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Three-Dimensional Transient Simulation of Supercritical RP-3 Pyrolysis and Flow Maldistribution in Parallel Regenerative Cooling Channels
Fluid Dynamics & Materials Processing 2026, 22(4): 7
Published: 07 May 2026
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To investigate transient flow instabilities in parallel-channel regenerative cooling systems subjected to nonuniform heat flux, a three-dimensional transient numerical model was developed to couple variations in supercritical fluid thermophysical properties with endothermic pyrolysis kinetics. The spatiotemporal evolution of RP-3 fuel within parallel channels was analyzed, and the role of a midstream interconnection structure in mitigating flow maldistribution was clarified. During the initial heating stage, the viscosity reduction of the supercritical fuel produced a drag-reduction effect that temporarily maintained a nearly uniform flow distribution. As the wall temperature increased and the pseudocritical region approached, the sharp decrease in density markedly increased the acceleration pressure drop, disrupting the pressure balance between channels. In combination with the progressive accumulation of pyrolysis products, this process led to a positive feedback loop characterized by flow rate reduction, insufficient heat absorption, and increasing flow resistance. The introduction of a midstream interconnection enabled pressure-driven lateral mass transfer between channels. The resulting crossflow was directed predominantly from the high-heat-flux channel toward the low-heat-flux channel, providing a release path for overheated, low-density, and strongly cracked fluid in the high-heat-flux channel and thereby weakening the downstream accumulation of thermal and compositional nonuniformities as well as the associated resistance amplification. Compared with the configuration without interconnection, the stage-averaged maximum flow-deviation coefficient decreased by 17.4% during the pseudocritical transition stage and by 48.3% during the deep-pyrolysis stage.

Open Access Article Issue
Numerical Analysis of Supercritical Fuel Cracking in Trapezoidal Rib Channels
Fluid Dynamics & Materials Processing 2026, 22(5): 6
Published: 27 May 2026
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Background

Conjugate heat transfer in supercritical hydrocarbon fuels within microchannels is strongly influenced by sharp thermophysical property variations and chemical reactions, posing significant challenges for accurate numerical prediction. To address this, a high-fidelity solver is developed within the OpenFOAM framework, incorporating detailed reaction mechanisms and demonstrating robust stability under steady supercritical conditions. In particular, to mitigate numerical oscillations and accuracy loss in the pseudo-critical region, a high-order variable-property transport model, based on an eight-segment, seventh-order polynomial formulation, is introduced and integrated in the solver. This model is tightly coupled with the Peng–Robinson equation of state and a simplified cracking mechanism, enhancing both stability and predictive capability for highly nonlinear supercritical reacting flows. The proposed approach is applied to compare the coupled thermal–hydraulic–chemical behavior of a baseline straight channel and a trapezoidal-ribbed configuration under supercritical pressure. Unlike conventional fully distributed rib arrangements, the proposed design achieves heat transfer enhancement using a limited number of rib elements. The ribs promote elevated turbulent kinetic energy in their wake and intensify near-wall mixing. As a result, peak wall temperature is reduced by 30–40 K under identical conditions, effectively suppressing localized hot spots. Although improved cooling slightly decreases the cracking conversion rate, the design markedly lowers the risk of fuel coking by eliminating high-temperature regions, thereby enhancing overall thermal management. The performance evaluation criterion (PEC) remains close to or slightly above unity across different mass flow rates, indicating a modest but meaningful thermo-hydraulic benefit and practical engineering potential.

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