Gas Turbine Fuel Heating System for Ice Crystal Removal
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Solution Overview
Problem
Gas turbine engines face performance degradation and potential engine stall due to ice crystal formation in fuel lines, which existing heat exchanger systems are slow to address, especially at high altitudes where they may not generate sufficient heat to melt ice crystals promptly.
Innovation Solution
A fuel heating system that utilizes compressed air heated by exhaust gas to rapidly melt ice crystals in the fuel lines, eliminating the need for engine oil heating and reducing wait times for ice removal, incorporating a dual-fluid plate-fin heat exchanger and a mechanically driven fan to enhance heat transfer.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If a heat exchanger using engine oil is used to remove ice crystals, then ice removal function is provided, but the response time is delayed due to oil heating time
Solution Approach 1:
The system pre-heats fuel using engine oil during normal operation before ice crystal formation occurs. This preliminary heating action ensures that when ice crystals do form, the fuel is already at a temperature that prevents or quickly melts the ice, eliminating the delay associated with heating oil on demand.
Solution Approach 2:
The heat exchanger continuously transfers heat from engine oil to fuel during engine operation, maintaining a continuous heating action rather than intermittent heating. This continuous thermal energy transfer ensures the fuel temperature remains consistently above the ice crystal formation point, providing uninterrupted ice prevention.
2Reliability
If a heat exchanger using engine oil is used to remove ice crystals, then ice removal function is provided, but at high altitude conditions adequate heat cannot be extracted to melt the ice
Solution Approach 1:
The system maintains fuel temperature above freezing point through continuous pre-heating during normal operation, preventing ice crystal formation before high altitude conditions are encountered. This preliminary thermal preparation ensures the fuel is already in a liquid state when altitude changes occur, eliminating the problem of insufficient heat extraction at high altitudes.
Solution Approach 2:
The engine oil serves dual purposes: it cools engine bearings and simultaneously heats the fuel to prevent ice crystal formation. This self-service approach uses the oil's thermal energy that would otherwise be wasted, creating a self-sustaining thermal management system that operates effectively across varying altitude conditions without requiring additional energy input.
3Reliability
If last-chance screens are used to remove ice crystals, then ice crystal removal is provided, but the screens must be periodically cleared to prevent blockage
Solution Approach 1:
The system extracts and removes ice crystals from the fuel through continuous thermal processing in the heat exchanger, preventing them from reaching the last-chance screens. By taking out the ice crystal removal function upstream through heating, the screens remain clear and do not require periodic manual clearing, eliminating the maintenance burden.
Solution Approach 2:
The heat exchanger performs preliminary ice crystal removal through continuous heating before the fuel reaches the last-chance screens. This preliminary action prevents ice crystals from accumulating on the screens, thereby eliminating the need for periodic screen clearing and maintenance interventions.
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 solution ensures immediate and efficient melting of ice crystals, preventing blockages and enhancing engine performance and safety by utilizing readily available heat from exhaust gases, thus improving operational efficiency and reliability.
Implementation Method 1
A fuel heating system that utilizes compressed air heated by exhaust gas to rapidly melt ice crystals in the fuel lines
Implementation Method 2
incorporating a dual-fluid plate-fin heat exchanger and a mechanically driven fan to enhance heat transfer
Implementation Method 3
incorporating a dual-fluid plate-fin heat exchanger and a mechanically driven fan to enhance heat transfer
Data Source
Figure 1
AI summary
A fuel heating system for a gas turbine engine comprises a first heat exchanger, a second heat exchanger, a fuel pump and a valve. The first heat exchanger produces a heated air flow. The second heat exchanger receives the heated air flow from the first heat exchanger. The fuel pump provides a fuel flow. The valve is coupled to the fuel pump to intermittently include the second heat exchanger in the fuel flow based on a temperature of the fuel flow. A method of heating fuel in a gas turbine engine comprises providing fuel to a gas turbine engine with a fuel pump to sustain a combustion process, heating a flow of air with exhaust gas from the combustion process, and heating fuel from the fuel pump en route to the gas turbine engine with the flow of air based on a temperature of the fuel.