Dual Combustor Gas Turbine Fuel Control for Efficiency
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Solution Overview
Problem
Gas turbine engine combustion systems face challenges in efficiently managing power across various flight conditions, leading to the production of unwanted combustion by-products due to the limitations of single fuel injector systems in optimizing for all flight phases.
Innovation Solution
A dual combustion system with a secondary annular combustor and primary annular combustor, each with dedicated fuel injectors, controlled by an electronic control unit to selectively activate and modulate fuel delivery based on power requirements, allowing the secondary combustor to assist the primary combustor for higher power conditions.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If a single fuel injector system is used to provide power for various flight conditions, then the device complexity is reduced, but the combustion efficiency deteriorates and unwanted by-products are produced
Solution Approach 1:
The fuel injector system is segmented into a primary fuel injector and a secondary fuel injector, each optimized for different power conditions. The primary fuel injector handles low to medium power requirements, while the secondary fuel injector activates for high power conditions, allowing each component to operate in its optimal range and improve overall combustion efficiency.
Solution Approach 2:
The system dynamically switches between primary and secondary fuel injectors based on real-time power requirements. The electronic control unit monitors flight conditions and activates the secondary fuel injector when high power is needed, creating a dynamic adaptation that optimizes combustion efficiency across varying operational demands.
2Power
If a single fuel injector system operates at maximum fuel delivery for all conditions, then the power requirement is met for high power conditions, but unwanted combustion by-products increase and energy is wasted during low power conditions
Solution Approach 1:
The fuel delivery function is segmented between primary and secondary injectors, with the primary injector handling low to medium power demands and the secondary injector providing additional fuel capacity for high power conditions. This segmentation prevents over-fueling during low power operations while maintaining sufficient power delivery capability when needed.
Solution Approach 2:
The system changes the operational parameters by switching between different fuel injector configurations based on power requirements. During low power conditions, only the primary injector operates at optimized fuel flow rates. During high power conditions, the secondary injector activates to increase total fuel delivery, dynamically adjusting the system's fuel delivery parameter to match demand.
3Quantity of substance
If the secondary fuel injector is activated for high power conditions, then the fuel amount requirement is met, but the device complexity increases
Solution Approach 1:
The combustion system is segmented into primary and secondary combustors with dedicated fuel injectors. This segmentation allows the system to meet high fuel amount requirements by activating only the necessary components, rather than requiring a single oversized system that would be unnecessarily complex for low power conditions.
Solution Approach 2:
The primary fuel injector is designed with multi-functionality, serving as the sole fuel source during low to medium power conditions and working in conjunction with the secondary fuel injector during high power conditions. This universal design reduces overall system complexity by having one component that can operate independently or in combination with another.
4Power
If fuel injectors are optimized for high power conditions, then the maximum fuel amount is delivered, but the combustion efficiency deteriorates during low power conditions producing unwanted by-products
Solution Approach 1:
The system segments the fuel delivery function into primary and secondary injectors, allowing the primary injector to be optimized for low to medium power combustion efficiency while the secondary injector provides the additional capacity needed for maximum power output. Each injector can be independently optimized for its specific operational range.
Solution Approach 2:
Different parts of the fuel delivery system have different local qualities optimized for different conditions. The primary fuel injector is designed with characteristics optimized for efficient combustion at lower fuel flow rates, while the secondary fuel injector is designed to supplement during high power conditions, creating local optimization throughout the system.
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 configuration enhances combustion efficiency, reduces unwanted by-products, and stabilizes the flame by optimizing each combustor for its respective power regime, enabling efficient power delivery across a range of flight conditions while minimizing environmental hazards.
Implementation Method 1
a combustion system comprising: a secondary annular combustor and a primary annular combustor in fluid communication with the secondary combustor and converging thereto; a secondary fuel injector associated with the secondary annular combustor; a primary fuel injector associated with the primary annular combustor
Data Source
AI summary
A gas turbine engine comprises a combustion system comprising a secondary annular combustor and a primary combustor in fluid communication with the secondary combustor, a secondary fuel injector associated with the secondary combustor, a primary fuel injector associated with the primary combustor, and a ECU controlling fuel delivery to the secondary and primary fuel injectors. The primary fuel injector delivers fuel to the primary combustor. The ECU allows fuel to be delivered to the secondary fuel injector in addition to the primary fuel injector only when a fuel amount higher is requested delivered by the primary fuel injector. A method of operating a gas turbine engine is also presented.