Dynamic Fuel Split Control for Gas Turbine Combustion
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Solution Overview
Problem
Existing combustion systems in gas turbine engines face challenges in controlling main and pilot fuel circuits for low power operation, emissions control, combustion stability, flameout/lean blowout protection, and fuel efficiency, particularly in determining optimal fuel flow ratios based on various engine conditions and criteria.
Innovation Solution
A method is introduced to determine and adjust the ratios of main fuel flow to pilot fuel flow based on a hierarchy of combustion criteria, including emissions limits, durability parameters, and acoustic considerations, using a fuel controller to prioritize and optimize fuel distribution across multiple ranges of ratios for different engine operating conditions.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Device complexity
If fixed pilot/main fuel splits are used, then the control system is simple, but emissions control and combustion stability are inadequate
Solution Approach 1:
The patent implements dynamic fuel split control where the pilot-to-main fuel ratio is continuously adjusted based on real-time engine operating conditions (power level, temperature, pressure) rather than using fixed ratios. This dynamic adaptation enables optimal emissions control and combustion stability across the entire operating range while maintaining manageable system complexity through automated sensor-feedback mechanisms.
Solution Approach 2:
The system changes the fuel flow parameters (pilot and main fuel flow rates) as a function of engine operating conditions. By varying these parameters dynamically based on sensed conditions, the system achieves superior emissions control and combustion stability compared to fixed splits, without requiring complex manual intervention.
2Device complexity
If fixed pilot/main fuel splits are used, then the control system is simple, but combustion stability and flameout protection are inadequate
Solution Approach 1:
The system dynamically adjusts the pilot fuel flow ratio based on real-time combustion conditions to maintain stable flame establishment and prevent blowout. During transient conditions or low-power operation, the controller increases pilot fuel proportion to ensure reliable combustion, automatically adapting to maintain stability without complex manual control.
Solution Approach 2:
The control system uses feedback from sensors monitoring combustion conditions (temperature, pressure, fuel flow) to continuously adjust the pilot/main fuel split. This closed-loop feedback ensures combustion stability and flameout protection by automatically correcting deviations from optimal combustion conditions.
3Device complexity
If fixed pilot/main fuel splits are used, then the control system is simple, but fuel efficiency is inadequate
Solution Approach 1:
The system optimizes fuel efficiency by dynamically changing the pilot and main fuel flow parameters based on engine load and operating conditions. At part-load conditions, the controller reduces overall fuel consumption by adjusting the fuel split ratios, while maintaining adequate combustion. This parameter optimization achieves superior fuel efficiency compared to fixed splits without requiring complex system architecture.
4Object-generated harmful factors
If dynamic fuel split control is implemented, then emissions control improves, but device complexity increases
Solution Approach 1:
The control system achieves multi-functionality by using a single dynamic fuel split control mechanism to simultaneously address emissions control, combustion stability, and fuel efficiency. This universal approach consolidates multiple control functions into one integrated system, reducing overall complexity compared to having separate control systems for each function.
5Loss of energy
If dynamic fuel split control is implemented, then fuel efficiency improves, but device complexity increases
Solution Approach 1:
The system achieves fuel efficiency optimization through dynamic parameter adjustment of fuel flow rates based on operating conditions. By automatically varying the pilot/main fuel split and total fuel flow to match actual engine demands, the system minimizes fuel consumption without requiring complex manual intervention or multiple separate control systems.
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 approach enhances low power operation, emissions control, combustion stability, and fuel efficiency, while protecting against flameout and lean blowout, and mitigates combustor damage and fuel nozzle coking, thereby improving overall engine performance and durability.
Implementation Method 1
fuel is burned to input heat to the engine cycle. Typical combustors incorporate one or more fuel injectors whose function is to introduce liquid fuel into an air flow stream so that it can atomize and burn
Implementation Method 2
fuel is burned to input heat to the engine cycle
Data Source
AI summary
A system and method for operating a combustion system comprising a fuel nozzle defining at least one main fuel circuit and at least one pilot fuel circuit is generally provided. The method includes determining an overall flow of fuel, the overall flow of fuel defining a sum total fuel through the main fuel circuit and the pilot fuel circuit; determining a plurality of ranges of ratios of main fuel flow through the main fuel circuit versus pilot fuel flow through the pilot circuit from the overall flow of fuel, wherein each range of ratios is based on a combustion criterion different from one another; determining a resultant range of ratios of main fuel flow versus pilot fuel flow based on a hierarchy of combustion criteria, wherein the hierarchy of combustion criteria provides a priority ranking of the combustion criterion; and flowing the overall flow of fuel to the main fuel circuit and the pilot fuel circuit based on the resultant range of ratios of main fuel flow versus pilot fuel flow.