling in tubular-wall thrust chambers can be performed as described in
section Channel-Wall Thrust Chamber Design with following deviations [4]:

– coefficient for calculation of the pressure drop is

given as:

• for cooling passages with circular cross

section εf ≈1

• for cooling passages with non-circular cross

section the coefficient εf can be estimated
from figure 5.

– coefficient  f is calculated in the same way as Figure 6: Tubular-wall thrust chamber

schematic
described before, obtaining parameters a , b
and δ as shown in figure 6.

Thermal Barrier Coating Layer

The thermal barrier coating (TBC) is used to reduce the temperature gradient across the
chamber wall.

The functional principle of a TBC, illustrated in figure below, is to increase the hot gas side
wall temperature Twg. This is achieved by applying a ceramic top layer (e.g. Y2O3-stabilized
ZrO2, PYSZ) onto the wall base material. The PYSZ ceramic offers a thermal conductivity λ of
about 1.5 W/(m K). In order to prevent a coating overheat (>1500 K) coating thicknesses of
less than 0.1 mm are required. These high hot gas side wall temperatures compared to the

18
maximum temperatures of the wall without coating lead to the significant reduction in heat
flux.

Figure 7: Functional principle of a TBC

With such a protective layer, the application range of existing regenerative or radiation cooling
thrust chambers can be enlarged towards higher combustion chamber pressures or an
increased thrust chamber life.

In general a TBC acts as an insulator to the inner liner, reducing the wall heat flux into the wall
base material.

For the analysis of thrust chambers with TBC the following equation is used:

1
q Tw q Tr
wg wg
= T wg −T wc
t1 t2 t
 ... N
1  2 N

where

t 1, t 2, ... ,t N – thicknesses of TBC layers and the base wall

λ 1, λ2, ... , λ N – thermal conductivities of TBC layers and the base wall

Loss in Specific Impulse

Loss in specific impulse due to friction in boundary layer is calculated using following relations
[8]:
xe

2  ∫  R cos  dx
0
f =
C if At p 0c

φ f = 1 − ξf

19
where
ξ f – friction loss coefficient
φf – performance correction factor for the friction loss

τ – viscosity stress (see section “Gas-Side Heat Transfer”)

i
C f – ideal thrust coefficient

A t – nozzle throat area

0
pc – stagnation pressure at nozzle inlet

x , R , θ – size and shape parameters of the thrust chamber as defined in figure 1

20
Computer Program RPA
The described numerical model has been implemented in the computer program RPA.

Graphical User Interface

Input Data
The screen Thermal Analysis consists of 3 tabs Heat Transfer Parameters, Thrust Chamber
Cooling and Thermal Analysis.
On the tab Heat Transfer Parameters the user can define heat transfer parameters used to
calculate the heat transfer rate distribution in the thrust chamber (figure 8).
On the tab Thrust Chamber Cooling the user can define design parameters of thrust chamber
cooling (figure 9). On this screen the user can add new cooling sections and define their
parameters.

Figure 8: Heat Transfer Parameters Figure 9: Thrust Chamber Cooling

          

Output Data
After specifying all required parameters and
starting the analysis, the user can see the
results on the tab Thermal Analysis (figure
10).

The thrust chamber geometry is printed out in

columns "Location" and "Radius".
The column "Heat flux" displays the
calculated heat flux (depending on heat
transfer parameters, either the sum of
convection heat flux and radiation heat flux or
convection heat flux only) at the
corresponding location. Figure 10: Thermal analysis results
The column "Twg" displays the temperature of

21
chamber wall on its hot gas side.
The column "Twi" displays the temperature between the thermal barrier coating layer and
chamber wall (if coating is available) or the temperature of chamber wall on its hot gas side
(the same as Twg).
The column "Twc" displays the temperature of chamber wall on its cold side.
The columns "Tc" and "wc" display the temperature and the velocity of the coolant (if
applicable).
Using context menu, the user can copy the content of the complete table or single selected
row into the clipboard.
The user can plot the the diagrams "Heat Flux vs. Location" or "Temperatures vs. Location",
clicking the button Plot at the bottom-right corner of the screen. The location of the nozzle
throat is shown on the diagram by vertical marker line (figures 11,12).

Figure 11: Diagram „Heat flux vs. Location“ Figure 12: Diagram „Temperatures vs. Location“

Verification
To verify the accuracy of the thermal analysis module of RPA, the comparison between
available reference data and RPA prediction has been performed.

The obtained agreement between the RPA prediction and referenced data is sufficient for the
tool used in conceptual and preliminary design studies (phase 0/A/B1).

Quantitative and qualitative differences in results can be explained by the following:

• RPA does not simulate fuel atomization and dispersion, as well as droplets burning.
• The hot gas properties for the thermal analysis are retrieved from the quasi one-
dimensional flow model.
• The heat transfer is simulated using semi-empirical relations.

22
SSME 40k
Design parameters [10]

40 K water cooled 40 K regeneratively cooled

Parameter Value Value Unit
Components mass ratio 6.0 6.0 O/F
Combustion chamber
10.87 20.47 MPa
pressure
Combustion chamber
43.8 43.8 mm
diameter
Contraction ratio 2.92 2.92 -
Chamber length (L') 355.6 355.6 mm
Nozzle exit area ratio 7 5 Ae/At

Figure 13: SSME 40 K calorimeter chamber heat flux profile Figure 14: SSME 40 K calorimeter chamber heat flux
[10] profile, predicted by RPA

Figure 15: SSME 40 K regenerative chamber predicted heat Figure 16: SSME 40 K regenerative chamber heat flux
flux profile [10] profile, predicted by RPA

23
Aestus
Design parameters (reference load point R) [11]
Parameter Value Unit
Oxidizer NTO (N2O4) -
Fuel MMH -
Components mass ratio 2.05 O/F
Combustion chamber pressure 10.3 bar
Combustion chamber diameter 210 mm
Nozzle throat diameter 136 mm
Chamber length (L') 310 mm
Length of regeneratively cooled chamber 591 mm
Nozzle exit area ratio 84 Ae/At

Figure 18: Calculated heat flux distribution, predicted

Figure 17: Calculated heat flux distribution [11] by RPA

Figure 19: Temperature distribution [11] Figure 20: Temperature distribution, predicted by RPA

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Future Work
The capabilities of Thermal Analysis Module for RPA will continue to be expanded upon.
Enhancements currently being developed include:

• Implementing the calculation of hot gas properties for the thermal analysis using
axisymmetric method of characteristics, replacing the present quasi one-
dimensional flow model.

• Refinement of the model for the film cooling analysis.

• Refinement of the models for the regenerative cooling analysis.

• Improved user interface to allow more flexible.

• Improved execution speed.

Conclusion
Thermal Analysis Module for RPA, a commercially available product, has been introduced to
the space propulsion community to assist in the design of liquid-propellant rocket engines.
This modern tool is suitable for use in conceptual and preliminary studies. Its friendly
graphical user interface and its ergonomics respond to the needs of flexibility and easy of use
in the daily activity. The tool has been executed and shown to be in good agreement with
published data.

25
References
1. Vasiliev A.P., Kudryavtsev V.M. et al. Basics of theory and analysis of liquid-propellant
rocket engines, vol.2. 4th Edition. Moscow, Vyschaja Schkola, 1993. (in Russian)

2. Lebedinsky E.V., Kalmykov G.P., et al. Working processes in liquid-propellant rocket

engine and their simulation. Moscow, Mashinostroenie, 2008. (in Russian)

3. Huzel, D.K., Hwang, D.H., Modern Engineering for Design of Liquid Rocket Engines,
ISBN 1-56347-013-6, American Institute of Aeronautics and Astronautics, 1992.

4. Dobrovolsky M.B. Liquid-propellant rocket engines. 2 nd Edition. Moscow, Bauman MSTU,

2005. (in Russian)

5. Sutton, G.P. and Biblarz, O. Rocket Propulsion Elements, 7 th Edition. John Wiley & Sons,
2001.

6. Babkin A.I., Belov S.I., et al. Basics of theory of automatic control of rocket engines.
Moscow, Mashinostroenie, 1986. (in Russian)

7. Katorgin B.I., Kiselev A.S., Sternin L.E., Chvanov V.K. Applied gas dynamics. Moscow,
Vusovskaja kniga, 2009. (in Russian)

8. Kurpatenkov V.D., Kesaev Kh.V. Analysis of thrust chamber of liquid-propellant rocket

engine. Moscow, MAI, 1993. (in Russian)

9. Ponomarenko A. RPA: Tool for Liquid Propellant Rocket Engine Analysis. 2010.

10. Carol E. Dexter, Mark F. Fisher, James R. Hulka, Konstantin P. Denisov, Alexander A.
Shibanov, and Anatoliy F. Agarkov. Scaling Techniques for Design, Development, and
Test. Liquid Rocket Thrust Chambers - Aspects of Modeling, Analysis, and Design -
Progress in Astronautics and Aeronautics, Volume 200.

11. Dieter Preclik, Oliver Knab, Denis Estublier, and Dag Wennerberg. Simulation and
Analysis of Thrust Chamber Flowfields: Storable Propellant Rockets. Liquid Rocket
Thrust Chambers - Aspects of Modeling, Analysis, and Design - Progress in Astronautics
and Aeronautics, Volume 200.

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