Combustor Wall Element with Segmented Cooling Channels
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Solution Overview
Problem
Current combustor wall elements require significant coolant consumption and complex manufacturing processes, which can lead to inefficient cooling and increased costs, while also facing challenges in maintaining uniform temperature distribution and reducing thermally induced stresses.
Innovation Solution
A combustor wall element design featuring a duct with cooling channels that utilize counterflow coolant distribution and a fuel supply system with strategically positioned fuel discharge conduits, combined with additive manufacturing methods like Selective Laser Melting, to enhance cooling efficiency and reduce manufacturing complexity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Loss of energy
If conventional cooling systems are used in combustor wall elements, then cooling coverage is provided, but coolant consumption is high and cooling uniformity is poor
Solution Approach 1:
The cooling system is segmented into multiple cooling channels with different flow directions (inward, outward, and axial flows) that divide the cooling task into distinct zones. This segmentation allows each channel to target specific thermal zones independently, improving overall cooling uniformity while optimizing coolant distribution efficiency
Solution Approach 2:
Different regions of the combustor wall are provided with tailored cooling characteristics through specifically designed cooling channels. The inward cooling channels address the front surface thermal load, outward channels handle the rear surface, and axial channels manage side wall temperatures, creating locally optimized cooling quality that reduces total coolant consumption while maintaining uniformity
2Manufacturing precision
If complex manufacturing processes are used for combustor wall elements with cooling channels, then precise cooling channel geometry can be achieved, but manufacturing complexity and cost increase
Solution Approach 1:
The combustor wall element is designed as an integrally formed single piece that combines the wall structure, swirl generator, fuel supply system, and cooling channels into one unified component. This merging eliminates the need for separate manufacturing and assembly steps for these subsystems, significantly reducing manufacturing process complexity while maintaining precise geometric control through additive manufacturing
Solution Approach 2:
Traditional mechanical manufacturing methods (machining, drilling, assembling) are replaced with additive manufacturing technology that directly builds the complex cooling channel geometries and integrated structure layer by layer. This substitution enables precise geometric control of intricate cooling passages without the complexity of conventional multi-step mechanical manufacturing processes
3Duration of action of stationary object
If thermally induced stresses are not addressed, then manufacturing is simpler, but cyclic lifetime is reduced
Solution Approach 1:
The cooling system parameters are optimized to achieve uniform temperature distribution across the combustor wall, which directly reduces thermally induced stresses. By controlling the coolant flow distribution and cooling intensity in different zones, the temperature gradients are minimized, extending cyclic lifetime without requiring complex stress relief structures
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 design achieves efficient and uniform cooling, reduces coolant consumption, and minimizes thermally induced stresses, thereby extending the cyclic lifetime of the combustor wall element while simplifying the manufacturing process.
Implementation Method 1
at least one cooling channel provided inside the wall extends between a first open end and a second open end
Implementation Method 2
counterflow coolant distribution and a fuel supply system with strategically positioned fuel discharge conduits, combined with additive manufacturing methods like Selective Laser Melting, to enhance cooling efficiency and reduce manufacturing complexity
Implementation Method 3
additive manufacturing methods like Selective Laser Melting
Data Source
Figure 1~2
Figure 3~4
Figure 5~6
AI summary
Disclosed is a combustor wall element (1). The combustor wall element comprises a wall (11), the wall comprising a front surface (12) and a back surface (13). The front surface is provided on a front side (14) of the wall and the back surface is provided on a back side (15) of the wall. A through opening (2) penetrates the wall from the front surface to the back surface. A duct (21) is provided extending from the back surface and to a back end of the combustor wall element, and said duct (21) is in fluid communication with the through opening (2). At least one cooling channel (6, 6i, 6ii) is provided inside the wall, wherein said cooling channel extends between a first open end (61) and a second open end (62). At least a section of the cooling channel (6, 6i, 6ii) extends at least essentially parallel to the front surface (12).