Auxiliary Compressor for Intercooled Cooling Air
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Solution Overview
Problem
Current gas turbine engines face challenges in providing sufficient cooling air to high-pressure turbine sections due to the limitations of existing heat exchanger technologies, which struggle with high temperatures and pressures, especially as overall pressure ratios increase, leading to inefficiencies and potential material failures.
Innovation Solution
The implementation of a heat exchanger system with an auxiliary compressor unit that compresses cooled air from the main compressor section to a higher pressure, utilizing a unique flow path with radially outward and inward passes within a bypass duct, and an auxiliary compressor unit pressure ratio between 1.1 and 6.0 to effectively deliver cooling air to the turbine section.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If air from the downstream most end of the compressor is tapped and passed through a heat exchanger to cool it, then the cooling air temperature is reduced, but the pressure ratio across the cooling path becomes insufficient for high-pressure turbine sections
Solution Approach 1:
The compressor cooling air path is segmented into multiple stages: a first compressor section that provides initial compression, a heat exchanger for cooling, and a second compressor section that provides additional compression. This segmentation allows the system to achieve both cooling and high pressure ratio by dividing the compression function across separate components.
Solution Approach 2:
The heat exchanger acts as an intermediary component between the compressor sections, cooling the air while maintaining pressure, and the second compressor section acts as an intermediary to boost the pressure further. This chain of intermediary components enables the system to overcome the pressure-temperature trade-off.
2Productivity
If the overall pressure ratio of the engine is increased to improve performance, then engine efficiency is improved, but the requirements for cooling air pressure and temperature management become more difficult to satisfy
Solution Approach 1:
The multi-stage compression system with integrated heat exchanger serves multiple functions: it provides the necessary pressure ratio for high-performance operation, delivers cooled air to the turbine sections, and maintains flexible control over the cooling air parameters. This multi-functional design allows the system to meet diverse requirements without proportionally increasing complexity.
Solution Approach 2:
The system allows dynamic adjustment of the cooling air pressure and temperature by controlling the operation of the first and second compressor sections independently. This dynamic capability enables the system to adapt to varying engine performance requirements while maintaining effective cooling.
3Device complexity
If a single-stage compressor is used for cooling air compression, then the device complexity is reduced, but the maximum pressure ratio is limited and cannot meet high-pressure turbine section requirements
Solution Approach 1:
The compression function is segmented into a first compressor section and a second compressor section, with the heat exchanger positioned between them. This segmentation enables each compressor section to operate at optimized pressure ratios, achieving a higher overall pressure ratio than a single-stage compressor while keeping each individual component relatively simple.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This solution enhances cooling efficiency and allows for increased overall pressure ratios, improving engine performance and reducing the risk of material failure by effectively managing high temperatures and pressures within the turbine section.
Implementation Method 1
A heat exchanger is fluidly connected downstream of the tap... cooling air from the main compressor section... to be cooled by bypass air
Implementation Method 2
An auxiliary compressor unit is fluidly connected downstream of the heat exchanger... configured to compress air cooled by the heat exchanger... to a higher pressure
Data Source
AI summary
A gas turbine engine includes a main compressor. A tap is fluidly connected downstream of the main compressor. A heat exchanger is fluidly connected downstream of the tap. An auxiliary compressor unit is fluidly connected downstream of the heat exchanger. The auxiliary compressor unit is configured to compress air cooled by the heat exchanger with an overall auxiliary compressor unit pressure ratio between 1.1 and 6.0. An intercooling system for a gas turbine engine is also disclosed.