Fuel-Cracking Catalyst for Gas Turbine Engine Heat Exchangers
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Solution Overview
Problem
Traditional fuel cooling methods in gas turbine engines face limitations above 350 °F due to coke deposit formation, which interferes with fuel flow and heat transfer, and fail to provide sufficient cooling capacity at supercritical temperatures near or above 850 °F, especially in hypersonic aircraft.
Innovation Solution
Incorporating a bi-functional fuel-cracking catalyst with a protonated solid acid support and transition metals like platinum, nickel, or copper in a heat exchanger to enhance fuel endothermicity and reduce coke formation at high temperatures, allowing for increased fuel cooling capacity and efficiency.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If traditional fuel cooling methods are used above 350 °F, then fuel flow and heat transfer are maintained, but coke deposits form that interfere with fuel flow and heat transfer
Solution Approach 1:
An oxygen scavenger compound is introduced as an intermediary substance that reacts with dissolved oxygen in the fuel before pyrolysis can occur. This mediator prevents the harmful oxidation reactions that lead to coke formation, allowing the fuel to be cooled to lower temperatures without deposit formation
Solution Approach 2:
The invention changes the chemical composition parameters of the fuel by adding oxygen scavenger compounds. This modification alters the fuel's reactivity characteristics, suppressing the oxidation reactions that normally occur between 350-850 °F and preventing coke deposit formation
2Temperature
If traditional fuel cooling methods are used above 850 °F, then fuel cooling capacity is maintained, but pyrolytic coke formation increases exponentially
Solution Approach 1:
The oxygen scavenger compound acts as a protective intermediary that eliminates oxygen from the fuel system. Since pyrolytic coke formation is suppressed by removing oxygen, the fuel can be cooled to higher temperatures without exponential increases in harmful deposit formation
Solution Approach 2:
By modifying the fuel's chemical composition with oxygen scavengers, the invention changes the temperature-dependent reaction kinetics. This parameter change suppresses the exponentially increasing pyrolytic coke formation that normally occurs above 850 °F
3Object-generated harmful factors
If oxygen concentration is lowered to mitigate autoxidative coking, then coke formation is reduced, but fuel cooling capacity is insufficient for supercritical conditions
Solution Approach 1:
The invention introduces oxygen scavenger compounds that chemically remove dissolved oxygen from the fuel. This parameter change in oxygen concentration prevents autoxidative coking while simultaneously enabling the fuel to absorb more heat through suppressed side reactions, thereby increasing cooling capacity for supercritical conditions
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 catalyst effectively increases fuel cooling capacity and reduces coke formation, enabling efficient heat transfer and engine operation at high temperatures without coking, thus enhancing engine efficiency and performance.
Implementation Method 1
the fuel heat sink is augmented by the onset of endothermic fuel cracking reactions, which both absorb heat with increasing temperature
Implementation Method 2
The cracked products are dehydrogenated compounds that have a greater endothermicity than the original fuel
Implementation Method 3
a heat exchanger (e.g. as described herein) in the turbine section or downstream of the nozzle section
Data Source
Figure 1~5
AI summary
A gas turbine engine includes a combustor, a turbine section downstream of the combustor, a nozzle section downstream of the turbine section, a heat exchanger in the turbine section, in the nozzle section, or downstream of the nozzle section, and a fuel supply line for conveying fuel through the heat exchanger and to the combustor. The heat exchanger includes a fuel-cracking catalyst that has a protonated solid acid support and one or more transition metals that includes at least platinum.