Patent Grant
10724741
The field of the invention relates generally to turbine engines, and more particularly, to combustors and fuel nozzle assemblies within turbine engines.
At least some known turbine engines include a forward fan, a core engine, and a power turbine. The core engine includes at least one compressor that provides pressurized air to a combustor where the air is mixed with fuel and ignited for use in generating hot combustion gases. Many such known turbine engines typically include a plurality of fuel nozzles for supplying fuel to the combustor in the core engine. The fuel is introduced at the front end of a burner in a highly atomized spray from at least one of the fuel nozzles. Compressed air flows around the fuel nozzle and mixes with the fuel to form a fuel-air mixture, which is ignited by the burner. The fuel nozzles have swirler assemblies that swirl the air passing through them to promote mixing of air with fuel prior to combustion. The swirler assemblies used in the combustors may be complex structures having axial, radial, or conical swirlers or a combination of them. Generated combustion gases flow downstream to one or more power turbines that extract energy from the gas to power the compressor and provide useful work, such as powering an aircraft.
In at least some known combustors, fuel and air are injected into an oxidizer stream from respective pluralities of circumferentially-spaced outlets. The independent streams of fuel and air interact to form a mixture, which produces a lean combustion flame that reduces NOx emissions. However, in some known systems, the fuel nozzles are configured such that fuel injection through the fuel nozzles sometimes results in fuel directed towards the liners of the combustor where combustion occurs. Such close proximity of combustion to the liners increases their thermal loading, thereby decreasing a margin to thermal parameters of the liners and potentially decreasing their service life. In general, in some such known fuel nozzles, the fuel nozzles include a plurality of circumferentially positioned fuel feed apertures that are substantially similar in size. A clockwise swirl within the fuel nozzle entrains fuel injected through the apertures at substantially similar fuel flow rates and some of the fuel injected from certain apertures is directed toward the liners.
In one aspect, a fuel nozzle assembly is provided. The fuel nozzle assembly includes a centerbody including an outer wall. The outer wall defines a plurality of fuel injection apertures that include a first portion of the plurality of fuel injection apertures configured to induce a first fuel flow rate. The plurality of fuel injection apertures also include a second portion of the plurality of fuel injection apertures configured to induce a second fuel flow rate. The second fuel flow rate is less than the first fuel flow rate.
In another aspect, a combustor for a turbine engine assembly is provided. The combustor includes a plurality of liners that at least partially define a combustion chamber. The combustor also includes a fuel nozzle assembly communicatively coupled with the combustion chamber. The fuel nozzle assembly includes a centerbody including an outer wall. The outer wall defines a plurality of fuel injection apertures that include a first portion of the plurality of fuel injection apertures configured to induce a first fuel flow rate. The plurality of fuel injection apertures also include a second portion of the plurality of fuel injection apertures configured to induce a second fuel flow rate. The second fuel flow rate is less than the first fuel flow rate.
In another aspect, a method of assembling a combustor is provided. The method includes defining a combustion chamber at least partially with a plurality of liners. The method also includes manufacturing a fuel nozzle assembly comprising fabricating a centerbody such that an outer wall of the centerbody comprising defining a plurality of fuel injection apertures therein. The method further includes configuring a first portion of the plurality of fuel injection apertures with a first configuration to induce a first fuel flow rate. The method also includes configuring a second portion of the plurality of fuel injection apertures with a second configuration to induce a second fuel flow rate. The second fuel flow rate is less than the first fuel flow rate. The method further includes coupling the fuel nozzle assembly communicatively with the combustion chamber.
These and other features, aspects, and advantages of the present disclosure will become better understood when the following detailed description is read with reference to the accompanying drawings in which like characters represent like parts throughout the drawings, wherein:
Unless otherwise indicated, the drawings provided herein are meant to illustrate features of embodiments of this disclosure. These features are believed to be applicable in a wide variety of systems comprising one or more embodiments of this disclosure. As such, the drawings are not meant to include all conventional features known by those of ordinary skill in the art to be required for the practice of the embodiments disclosed herein.
In the following specification and the claims, reference will be made to a number of terms, which shall be defined to have the following meanings.
The singular forms “a”, “an”, and “the” include plural references unless the context clearly dictates otherwise.
Approximating language, as used herein throughout the specification and claims, is applied to modify any quantitative representation that could permissibly vary without resulting in a change in the basic function to which it is related. Accordingly, a value modified by a term or terms, such as “about”, “approximately”, and “substantially”, are not to be limited to the precise value specified. In at least some instances, the approximating language may correspond to the precision of an instrument for measuring the value. Here and throughout the specification and claims, range limitations are combined and interchanged; such ranges are identified and include all the sub-ranges contained therein unless context or language indicates otherwise.
As used herein, the term “first end” is used throughout this application to refer to directions and orientations located upstream in an overall axial flow direction of fluids with respect to a center longitudinal axis of a combustion chamber. The terms “axial” and “axially” are used throughout this application to refer to directions and orientations extending substantially parallel to a center longitudinal axis of a combustion chamber. Terms “radial” and “radially” are used throughout this application to refer to directions and orientations extending substantially perpendicular to a center longitudinal axis of the combustion chamber. Terms “upstream” and “downstream” are used throughout this application to refer to directions and orientations located in an overall axial flow direction with respect to the center longitudinal axis of the combustion chamber.
The fuel injection systems described herein facilitate decreasing fuel injected into a combustor through a plurality of fuel nozzles from approaching and combusting in the vicinity of the combustors' outer liners and/or the inner liners. Also, a smaller portion of high-temperature combustion gases is directed toward the outer liners and the inner liners. As such, the thermal loading, i.e., temperature of the outer liners and the inner liners is significantly decreased, thereby increasing a margin to thermal parameters for the outer liners and the inner liners and extending their service life. In the embodiments disclosed herein, at least a portion of circumferential apertures defined in the center bodies of the fuel nozzles are sized differently, thereby tuning the fuel nozzles. More specifically, a first portion of selected apertures are increased in size to substantially maintain a predetermined total fuel flow through the full set of apertures into the fuel nozzles while a second portion of selected apertures are decreased in size to facilitate a decrease in flow through the selected apertures. The selection of the apertures to decrease in size is at least partially based on the characteristics of the clockwise swirl induced within the centerbody. As such, the flow rate of fuel is controlled at each injection point, i.e., aperture to preferentially distribute the fuel injection to facilitate regulation of the temperature on the inner and outer liners through a known relationship between a percentile biasing of the fuel flow through each aperture to attain a predetermined temperature change in the temperature of the liners.
Fan section 14 includes a rotatable, axial-flow fan rotor 32 that is surrounded by an annular fan casing 34. It will be appreciated that fan casing 34 is supported from core engine 12 by a plurality of substantially radially-extending, circumferentially-spaced outlet guide vanes 36 and fan frame struts 36 (both labeled 36). In this way, fan casing 34 encloses the fan rotor 32 and a plurality of fan rotor blades 38. A downstream section 40 of fan casing 34 extends over an outer portion of core engine 12 to define a secondary, or bypass, airflow conduit 42 that provides propulsive jet thrust.
In operation, an initial air flow 43 enters turbine engine assembly 11 through an inlet 44 to fan casing 34. Air flow 43 passes through fan blades 38 and splits into a first air flow (represented by arrow 45) and a second air flow (represented by arrow 46) which enters booster compressor 20. The pressure of the second air flow 46 is increased and enters high pressure compressor 21, as represented by arrow 47. After mixing with fuel and being combusted in combustor 22 combustion products 48 exit combustor 22 and flow through the first turbine 26. Combustion products 48 then flow through the second turbine 28 and exit the exhaust nozzle 30 to provide thrust for the turbine engine assembly 11.
Fuel nozzles 25 disposed within main swirler 24 intake fuel from a fuel supply (e.g., liquid and/or gas fuel), mix the fuel with air, and distribute the air-fuel mixture into combustor 22 in a suitable ratio for optimal combustion, emissions, fuel consumption, and power output. Turbine engine assembly 11 includes main swirler 24 including the one or more fuel nozzles 25, having a fuel injection system, described in further detail below.
Centerbody 108 is substantially annular and includes an outer sidewall 120 and an end wall 122 extending inward from outer sidewall 120. Outer sidewall 120 has a plurality of circumferentially spaced fuel injection apertures 124 and end wall 122 has a plurality of cooling apertures 126. Venturi 110 includes a tubular segment 128 and a flange 130 extending outward from tubular segment 128. Centerbody 108 includes an inner wall 132, where inner wall 132, outer sidewall 120, and end wall 122 define a substantially annular passage 134.
Fuel delivery system 104 includes a fuel nozzle stem 136 coupled to a fuel source (not shown) where fuel nozzle stem 136 delivers fuel to the remainder for fuel nozzle assembly 100. Fuel nozzle assembly 100 further includes a pilot swirler 138 (sometimes referred to as a pilot mixer) that receives air flow 47 from high pressure compressor 21 (both shown in
In operation when thrust is necessary, e.g., without limitation, take-off and climbing, fuel (not shown in
As used herein, references to fuel nozzle assembly 100 in terms of orientation within turbine engine assembly 11 (e.g., references such as “forward,” “aft,” “radially outward,” and “radially inward”) are intended to mean that fuel nozzle assembly 100, or individual components thereof, is configured to be oriented in such a manner that when fuel nozzle assembly 100 is mounted within turbine engine assembly 11 as described herein, and such references to orientation are not intended to limit the scope of this disclosure to only those fuel nozzle assemblies that are actually mounted within turbine engine assembly 11. Rather, this disclosure is intended to apply to fuel nozzle assemblies in general, whether mounted within a turbine engine assembly or not.
In the exemplary embodiment, a first portion 142 of fuel injection apertures 124 includes apertures 1-6 and 10. Apertures 1-6 and 10 have a first configuration defined by a first area, e.g., each of apertures 1-6 and 10 are substantially circular with a first diameter D1. A second portion 144 of fuel injection apertures 124 includes apertures 7-9. Apertures 7-9 have a second configuration defined by a second area, e.g., each of apertures 7-9 are substantially circular with a second diameter D2 that is less than first diameter D1. In alternative embodiments, apertures 1-6 and 10 and apertures 7-9 have any diameters that enable operation of centerbody 108 as described herein, including, without limitation, a different diameter for each of the ten apertures 124. Further, in alternative embodiments, first portion 142 and second portion 144 of fuel injection apertures 124 have any number of apertures therein that enables operation of centerbody 108 as described herein, e.g., and without limitation, an alternative first portion 142 includes apertures 1-6 and 10, while an alternative second portion 144 includes apertures 7-9.
Also, in the exemplary embodiment, first portion 142 defines a first arc 143 of a circle defined circumferentially on outer sidewall 120 and second portion 144 defines a second arc 145 of the circle defined circumferentially on outer sidewall 120. A first radial fuel exit stream 146 (only shown in
Further, in the exemplary embodiment, air 152 is introduced into swirl chamber 139 through swirl vanes (not shown) of main swirler 24. Air 152 mixes with fuel 140 to form a fuel-air mixture swirl 154 that is directed towards combustion chamber 52.
Moreover, in the exemplary embodiment, apertures 7-9 were selected for a reduction in diameter as a function of observed and/or modeled swirl patterns of fuel-air mixture swirl 154. The observed and/or modeled fuel flow from centerbody 124 results in decreasing fuel injected into combustor chamber 52 through each fuel nozzle assembly 100 from approaching and combusting in the vicinity of outer liners 54. Also, a smaller portion of high-temperature combustion gases is directed toward outer liners 54 since the reduced fuel exiting apertures 7-9 that is combusted achieves in a reduction in the combustion gases resulting therefrom. As such, the thermal loading of outer liners 54 is significantly decreased, thereby increasing a margin to thermal parameters for outer liners 54 and extending their service life. In the exemplary embodiment, the reduction in thermal loading of outer liners 54 is achieved through reducing the diameter of fuel apertures 7-9 and increasing the diameter of apertures 1-6 and 10. Alternatively, similar results may be achieved through one or more of, and without limitation, selectively altering the respective shapes of apertures 1 through 10, e.g., and without limitation, ovular shaped apertures, and installing flow restriction devices within apertures 7-9. Alternative embodiments including non-equidistantly spaced apertures 124 are discussed below with respect to
In one embodiment of centerbody 108, as described above, apertures 7-9 induce a total second radial fuel exit stream 150 representing an approximate 15% reduction in the total flow rate. As such, apertures 1-6 and 10 are sized to induce a total first radial fuel exit stream that recovers the 15% reduction such that the total fuel injection through exemplary centerbody 108 and the known centerbody are substantially similar. As a result, a reduction of approximately 27 degrees Celsius (° C.) (80 degrees Fahrenheit (° F.)) to approximately 49° C. (120° F.) of outer liners 54 is achieved. The 27° C. to 49° C. range of temperature reduction is dependent on factors such as, and without limitation, the decrease in fuel flow rate, specific heat content of the fuel, and the fuel-air ratio in the combustor. Therefore, fuel nozzle assembly 100 inclusive of centerbody 108 is configured with a predetermined configuration to attain the predetermined decreases in temperatures of inner liners 56 and outer liners 54 through preferential distribution of fuel injection.
Similarly, in an alternative embodiment of centerbody 160 (only shown in
Further, in this alternative embodiment, apertures 2-4 were selected for a reduction in diameter as a function of observed and/or modeled swirl patterns of fuel-air mixture swirl 154. The observed and/or modeled fuel flow from centerbody 124 results in decreasing fuel injected into combustor chamber 52 through each fuel nozzle assembly 100 from approaching and combusting in the vicinity of inner liners 56. Also, a smaller portion of high-temperature combustion gases is directed toward inner liners 56 since the reduced fuel exiting apertures 2-4 that is combusted achieves in a reduction in the combustion gases resulting therefrom. As such, the thermal loading of inner liners 56 is significantly decreased, thereby increasing a margin to thermal parameters for inner liners 56 and extending their service life. In this alternative embodiment, the reduction in thermal loading of inner liners 56 is achieved through reducing the diameter of fuel apertures 2-4 and increasing the diameter of apertures 1 and 5-10. Alternatively, similar results may be achieved through one or more of, and without limitation, selectively altering the respective shapes of apertures 1 through 10, e.g., and without limitation, ovular shaped apertures, and installing flow restriction devices within apertures 2-4.
In further alternative embodiments, both embodiments 108 and 160 are combined in that apertures 2-4 and 7-9 are tuned to bias both streams 150 and 164 to reduce the thermal loading of both outer liners 54 and inner liners 56. Specifically, both sets of apertures 2-4 and 7-9 have smaller diameters than apertures 1, 5-6, and 10. In still further alternative embodiments, any of, including all of, apertures 1-10 are tuned to facilitate reducing the thermal loading of outer liners 54 and/or inner liners 56.
In operation, fuel 140 is delivered to centerbody 108 from fuel nozzle stem 136 (shown in
Also, in this alternative embodiment, air 152 is introduced into swirl chamber 139 through swirl vanes (not shown) of main swirler 24. Air 152 mixes with fuel 140 to form fuel-air mixture swirl 154 that is directed towards combustion chamber 52.
Further, in this alternative embodiment, apertures 7-9 were selected for a reduction in diameter as a function of observed and/or modeled swirl patterns of fuel-air mixture swirl 154. The observed and/or modeled fuel flow from centerbody 170 results in decreasing fuel injected into combustor chamber 52 through each fuel nozzle assembly 100 from approaching and combusting in the vicinity of outer liners 54. Also, a smaller portion of high-temperature combustion gases is directed toward outer liners 54 since the reduced fuel exiting apertures 7-9 that is combusted achieves in a reduction in the combustion gases resulting therefrom. As such, the thermal loading of outer liners 54 is significantly decreased, thereby increasing a margin to thermal parameters for outer liners 54 and extending their service life. In the exemplary embodiment, the reduction in thermal loading of outer liners 54 is achieved through reducing the diameter of fuel apertures 7-9 and increasing the diameter of apertures 1-6 and 10. Alternatively, similar results may be achieved through one or more of, and without limitation, selectively altering the respective shapes of apertures 1 through 10, e.g., and without limitation, ovular shaped apertures, and installing flow restriction devices within apertures 7-9. In one embodiment of alternative centerbody 170, as described above, apertures 7-9 induce a total second radial fuel exit stream 176 representing an approximate 15% reduction in the total flow rate. As such, apertures 1-6 and 10 are sized to induce a total first radial fuel exit stream that recovers the 15% reduction such that the total fuel injection through exemplary centerbody 170 and the known centerbody are substantially similar.
Further, in another alternative embodiment, a fifth pair of adjacent apertures 1 and 2 define a fifth circumferential distance CD5 therebetween and a sixth pair of adjacent apertures 4 and 5 define a sixth circumferential distance CD5 therebetween, where CD5 and CD6 are substantially equal. CD5 and CD6 are substantially equal to CD1 and CD2. Alternatively, CD5 and CD6 are different from CD1 and CD2. Also, in this embodiment, a third pair of adjacent apertures 2 and 3 define a seventh circumferential distance CD7 therebetween and an eighth pair of adjacent apertures 3 and 4 define an eighth circumferential distance CD8 therebetween. CD7 is less than CD8, CD8 is greater than CD5 and CD6, and CD7 is less than CD5 and CD6.
In operation, fuel 140 is delivered to centerbody 108 from fuel nozzle stem 136 (shown in
Further, in this alternative embodiment, apertures 2-4 were selected for a reduction in diameter as a function of observed and/or modeled swirl patterns of fuel-air mixture swirl 154. The observed and/or modeled fuel flow from centerbody 170 results in decreasing fuel injected into combustor chamber 52 through each fuel nozzle assembly 100 from approaching and combusting in the vicinity of inner liners 56. Also, a smaller portion of high-temperature combustion gases is directed toward inner liners 56 since the reduced fuel exiting apertures 2-4 that is combusted achieves in a reduction in the combustion gases resulting therefrom. As such, the thermal loading of inner liners 56 is significantly decreased, thereby increasing a margin to thermal parameters for inner liners 56 and extending their service life. In the exemplary embodiment, the reduction in thermal loading of inner liners 56 is achieved through reducing the diameter of fuel apertures 2-4 and increasing the diameter of apertures 1 and 5-10. Alternatively, similar results may be achieved through one or more of, and without limitation, selectively altering the respective shapes of apertures 1 through 10, e.g., and without limitation, ovular shaped apertures, and installing flow restriction devices within apertures 2-4. In one embodiment of alternative centerbody 170, as described above, apertures 2-4 induce a total second radial fuel exit stream 180 representing an approximate 15% reduction in the total flow rate. As such, apertures 1 and 5-10 are sized to induce a total first radial fuel exit stream that recovers the 15% reduction such that the total fuel injection through exemplary centerbody 170 and the known centerbody are substantially similar.
The above-described fuel injection systems facilitate decreasing fuel injected into a combustor through a plurality of fuel nozzles from approaching and combusting in the vicinity of the combustors' outer liners and/or the inner liners. Also, a smaller portion of high-temperature combustion gases is directed toward the outer liners and the inner liners. As such, the thermal loading, i.e., temperature of the outer liners and the inner liners is significantly decreased, thereby increasing a margin to thermal parameters for the outer liners and the inner liners and extending their service life. In the embodiments disclosed herein, at least a portion of circumferential apertures defined in the center bodies of the fuel nozzles are sized differently, thereby tuning the fuel nozzles. More specifically, a first portion of selected apertures are increased in size to substantially maintain a predetermined total fuel flow through the full set of apertures into the fuel nozzles while a second portion of selected apertures are decreased in size to facilitate a decrease in flow through the selected apertures. The selection of the apertures to decrease in size is at least partially based on the characteristics of the clockwise swirl induced within the centerbody. As such, the flow rate of fuel is controlled at each injection point, i.e., aperture to preferentially distribute the fuel injection to facilitate regulation of the temperature on the inner and outer liners through a known relationship between a percentile biasing of the fuel flow through each aperture to attain a predetermined temperature change in the temperature of the liners.
An exemplary technical effect of the methods, systems, and apparatus described herein includes at least one of: (a) tuning the fuel nozzles to inject fuel through the associated apertures at predetermined flow rate based on the characteristics of the swirling pattern in the centerbody of the fuel nozzle; (b) decreasing fuel and hot gas injection toward the outer liners and the inner liners of the combustors; (c) decreasing the thermal loading, i.e., the temperatures of the outer liners and the inner liners away from thermal parameters; and (d) extending the service life of the outer liners and the inner liners in the combustors.
Exemplary embodiments of methods, systems, and apparatus for a fuel injection system are not limited to the specific embodiments described herein, but rather, components of systems and steps of the methods may be utilized independently and separately from other components and steps described herein. For example, the methods may also be used in combination with other fuel injection assemblies, and are not limited to practice with only the fuel injection system and methods as described herein. Rather, the exemplary embodiment can be implemented and utilized in connection with many other applications, equipment, and systems that may benefit from the advantages described herein.
Although specific features of various embodiments of the disclosure may be shown in some drawings and not in others, this is for convenience only. In accordance with the principles of the disclosure, any feature of a drawing may be referenced and claimed in combination with any feature of any other drawing.
This written description uses examples to disclose the embodiments, including the best mode, and also to enable any person skilled in the art to practice the embodiments, including making and using any devices or systems and performing any incorporated methods. The patentable scope of the disclosure is defined by the claims, and may include other examples that occur to those skilled in the art. Such other examples are intended to be within the scope of the claims if they have structural elements that do not differ from the literal language of the claims, or if they include equivalent structural elements with insubstantial differences from the literal language of the claims.
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