Dry Fog Nozzle Agglomeration for Gas Turbine Particle Separation

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Solution Overview

Problem

Gas turbine engines operating in environments with fine sand and dust particles, such as deserts, face ingestion issues due to the small particle size, which reduces cooling effectiveness and leads to increased maintenance needs.

Innovation Solution

A dry fog inlet particle separator system that uses a separator manifold with external dry fog nozzles to agglomerate fine particles with a spray of dry fog, creating larger particles that can be separated from the airflow using a scavenging system, thereby reducing the ingestion of fine sand and dust into the gas turbine engine.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Adaptability or versatility

If fine sand and dust particles are present in atmospheric air, then the gas turbine engine can operate in desert environments, but the particles are ingested by the turbine and accumulate in cooling circuits, reducing cooling effectiveness

Engineering Contradiction:

Improveability to operate in desert environmentsVSAvoidcooling effectiveness of turbine

Core Design Contradiction:

Adaptability or versatilityVSReliability

Solution Approach 1:

The dry fog nozzles inject fog droplets into the airflow upstream of the turbine inlet, before the particles can be ingested. This preliminary action allows particles to agglomerate with droplets and be removed by the scavenging system, preventing them from entering the turbine and accumulating in cooling circuits

Inventive Principle:

Principle #10Preliminary action

Solution Approach 2:

Dry fog droplets serve as an intermediary substance between the atmospheric air and the turbine. The droplets agglomerate with fine particles, making them larger and easier to remove, while the scavenging system removes the particle-droplet aggregates, preventing direct contact between particles and the turbine

Inventive Principle:

Principle #24Intermediary (Mediator)

2Reliability

If dry fog nozzles are used to agglomerate fine particles, then particle ingestion is reduced, but liquid may enter the gas turbine engine

Engineering Contradiction:

Improvereduction of particle ingestionVSAvoidliquid entry into engine

Core Design Contradiction:

ReliabilityVSObject-affected harmful factors

Solution Approach 1:

The system uses dry fog with specifically controlled droplet sizes (1-10 micrometers) and low liquid content. By changing the parameter of droplet size and using pressurized air to atomize water into fine mist, the system achieves particle agglomeration while minimizing liquid volume that could harm the engine

Inventive Principle:

Principle #35Parameter changes

Solution Approach 2:

Pressurized air is used to atomize water into dry fog and to transport the fog through tubing to the nozzle. The pneumatic system enables precise control of droplet generation and delivery, creating a dry fog that can agglomerate particles without introducing excessive liquid into the engine

Inventive Principle:

Principle #29Pneumatics and hydraulics

3Reliability

If a scavenging system is added to remove agglomerated particles, then particle ingestion is reduced, but device complexity increases

Engineering Contradiction:

Improveparticle separation efficiencyVSAvoidsystem complexity

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The scavenging system is designed to perform multiple functions: it removes agglomerated particles from the airflow, and the removed particles can be disposed of or analyzed. The system integrates with the existing air intake structure, using the airflow itself to transport particles to the removal location, reducing the need for additional complex components

Inventive Principle:

Principle #6Universality (Multi-functionality)

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 effectively reduces the ingestion of fine particles by up to 84% into the gas turbine engine, prolonging its operational life and reducing maintenance, while minimizing liquid entry into the engine.

Implementation Method 1

direct a spray of dry fog in a direction transverse to the incoming airflow to agglomerate with fine particles in the incoming airflow to form agglomerated particles

Methodology Applied

Scientific EffectAgglomeration: Coagulation

Implementation Method 2

a scavenging system coupled to the separator manifold downstream from the manifold inlet, and the scavenging system removes the agglomerated particles from the separator manifold

Methodology Applied

Scientific EffectParticle separation: Cyclone Separation

Data Source

PatentUS11261788B2Systems and methods for dry fog inlet particle separator

Publication Date: 2022.03.01 HONEYWELL INTERNATIONAL INC

AI summary

An inlet particle separator system for a gas turbine engine includes a separator manifold. The separator manifold includes an inlet upstream from an outlet. The inlet is to receive an incoming airflow, and the outlet is to be fluidly coupled to an inlet of the gas turbine engine. The inlet particle separator system includes at least one dry fog nozzle coupled proximate the inlet so as to face at least partially away from the inlet. The dry fog nozzle is external to the separator manifold, and the dry fog nozzle is to direct a spray of dry fog in a direction transverse to the incoming airflow to agglomerate with fine particles in the incoming airflow to form agglomerated particles. The inlet particle separator system includes a scavenging system coupled to the separator manifold downstream from the inlet, and the scavenging system removes the agglomerated particles from the separator manifold.