Fuel Air Heat Exchanger Integration in Gas Turbine Plenum
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Solution Overview
Problem
Gas turbine engines face inefficiencies due to high turbine inlet gas temperatures, which require increased cooling of turbine components, and existing heat exchangers are heavy and costly due to the need for high-pressure casings and ducts to circulate pressurized air.
Innovation Solution
A heat exchanger is positioned within the high-pressure plenum of a gas turbine engine, using annular ducts with perforated baffles and concentric fuel conduits to facilitate heat exchange between fuel and compressed air, reducing the need for high-pressure casings and minimizing weight by using lightweight materials for air conduits.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If fuel is put into heat exchange relationship with pressurized air from the combustor to cool the turbine components, then cooling efficiency is improved, but weight increases due to high pressure casing and heavy air ducts
Solution Approach 1:
The invention extracts the heat exchange function from a separate high-pressure casing system and integrates it directly into the combustor structure. The combustor walls and internal structures serve dual purposes: combustion chamber and heat exchanger, eliminating the need for separate high-pressure casings and heavy air ducts while maintaining effective cooling of turbine components
Solution Approach 2:
The invention merges the combustor and heat exchanger into a single integrated structure. The combustor housing serves as the heat exchanger housing, and combustion gases directly heat the fuel while cooling the turbine components, combining multiple functions into one compact system that reduces overall weight
2Ease of operation
If a heat exchanger is located outside the engine casing, then accessibility is improved, but device complexity increases due to required high pressure casing and air ducts
Solution Approach 1:
The invention combines the heat exchanger with the combustor assembly, which is already an integral part of the engine casing. This integration eliminates the need for separate high-pressure casings and complex air ducting systems, reducing overall device complexity while maintaining accessibility for maintenance and operation
3Productivity
If higher turbine inlet gas temperatures are used, then engine efficiency is improved, but cooling requirements increase
Solution Approach 1:
The invention converts the hot combustion gases, which would otherwise be waste heat, into a useful cooling medium. The combustion gases flow through the heat exchanger to cool the turbine components, transforming what would be thermal energy loss into an effective cooling mechanism that enables higher turbine inlet temperatures without excessive cooling energy requirements
Solution Approach 2:
The system uses its own combustion gases to provide the cooling function. The hot gases generated during combustion directly cool the turbine components through the heat exchanger, creating a self-sufficient cooling system that doesn't require additional external cooling resources
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 cooling efficiency while reducing the weight and potential fire hazards of the heat exchanger, allowing for effective temperature control and leak detection, thus improving engine performance and safety.
Implementation Method 1
fuel is put into heat exchange relationship with the pressurized air from the combustor to heat the fuel before combustion and cool the pressurized air surrounding the high pressure turbine
Data Source
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AI summary
A gas turbine engine (10) with a fuel air heat exchanger (22) located in the high pressure plenum (20). The heat exchanger (22) includes at least one air conduit (34a,34b) and at least one fuel conduit (36) in heat exchange relationship with one another, with a fuel flow communication between a fuel source and fuel distribution members of the combustor (16) being provided at least partly through the at least one fuel conduit (36), and the at least one air conduit (34a,34b) defining a fluid flow communication between the high pressure plenum (20) and an engine component to be cooled by the compressed air.