Gas Turbine Fuel System Ice Prevention via Heat Exchanger
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Solution Overview
Problem
Gas turbine engine fuel systems face efficiency and operational issues due to ice formation from residual water in fuel at low ambient temperatures, which can reduce system performance and potentially block components.
Innovation Solution
A fuel system with a series of heat exchangers, including a fuel-to-fuel heat exchanger and a Fuel-to-Oil Heat Exchanger, is implemented to preheat the fuel, reducing the likelihood of ice formation, combined with a thermal and pressure bypass system to manage temperature and pressure fluctuations.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If traditional fuel heating systems are used to prevent ice formation, then ice prevention is achieved, but system weight and complexity increase
Solution Approach 1:
The patent combines the fuel heating function with the existing fuel metering unit and ejector pump system. The fuel-to-fuel heat exchanger is integrated into the fuel flow path, using a portion of the fuel itself as the heating medium. This merging eliminates the need for separate external heating systems, thereby preventing ice formation while reducing system complexity and weight.
Solution Approach 2:
The system uses a portion of the fuel flow itself as the heating medium in the heat exchanger. The fuel that would otherwise be burned is diverted to heat the main fuel flow, creating a self-contained heating system that requires no external energy source. This self-service approach prevents ice formation while minimizing additional system components.
2Reliability
If fuel is heated to prevent ice formation, then ice prevention is achieved, but energy loss increases
Solution Approach 1:
The patent converts what would be wasted fuel energy into a useful heating source. By diverting a portion of the fuel flow through the heat exchanger to warm the main fuel stream, the system transforms potential energy waste into a beneficial thermal source that prevents ice formation without requiring additional energy input.
Solution Approach 2:
Instead of discarding the thermal energy that would be lost in traditional systems, the patent recovers and utilizes this energy by routing fuel through the heat exchanger. The thermal energy that would otherwise be wasted is captured and used to prevent ice formation in the main fuel flow, reducing overall energy loss.
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 solution effectively prevents ice formation, enhances fuel system reliability, and extends operational temperature ranges, while being lightweight and less complex than traditional systems, with the ability to be retrofitted into existing systems.
Implementation Method 1
a first heat exchanger and a second heat exchanger disposed in serial flow communication within the main fuel line between the at least one pump and the fuel metering unit... the first heat exchanger being a fuel-to-fuel heat exchanger providing heat transfer communication between the main fuel line and the motive flow line
Data Source
AI summary
A gas turbine fuel system including a main fuel line providing fuel flow from a fuel tank to a combustor, and at least one pump, including an ejector pump, pumping fuel from the fuel tank to the combustor via a fuel metering unit. The fuel metering unit directs a portion of the fuel into a motive flow line which returns a portion of the fuel to the ejector pump. First and second heat exchangers are disposed in serial flow communication within the main fuel line between the pump and the fuel metering unit. The first heat exchanger is a fuel-to-fuel heat exchanger.