Improve Combustion Performance Research Articles

Numerical Simulation and Analysis of Semi-Industrial Retrofit for Tangentially Fired Boilers with Slag-Tap Technology

High-alkali Zhundong coal presents significant challenges for power generation, due to its propensity for fouling and slagging. This study investigates a retrofit of a 300 MW tangentially fired boiler with the integration of a slag-tap chamber to improve combustion performance. Computational fluid dynamics (CFD) simulations are employed to examine the influence of this modification on combustion dynamics and the effects of Zhundong coal blending ratios on heat and mass transfer. The results demonstrate that the retrofit facilitates stable airflow recirculation, optimizing combustion efficiency with a peak temperature of 2080 K in the combustion chamber. The flue gas temperature decreases to approximately 1650 K upon exit, which can be attributed to the slag catcher cooling. The integration of the liquid slagging chamber significantly mitigates slag formation, while enhancing oxygen and CO2 distribution throughout the furnace. As the blending ratio of Zhundong coal increases, oxygen concentrations rise in the bottom burner region, indicating improved air–fuel mixing. With a 30% Zhundong coal ratio, the combustion chamber temperature increases by 3%, and flow velocity in the upper and middle furnace sections decreases by 15%, leading to enhanced combustion intensity. This retrofit demonstrates substantial improvements in combustion stability, slagging control, and the efficient utilization of high-alkali coal.

Composite Structure MgB2@KNO3 With Multi-Effect Synergies to Improve Combustion Performance and Energy Release of B

ABSTRACT With the deepening of research, boron compounds have gradually gained favor among researchers due to their high calorific value and excellent ignition and combustion performance. In this paper, MgB2@KNO3, which exhibits excellent ignition and combustion properties, was synthesized using ultrasonic dispersion and magnetic stirring. The improved ignition mechanism and energy release characteristics of MgB2@KNO3 were elucidated using DSC/TG, SEM, EDS, XRD, and optical characterization, in conjunction with computational results from NASA-CEA. The surface activation energy and ignition energy of MgB2@KNO3 are 35.7% and 25%, respectively, lower than those of conventional B/KNO3 mixtures. Compared to the mixed sample of B/KNO3, the heat release of MgB2@KNO3 increased by 72.4%. The synergistic and effective interactions between oxygen, magnesium vapor, and boron in MgB2@KNO3 systems result in efficient energy release performance, making MgB2@KNO3 a promising material for use as a high-energy fuel in propellants, explosives, and pyrotechnic products.

Combustion performance of an evaporative flameholder under subsonic-supersonic mixing inflow

The combustion process in rocket-assisted subsonic ramjet engines represents a key advancement in integrated aerospace propulsion, particularly for embedded rocket-based systems. These engines offer the potential to improve combustion performance at altitudes of 25–35 km. However, the significant temperature and velocity differentials between the rocket jet and the subsonic ramjet flow restrict heat and mass transfer. Investigating the relationship between combustion performance and inlet parameters under subsonic-supersonic mixing conditions offers a promising approach to enhancing thrust performance. This study introduces subsonic and supersonic airflow mixing via a flat-plate shear layer in a rectangular channel, with an evaporative flameholder placed centrally to assess combustion. Results reveal that combustion efficiency decreases as the equivalence ratio exceeds 0.2, while the static temperature ratio has minimal impact on efficiency but strongly influences the maximum flame stabilization limit. As the temperature ratio increases from 1.30 to 1.80, the flame limit narrows from 1.656 to 0.237. Higher pressure ratios initially enhance combustion efficiency and flame coverage but eventually cause a decrease. The flame limit broadens from 0.900 to 1.626 as the pressure ratio increases from 1.12 to 1.50. While Mach number changes have little effect on efficiency, the flame limit exhibits an initial rise followed by a drop. Novel findings include an asymmetrical flame pattern and a “Z” shaped outlet temperature distribution, contributing to optimized combustion strategies for combined-cycle engines.

Additively-manufactured shear tri-coaxial rocket injector mixing and combustion characteristics

A monolithic tri-coaxial propellant injection scheme for enhanced mixing of methane-oxygen in liquid-propellant rocket systems is enabled by additive manufacturing. Mixing and combustion characteristics of the tri-coaxial design are assessed experimentally from 1–69 bar using laser absorption tomography and chemiluminescence imaging, and are compared to a traditionally-manufactured bi-coaxial design. Quantitative two-dimensional images of temperature and carbon monoxide mole fraction are generated from the laser absorption spectroscopy methods, while OH* chemiluminescence provides an approximate metric for combustion heat release defining flame length and injector standoff distance. At similar pressures and oxidizer-to-fuel ratios, the tri-coaxial injector design is shown to enhance mixing and combustion progress, reducing characteristic mixing length scales and achieving improved combustion performance relative to more conventional bi-coaxial designs. Despite enhanced mixing, the tri-coaxial design exhibits more limited reduction in flame standoff distance from the injector face, suggesting that increased heat flux to the injector face can be managed. The tri-coaxial injector highlights the potential to leverage additive manufacturing to enhance performance and simplify the fabrication of liquid-propellant rocket engines.

Improved combustion performance of solid propellant with sliver nanoparticle decorated Al addition

The oxide layer on the Al particle surface seriously limits application in solid propellants, resulting in low combustion efficiency. This work prepares a series of Al decorated by nano-silver (namely Al/Ag) via in-situ reduction to enhance combustion performance Thanks to silver’s smaller specific heat capacity, surplus heat energy is transferred to the Al core through a tight combination with decorated noble metal nanoparticles. Along with the intermetallic reaction, the thermal stress on Al would accelerate the oxide shell rupture to reduce the oxygen gas diffusion barrier during combustion. The oxidation temperature of Al/Ag-2 composites decreases from 1017.3 °C to 982.93 °C. Hence, the combustion performance of solid propellants containing Al/Ag composites is improved with the higher maximum flame temperature and emission spectra intensity. In addition, the thermal decomposition of ammonium perchlorate (AP) is catalyzed via nano-silver. The combustion efficiency of the propellant containing Al/Ag-2 is effectively improved by the synergistic effect in which the potential energy from Al and AP is exploited as far as possible. This work demonstrates that metal surface modification significantly improves the combustion performance of solid propellants.

Research on combustion cycle-by-cycle variations under high load in SACI mode and application potential of i-EGR coupling air dilution when fueled with methanol and gasoline

Spark assist compression ignition (SACI) is a efficient combustion mode but roughness combustion under high load limits its application. This test analyzed the combustion parameters variation coefficient and quantified the correlation between combustion parameters with spark ignition ratio under high load SACI mode for engine fueled with methanol and gasoline, further studied the potential of i-EGR combining air dilution on improving combustion performance. Results showed that fueled with methanol can reduce in-cylinder pressure and pressure rise rate, and relieve the combustion roughness. However, compared with gasoline engine, the combustion parameters was more sensitive to ignition timing and i-EGR rate, especially for combustion phase parameters like ignition delay, combustion center and so on. Introducing small amount of high-temperature exhaust gas into cylinder will induce rougher combustion, but cylinder pressure significantly reduced and combustion phase parameters fluctuated with i-EGR rate increasing. Under high i-EGR rate, methanol as an oxygenated fuel was more beneficial to maintain stable combustion. I-EGR coupling air dilution can significantly improve the economic performance under high load SACI mode, fuel economy improvements of up to about 17.4% and 19% compared to the origin point when fueled with gasoline and methanol. EGR combining air dilution can simultaneously improve BSNOX, BSTHC, and BSCO emissions.

Combustion and co-combustion of biochar: Combustion performance and pollutant emissions

Biomass is a renewable and clean energy source, offering the potential to reduce fossil fuel consumption and greenhouse gas emissions when it is used as a biofuel. However, the disadvantages of raw biomass such as poor grindability, high moisture content, and low calorific value hinder its widespread industrial combustion. Thermochemical conversion techniques are widely used to convert biomass to biochar, which serves not only as an adsorbent and soil amendment but also as solid fuels alternative to fossil energy. The upgraded biochar exhibits better physicochemical properties and improved combustion performance. This paper focuses on the properties and combustion behavior of biochar as a solid fuel, reviewing common production techniques of biochar and their effects on yields and properties of biochar. It also examines the combustion characteristics and kinetics of biochar in single- and co-combustion scenarios with other fuels, such as coal, sludge, and petroleum coke, analyzing the influencing factors of combustion behavior and kinetic parameters. This study further investigates the emission characteristics during the combustion of biochar, including gaseous pollutants (such as CO, NOx, SOx, and HCl), ash-related issues, and particulate matter (PM) emissions. Additionally, a new fuel type named “bioslurry”, which is developed with biochar as a main material, is introduced. Furthermore, this paper discusses the techno-economic and environmental aspects of biochar application, exploring the feasibility of its industrial production and utilization.

Jet ignition characteristics of ammonia-hydrogen passive pre-chamber: Emphasis on equivalence ratio and hydrogen/ammonia ratio

Ammonia-hydrogen blend fuels offer the potential for zero-carbon emissions in internal combustion (IC) engines. To improve combustion performance, considerable attention has been focused on pre-chamber jet ignition technologies. Passive pre-chamber featuring a simple structure can be installed in the spark plug hole without modifying the cylinder head. However, the jet ignition characteristics of ammonia-hydrogen passive pre-chambers are not fully understood, and there is a lack of visualized evidence on how critical parameters (e.g., equivalence ratio and hydrogen/ammonia ratio) impact ignition processes. This work investigated the effects of equivalence ratio and hydrogen/ammonia ratio on ammonia-hydrogen jet ignition characteristics in a rapid compression machine with passive pre-chamber. High-speed photography and instantaneous pressure acquisition were employed to capture detailed ignition and combustion evolutions. Results show that under low hydrogen/ammonia ratio conditions, there exists a combustion regime with noticeable fluctuations in jet penetration, indicating degenerate ignition performance. As the hydrogen/ammonia ratio increases from 0 % to 20 %, the ignition delay time of mixtures in the main chamber is reduced by 70 %, suggesting an improved overall ignition performance. Regarding the equivalence ratio, more pronounced effects on jet ignition and flame propagation are identified under lean-burning conditions. For mixtures at the hydrogen/ammonia ratio of 20 %, as the equivalence ratio increases from 0.6 to 0.8 and from 0.8 to 1.0, the decay rates for 10 %–90 % combustion duration are 82.5 % and 20.6 %, respectively. Besides, with the increase of equivalence ratio, flame initiation is shifted from the jet head to the side surface. The role of hydrogen/ammonia ratio and equivalence ratio is different, with the former modifying mixture reactivity while the latter affecting ignition energy.

Investigation of Slagging-Fouling and Mineral Contents in Low-Rank Coals for Improved Combustion Performance

ABSTRACT Despite the problems associated with low-rank coal, this type of coal is still widely used in various applications including the power generation sector. In this study, three low-rank coals (LRC) with high mineral content of SiO2, Al2O3, and MgO were selected and comprehensively investigated. Investigations include ash fusion temperature (AFT), theoretical calculation, combustion experiment with drop tube furnace (DTF), and ash analysis using scanning electron microscope (SEM) and x-ray diffraction (XRD). The investigation revealed that T-Coal with high SiO2 and P-Coal with high Al2O3 mineral produce ash deposition which did not adhere on the probe surface of either slagging or fouling area. T-Coal ash consists of fine and solid particles, but the presence of the dominant albite mineral, 29.09% in slagging probe and 28.71% in fouling probe, may have a negative impact on ash deposition. P-Coal ash is dominated by fine particles with a predominance of quartz and other high-melting minerals. A-Coal with high MgO mineral has good results in slagging aspects. However, the high Fe2O3 on A-Coal results in low ash fusion and produces more hematite mineral (17.70%) in the fouling probe. This study shows that several types of LRC have good evaluation on ash-related problems which potentially can be used as coal blending for further utilization in power generation.

Simulation of DME-O2 Combustion in a Hollow Cone Impinging Jet Combustor for Direct-Fired Supercritical CO2 Power Cycle

ABSTRACT Combustion is critical in the direct-fired supercritical CO2 power cycle. A hollow cone impinging jet combustor is designed. Instead of methane, dimethyl ether is used as the fuel for the direct-fired supercritical CO2 cycle, with a higher hydrocarbon ratio and oxygen. The dimethyl ether combustion process is simulated by Fluent, based on the k-ε turbulence model and Eddy-Dissipation Concept combustion model, combined with the dimethyl ether combustion mechanism. The effects of the CO2 recycling ratio, the excess oxygen coefficient, and in-combustor pressure are investigated to support improving combustion performance. The results indicate that the recycled CO2 intensifies the movement of the mixture in the combustor, reduces the peak temperature, and makes temperature distribution more uniform. As the excess oxygen coefficient increases, the peak temperature is enhanced, and the combustion is more sufficient. The effect of in-combustor pressure is complex. On the one hand, increasing in-combustor pressure reduces the jet penetration and inhibits the contact between dimethyl ether and O2, leading to a lower peak temperature. On the other hand, it prolongs the residence time of the high-temperature exhaust, making the reaction between dimethyl ether and O2 more sufficient. The optimal operating condition of the combustor is a CO2 recycling ratio of 0.95, an excess oxygen coefficient of 1.20, and an in-combustor pressure of 30 MPa. Moreover, the obtained combustion products parameters, such as temperature, component concentration, and mass flow rate, can guide the performance analysis for the direct-fired supercritical CO2 power cycle.

Ab Initio Driven Exploration on the Thermal Properties of Al-Li Alloy.

Al-Li alloys are feasible and promising additives in advanced energy and propellant systems due to the significantly enhanced heat release and increased specific impulse. The thermal properties of Al-Li alloys directly determine the manufacturing, storage safety, and ignition delay of propellants. In this study, a neural network potential (NNP) is developed to investigate the thermal behaviors of Al-Li alloys from an atomistic perspective. The novel NNP demonstrates an excellent predictive ability for energy, atomic force, mechanical behaviors, phonon vibrations, and dynamic evolutions. A series of NNP-based molecular dynamics simulations are performed to investigate the effect of Li doping on the thermal properties of Al-Li alloys. All calculated results for Al-Li alloys are consistent with experimental values for Al, ensuring their validity in predicting Al-Li interactions. The simulation results suggest that a minor increment in the Li content results in a slight change in the melting point, thermal expansion, and radical distribution functions. These three properties are associated with the lattice characteristics; nonetheless, it causes a substantial reduction in thermal conductivity, which is related to the physical properties of the elements. The lower thermal conductivity allows heat accumulation on the particle surface, thereby speeding up the surface premelt and ignition. This provides an alternative atomic explanation for the improved combustion performance of Al-Li alloys. These findings integrate insights from the field of alloy material science into crucial combustion applications, serving as an atomistic guide for developing manufacturing techniques.

Comparative analysis of adding cotton straw and corn stover to improve the combustion performance of municipal sludge

To address issues of high water content and low calorific value during combustion of municipal sludge, we added water-absorbent, easy-to-burn agricultural waste to improve the overall combustion performance. Cotton straw or corn stover were added to the sludge and mixed at high-speed to compare their capacities for improving combustion performance. Scanning Electron Microscopy (SEM) revealed that cotton straw or corn stover attached to the surface of the municipal sludge particles after blending, while analysis of thermogravimetric curves and activation energies of the blends showed that combustion and exhaustion rates increased significantly when 40% cotton straw or corn stover were blended into the sludge. Using the quadrilateral cut-ring boiler as a prototype, the mix of sludge with cotton straw or corn stover was simulated, and FLUENT software was used to obtain the temperature and pollutant emissions of the boiler. Sludge blended with cotton straw or corn stover increased furnace temperature and reduced SO2 and NO emissions, while that with cotton straw burned at higher temperatures with lower SO2 and NO emissions. Overall, the CO content of sludge combustion was lower when blended with proportions of cotton straw or corn stover under 50%. The findings of this study lay a theoretical foundation for treatment of municipal sludge according to local conditions.

Feasibility of co-disposal of lignite and eucalyptus wood in coal-fired power plants: thermogravimetric characterization, typical gaseous pollutant emission characteristics, and economic analysis

ABSTRACT Energy issues are becoming increasingly prominent, and biomass blending in coal-fired power plants can improve combustion performance and reduce gaseous pollutant emissions, thereby improving economic efficiency. In this study, a thermogravimetric analyzer, a horizontal tube furnace, and an infrared flue gas analyzer were used to investigate the combustion behavior and gaseous pollutant emissions of the co-combustion of LC and EW. The results show that blending EW into LC cofiring can inhibit the release of volatile matter and promote the decomposition of fixed carbon and lignin simultaneously. The HHV of EW (15.88 MJ/kg) reaches 63.7% of LC’s (24.90 MJ/kg), indicating EW has a high energy utilization value. With increasing combustion temperature, the average value of CR S increased from 47.09% to 59.94%, and the average value of CR Cl increased from 26.15% to 52.15%, leading to a significant increase in SO2 and HCl emissions. The decrease in combustion temperature slightly promoted the release of N (CR N increased from 11.76% to 14.45%). The results of the economic analysis show that the cost of CaO and NH3·H2O used for removing gaseous pollutants decreased the most, and the economic efficiency increased the fastest to 14,000 RMB/day when the EW blending ratio increased from 10% to 20%.

Effect of excitation Strouhal number on a backward-inclined jet flame in crossflow

Combustion is often accompanied by environmental pollution due to incomplete reaction. A non-excited flame usually exhibits poor combustion performance with features of diffusion flame such as dual-peak temperature distributions and large combustion product concentrations. Efficient fuel-air mixing has been identified as a key factor in mitigating this issue. The present study investigated the effects of the acoustic excitation Strouhal number on the combustion performance of a backward-inclined jet flame in crossflow. A loudspeaker was used to induce jet pulsations with excitation Strouhal numbers ranging from 0.47 to 1.54 at a pulsation intensity of 0.90. Time-averaged and instantaneous flame images were captured using digital cameras. A customized R-type thermocouple and a commercial gas analyzer were employed to analyze the thermochemical structures. A critical excitation Strouhal number of approximately 0.9, distinguishing two characteristic flame modes: strongly affected flame (SA flame) and weakly affected flame (WA flame), was found. At excitation Strouhal numbers lower than the critical value, the SA flame featured single-peak temperature profiles and low unburned hydrocarbon, carbon monoxide, and nitric oxide emissions. The combustion performance was significantly improved due to the strong mixing effect induced by the acoustic excitation. The WA flame appeared at excitation Strouhal numbers higher than the critical value. It exhibited dual-peak temperature distributions and slightly improved combustion performance. The dynamic behavior and emissions of acoustically excited jet flames offered a fascinating insight into the influence of excitation Strouhal numbers on combustion characteristics. More excitation conditions were expected for future research.

Analysis of landfill leachate promoting efficient application of weathered coal anaerobic fermentation

This research aimed to develop a new method for clean utilization and treatment of landfill leachate and solid waste weathered coal. Landfill leachate and weathered coal were adopted for combined anaerobic fermentation for methane production. The characteristics of microbial community, mechanism of biological methane production, and utilization characteristics of fermentation broth and solid residue for co-fermentation were analyzed through metagenomics, soluble organic matter detection and thermogravimetric (TG) analysis. The obtained results revealed that combined anaerobic fermentation increased methane production by 80.1%. Syntrophomonas, Salipiger, Methanosaeta and Methanothrix were highly correlated. Gene abundances of 2-oxoacid ferredoxin oxidoreductase and enolase were increased in methane conversion pathway mainly by acetic acid. Pyruvate-ferroredoxin oxidoreductase, 2-oxoglutarate synthase and succinate dehydrogenase acetate synthase intensified electron transfer pathways among microorganisms. Fulvic acid, tyrosine and tryptophan contents were high in fermentation broth. Volatile decomposition temperature, ignition point and residual char combustion temperature of residual coal were decreased and combustion was more stable. The obtained results showed that the co-fermentation of landfill leachate and weathered coal improved biological methane gas production, degraded weathered coal and improved combustion performance, which provided a new idea for weathered coal clean utilization.

Combustion Enhancement of Gel Propellant Containing High Concentration Aluminum Particles Based on Carbon Synergistic Effect.

The addition of aluminum particles to gel propellants can improve combustion performance. However, the agglomeration of aluminum during the combustion process can result in a series of negative effects. In this paper, the aluminum agglomeration inhibition method of gel propellant based on carbon synergistic effect is proposed. Carbon particles exhibit excellent combustion properties, and the gaseous product CO2 generated during combustion can mitigate the agglomeration of aluminum. The research demonstrates that incorporating carbon particles into aluminum-containing gel effectively reduces the incomplete combustion of aluminum particles and increases the volumetric calorific value of the gel. When the mass fraction of carbon is 5 wt%, the volume calorific value of the gel reaches the highest. Meanwhile, the rheological experiments show that the addition of carbon particles can improve the shear-thinning properties of the gel, which is beneficial to the atomization and combustion processes of the gel.

Comprehensive comparison of single-stage and novel two-stage hydrogen direct injection strategies on the combustion and thermodynamic performance of X-type rotary engine using gasoline-hydrogen fuel

In this paper, the CFD simulation model of a high-efficiency X-type rotary engine using premixed gasoline and hydrogen direct injection is established. The effect of hydrogen injection timing on combustion, pollutant emissions, and thermodynamic performances is investigated under hydrogen single-stage direct injection (HSDI). Furthermore, a novel hydrogen two-stage direct injection (HTDI) strategy using different first injection mass fractions (FIMF) and the same total injection pulse width of 3.5 °CA is proposed for improving combustion performance in the later phase under HSDI. The results show that the hydrogen injection timing of 290 °CA presents a 6.09% higher indicated thermal efficiency than that of 270 °CA under HSDI. The delay of the hydrogen injection timing leads to a decrease in soot emission. The optimal HTDI strategy is obtained at the FIMF of 60%, which shows a 6.35% higher combustion efficiency and a 0.89% higher indicated thermal efficiency than the optimal HSDI.

Physics-based reduced-order modeling of flash-boiling sprays in the context of internal combustion engines

Flash-boiling injection is one of the most effective ways to accomplish improved atomization compared to the high-pressure injection strategy. The tiny droplets formed via flash-boiling lead to fast fuel–air mixing and can subsequently improve combustion performance in engines. While most of the previous studies related to the topic focused on modeling flash-boiling sprays using three-dimensional (3D) computational fluid dynamics (CFD) techniques such as direct numerical simulations (DNS), large-eddy simulations (LES), and Reynolds-averaged Navier–Stokes (RANS) simulations, the present work introduces a reduced-order cross-sectionally averaged spray (CAS) model with significantly reduced computational cost. The proposed CAS model incorporates several physical submodels in flash-boiling sprays such as those for air entrainment, drag, superheated droplet evaporation, flash-boiling induced breakup, and aerodynamic breakup models. The CAS model is then applied to different fuels to investigate macroscopic spray characteristics such as liquid and vapor penetration lengths under flash-boiling conditions. It is found that the newly developed CAS model captures the trends in global flash-boiling spray characteristics reasonably well for different operating conditions and fuels. Moreover, the CAS model is shown to be faster by up to four orders of magnitude compared with simulations of 3D flash-boiling sprays. The novelty of the present work lies in providing a reduced-order flash-boiling spray model that offers cost-effective computational representations of complex phenomena. The proposed model can be very valuable for applications, such as experimental design, fuel screening, and creating digital twins, thus playing a crucial role in the advancement of research and development in the field of spray combustion.

Synthesis of Al/B/graphite fluoride microspheres with enhanced energetic properties

Aluminum (Al) is one of the most widely used metal fuels in the fields of automotive airbags, solid propellants, explosives and pyrotechnics. Unfortunately, it is hard to meet further demand of practical applications owing to the comparatively low calorific value. Herein, graphite fluoride (CF) and boron (B) are employed to construct Al/B/CF microspheres through self-assembly in emulsion to obtain high energy density and significantly improved combustion performance resulted from synergistic reaction between Al and B reacted with fluorine. The Al/B/CF microspheres with pore structure have uniformly distribution of components and the average size range from 60 to 600 μm. Based on the experimental results, CF content and Al/B mass ratio have significant important effects on the combustion behavior and pressure output. The highest burning rate (301.74 m/s) and pressurization rate (77.78 MPa/s) are obtained for the Al/B/CF microspheres with CF content of 50 wt% and Al/B mass ratio of 3 to 1, respectively. Furthermore, the combustion reaction process of single Al/B/CF microsphere are studied for the first time to understand the synergistic reaction between high reactivity of Al and high energy of B reacted with fluorine. This work demonstrates that introducing CF and B to construct Al/B/CF microspheres is an efficient strategy to achieve high energy density and reactivity for the practical applications.

Preparation of microstructure controllable Al/WO3/F2603 MICs by droplet microfluidic technology to improve combustion performance

The microstructure of metastable intermolecular composites (MICs) is crucial for their energy release and combustion performance. In this paper, Al/WO3/F2603 composites with controllable microstructure were prepared by droplet microfluidic technology. The microstructure control method of composite materials based on droplet microfluidic technology (DMT) was studied. Particles with controllable size, shape, composition, structure and function were prepared by droplet template, and the formation mechanism of particle microstructure was introduced. The Al/W/F-2 composites with high-quality spherical encapsulation have excellent flow properties and wettability. The ignition delay, combustion time and pressure output of the composites were monitored by a combustion and pressure test system. Compared with the physically mixed samples, the Al/W/F-x composites prepared by DMT have shorter ignition delay, shorter combustion duration, and higher pressurization rate. The analysis of combustion products showed that the encapsulated Al/W/F-x composites reduced the sintering and agglomeration of reactants and promoted the combustion efficiency. The results show that the characteristic structure design of the composite material can establish the interface synergy, enhance the thermal mass transfer between the components, and thus reduce the ignition delay and improve the combustion performance. DMT can realize the controllable preparation of composite microstructure, which provides a reference for the design and preparation of other composite materials.