Fuel Coke Formation Control via Deoxygenation and Thermal Management
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Solution Overview
Problem
Coke formation in turbine engine fuel systems due to oxidation of liquid hydrocarbon fuel at high temperatures leads to clogging and maintenance issues, necessitating effective methods for determining and controlling coke formation rates.
Innovation Solution
A system comprising a controller that estimates coke formation rates and adjusts fuel system parameters, such as temperature and oxygen levels, using a thermal management system with heat exchangers and deoxygenation systems to manage coke formation, thereby extending maintenance intervals and ensuring system performance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Power
If liquid hydrocarbon fuel is stored and combusted at high temperatures, then engine power output is improved, but coke formation increases causing clogging and maintenance issues
Solution Approach 1:
The system performs preliminary deoxygenation of the liquid hydrocarbon fuel before combustion to remove dissolved oxygen that would otherwise cause coke formation during high-temperature combustion, thereby enabling sustained high power output without excessive coking
Solution Approach 2:
The system changes the chemical composition parameter of the fuel by controlling the oxygen content through deoxygenation processes, transforming the fuel from an oxygen-containing state (prone to coking) to a deoxygenated state (resistant to coking), thereby resolving the contradiction between power output and coke formation
2Productivity
If fuel temperature is increased to improve combustion efficiency, then combustion efficiency is improved, but coke formation rate increases
Solution Approach 1:
The system performs deoxygenation of the fuel before it enters the high-temperature combustion zone, removing the oxygen that would catalyze coke formation at elevated temperatures, thereby allowing high combustion efficiency without proportional increase in coke formation rate
Solution Approach 2:
The deoxygenation system acts as an intermediary process between fuel storage and combustion, removing dissolved oxygen and preventing the harmful interaction between oxygen and high-temperature fuel that would otherwise produce coke, thereby decoupling combustion efficiency from coke formation rate
3Productivity
If dissolved oxygen in fuel is increased to improve combustion, then combustion quality is improved, but oxidation and coke formation increase
Solution Approach 1:
The system precisely controls the oxygen content parameter in the fuel by adjusting deoxygenation levels, optimizing the balance between sufficient oxygen for complete combustion and excessive oxygen that causes oxidation and coking, thereby improving combustion quality while minimizing harmful effects
Solution Approach 2:
The system applies different oxygen content characteristics to different stages of fuel processing: maintaining adequate oxygen for combustion quality during the combustion phase while removing excess oxygen during storage and transport phases to prevent oxidation and coke formation
4Reliability
If fuel system components are cleaned frequently to prevent clogging, then system reliability is improved, but maintenance time and operational downtime increase
Solution Approach 1:
The system performs preliminary deoxygenation of fuel to prevent coke formation before it occurs, thereby reducing the frequency of maintenance interventions and extending operational intervals between cleanings, which improves reliability while reducing maintenance time loss
Solution Approach 2:
The system monitors coke formation rates and uses this feedback to dynamically adjust deoxygenation levels and operational parameters, preventing clogging before it occurs and enabling more efficient maintenance scheduling, thereby improving reliability with reduced operational downtime
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 regulates coke formation, reducing maintenance needs and maintaining engine efficiency by controlling fuel temperature and oxygen levels, thereby prolonging service intervals and preventing clogging.
Implementation Method 1
a thermal management system with heat exchangers and deoxygenation systems to manage coke formation
Implementation Method 2
The combination of liquid hydrocarbon fuel, which inherently includes dissolved oxygen, and high temperatures in the liquid fuel supply system causes oxidation and partial decomposition of the liquid fuel in the liquid fuel supply system and produces coke
Data Source
AI summary
Systems and methods are disclosed for estimating or determining a rate or an amount of fuel coke formation in a fuel system, such as of a gas turbine engine. The system is operable to control a rate of fuel coke formation. The system may include a sensor that measures an operating parameter associated with fuel coke formation in the fuel system. A controller is in communication with the sensor to receive the signal therefrom for determining an amount or a rate of fuel coking in the fuel system. Based on this determination the controller may adjust the rate of fuel coke formation by adjusting the operation of the turbine engine, a thermal management system of the turbine engine, or the fuel system.