Intercooled Cooling Air Gas Turbine Engine
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Solution Overview
Problem
Current gas turbine engine cooling systems face challenges in efficiently providing cooling air to high-pressure turbine sections due to limitations in heat exchanger technology, particularly at elevated temperatures and pressures exceeding 1350°F (732°C), which can lead to increased energy requirements and component stress.
Innovation Solution
A system that includes a mixer downstream of the cooling compressor to combine air from a second tap with air from the high-pressure feed, allowing for selective modulation of airflow through a valve assembly, which can bypass the heat exchanger or connect directly to the compressor section, and positions the heat exchanger in a bypass duct or pylon for efficient cooling, utilizing existing heat exchanger technology to reduce the need for additional components.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of operation
If air is tapped from the downstream most end of the compressor section for cooling, then the cooling air is readily available, but the air temperature is elevated which increases energy requirements and component stress
Solution Approach 1:
The compressor discharge is segmented into multiple taps at different locations. The system uses taps from intermediate compressor stages rather than solely from the downstream most end, allowing selection of cooler air sources while maintaining adequate pressure for cooling functions
Solution Approach 2:
A heat exchanger is introduced as an intermediary component between the compressor discharge and the turbine cooling system. The heat exchanger reduces the temperature of the high-pressure cooling air before it enters the turbine section, thereby lowering the temperature parameter while maintaining the availability of cooling air
2Temperature
If a heat exchanger is used to cool the compression air, then the air temperature is reduced, but the energy required to compress and cool the air increases
Solution Approach 1:
Cooling action is applied preliminarily during the compression process itself by tapping air at intermediate stages and cooling it before final compression is complete. This preliminary cooling reduces the temperature of air that will undergo further compression, thereby reducing the energy required for the remaining compression steps
Solution Approach 2:
The system changes the pressure and temperature parameters of cooling air by tapping at different compressor stages and using heat exchangers. By optimizing the tap location and heat exchanger operation, the system achieves effective cooling while minimizing the total energy consumption for compression and cooling operations
3Productivity
If high pressure ratios are used in the compressor section, then engine efficiency is improved, but the temperature and stress on components increase
Solution Approach 1:
Different sections of the compressor operate at different pressure ratios and temperature levels. By tapping cooling air at intermediate stages where pressure and temperature are lower, the system provides localized cooling to high-stress turbine components without requiring the entire compression system to operate at reduced pressure ratios, thereby maintaining overall engine efficiency while protecting specific components from excessive stress
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 configuration reduces the energy required to compress air, decreases the size and weight of cooling components, and enhances overall engine efficiency by providing inter-cooled air at lower temperatures, effectively managing high-pressure ratios and temperatures in the turbine section.
Implementation Method 1
passed through a heat exchanger, which may sit in the bypass duct
Implementation Method 2
The heat exchanger is positioned in a bypass duct between an outer fan housing an inner core housing
Data Source
Figure 1
Figure 2~3
Figure 4
AI summary
A gas turbine engine (201) includes a plurality of rotating components housed within a compressor section and a turbine section. A first tap (156) is connected to the compressor section and configured to deliver air at a first pressure. A heat exchanger (158) is connected downstream of the first tap (156) and configured to deliver air to an aircraft fuselage (152). A cooling compressor (164) is connected downstream of the heat exchanger (158). A high pressure feed (200) is configured to deliver air at a second pressure which is higher than the first pressure. The cooling compressor (164) is configured to deliver air to at least one of the plurality of rotating components. A valve assembly (202) can select whether air from the first tap (156) or air from the high pressure feed (200) is delivered to the aircraft fuselage (152).