Refractory Carbide Hot Gas Path Stabilization

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Solution Overview

Problem

Current gas turbine performance is limited by the temperature capabilities of hot-section materials, which require cooling and are prone to oxidation and recession at high temperatures, especially above 2200°F, necessitating specialized coatings and cooling systems for refractory carbides like ceramic matrix composites (CMCs).

Innovation Solution

A method and system that utilize a high carbon activity gas to form a continuously renewed, chemically stabilizing film on refractory carbide hot gas path components, suppressing oxidation and volatilization by maintaining a high carbon activity layer on both external and internal surfaces, thereby eliminating the need for environmental barrier coatings.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Temperature

If refractory carbide hot gas path components are used at high temperatures above 2200°F, then temperature capability and engine efficiency are improved, but oxidation and recession of the material occur excessively

Engineering Contradiction:

Improvetemperature capabilityVSAvoidmaterial stability

Core Design Contradiction:

TemperatureVSReliability

Solution Approach 1:

The patent introduces a carbon-rich atmosphere (inert environment) by delivering hydrocarbon gas to the hot gas path component surfaces. This carbon-rich environment prevents oxidation of the refractory carbide material by creating a protective atmospheric condition that suppresses reactive oxygen exposure, thereby maintaining material stability at temperatures above 2200°F without requiring traditional environmental barrier coatings.

Inventive Principle:

Principle #39Inert atmosphere (Inert environment)

2Reliability

If environmental barrier coatings are applied to prevent oxidation and recession, then material protection is improved, but device complexity and coating damage concerns increase

Engineering Contradiction:

Improvematerial protectionVSAvoidcoating system complexity

Core Design Contradiction:

ReliabilityVSDevice complexity

Solution Approach 1:

The patent extracts and eliminates the environmental barrier coating layer from the component structure. Instead of applying complex multi-layer coatings (such as mullite and Ba-Sr-aluminosilicate), the invention uses a carbon-rich atmospheric environment to provide oxidation protection directly to the refractory carbide surface, thereby simplifying the overall device structure while maintaining material protection.

Inventive Principle:

Principle #2Taking out (Extraction)

Solution Approach 2:

The system uses the fuel combustion process itself to generate the protective carbon-rich atmosphere. By delivering unburned or partially burned hydrocarbon gas to the component surfaces, the combustion system serves a dual purpose: generating thermal energy while simultaneously creating a protective environment that prevents oxidation, eliminating the need for separate protective coating systems.

Inventive Principle:

Principle #25Self-service

3Temperature

If compressor discharge air is used for cooling hot gas path components, then thermal management is improved, but engine efficiency decreases due to cooling penalty

Engineering Contradiction:

Improvethermal managementVSAvoidcooling penalty

Core Design Contradiction:

TemperatureVSLoss of energy

Solution Approach 1:

The patent converts the harmful effect of unburned hydrocarbon gas (which would otherwise be wasted energy) into a beneficial protective atmosphere. By directing this carbon-rich gas to the hot gas path component surfaces, the system simultaneously achieves thermal management and oxidation protection, eliminating the need for separate cooling air extraction and reducing the cooling penalty on engine efficiency.

Inventive Principle:

Principle #22Blessing in disguise (Convert harm into benefit)

4Reliability

If traditional cooling systems and environmental barrier coatings are used, then material integrity is maintained, but manufacturing complexity and cost increase

Engineering Contradiction:

Improvematerial integrityVSAvoidmanufacturing simplicity

Core Design Contradiction:

ReliabilityVSEase of manufacture

Solution Approach 1:

Inventive Principle:

Principle #2Taking out (Extraction)

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

Enables refractory carbides to withstand temperatures above 3000°F with enhanced structural stability and strength, reducing material loss and degradation, and increasing engine efficiency by eliminating the need for compressor discharge air cooling and environmental barrier coatings.

Implementation Method 1

A high carbon activity gas is delivered to at least a portion of a component of a hot gas path that is thermally coupled to the hot gas path

Methodology Applied

Scientific EffectChemical film formation: Adsorption

Implementation Method 2

suppressing oxidation and volatilization by maintaining a high carbon activity layer on both external and internal surfaces

Methodology Applied

Scientific EffectOxidation suppression: Oxidation

Data Source

PatentEP2604588B1Method for stabilizing a refractory carbide hot gas path component

Publication Date: 2020.02.05 GENERAL ELECTRIC CO

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AI summary

A turbine power generation system 100 with enhanced stabilization of refractory carbides provided by hydrocarbon from high carbon activity gases 25 is disclosed. The disclosure also includes a method of using high carbon activity gases 25 to stabilize hot gas path components.