Catalyst-Coated Heat Exchanger for Gas Turbine Engine Cooling

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Solution Overview

Problem

Aircraft components, particularly those in gas turbine engines, face excessive heat during high-speed flight, leading to temperature issues that exceed structural and operational capabilities, necessitating expensive materials and operational changes.

Innovation Solution

A gas turbine engine system incorporating a heat exchanger with a catalyst-coated surface, utilizing hydrocarbon fuel and oxygen to crack hydrocarbons endothermically, effectively reducing heat through hydrocarbon cracking and reforming fuel for improved propulsive efficiency.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Temperature

If expensive or exotic materials are used to withstand high temperatures, then structural and operational capabilities are maintained, but cost increases significantly

Engineering Contradiction:

Improvecomponent temperature capabilityVSAvoidmanufacturing cost

Core Design Contradiction:

TemperatureVSEase of manufacture

Solution Approach 1:

The invention converts the harmful heat that threatens component integrity into a beneficial resource by using it to drive endothermic hydrocarbon cracking reactions in the heat exchanger, thereby cooling the air while producing valuable reformed fuel

Inventive Principle:

Principle #22Blessing in disguise (Convert harm into benefit)

Solution Approach 2:

The invention changes the thermal parameters of the air stream by introducing endothermic reactions that absorb heat, transforming the temperature profile from a harmful condition into a controlled process parameter that produces both cooling and chemical conversion

Inventive Principle:

Principle #35Parameter changes

2Reliability

If operating characteristics are changed to withstand heat, then component reliability is maintained, but propulsive efficiency decreases

Engineering Contradiction:

Improvecomponent reliability under heatVSAvoidpropulsive efficiency

Core Design Contradiction:

ReliabilityVSProductivity

Solution Approach 1:

The invention converts the harmful thermal environment into a beneficial chemical processing opportunity, using the heat to drive fuel reforming reactions that improve overall system efficiency rather than merely surviving the thermal conditions

Inventive Principle:

Principle #22Blessing in disguise (Convert harm into benefit)

Solution Approach 2:

The system uses its own operational heat output to drive the cracking and reforming processes, making the heat management system self-powered and eliminating the need for separate cooling energy inputs

Inventive Principle:

Principle #25Self-service

3Temperature

If heat is removed from aircraft components, then temperature control is achieved, but energy is lost

Engineering Contradiction:

Improvecomponent temperature controlVSAvoidheat energy loss

Core Design Contradiction:

TemperatureVSLoss of energy

Solution Approach 1:

The invention transforms waste heat that would otherwise be lost into a valuable resource by using it to drive endothermic cracking reactions, simultaneously achieving cooling and producing reformed fuel with higher efficiency

Inventive Principle:

Principle #22Blessing in disguise (Convert harm into benefit)

Solution Approach 2:

The system recovers energy that would normally be discarded by capturing the thermal energy in the air stream and converting it into chemical energy through hydrocarbon cracking and reforming processes

Inventive Principle:

Principle #34Discarding and recovering

4Temperature

If conventional cooling systems are used, then heat removal is achieved, but system complexity and cost increase

Engineering Contradiction:

Improveheat removal capabilityVSAvoidcooling system complexity

Core Design Contradiction:

TemperatureVSDevice complexity

Solution Approach 1:

The heat exchanger performs multiple functions simultaneously: it cools the incoming air, drives endothermic cracking reactions, and produces reformed fuel, eliminating the need for separate cooling and fuel processing systems

Inventive Principle:

Principle #6Universality (Multi-functionality)

Solution Approach 2:

The invention merges the cooling function with the fuel processing function into a single integrated heat exchanger system, reducing overall system complexity while achieving both objectives

Inventive Principle:

Principle #5Merging (Combining)

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

The system reliably and durably removes heat from aircraft components, capturing heat energy to enhance propulsive efficiency and reduce material costs by using the reformed fuel for propulsion.

Implementation Method 1

crack hydrocarbons endothermically, effectively reducing heat through hydrocarbon cracking

Methodology Applied

Scientific EffectEndothermic reaction: Endothermic Reaction

Implementation Method 2

an internal surface coated with a catalyst, the heat exchanger being located upstream of the compressor

Methodology Applied

Scientific EffectCatalysis: Catalysis

Data Source

PatentUS11674442B2Gas turbine engine and method of operating

Publication Date: 2023.06.13 GENERAL ELECTRIC CO

AI summary

A gas turbine engine includes; a compressor, a combustor, and a turbine in serial flow relationship; a heat exchanger, the heat exchanger having an inlet, an outlet, and an internal surface coated with a catalyst, the heat exchanger being located upstream of the compressor; a source of hydrocarbon fuel in fluid communication with the inlet of the heat exchanger; a source of oxygen in fluid communication with the inlet of the heat exchanger; and a distribution system for receiving reformed hydrocarbon fuel from the heat exchanger.