Gas Turbine Injector Assembly Reducing Pressure Loss
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Solution Overview
Problem
Gas turbine engines face challenges in reducing NOx emissions due to high residence time and pressure loss in combustion systems, and traditional manufacturing techniques are inadequate for producing complex geometries and miniaturized features required for efficient combustor components.
Innovation Solution
The integration of a distributed combustion system with advanced ducting arrangements and the use of 3D Printing/Additive Manufacturing technologies to create injector assemblies that reduce pressure loss and enhance mixing of reactants with combustion gases, featuring flow-accelerating structures and optimized injection angles, and the manufacturing of complex geometries and miniaturized features using techniques like laser sintering and selective laser melting.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Object-affected harmful factors
If traditional combustion systems are used in gas turbine engines, then the combustion process is simple to implement, but NOx emissions increase due to high residence time
Solution Approach 1:
The combustion system is divided into multiple combustion zones with separate injector assemblies, allowing fuel to be injected at different locations and timings. This segmentation enables reduced residence time in each zone while maintaining overall combustion efficiency, thereby reducing NOx emissions.
Solution Approach 2:
The injector assemblies incorporate movable or adjustable components that can dynamically control fuel injection timing and distribution. This dynamic control optimizes the combustion process to minimize residence time and NOx formation while adapting to varying operating conditions.
2Loss of energy
If complex ducting arrangements and flow-accelerating structures are implemented, then pressure loss is reduced and mixing is enhanced, but device complexity increases
Solution Approach 1:
Multiple functions are merged into the injector assembly design, combining fuel injection, flow acceleration, and mixing enhancement features into a single integrated component. This reduces the need for separate ducting arrangements while achieving the desired pressure loss reduction and mixing performance.
Solution Approach 2:
The injector assembly is designed as a multi-functional component that performs injection, flow conditioning, and mixing tasks simultaneously. This universal design simplifies the overall system by eliminating the need for additional specialized components.
3Manufacturing precision
If 3D Printing/Additive Manufacturing is used to create injector assemblies with complex geometries, then manufacturing precision and feature miniaturization are improved, but manufacturing cost and process complexity increase
Solution Approach 1:
The design leverages the capabilities of additive manufacturing by incorporating geometries and features that are specifically optimized for this manufacturing process. By changing the design parameters to match the strengths of 3D printing, high precision complex geometries can be manufactured efficiently.
Solution Approach 2:
The complex internal geometries and miniaturized features are directly created through digital modeling and additive manufacturing processes, eliminating the need for traditional tooling and multiple manufacturing steps. The digital model serves as the master copy that directly guides the manufacturing process.
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 approach effectively reduces NOx emissions and maintains low pressure loss while achieving efficient mixing, enabling stable operation at high turbine inlet temperatures with reduced cooling air consumption and improved manufacturing efficiency.
Implementation Method 1
manufacturing of complex geometries and miniaturized features using techniques like laser sintering and selective laser melting
Implementation Method 2
manufacturing of complex geometries and miniaturized features using techniques like laser sintering and selective laser melting
Implementation Method 3
enhance mixing of reactants with combustion gases
Data Source
Figure 1~2
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Figure 5~6
AI summary
Injector assembly and ducting arrangement including such assemblies for a combustor system in a gas turbine engine are provided. A reactant-guiding structure (42) may be configured to define a curvilinear flow path (47) to route a flow of reactants from a first flow direction (50) to a second flow direction (52) toward a cross-flow of combustion gases (60). A cross-flow guiding structure (54) may further define a flow path (58) to route a portion of the cross-flow of combustion gases toward an outlet side of the cross-flow guiding structure. Disclosed injector assemblies can be configured to reduce pressure loss while providing an effective level of mixing of the injected reactants with the passing cross-flow. Respective injector assemblies or the entire ducting arrangement may be formed as a unitized structure, such as a single piece using a rapid manufacturing technology, such as 3D Printing/Additive Manufacturing (AM) technology.