The present disclosure is directed toward centrifugal compressors. More specifically, the present disclosure is directed towards systems and methods for cooling a centrifugal or radial compressor of a gas turbine engine to reduce the temperature rise of air passing through the compressor and thereby reduce the power required by the compressor.
A gas turbine engine extracts energy from a flow of hot gas that is produced by the combustion of gaseous or liquid fuel with compressed air. In its basic form, a gas turbine engine employs a rotary air compressor driven by a turbine with a combustion chamber disposed between the compressor and the turbine.
Principles of thermodynamics teach that when the temperature of the gases entering the turbine exceeds that entering the compressor, the turbine can deliver more power than the compressor consumes. In this regard, the engine can produce a net power output contingent upon other criteria being met. The efficiency with which the engine converts thermal energy into mechanical energy depends on many factors including compressor and turbine efficiencies, temperature and pressure levels, and the presence or absence of enhancements such as regeneration and compressor air stream cooling (intercooling). The power produced is proportional to the efficiency as well as the mass flow rates of air and fuel. Turboshaft engines deliver mechanical power through a rotating output shaft. Turbojet or turbofan engines require only enough turbine power to operate the compressor (with or without a fan) and the excess fluid power is available in the form of jet thrust.
Conventional gas turbine engines operate approximately according to the ideal “Gas Turbine” or “Brayton” cycle which, by definition, embodies reversible adiabatic (without heat transfer) compression of atmospheric air, addition of heat at constant pressure, reversible adiabatic expansion through a turbine back to atmospheric pressure, and finally exhausting to the atmosphere. Deviations from the ideal cycle (e.g., irreversibilities) arise due fluid friction and turbulence, inefficiencies in compressors and turbines, combustion heat loss, and the like.
The Ericsson Cycle patented in 1830 embodies constant pressure regeneration, isothermal compression, and isothermal expansion (reheat), but proposes no means of accomplishing either isothermal compression or expansion. The ideal Ericsson Cycle has “Carnot” efficiency (classical thermodynamics proves that no ideal heat engine operating between given source and sink temperatures can exceed Carnot Cycle efficiency). While the visionary scientists of the nineteenth century, Nicolas Carnot, James Joule, Lord Kelvin, Rudolf Clausius, and Ludwig Boltzman who developed the new branch of science (i.e., Thermodynamics) as well as modern engineers have recognized the benefits of isothermal compression and turbine reheat, no known practical method of achieving or approximating approximate isothermal compression (or expansion) has been perfected.
One attempt to remove compression heat from the engine (“external intercooling”) diverts air out of each stage of an axial compressor, passes the air through a separate heat exchanger/radiator, and re-injects the cooled air into the inlet of the next compressor stage. However, the circuitous piping and multiple changes in flow direction could defeat much, or all of any thermodynamic advantage of external intercooling.
Another disadvantage of external-intercooling is how the increased complexity of such systems significantly increases the weight of a turbine engine. This is especially relevant to aircraft applications where turbine engines are often utilized due to their high power to weight ratio. That is, in most cases, gas turbine engines are considerably smaller and lighter than reciprocating engines of the same power rating. For this reason, turboshaft engines are used to power almost all modern helicopters. However, incorporation of external intercoolers into turbine engines would result in a significant addition of weight which would more than offset any power gain benefits for such applications.
Provided herein are systems and methods (i.e., utilities) that implement what is termed “Approximated Isothermal Compression” (AIC) in a centrifugal compressor of a gas turbine engine. AIC provides significant improvements in heat rate and power (10-25% depending on turbine design) by implementing centrifugal or radial compressor cooling that lowers the work required by a turbine engine to compress air. In various utilities, a liquid coolant is supplied to a compressor housing that houses a centrifugal compressor. In various aspects, which may be utilized together and/or independently, the liquid coolant is the fuel utilized by the combustor of the turbine engine. Use of the fuel as the coolant makes the utilities well suited for use in aircraft applications as the aircraft are not required to carry separate coolant and/or complex plumbing, pumps and radiators to reject heat from the coolant.
Disclosed herein are various apparatuses, systems and methods to achieve what will be referred to herein as “external intercooling”. External intercooling is the cooling of a centrifugal compressor airstream without disrupting the normal flow path of the airstream through the centrifugal compressor. Such external cooling can expel much of the compression heat in the centrifugal compressor to approximate isothermal compression in the centrifugal compressor stage and thereby reduce the consumption of power by the centrifugal compressor. That is, various aspects of the presented inventions are directed to practical and effective means of expelling much of the compression heat in order to reduce the consumption of power by the compressor. While cooling of the centrifugal compressor reduces the compressor discharge temperature, such cooling can cause an increase in the fuel flow rate needed to maintain the turbine inlet temperature at its set value, the incremental increase in the required combustion heat is the same as the incremental decrease in compressor specific work. Thus, the turbine net specific work (i.e., total turbine specific work minus compressor specific work) increases by that same amount (i.e., the output power increases by exactly the same amount as the increase in combustion heat rate). As efficiency is given by net-power/combustion-heat-rate, efficiency actually increases because the same increment is added to the numerator and denominator of a fraction less than 1.0 (i.e., this causes an increase in the value of the fraction).
One of the utilities disclosed herein includes specially designed compressor impellor housing that absorbs thermal energy which can then be transferred away from the airflow through the compressor. The apparatus generally includes an annular compressor housing including inside and outside surfaces, and inlet and outlet ends, such that air generally moves in an air flow direction from the inlet end towards the outlet end. A sidewall extends between the inlet and outlet. Formed within the sidewall are one or more fluid path that allow for circulating fluid (i.e., coolant) though the housing. In one arrangement, fuel of a gas turbine engine using the compressor housing is used as the coolant. This arrangement allows for both removing heat from the compressed air, thereby reducing the power needed by the compressor to compress the intake air, and preheating the fuel prior to combustion. In another arrangement, the coolant may be a closed system where coolant is circulated through the compressor housing and the heat absorbed from the coolant is rejected using, for example, a radiator. In this arrangement, the heated coolant may be utilized to preheat the fuel using, for example, a separate heat exchanger.
Reference will now be made to the accompanying drawings, which assist in illustrating the pertinent features of the various novel aspects of the present disclosure. Although described primarily with respect to compressor cooling systems, apparatuses and methods (i.e., utilities) that may or may not be combined with recuperation and used with a turbine engine (e.g., in aircraft applications), aspects of the utilities are applicable to centrifugal compressors that may be utilized for gas compression applications such as gas pipeline compressors. In this regard, the following description is presented for purposes of illustration and description. Furthermore, the description is not intended to limit the inventive aspects to the forms disclosed herein. Consequently, variations and modifications commensurate with the following disclosures are within the scope of the present inventive aspects.
The presented centrifugal compressor cooling systems and methods discussed herein may be utilized with a variety of different gas turbine engines. The present description describes the centrifugal compressor cooling utilities in relation to the Rolls-Royce Model 250 family of engines (US military designation T63). However, discussion of the presented utilities with the Model 250 engine is presented by way of illustration and not by way of limitation. The presented utilities may be unitized with various gas turbine engines including other aircraft engines and ground based engines as well as other centrifugal compressors.
The Model 250 engine 10, as schematically shown in the perspective, side and front views of
Gas turbine engines are described thermodynamically by the idealized Brayton cycle, in which air is compressed isentropically, combustion occurs at constant pressure, and expansion over the turbine occurs isentropically back to the starting pressure. In practice, friction and turbulence cause non-isentropic compression. Specifically, the compressor tends to deliver compressed air at a temperature that is higher than ideal. Furthermore, pressure losses in the air intake, combustor and exhaust reduce the expansion available to provide useful work. By some estimates, up to half of the power produced by the engine goes to powering the compressor.
In assembly, the first and second halves 115, 116 of the housing may be interconnected together (e.g., via bolts and apertures, not labeled) such that the stator casing 100 surrounds the shaft 110 and rotor sections 112 and a longitudinal axis (not shown) of the rotating shaft 110 is coincident with the central axis of the axial compressor housing 100. At this point, the stator sections 102 and rotor sections 112 may alternate and the rotor sections 112 may be operable to rotate in the spaces between the stator sections 102. The angles of each of the stator and rotor sections 102, 112 may also alternate. Furthermore, the various stator and rotor sections 102, 112 may have different spacing (e.g., blade density) as well as different angles from the previous rows of blades.
As further shown in
The increase in the temperature of the air as it passes through the compressors 20 and 22 results in the air expanding and thus working against its compression. Stated otherwise, the addition of heat to the compressed air is parasitic and requires that the engine supply more compression power to achieve the desired output pressure. Accordingly, utilities disclosed herein are directed to reducing the temperature gain of air flowing through the centrifugal compressor to reduce compression power requirements and thereby increase the available shaft output power of the engine.
Aspects of the present disclosure are based on the realization that significant reduction in the temperature rise of the compressed intake air may be achieved via cooling the centrifugal compressor housing. In various arrangements near isothermal compression may be achieved through the centrifugal compressor via centrifugal compressor housing cooling which reduces the power requirements of the compressor improving overall efficiency of the engine. Along these lines, it is been determined that the centrifugal compressor housing 50 may be formed by a plurality of internal fluid paths through which coolant may be circulated. The coolant passing through the compressor housing 50 removes thermal energy from the compressor housing lowering its temperature and thereby permits heat exchange between the hot intake air passing through the interior of the cooled housing.
Within the sidewall 60 between the inside surface 62 an outside surface 64 are plurality of fluid passages or fluid paths 70. The fluid paths 70 extends between a first inlet/outlet port 72 and a second inlet/outlet port 74 formed into the outside surface 64 of the housing 50. Accordingly, appropriate fluid conduits may be connected to the ports 72, 74 to circulate fluid through the housing 50 while the impeller is operating therein. Such fluid flow permits the removal of thermal energy from the housing which in turn reduces the temperature of the air being compressed by the impeller. In a further embodiment, surface features may be added to the interior surface of the housing (e.g., grooves, ridges, vanes, etc.) to increase the surface area of the interior surface and thus increase the heat exchange of the cooled housing.
The exemplary fluid path 70 is a spiraled or roughly helical fluid path that extends multiple rotations around the center axis of the housing. Though using the word helical, it will be appreciated that the radius and or pitch of the spiral may be varied throughout the sidewall. In an embodiment utilizing a spiraled or helical type fluid path, the fluid path may be a single passage or a manifold of passages that extends between the first and second ports 72, 74. As shown in
In an embodiment well suited for use in aircraft applications, the first port 72 may be connected to the fuel tank of the aircraft via a first conduit 82. See
In another embodiment, a secondary coolant loop is incorporated. See
The impeller housing 50 including the internal fluid path(s) 60 may, in one embodiment, be formed using a three-dimensional printing technique. For instance, the impellor housing may be formed in a direct metal laser sintering (DMLS) process. DMLS is an additive manufacturing technique that uses a carbon dioxide laser fired into a magnesium substrate to sinter powdered material (typically metal), aiming the laser automatically at points in space defined by a 3D model, binding the material together to create a solid structure. Thus, any 3D model may be formed in a DMLS process. Alloys used in the process include, without limitation, 17-4 and 15-5 stainless steel, maraging steel, cobalt chromium, inconel 625 and 718, and titanium Ti6A14V. It will be appreciated that any appropriate printing process may be utilized. Alternatively, the impeller housing may be machined where, for example, the inner surface is connected (e.g., bonded, welded, etc.) to the sidewall containing milled fluid paths.
The ability to provide cooling to the impellor housing can significantly reduce the compressor air outlet temperature. That is, compressed air temperature rise may be significantly reduced in comparison to the temperature rise in a conventional turbine engine. This reduced compressor output temperature is a modification of the basic gas turbine Brayton cycle. In a theoretical limit, compression may be done at constant temperature or ‘isothermal’ compression with the remainder of the cycle being the same as the Brayton cycle—constant pressure combustion and isentropic expansion. This modified cycle is referred to herein as the ‘Approximated Isothermal Compression’ AIC cycle, which utilizes isothermal or reduced temperature rise compression.
To improve engine efficiency and power output, any appropriate manner of achieving regeneration may be included along with the apparatuses and methods disclosed herein for cooling a centrifugal compressor and/or the airstream flowing therethrough. Regeneration is the use of a heat exchanger to transfer heat from an engine exhaust stream to the compressor discharge air (thus preheating the compressor discharge air) in a turbine engine such that less fuel energy is required to achieve the required turbine inlet temperature for the compressed air. By recovering some of the energy usually lost as waste heat, a regenerator can make a gas turbine engine significantly more efficient. Such a system is disclosed in U.S. patent application Ser. No. 12/650,857, entitled “Recuperator for Gas Turbine Engines,” which in incorporated herein by reference.
The present application claims the benefit of U.S. Provisional Patent Application No. 62/432,435 having a filing date of Dec. 9, 2016, the entire contents of which is incorporated herein by reference.
Number | Date | Country | |
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62432435 | Dec 2016 | US |