This disclosure relates generally to exhaust systems for aircraft gas turbine engines and more particularly to exhaust systems configured for treating combustion exhaust gases of aircraft gas turbine engines.
It is generally known in the art to power aircraft gas turbine engines with gases expelled from combustion chambers. In the gas turbine engine, a fuel is combusted in an oxygen rich environment. The fuel may be any appropriate fuel such as a liquid or gas. Exemplary fuels include hydrocarbons (for example methane or kerosene) or hydrogen. Generally, these combustion systems may emit undesirable compounds such as nitrous oxide compounds (NOx) and carbon containing compounds. It is generally desirable to decrease various emissions as much as possible so that selected compounds may not enter the atmosphere. In particular, it has become desirable to reduce NOx, emissions to a substantially low amount. There is a need in the art, therefore, for improved systems and methods for reducing NOx, emissions from aircraft gas turbine engines.
It should be understood that any or all of the features or embodiments described herein can be used or combined in any combination with each and every other feature or embodiment described herein unless expressly noted otherwise.
According to an aspect of the present disclosure, a gas turbine engine for an aircraft includes a turbine section and an exhaust section configured to receive an exhaust gas stream from the turbine section. The exhaust section includes a monolithic catalyst structure.
In any of the aspects or embodiments described above and herein, the gas turbine engine further includes a fixed structure surrounding at least a portion of the turbine section. The exhaust section further includes a diffuser nozzle mounted to the fixed structure downstream of the turbine section and configured to receive the exhaust gas stream from the turbine section. The monolithic catalyst structure is located within the diffuser nozzle.
In any of the aspects or embodiments described above and herein, the gas turbine engine may be a turboprop or a turboshaft gas turbine engine.
In any of the aspects or embodiments described above and herein, the monolithic catalyst structure may include a plurality of cells defining a respective plurality of channels extending therethrough.
In any of the aspects or embodiments described above and herein, the plurality of cells may include a catalytic washcoat.
In any of the aspects or embodiments described above and herein, the turbine section may include a reducing agent injection system configured to inject a reducing agent into a core flow path of the gas turbine engine.
In any of the aspects or embodiments described above and herein, the reducing agent injection system may be located upstream of the turbine section.
In any of the aspects or embodiments described above and herein, the reducing agent injection system may be located downstream of the turbine section.
In any of the aspects or embodiments described above and herein, the reducing agent may be an ammonia-based reducing agent.
In any of the aspects or embodiments described above and herein, the gas turbine engine further may include a nacelle defining an exterior housing of the gas turbine engine. The diffuser nozzle may be entirely located within the nacelle.
In any of the aspects or embodiments described above and herein, the monolithic catalyst structure may be located in a first axial portion of the housing. A first diameter of the housing in the first axial portion may be greater than a second diameter of a nozzle inlet of the diffuser nozzle and a third diameter of a nozzle outlet of the diffuser nozzle.
According to another aspect of the present disclosure, a method for treating exhaust gases from a gas turbine engine for an aircraft is provided. The method includes directing an exhaust gas stream from a turbine section of the gas turbine engine into an exhaust section of the gas turbine engine and directing the exhaust gas stream through a monolithic catalyst structure of the exhaust section to remove nitrogen oxides (NOx) from the exhaust gas stream.
In any of the aspects or embodiments described above and herein, the exhaust section may further include a diffuser nozzle configured to receive the exhaust gas stream from the turbine section and the monolithic catalyst structure may be located within the diffuser nozzle.
In any of the aspects or embodiments described above and herein, the monolithic catalyst structure may include a plurality of cells defining a respective plurality of channels extending therethrough.
In any of the aspects or embodiments described above and herein, the method may further include injecting a reducing agent into a core flow path of the gas turbine engine.
In any of the aspects or embodiments described above and herein, the step of injecting the reducing agent into the core flow path of the gas turbine engine may include injecting the reducing agent into the core flow path upstream of the turbine section.
In any of the aspects or embodiments described above and herein, the step of injecting the reducing agent into the core flow path of the gas turbine engine may include injecting the reducing agent into the core flow path downstream of the turbine section.
In any of the aspects or embodiments described above and herein, the step of injecting the reducing agent into the core flow path of the gas turbine engine may include injecting an ammonia-based reducing agent into the core flow path of the gas turbine engine.
In any of the aspects or embodiments described above and herein, the diffuser nozzle may be located entirely within a nacelle defining an exterior housing of the gas turbine engine.
In any of the aspects or embodiments described above and herein, the method may further include diffusing exhaust gas stream with the diffuser nozzle at a first axial location within the diffuser nozzle and subsequently concentrating the exhaust gas stream with the diffuser nozzle at a second axial location within the diffuser nozzle which is different than the first axial location.
The present disclosure, and all its aspects, embodiments and advantages associated therewith will become more readily apparent in view of the detailed description provided below, including the accompanying drawings.
The gas turbine engine 20 of
The gas turbine engine 20 of
In some embodiments, the gas turbine engine 20 may include a diffuser nozzle 54 in the exhaust section 30 of the gas turbine engine 20. The diffuser nozzle 54 is configured to direct combustion exhaust gases and to decelerate the combustion exhaust gases for post-combustion treatment to reduce or otherwise mitigate the emission of air pollutants from the gas turbine engine 20 including, but not limited to, nitrogen oxides (NOx). The gas turbine engine 20 may include a fixed structure 55 such as a casing or cowl surrounding at least a portion of the turbine section 28. The diffuser nozzle 54 may be mounted to the fixed structure 55 axially downstream of the turbine section 28. As shown in
Referring to
In an upstream-to-downstream direction as shown in
The present disclosure exhaust section 30 of the gas turbine engine 20 includes a monolithic catalyst structure 82 configured to treat air pollutants such as NOx, from the exhaust gas stream 68 as the exhaust gas stream 68 passes through the monolithic catalyst structure 82. In some embodiments, the monolithic catalyst structure 82 may be part of and located within the diffuser nozzle 54, as shown in
The monolithic catalyst structure 82 may be made from a ceramic material forming a plurality of substrate cells 84. The plurality of substrate cells 84 define a respective plurality of channels 86 extending through the monolithic catalyst structure 82 in a generally axial direction. The monolithic catalyst structure 82 includes a catalyst washcoat applied to the surfaces of the substrate cells 84. The catalyst washcoat serves as a carrier for a catalyst such as, but not limited to, platinum, palladium, rhodium, and/or zeolite, which catalyst is used to stimulate and accelerate a NOx, reduction chemical reaction of the monolithic catalyst structure 82. As shown in
Combustion exhaust gases of the exhaust gas stream 68 passing through the diffuser nozzle 54 are directed through the monolithic catalyst structure 82 where the exhaust gas stream 68 is treated through chemically interaction with the catalyst washcoat applied to the surfaces of the plurality of substrate cells 84. Diffusion of the exhaust gas stream 68 within the diffusing axial portion 76 of the diffuser nozzle 54 from the nozzle inlet 64 to the maximum cross-sectional area provided by the treatment axial portion 78 provides for an increase in the static pressure of the exhaust gas stream 68 and a reduction in velocity of the exhaust gas stream 68, within the treatment axial portion 78 of the diffuser nozzle 54. By reducing the velocity of the exhaust gas stream 68 within the treatment axial portion 78, the length of time for chemical interaction between the exhaust gas stream 68 and the monolithic catalyst structure 82 may be increased, thereby improving post-combustion treatment of the exhaust gas stream 68. Moreover, the pressure losses of the exhaust gas stream 68 passing through the monolithic catalyst structure 82 are reduced. Concentration of the exhaust gas stream 68 within the concentrating axial portion 80 of the diffuser nozzle 54 from the treatment axial portion 78 to the nozzle outlet 66 provides for a decrease in the static pressure of the exhaust gas stream 68 and an increase in velocity of the exhaust gas stream 68 which exits the nozzle outlet 66 of the diffuser nozzle 54, thereby providing some amount of usable thrust. Accordingly, the configuration of the diffuser nozzle 54 may provide a tradeoff whereby an axial length of the diffuser nozzle 54 may be decreased while a diameter of the diffuser nozzle 54 (e.g., the diameter D1 of the housing 56 along the treatment axial portion 78) may be increased, while maintaining the post-combustion treatment capability of the diffuser nozzle 54 with respect to the exhaust gas stream 68. The diffuser nozzle 54 may, therefore, provide a form factor which can more readily be incorporated into gas turbine engines such as the gas turbine engine 20 and, for example, be retained within a nacelle for the respective gas turbine engine.
Referring to
In some embodiments, the reducing agent injection system 88 may be configured to implement an SCR process to treat NOx, found within the exhaust gas stream 68 along the core flow path 21. As shown in
4NO+4NH3+O2→4N2+6H2O [1]
NO+NO2+2NH3→2N2+3H2O [2]
6NO2+8NH3→7N2+12H2O [3]
The SCR process uses the catalyst of the monolithic catalyst structure 82 to reduce the necessary activation energy for the above-noted SCR reduction reactions. Accordingly, the SCR process can eliminate as much as 95 percent of NOx, within the exhaust gas stream 68, with a sufficiently large and appropriately sized monolithic catalyst structure 82.
In some embodiments, the reducing agent injection system 88 may be configured to implement a SCR process and a SNCR process to treat NOx found within the exhaust gas stream 68 along the core flow path 21. As shown in
4NO+4NH3+O2+4N2+6H2O [4]
Because of the very short time that the mixed exhaust gas stream 68 and reducing agent 90 may spend in the temperature range necessary for the SNCR process to occur, the SNCR process may result in a NOx, reduction of less than 10 percent in aircraft gas turbine engine applications. Accordingly, the possible increased cost and complexity of positioning the reducing agent injection system 88 upstream of the high-pressure turbine 39 (in contrast to placement of the reducing agent injection system 88 downstream of the turbine section 28) may be considered with the expected NOx, reduction provided by the associated SNCR process, for the particular NOx, emissions reduction application.
In some embodiments, the reducing agent injection system 88 may include an annular manifold 92, as shown in
It is noted that various connections are set forth between elements in the preceding description and in the drawings. It is noted that these connections are general and, unless specified otherwise, may be direct or indirect and that this specification is not intended to be limiting in this respect. A coupling between two or more entities may refer to a direct connection or an indirect connection. An indirect connection may incorporate one or more intervening entities. It is further noted that various method or process steps for embodiments of the present disclosure are described in the following description and drawings. The description may present the method and/or process steps as a particular sequence. However, to the extent that the method or process does not rely on the particular order of steps set forth herein, the method or process should not be limited to the particular sequence of steps described. As one of ordinary skill in the art would appreciate, other sequences of steps may be possible. Therefore, the particular order of the steps set forth in the description should not be construed as a limitation.
Furthermore, no element, component, or method step in the present disclosure is intended to be dedicated to the public regardless of whether the element, component, or method step is explicitly recited in the claims. No claim element herein is to be construed under the provisions of 35 U.S.C. 112(f) unless the element is expressly recited using the phrase “means for.” As used herein, the terms “comprises”, “comprising”, or any other variation thereof, are intended to cover a non-exclusive inclusion, such that a process, method, article, or apparatus that comprises a list of elements does not include only those elements but may include other elements not expressly listed or inherent to such process, method, article, or apparatus.
While various aspects of the present disclosure have been disclosed, it will be apparent to those of ordinary skill in the art that many more embodiments and implementations are possible within the scope of the present disclosure. For example, the present disclosure as described herein includes several aspects and embodiments that include particular features. Although these particular features may be described individually, it is within the scope of the present disclosure that some or all of these features may be combined with any one of the aspects and remain within the scope of the present disclosure. References to “various embodiments,” “one embodiment,” “an embodiment,” “an example embodiment,” etc., indicate that the embodiment described may include a particular feature, structure, or characteristic, but every embodiment may not necessarily include the particular feature, structure, or characteristic. Moreover, such phrases are not necessarily referring to the same embodiment. Further, when a particular feature, structure, or characteristic is described in connection with an embodiment, it is submitted that it is within the knowledge of one skilled in the art to effect such feature, structure, or characteristic in connection with other embodiments whether or not explicitly described. Accordingly, the present disclosure is not to be restricted except in light of the attached claims and their equivalents.