Thermal Coking Sensor Feedback for Fuel/Oil Cooler Heat Control
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Solution Overview
Problem
Existing gas turbine engines face limitations in utilizing fuel as a heat sink due to the risk of coking at temperatures around 400°F, restricting the amount of heat that can be added to the fuel, which affects engine efficiency and the use of Sustainable Aviation Fuels (SAFs) with higher coking temperatures.
Innovation Solution
A thermal coking sensor using two heated wires measures real-time fuel temperature to determine the onset of coking, allowing the system to actively control fuel temperature and prevent coking by adjusting heat transfer through a fuel/oil cooler, optimizing heat utilization.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Use of energy by moving object
If fuel temperature is increased to improve engine efficiency, then engine efficiency improves, but fuel coking occurs at temperatures around 400°F
Solution Approach 1:
The thermal coking sensor performs preliminary detection of fuel temperature and coking conditions before actual coking occurs. The sensor continuously monitors fuel temperature and provides early warning signals, allowing the control system to take preventive action by adjusting heat transfer or fuel flow before the harmful coking process begins, thus enabling higher fuel temperatures for improved efficiency while preventing coking damage
Solution Approach 2:
The patent implements a feedback control system where the thermal coking sensor continuously monitors fuel temperature and provides real-time signals to the controller. The controller adjusts heat transfer operations based on this feedback, dynamically maintaining fuel temperature below the coking threshold while maximizing heat utilization for engine efficiency improvement
2Loss of energy
If heat transfer from oil to fuel is increased to utilize waste heat, then engine efficiency improves, but fuel temperature approaches coking temperature
Solution Approach 1:
The thermal coking sensor provides continuous feedback on fuel temperature during heat transfer operations. The controller uses this feedback to dynamically adjust the heat transfer process, maximizing waste heat utilization from oil while maintaining fuel temperature within safe limits below the coking threshold, thus resolving the contradiction between energy recovery and temperature control
Solution Approach 2:
The system dynamically adjusts heat transfer operations based on real-time fuel temperature conditions detected by the thermal coking sensor. The heat transfer rate is continuously optimized to maximize waste heat recovery while adapting to changing fuel temperature conditions, ensuring the fuel temperature remains below the coking point throughout varying operational conditions
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 efficient use of waste heat from the engine to increase fuel temperature, improving engine efficiency by 0.3% for every 100°F rise while preventing fuel coking, and enhancing the use of SAFs by adapting to their higher coking temperatures.
Implementation Method 1
A thermal coking sensor...is configured to generate a signal in response to interacting with the fuel...determine a coking temperature indicating an onset of coking in the fuel based on the signal
Implementation Method 2
the fuel/oil cooler configured to transfer heat from the heated oil to the fuel
Implementation Method 3
the first heat loss is generated in response to constantly receiving a first electrical current
Implementation Method 4
the second heat loss is generated in response to periodically receiving a second electrical current
Data Source
AI summary
A gas turbine engine fuel system includes a fuel delivery system, an oil cooling subsystem, and a fuel conditioning subsystem. The fuel delivery subsystem delivers fuel to a gas turbine engine, and the oil cooling subsystem receives heated oil from the gas turbine engine. The fuel conditioning subsystem includes a fuel/oil cooler that is in fluid communication with the fuel delivery subsystem to receive the fuel and is in fluid communication with the oil cooling subsystem to receive the heated oil, the fuel/oil cooler configured to transfer heat from the heated oil to the fuel. A thermal coking sensor is in fluid communication with the fuel and is configured to generate a signal in response to interacting with the fuel. A controller is configured to determine a coking temperature indicating an onset of coking in the fuel based on the signal.