The embodiments described herein are generally directed to a fuel injector, and, more particularly, to a fuel injector with purge holes and fuel-injection outlets that reduce the fuel injector's propensity to flashback.
A lean premixed fuel injector is susceptible to flashback if specific criteria or operating conditions are met. Thus, it is necessary to include features that reduce or remove the fuel injector's propensity to flashback. For example, U.S. Patent Publication No. 2013/0189632 A1 describes a fuel nozzle with a nozzle collar that includes a number of air vanes. Purge holes are positioned through the air vanes to create a flow of purge air that is intended to disrupt recirculation zones downstream from the fuel nozzle. The present disclosure is directed toward overcoming one or more of the problems discovered by the inventors.
In an embodiment, an injector head for a fuel injector is disclosed that comprises: an injector body comprising an injector portion shaped as a hyperbolic funnel rotated around an assembly axis, wherein, in a cross section along the assembly axis, a wall of the injector portion transitions from a radial axis, which is orthogonal to the assembly axis, to an axis that is parallel to the assembly axis; and a premix barrel encircling the injector portion around the assembly axis and defining a premix passage between the premix barrel and the injector portion, wherein a radial portion of the wall of the injector portion that is along the radial axis comprises a plurality of purge holes that connect the premix passage to an injector cavity, which is interior to the injector portion.
The details of embodiments of the present disclosure, both as to their structure and operation, may be gleaned in part by study of the accompanying drawings, in which like reference numerals refer to like parts, and in which:
The detailed description set forth below, in connection with the accompanying drawings, is intended as a description of various embodiments, and is not intended to represent the only embodiments in which the disclosure may be practiced. The detailed description includes specific details for the purpose of providing a thorough understanding of the embodiments. However, it will be apparent to those skilled in the art that embodiments of the invention can be practiced without these specific details. In some instances, well-known structures and components are shown in simplified form for brevity of description.
For clarity and ease of explanation, some surfaces and details may be omitted in the present description and figures. In addition, references herein to “upstream” and “downstream” are relative to the flow direction of the primary gas (e.g., air) used in the combustion process, unless specified otherwise. It should be understood that “upstream” refers to a position that is closer to the source of the primary gas or a direction towards the source of the primary gas, and “downstream” refers to a position that is farther from the source of the primary gas or a direction that is away from the source of the primary gas.
In an embodiment, gas turbine engine 100 comprises, from an upstream end to a downstream end, an inlet 110, a compressor 120, a combustor 130, a turbine 140, and an exhaust outlet 150. In addition, the downstream end of gas turbine engine 100 may comprise a power output coupling 104. One or more, including potentially all, of these components of gas turbine engine 100 may be made from stainless steel and/or durable, high-temperature materials known as “superalloys.” A superalloy is an alloy that exhibits excellent mechanical strength and creep resistance at high temperatures, good surface stability, and corrosion and oxidation resistance. Examples of superalloys include, without limitation, Hastelloy, Inconel, Waspaloy, Rene alloys, Haynes alloys, Incoloy, MP98T, TMS alloys, and CMSX single crystal alloys.
Inlet 110 may funnel a working fluid F (e.g., a gas, such as air) into an annular flow path 112 around longitudinal axis L. Working fluid F flows through inlet 110 into compressor 120. While working fluid F is illustrated as flowing into inlet 110 from a particular direction and at an angle that is substantially orthogonal to longitudinal axis L, it should be understood that inlet 110 may be configured to receive working fluid F from any direction and at any angle that is appropriate for the particular application of gas turbine engine 100.
Compressor 120 may comprise a series of compressor rotor assemblies 122 and stator assemblies 124. Each compressor rotor assembly 122 may comprise a rotor disk that is circumferentially populated with a plurality of rotor blades. The rotor blades in a rotor disk are separated, along the axial axis, from the rotor blades in an adjacent disk by a stator assembly 124. Compressor 120 compresses working fluid F through a series of stages corresponding to each compressor rotor assembly 122. The compressed working fluid F then flows from compressor 120 into combustor 130.
Combustor 130 may comprise a combustor case 132 housing one or more, and generally a plurality of, fuel injectors 134. In an embodiment with a plurality of fuel injectors 134, fuel injectors 134 may be arranged circumferentially around longitudinal axis L within combustor case 132 at equidistant intervals. Combustor case 132 diffuses working fluid F, and fuel injector(s) 134 inject fuel into working fluid F. This injected fuel is ignited to produce a combustion reaction in one or more combustion chambers 136. The combusting fuel-gas mixture drives turbine 140.
Turbine 140 may comprise one or more turbine rotor assemblies 142. As in compressor 120, each turbine rotor assembly 142 may correspond to one of a series of stages. Turbine 140 extracts energy from the combusting fuel-gas mixture as it passes through each stage of the one or more turbine rotor assemblies 142. The energy extracted by turbine 140 may be transferred (e.g., to an external system) via power output coupling 104.
The exhaust E from turbine 140 may flow into exhaust outlet 150. Exhaust outlet 150 may comprise an exhaust diffuser 152, which diffuses exhaust E, and an exhaust collector 154 which collects, redirects, and outputs exhaust E. It should be understood that exhaust E, output by exhaust collector 154, may be further processed, for example, to reduce harmful emissions, recover heat, and/or the like. In addition, while exhaust E is illustrated as flowing out of exhaust outlet 150 in a specific direction and at an angle that is substantially orthogonal to longitudinal axis L, it should be understood that exhaust outlet 150 may be configured to output exhaust E towards any direction and at any angle that is appropriate for the particular application of gas turbine engine 100.
Flange assembly 210 may comprise a flange 212, a main fuel fitting 214, a pilot fuel fitting 216, and one or more handles 218. Flange 212 may be a cylindrical disk comprising apertures for fastening fuel injector 134 to combustor case 130. Main fuel fitting 214 and pilot fuel fitting 216 may provide inlets for the introduction of dual fuel sources to separate and distinct main fuel and pilot fuel circuits, respectively. As illustrated, the center of flange 212, through which primary fuel fitting 214 extends, may be offset from assembly axis A.
Distribution block 220 may extend in an axial downstream direction from flange 212. Flange 212 and distribution block 220 may be formed from a single integral piece of material, or may be formed as separate pieces of material that are joined by any known means. Distribution block 220 acts as a manifold for one or more fuel circuits that distribute the flow of fuel through multiple fuel tubes 230.
Fuel tubes 230 may comprise a tube stem 232, a first main tube 234, a second main tube 236, and a secondary tube 238. First main tube 234 and second main tube 236, which may be parallel to each other and to assembly axis A, may form part of a first main fuel circuit. Secondary tube 238 may extend between distribution block 220 and injector head 230 at an angle relative to assembly axis A, first main tube 234, and second main tube 236, and form part of the first main fuel circuit or a second main fuel circuit. In an embodiment, secondary tube 238 forms a part of the first main fuel circuit with first main tube 234 and second main tube 236. In addition, secondary tube 238 may act as a support tube for injector head 240 to prevent deflection of injector head 240.
Injector head 240 may be connected to fuel tubes 230 via respective fittings, and may comprise an injector body 242, premix barrel 244, and outer cap 246. The fittings of fuel tubes 230 to injector head 240 may be configured to join fluid passageways through tube stem 232, first main tube 234, second main tube 236, and secondary tube 238 to passageways in injector body 242. In addition, outer cap 246 may comprise one or more openings that enable discharge gas (e.g., air) from compressor 120 to enter injector body 242.
Fuel injector 134 may comprise a plurality of internal passageways therethrough, including one or more main fuel circuits that are in fluid communication with main fuel fitting 214 and a pilot fuel circuit that is in fluid communication with pilot fuel fitting 216. Together, these passageways can form a dual-fuel delivery system for receiving main fuel and pilot fuel at flange assembly 210 and distributing the main fuel and pilot fuel through injector head 240 into a premix passage 248 illustrated in
As illustrated in
In an embodiment, the main fuel circuit, which may comprise passageways through first main tube 234, second main tube 236, and secondary tube 238, provides fluid communication from main fuel fitting 214 to an annular cavity 412 that extends circumferentially around assembly axis A within first portion 410. Annular main fuel cavity 412 is in fluid communication with an annular main fuel gallery 414, which also extends circumferentially around assembly axis A, via an annular perforated plate 416 between main fuel cavity 412 and main fuel gallery 414. The perforations in perforated plate 146 may be configured in size, shape, spacing, and/or density to restrict fluid flow and dampen the oscillation response of combustor 130.
Main fuel gallery 414 may be in fluid communication with a plurality of first main fuel passages 422 through second portion 420. In turn, each first main fuel passage 422 may be in fluid communication with a respective second main fuel passage 462 into one of the plurality of vanes 460. Each of these vanes 460 may comprise one or more main fuel outlets 464 from its respective second main fuel passage 462 to an exterior of the vane 460, so as to be in fluid communication with premix passage 248. The combinations of each first main fuel passage 422 with a respective second main fuel passage 462 form a plurality of axial main fuel passageways, spaced circumferentially around assembly axis A, that each provide a flow path from main fuel gallery 414 through one of the plurality of vanes 460 and out that vane's main fuel outlet(s) 464 to premix passage 248.
In an embodiment, each vane 460 comprises a set of five main fuel outlets 464 arranged along an axial line with respect to each other. Each main fuel outlet 464 may extend transversely through a wall of the respective vane 460. Main fuel outlets 464 may be provide a flow path through an exterior surface of each vane 460 between adjacent vanes 460, such that the main fuel flows out of main fuel outlets 464 into spaces between adjacent vanes 460. In other words, each main fuel outlet 464 may connect to premix passage 248 on a side of its respective vane 460 that faces a space between the respective vane 460 and an adjacent vane 460. Each vane 460 may have a wedge shape with a truncated tip that is configured to direct gas (e.g., air) into premix passage 248. However, the shape of vanes 460 is not limited to such a shape. In general, vanes 460 may be shaped to generate swirl to promote the formation of zones of recirculation of the fuel-gas mixture in combustion chamber 136.
Main fuel outlets 464 on a given vane 460 may be spaced apart from each other at equidistant intervals along an axial line, and the main fuel outlets 464 on each end of the axial line of main fuel outlets 464 may be spaced apart from an axial end of vane 460 by a distance. These intervals and distances may be selected according to an oscillation response of combustor 130. In an embodiment, each main fuel outlet 464 is circular in profile and identical. However, main fuel outlets 464 may have non-circular profiles (elliptical, rectangular, triangular, irregular polygonal, etc.) and/or may be differ from each other in size, shape, and/or relative spacing.
In an embodiment, the pilot fuel circuit, which may comprise a passageway through pilot fuel tube 233 in tube stem 232, provides fluid communication from pilot fuel fitting 216 to an annular pilot fuel gallery 441 that extends circumferentially around assembly axis A in central portion 440. Pilot fuel gallery 441 may be in fluid communication with one or more axial pilot fuel distribution passages 442, which may be configured in size, spacing, shape, and/or density for dampening the oscillation response of combustor 130. In turn, each pilot fuel distribution passage 442 may be in fluid communication with an annular central pilot fuel cavity 443 that extends circumferentially around assembly axis A and encircles pilot tube 430. In turn, central pilot fuel cavity 443 may be in fluid communication with one or more axial pilot-block passages 444. In turn, each pilot-block passage 444 may be in fluid communication with a pilot premix passage 445 that is open to premix passage 248 at the downstream end. The downstream tip of central portion 440 may also comprise one or more radial tip passages 446 that provide fluid communication between pilot premix passage 445 and an injector cavity 452 within injector portion 450.
In an embodiment, first portion 410 comprises an annular feed passage 451 that extends circumferentially around assembly axis A and receives a gas (e.g., air), at its upstream end, from compressor 120 via opening(s) in outer cap 246. Feed passage 451 may be in fluid communication, at a downstream end, with an annular injector cavity 452 in injector portion 450 that extends circumferentially around assembly axis A and encircles central portion 440. In turn, injector cavity 452 may be in fluid communication with one or more axial gas passages 453 in injector portion 450. In turn, each gas passage 453 may be in fluid communication with an annular tip cavity 454 in injector portion 450 that extends circumferentially around assembly axis A and encircles the downstream tip of central portion 440. In turn, tip cavity 454 may be in fluid communication with an injector opening 455 at the downstream end of injector portion 450. The combination of feed passage 451, injector cavity 452, axial gas passage(s) 453, tip cavity 454, and injector opening 455 provides a flow path for gas (e.g., air) through injector portion 450 around assembly axis A. In addition, radial tip passage(s) 446 through the downstream tip of central portion 440 provide a flow path for gas from injector cavity 452 into pilot premix passage 445 of central portion 440.
In an embodiment, injector portion 450 may be shaped as a hyperbolic funnel rotated around assembly axis A. Thus, as illustrated in
Gas turbine engines 100 are used in various industrial applications. Examples of such applications include, the oil and fuel industry (e.g., for the transmission, collection, storage, withdrawal, and/or lifting of oil and natural gas), the power generation and cogeneration industries, the aerospace industry, other transportation industries, and the like.
In an embodiment, during operation of gas turbine engine 100, compressed working fluid F (e.g., air) from compressor 120 enters premix passage 248 through the spaces between vanes 460. This working fluid F mixes with the main fuel discharged from main fuel outlets 464. Premix passage 248 discharges this fuel-gas (e.g., fuel-air) mixture into a combustion chamber 136 for combustion.
The configuration and position of main fuel outlets 464 and purge holes 457 in fuel injector 134 alters the stoichiometry (e.g., fuel-to-air ratio) in premix passage 248, in a manner that reduces flame propagation towards vanes 460 and flashback. Specifically, regions of premix passage 248 near the trailing edges of vanes 460 are prone to have recirculation and a fuel-gas mixture that is conducive to a reaction. Purge holes 457 at or near the bases of vanes 460 remove stagnant recirculation zones and introduce gas (e.g., air) that manipulate the gas side of local fuel-to-gas ratio to lean out the fuel-gas mixture within combustion chamber 136 along the wall of injector portion 450. In addition, the size, arrangement, and position of main fuel outlets 464 manipulate the fuel side of the local fuel-to-gas ratio to obtain an appropriate local stoichiometry. These effects reduce the reaction in these regions of premix passage 248 and thereby reduce the propensity for flashback in these regions. In other words, the disclosed features lower the flammability of the fuel-gas mixture along the exterior surface of injector portion 450, and therefore, reduce the propensity for a flame to travel along this exterior surface to vanes 460 and flashback. In an embodiment, to improve these effects, vanes 460 do not comprise any purge holes along their trailing edges.
It will be understood that the benefits and advantages described above may relate to one embodiment or may relate to several embodiments. Aspects described in connection with one embodiment are intended to be able to be used with the other embodiments. Any explanation in connection with one embodiment applies to similar features of the other embodiments, and elements of multiple embodiments can be combined to form other embodiments. The embodiments are not limited to those that solve any or all of the stated problems or those that have any or all of the stated benefits and advantages.
The preceding detailed description is merely exemplary in nature and is not intended to limit the invention or the application and uses of the invention. The described embodiments are not limited to usage in conjunction with a particular type of gas turbine engine or a particular combustor. Hence, although the present embodiments are, for convenience of explanation, depicted and described as being implemented in a particular fuel injector for a particular combustor in a particular gas turbine engine, it will be appreciated that it can be implemented in various other types of fuel injectors (e.g., dual fuel injectors, such as Dry Low Emissions (DLE) dual fuel (DF) and Lean Direction Injection (LDI) DF fuel injection systems), combustors, gas turbine engines, and/or turbomachines, and in various other systems and environments. Furthermore, there is no intention to be bound by any theory presented in any preceding section. It is also understood that the illustrations may include exaggerated dimensions and graphical representation to better illustrate the referenced items shown, and are not consider limiting unless expressly stated as such.
Number | Name | Date | Kind |
---|---|---|---|
5778676 | Joshi | Jul 1998 | A |
8065880 | Ishizaka et al. | Nov 2011 | B2 |
8991188 | Bailey et al. | Mar 2015 | B2 |
9441835 | Overby et al. | Sep 2016 | B2 |
10641493 | Johnson et al. | May 2020 | B2 |
20040003596 | Chin | Jan 2004 | A1 |
20050262843 | Monty | Dec 2005 | A1 |
20080000234 | Commaret et al. | Jan 2008 | A1 |
20080066720 | Piper | Mar 2008 | A1 |
20100293954 | Widener | Nov 2010 | A1 |
20110271682 | Sandelis | Nov 2011 | A1 |
20120111012 | Axelsson | May 2012 | A1 |
20130189632 | Menon et al. | Jul 2013 | A1 |
20140331677 | Cramb | Nov 2014 | A1 |
20140332602 | Cramb | Nov 2014 | A1 |
20170003030 | Benjamin et al. | Jan 2017 | A1 |
20170191457 | Spivey | Jul 2017 | A1 |
20170191667 | Spivey | Jul 2017 | A1 |
20170299190 | Patel | Oct 2017 | A1 |
20180100652 | Vranjic | Apr 2018 | A1 |
20200033006 | Miyamoto | Jan 2020 | A1 |
Number | Date | Country |
---|---|---|
1873455 | May 2015 | EP |
4571612 | Aug 2010 | JP |
4899221 | Jan 2012 | JP |
2020-034271 | Mar 2020 | JP |
Entry |
---|
Written Opinion and International Search Report for Int'l. Patent Appln. No PCT/US2021/051204, dated Jul. 8, 2022 (10 pgs). |
Number | Date | Country | |
---|---|---|---|
20220128237 A1 | Apr 2022 | US |