Single-Piece Swirler Combustor Nozzle Casting
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Solution Overview
Problem
Existing combustor nozzle designs often result in increased manufacturing and maintenance costs due to the presence of multiple braze and weld joints, which can lead to localized hot spots, NOx emissions, and flame flashback issues, especially when using high-reactive fuels like hydrogen.
Innovation Solution
A single-piece swirler combustor nozzle design featuring a center body with radially extending vanes and a shroud, fabricated through casting, which eliminates the need for braze joints and improves fuel-air mixing, reducing localized hot spots and NOx emissions.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If multiple fuel channels, swirlers, and fuel injectors are incorporated into the nozzle design, then fuel-air mixing is improved and localized hot spots are reduced, but the number of braze and weld joints increases, leading to increased manufacturing and maintenance costs
Solution Approach 1:
The patent merges multiple functional components (swirler, fuel channels, fuel injectors) into a single integrated nozzle structure. This consolidation eliminates the need for separate braze and weld joints while maintaining the fuel-air mixing functions, thereby reducing manufacturing complexity and cost while preserving mixing uniformity.
Solution Approach 2:
The integrated nozzle structure performs multiple functions simultaneously: it provides fuel distribution, creates swirling flow patterns, ensures uniform fuel-air mixing, and maintains structural integrity. This multi-functionality in a single component eliminates the need for multiple separate parts and joints, reducing both manufacturing cost and maintenance requirements.
2Adaptability or versatility
If multiple braze and weld joints are used in the nozzle, then complex fuel distribution and mixing functions can be achieved, but the reliability decreases due to potential joint failures and increased maintenance needs
Solution Approach 1:
By combining all fuel distribution, swirling, and mixing functions into a single integrated nozzle structure, the patent eliminates multiple joints that could fail. The unified structure ensures consistent fuel distribution and mixing performance while significantly improving reliability by removing potential failure points at joints.
3Ease of manufacture
If a single-piece swirler design is used, then manufacturing cost and complexity are reduced, but the ability to optimize fuel-air mixing may be compromised
Solution Approach 1:
The single-piece swirler integrates all mixing and distribution functions into one component, eliminating the need for multiple assembled parts. This unified structure maintains fuel-air mixing quality while significantly reducing manufacturing complexity and cost, as there are no joints or assembly operations required.
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 single-piece swirler design enhances durability, reduces manufacturing costs, and improves fuel-air mixing, minimizing NOx emissions and flame flashback, while maintaining high thermodynamic efficiency.
Implementation Method 1
a single-piece swirler. The single-piece swirler includes a center body extending axially along the single-piece swirler, a first fuel passage inside the center body, and a plurality of vanes extending radially from the center body
Implementation Method 2
casting a single-piece swirler having a center body and a plurality of vanes extending radially from the center body
Data Source
AI summary
A combustor nozzle includes a single-piece swirler. The single-piece swirler includes a center body extending axially along the single-piece swirler, a first fuel passage inside the center body, and a plurality of vanes extending radially from the center body. A method for fabricating a combustor nozzle includes casting a single-piece swirler having a center body and a plurality of vanes extending radially from the center body.