Fuel Oxygen Reduction Unit with Level Control
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Solution Overview
Problem
Gas turbine engines face issues with fuel coking due to high heat generation, which can lead to solid particle formation and system clogging, and existing methods do not effectively reduce oxygen levels in fuel to prevent this.
Innovation Solution
A fuel oxygen reduction unit comprising a contactor, separator, and level control device that mixes fuel with a stripping gas to reduce oxygen content, with a self-regulating level control device ensuring continuous fuel availability and preventing overflow or starvation.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Use of energy by moving object
If fuel is heated to increase combustion efficiency, then heat capacity utilization is improved, but fuel coking occurs leading to solid particle formation and system clogging
Solution Approach 1:
The patent applies preliminary action by reducing oxygen content in fuel before heating occurs. The oxygen reduction unit removes oxygen from fuel in advance, preventing the chemical reactions that would otherwise cause coking during subsequent heating and combustion processes. This proactive approach eliminates the harmful effect before it can manifest during high-temperature operation.
Solution Approach 2:
The patent changes the chemical composition parameter of the fuel by reducing oxygen content to below 10 ppm. This parameter change fundamentally alters the fuel's behavior under heat, preventing coking while maintaining combustibility. The modified fuel composition allows efficient heat utilization without the harmful side effects of solid particle formation.
2Reliability
If oxygen content in fuel is reduced to prevent coking, then fuel system reliability is improved, but fuel flow control becomes more complex
Solution Approach 1:
The level control device applies self-service by automatically maintaining the fuel/gas mixture level in the separator without external intervention. The device monitors and adjusts fuel flow to the contactor based on level feedback, ensuring continuous proper operation of the oxygen reduction unit. This self-regulating mechanism handles the complexity of flow control internally, preventing system shutdowns while maintaining reliable oxygen-reduced fuel supply.
Solution Approach 2:
The level control device implements feedback control by continuously monitoring the fuel/gas mixture level in the separator and adjusting the fuel flow accordingly. When the level drops, the device increases fuel flow to the contactor; when the level rises, it reduces flow. This closed-loop feedback ensures stable operation and maintains fuel system reliability without requiring complex manual control systems.
3Productivity
If fuel is continuously supplied to maintain engine operation, then engine productivity is maintained, but separator overflow or fuel starvation may occur
Solution Approach 1:
The level control device uses feedback control to balance fuel supply with engine demands. It continuously monitors separator level and dynamically adjusts fuel flow to the contactor, ensuring that fuel is supplied at the right rate to maintain continuous engine operation without causing separator overflow or fuel starvation. This maintains both productivity and reliability simultaneously.
Solution Approach 2:
The system applies dynamics by making the fuel flow rate adjustable and responsive to changing conditions. The level control device dynamically modifies fuel flow based on real-time separator level measurements, allowing the system to adapt to varying engine demands while maintaining stable operation. This dynamic control prevents both overflow and starvation conditions that would occur with fixed flow rates.
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 reduces oxygen levels in fuel, minimizing the risk of coking and ensuring consistent fuel delivery to the engine, thereby maintaining engine efficiency and preventing system clogging.
Implementation Method 1
a contactor (202) including a fuel inlet (250) that receives an inlet fuel flow (226) and a stripping gas inlet (252) that receives an inlet stripping gas flow (220), the contactor (202) configured to form a fuel/gas mixture (228)
Implementation Method 2
a separator (204) that receives the fuel/gas mixture (228)
Data Source
AI summary
A fuel oxygen reduction unit for an engine is provided. The fuel oxygen reduction unit includes a contactor including a fuel inlet that receives an inlet fuel flow and a stripping gas inlet that receives an inlet stripping gas flow, the contactor configured to form a fuel/gas mixture; a separator that receives the fuel/gas mixture, the fuel oxygen reduction unit defining a circulation gas flowpath from the separator to the contactor; and a level control device that controls a level of the fuel/gas mixture inside the separator by regulating the inlet fuel flow to the contactor.