Design of Experiments-Based Optimization of Supersonic Nozzles for Enhanced Methane Capture

Design of Experiments-Based Optimization of Supersonic Nozzles for Enhanced Methane Capture | Research Square window.SnipcartSettings = { analytics: { enabled: false } }; (function() { var accessVector = localStorage.getItem('access_vector') || ''; window.dataLayer = window.dataLayer || []; if (accessVector) { window.dataLayer.push({ user: { profile: { profileInfo: { snid: accessVector } } } }); } })(); (function(w,d,s,l,i){w[l]=w[l]||[];w[l].push({'gtm.start':new Date().getTime(),event:'gtm.js'});var f=d.getElementsByTagName(s)[0],j=d.createElement(s),dl=l!='dataLayer'?'&l='+l:'';j.async=true;j.src='https://www.googletagmanager.com/gtm.js?id='+i+dl;f.parentNode.insertBefore(j,f);})(window,document,'script','dataLayer','GTM-K279D39R'); Browse Preprints In Review Journals COVID-19 Preprints AJE Video Bytes Research Tools Research Promotion AJE Professional Editing AJE Rubriq About Preprint Platform In Review Editorial Policies Our Team Advisory Board Help Center Sign In Submit a Preprint Cite Share Download PDF Article Design of Experiments-Based Optimization of Supersonic Nozzles for Enhanced Methane Capture Kapil Das Sahu, Shyam Sunder Yadav, Mani Sankar Dasgupta This is a preprint; it has not been peer reviewed by a journal. https://doi.org/ 10.21203/rs.3.rs-6911999/v1 This work is licensed under a CC BY 4.0 License Status: Posted Version 1 posted You are reading this latest preprint version Abstract Computational fluid dynamics (CFD) simulations are employed in this study to optimize key geometric parameters of supersonic nozzles, aiming to enhance methane capture efficiency through non-equilibrium condensation mechanisms. A Design of Experiments (DoE) approach was used to systematically vary key geometric parameters of a converging-diverging Laval nozzle, including inlet radius, throat radius, divergence angle, and section lengths. The non-equilibrium condensation of CH 4 under metastable conditions was modeled using a custom implementation of Classical Nucleation Theory. The computational model demonstrated high accuracy when validated against experimental data for both steam and CO₂, supporting its reliability for multi-species condensation simulations. Performance metrics including exergy loss, thermal efficiency, and condensation efficiency were evaluated across 32 nozzle configurations. Four designs demonstrated superior performance, with one configuration (Run ID 22) emerging as optimal, exhibiting the highest condensation efficiency and extensive supercooling zones. The optimized design maintained stable performance across a range of inlet temperatures (240–260 K) and pressures (65–75 bar). The optimized design maintained thermal efficiencies above 91% and exergy losses below 10% and maximum condensation efficiency of 17% across a range of inlet conditions. This work establishes a foundation for designing efficient supersonic separators for methane capture, with potential applications in natural gas processing and greenhouse gas mitigation. Physical sciences/Energy science and technology Physical sciences/Engineering Physical sciences/Mathematics and computing Methane Capture Supersonic Separation Supersonic Nozzle Design of Experiment (DoE) Non equilibrium condensation Computational Fluid Dynamics (CFD) Full Text Additional Declarations No competing interests reported. Cite Share Download PDF Status: Posted Version 1 posted You are reading this latest preprint version Research Square lets you share your work early, gain feedback from the community, and start making changes to your manuscript prior to peer review in a journal. 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Also discoverable on Platform About Our Team In Review Editorial Policies Advisory Board Help Center Resources Author Services Accessibility API Access RSS feed Manage Cookie Preferences © Research Square 2026 | ISSN 2693-5015 (online) Privacy Policy Terms of Service Do Not Sell My Personal Information {"props":{"pageProps":{"initialData":{"identity":"rs-6911999","acceptedTermsAndConditions":true,"allowDirectSubmit":true,"archivedVersions":[],"articleType":"Article","associatedPublications":[],"authors":[{"id":473420670,"identity":"3744340f-a8ad-4a21-9b2a-43d5b867fff4","order_by":0,"name":"Kapil Das Sahu","email":"data:image/png;base64,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","orcid":"","institution":"Birla Institute of Technology \u0026 Science","correspondingAuthor":true,"prefix":"","firstName":"Kapil","middleName":"Das","lastName":"Sahu","suffix":""},{"id":473420672,"identity":"1a13c3e2-fb38-4c25-9987-5b28bd1f2b43","order_by":1,"name":"Shyam Sunder Yadav","email":"","orcid":"","institution":"Birla Institute of Technology \u0026 Science","correspondingAuthor":false,"prefix":"","firstName":"Shyam","middleName":"Sunder","lastName":"Yadav","suffix":""},{"id":473420673,"identity":"0af25004-516e-4cdc-940a-0746f514ca20","order_by":2,"name":"Mani Sankar Dasgupta","email":"","orcid":"","institution":"Birla Institute of Technology \u0026 Science","correspondingAuthor":false,"prefix":"","firstName":"Mani","middleName":"Sankar","lastName":"Dasgupta","suffix":""}],"badges":[],"createdAt":"2025-06-17 08:23:28","currentVersionCode":1,"declarations":"","doi":"10.21203/rs.3.rs-6911999/v1","doiUrl":"https://doi.org/10.21203/rs.3.rs-6911999/v1","draftVersion":[],"editorialEvents":[],"editorialNote":"","failedWorkflow":false,"files":[{"id":85917934,"identity":"c6e05b32-f213-44f3-b705-50ce6362a9e2","added_by":"auto","created_at":"2025-07-03 07:17:11","extension":"pdf","order_by":1,"title":"","display":"","copyAsset":false,"role":"manuscript-pdf","size":964450,"visible":true,"origin":"","legend":"","description":"","filename":"MethaneCaptureDoE.pdf","url":"https://assets-eu.researchsquare.com/files/rs-6911999/v1_covered_feb4f6ed-4bd1-4e0e-8b30-e1f48fff57ba.pdf"}],"financialInterests":"No competing interests reported.","formattedTitle":"Design of Experiments-Based Optimization of Supersonic Nozzles for Enhanced Methane Capture","fulltext":[],"fulltextSource":"","fullText":"","funders":[],"hasAdminPriorityOnWorkflow":false,"hasManuscriptDocX":false,"hasOptedInToPreprint":true,"hasPassedJournalQc":"","hasAnyPriority":false,"hideJournal":true,"highlight":"","institution":"","isAcceptedByJournal":false,"isAuthorSuppliedPdf":true,"isDeskRejected":"","isHiddenFromSearch":false,"isInQc":false,"isInWorkflow":false,"isPdf":true,"isPdfUpToDate":true,"isWithdrawnOrRetracted":false,"journal":{"display":true,"email":"[email protected]","identity":"researchsquare","isNatureJournal":false,"hasQc":true,"allowDirectSubmit":true,"externalIdentity":"","sideBox":"","snPcode":"","submissionUrl":"/submission","title":"Research Square","twitterHandle":"researchsquare","acdcEnabled":true,"dfaEnabled":false,"editorialSystem":"","reportingPortfolio":"","inReviewEnabled":false,"inReviewRevisionsEnabled":true},"keywords":"Methane Capture, Supersonic Separation, Supersonic Nozzle, Design of Experiment (DoE), Non equilibrium condensation, Computational Fluid Dynamics (CFD)","lastPublishedDoi":"10.21203/rs.3.rs-6911999/v1","lastPublishedDoiUrl":"https://doi.org/10.21203/rs.3.rs-6911999/v1","license":{"name":"CC BY 4.0","url":"https://creativecommons.org/licenses/by/4.0/"},"manuscriptAbstract":"\u003cp\u003eComputational fluid dynamics (CFD) simulations are employed in this study to optimize key geometric parameters of supersonic nozzles, aiming to enhance methane capture efficiency through non-equilibrium condensation mechanisms. A Design of Experiments (DoE) approach was used to systematically vary key geometric parameters of a converging-diverging Laval nozzle, including inlet radius, throat radius, divergence angle, and section lengths. The non-equilibrium condensation of CH\u003csub\u003e4\u003c/sub\u003e under metastable conditions was modeled using a custom implementation of Classical Nucleation Theory. The computational model demonstrated high accuracy when validated against experimental data for both steam and CO₂, supporting its reliability for multi-species condensation simulations. Performance metrics including exergy loss, thermal efficiency, and condensation efficiency were evaluated across 32 nozzle configurations. Four designs demonstrated superior performance, with one configuration (Run ID 22) emerging as optimal, exhibiting the highest condensation efficiency and extensive supercooling zones. The optimized design maintained stable performance across a range of inlet temperatures (240\u0026ndash;260 K) and pressures (65\u0026ndash;75 bar). The optimized design maintained thermal efficiencies above 91% and exergy losses below 10% and maximum condensation efficiency of 17% across a range of inlet conditions. 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