Diffuser Fuel-Air Heat Exchanger for Gas Turbine Cooling
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Solution Overview
Problem
Current gas turbine engines face limitations in cooling internal components due to the inefficiency and weight increase caused by air-to-air heat exchangers used to cool the high-pressure compressor and turbine sections, which restrict the cooling capacity and efficiency.
Innovation Solution
A thermal energy exchange system is introduced, where a heat exchanger is positioned at the diffuser between the compressor and combustor, utilizing a fuel flow through a fuel nozzle to exchange thermal energy with cooling airflow, effectively cooling turbine components while increasing combustor efficiency and specific fuel consumption.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If air-to-air heat exchangers are used to cool the high pressure compressor and turbine section, then cooling is provided to these components, but weight and packaging volume increase and cooling efficiency decreases
Solution Approach 1:
The patent combines the cooling function with the existing fuel system by integrating a heat exchanger into the fuel flow path. The fuel acts as both a thermal energy carrier and a cooling medium, merging two functions (fuel delivery and cooling) into a single integrated system, thereby eliminating the need for separate air-to-air heat exchangers and reducing overall weight
Solution Approach 2:
The fuel flow serves dual purposes: it delivers thermal energy to the combustor while simultaneously acting as the cooling medium. The fuel absorbs excess heat from the high-pressure compressor and turbine sections, utilizing its own flow path and thermal capacity to provide cooling without requiring external cooling infrastructure
2Temperature
If air-to-air heat exchangers are used to cool the high pressure compressor and turbine section, then cooling is provided to these components, but device complexity increases
Solution Approach 1:
The cooling system is merged with the fuel delivery system, combining multiple functions (fuel transport, thermal energy transfer, and cooling) into a single integrated pathway. This eliminates the need for separate cooling loops, ducting, and control systems, thereby reducing device complexity
Solution Approach 2:
The fuel flow is given multiple functions: it serves as the working fluid for combustion, the cooling medium for heat exchange, and the thermal energy carrier between components. This multi-functionality eliminates the need for dedicated single-purpose systems, simplifying the overall device architecture
3Temperature
If air-to-air heat exchangers are used to cool the cooling air, then cooling capacity is provided, but the heat removed from the cooling air is lost to the cycle
Solution Approach 1:
The patent converts the previously wasted thermal energy into a useful resource by using it to preheat the fuel before combustion. The heat that would have been discarded to the atmosphere is now captured and transferred to the fuel, improving overall thermal efficiency and converting energy loss into energy gain
Solution Approach 2:
Instead of discarding the thermal energy removed from the cooling air, the system recovers it by transferring the heat to the fuel flow. This recovered thermal energy is then utilized in the combustor, transforming a waste stream into a valuable energy source and improving cycle efficiency
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 for turbine components, reduces weight and packaging volume, and improves overall engine performance by leveraging thermal energy exchange between cooling airflow and fuel flow, addressing the inefficiencies of traditional air-to-air heat exchangers.
Implementation Method 1
An airflow inlet directs a cooling airflow through the heat exchanger to reduce an airflow temperature via thermal energy exchange between the cooling airflow and the flow of fuel
Data Source
AI summary
A thermal energy exchange system for cooling air of a gas turbine engine includes a heat exchanger located at a diffuser of the gas turbine engine. The diffuser is positioned axially between a compressor and a combustor of the gas turbine engine. A fuel source is operably connected to the heat exchanger to direct a flow of fuel through the heat exchanger via a fuel pipe and toward a fuel nozzle of the combustor. An airflow inlet directs a cooling airflow through the heat exchanger to reduce an airflow temperature via thermal energy exchange between the cooling airflow and the flow of fuel. An airflow outlet directs the cooling airflow from the heat exchanger toward one or more of components of the turbine to cool the one or more components.