Purdue University Zucrow Research Lab ZL8 High Pressure Combustion Lab

Purdue University is a public research university that advances discoveries in science, technology, engineering, and math. Maurice J. Zucrow Laboratories is the largest academic propulsion lab in the world and the ZL8 project was initiated to fill the private and governmental combustion testing needs.

Built adjacent to existing facilities and a landlocked site next to the Purdue University Airport, the project was challenged to integrate this new high-tech facility within its current footprint and connect process services across multiple buildings. The addition of a new 1500-degree F, 800 pounds per square inch (psi) air heater required in-depth and custom solutions for the specialty alloy piping, insulation, pipe supports, and thermal expansion design. Extensive ASME code and pipe stress analysis was required to validate the design compliance for safety and quality standards.

Opened in 2017, the High Pressure Combustion Laboratory (ZL8) is the only facility of its kind in the world.  The Tebbe TDI Laser Lab, a 2,000 square-foot climate controlled facility, runs adjacent to 5 brand new test cells, for optimal inclusion of laser diagnostic measurements in the experiments. Four of the test cells house airbreathing combustion and sprays experiments, while the fifth test cell houses a state-of-the-art turbine lab for studying aerodynamics and heat transfer in advanced turbine systems. ZL8 also includes a machine shop, control rooms, and electronics/instrumentation rooms.

The adjacent air heater has capacity to deliver 1500°F high pressure air to experiments permitting the researchers to simulate compressor discharge exit conditions for some of the most modern high pressure ratio gas turbine engines.

The design solution included the service of over 20 process and HVAC utilities to each test cell. The overall integration with the existing utilities and buildings on the Zucrow campus provided a collaborative and cohesive addition to the site. MNA’s experience and knowledge of high pressure gaseous and fluid systems as well as test cell design was critical in a successful project outcome.