This invention relates to a combustion engine, such as a gas turbine, and more particularly to a fuel injector that provides alternate pathways for gaseous fuels of widely different energy densities.
In gas turbine engines, air from a compressor section and fuel from a fuel supply are mixed together and burned in a combustion section. The products of combustion flow through a turbine section, where they expand and turn a central shaft. In a can-annular combustor configuration, a circular array of combustors is mounted around the turbine shaft. Each combustor may have a central pilot burner surrounded by a number of main fuel injectors. A central pilot flame zone and a main fuel/air mixing region are formed. The pilot burner produces a stable flame, while the injectors deliver a stream of mixed fuel and air that flows past the pilot flame zone into a main combustion zone. Energy released during combustion is captured downstream by turbine blades, which turn the shaft.
In order to ensure optimum combustor performance, it is preferable that the respective fuel-and-air streams are well mixed to avoid localized, fuel-rich regions. As a result, efforts have been made to produce combustors with essentially uniform distributions of fuel and air. Swirler elements are used to produce a stream of fuel and air in which air and injected fuel are evenly mixed. Within such swirler elements are holes releasing fuel supplied from manifolds designed to provide a desired amount of a given fluid fuel, such as fuel oil or natural gas.
Fuel availability, relative price, or both may be factors for an operation of a gas turbine, so there is an interest not only in efficiency and clean operation but also in providing fuel options in a given turbine unit. Consequently, dual fuel devices are known in the art.
Synthetic gas, or syngas, is gas mixture that contains varying amounts of carbon monoxide and hydrogen generated by the gasification of a carbon-containing fuel such as coal to a gaseous product with a heating value. Modern turbine fuel system designs should be capable of operation not only on liquid fuels and natural gas but also on synthetic gas, which has a much lower BTU (British Thermal Unit) energy value per unit volume than natural gas. This criterion has not been adequately addressed. Thus, there is a need for a flex-fuel mixing device that provides efficient operation using fuels with low energy density, such as syngas, as well as higher energy fuels, such as natural gas.
The invention is explained in the following description in view of the drawings that show:
Compressed air 40 from a compressor 42 flows between support ribs 44 through the swirler assemblies 36. Within each main swirler assembly 36, a plurality of swirler vanes 46 generate air turbulence upstream of main fuel injection ports 22 to mix compressed air 40 with fuel 26 to form a fuel/air mixture 48. The fuel/air mixture 48 flows into the main combustion zone 28 where it combusts. A portion of the compressed air 50 enters the pilot flame zone 38 through a set of vanes 52 located inside a pilot swirler assembly 54. The compressed air 50 mixes with the pilot fuel 56 within pilot cone 32 and flows into pilot flame zone 38 where it combusts. The pilot fuel 56 may diffuse into the air supply 50 at a pilot flame front, thus providing a richer mixture at the pilot flame front than the main fuel/air mixture 48. This maintains a stable pilot flame under all operating conditions.
The main fuel 26 and the pilot fuel 56 may be the same type of fuel or different types, as disclosed in U.S. patent application Ser. No. 11/454,698, filed Jun. 16, 2006, of the present assignee, which is incorporated herein by reference. For example, natural gas may be used as a main fuel simultaneously with dimethyl ether (CH3OCH3) used as a pilot fuel.
The prior design of
Existing swirler assemblies 36 have been refined over the years to achieve ever-increasing standards of performance. Altering a proven swirler design could impair its performance. For example, increasing the thickness of the vanes 47A to accommodate a wider radial passage for a lower-energy-density fuel would increase pressure losses through the swirler assemblies, since there would be less open area through them. To overcome this problem, higher fuel pressure could be provided for the low-energy-density fuel instead of wider passages. However, this causes other complexities and expenses. Accordingly, it is desirable to maintain current design aspects of the swirler assembly with respect to a first fuel such as natural gas as much as possible, while adding a capability to alternately use a lower-energy-density fuel such as synthetic gas.
The first fuel delivery pathway 19A, 21A, 23A provides a first flow rate at a given backpressure. Herein “backpressure” means pressure exerted on a moving fluid against the direction of flow by obstructions, bends, and turbulence in a passage along which it is moving. In order to accommodate fuels with dissimilar energy densities, the second fuel delivery pathway 19B, 21B, 23B provides a second flow rate at approximately the given backpressure. The first and second flow rates may differ from each other by at least a factor of two. This difference may be achieved by different cross-sectional areas in one or more respective portions of the two fuel delivery pathways, as known in fluid dynamics, and may be enhanced by differences in the shapes of the two pathways. For example, it was found that a rounded or gradual transition area 25 between the second fuel supply channel 19B and the second radial passages 21B substantially increases the second fuel flow rate at a given backpressure, due to reduction of turbulence in the radial passages 21B. Such transition area may take a curved form as shown, or may take a graduated form, such as a 45-degree transitional segment. Rounding or graduating of the transition 25 area may be done in an axial plane of the injector as shown and/or in a plane normal to the flow direction 40 (not shown).
The first fuel delivery pathway 19A, 21A, 23A provides a first flow rate at a given backpressure. In order to accommodate fuels with dissimilar energy densities, the second fuel delivery pathway 19B, 21C, 21D, 23C, 23D provides a second flow rate at the given backpressure. The first and second flow rates may differ by at least a factor of two. This difference may be achieved by providing different cross-sectional areas of one or more respective portions of the first and second fuel delivery pathways, and may be enhanced by differences in the shapes of the two pathways. It was found that contouring the transition area 31 between the fuel supply channel 19B and the second and third radial passages 21C, 21D increases the fuel flow rate at a given backpressure, due to reduction of fuel turbulence. A more equal fuel pressure between the radial passages 21C and 21D was achieved by providing an equalization area or plenum 31 in the transition area, as shown. This equalization area 31 is an enlarged and rounded or graduated common volume of the proximal ends of the radial passages 21C and 21D. A partition 33 between the radial passages 21C and 21D may start radially outwardly of the second fuel supply channel 19B. This creates a small plenum 31 that reduces or eliminates an upstream/downstream pressure differential at the proximal ends of the respective radial passages 21D, 21C. Rounding or graduating of the equalization area 31 may be done in an axial plane of the injector as shown and/or in a plane normal to the flow direction 40 (not shown).
Main injector assemblies embodying the present invention may be used with diffusion or pre-mixed pilots.
The first fuel delivery pathway 19A, 21A, 23A provides a first flow rate at a given backpressure. In order to accommodate fuels with dissimilar energy densities, the second fuel delivery pathway 19B, 21F, 21G, 23F, 23G provides a second flow rate at the given backpressure. The first and second flow rates may differ by at least a factor of two. This difference may be achieved by providing different cross-sectional areas of one or more respective portions of the first and second fuel delivery pathways, and may be enhanced by differences in the shapes of the two pathways. It was found that contouring the transition area 41 between the second fuel supply channel 19B and the second and third radial passages 21F, 21G increases the fuel flow rate at a given backpressure, due to reduction of fuel turbulence. Fuel pressure differences between the radial passages 21F and 21G may be equalized by providing an equalization area or plenum 41 in the transition area, as shown. This equalization area 41 is an enlarged and rounded or graduated common volume of the proximal ends of the radial passages 21F and 21G. A partition 33 between the radial passages 21F and 21G may start radially outwardly of the second fuel supply channel 19B. For example, it may start radially flush with an inner diameter of the first fuel supply tube 20C. This creates a small plenum 41 that reduces or eliminates an upstream/downstream pressure differential at the proximal ends of the respective radial passages 21F, 21G. Rounding or graduating of the equalization area may be done in an axial plane of the injector as shown and/or in a plane normal to the flow direction 40 (not shown).
The vanes 47B, 47C, 47D, 47E of the present invention may be fabricated separately or integrally with the fuel delivery tube structure 20B, 20C, 20D or with a hub (not shown) to be attached to the fuel delivery structure 20B, 20C, 20D. If formed separately, the radial passages 21A, 21B, 21C and transition areas 25, 31, 41 may be formed by machining. Alternately, the vanes may be formed integrally with the fuel delivery tube structure 20B or a hub. For example, the fuel channels and/or radial passages may be formed of a high-nickel metal in a lost wax investment casting process with fugitive curved ceramic cores or by sintering a powdered metal or a ceramic/metal powder in a mold with a fugitive core such as a polymer that vaporizes at the sintering temperature to leave the desired internal void structure.
The embodiment of
In any of the embodiments herein, any of the injector “vanes” may be aerodynamic swirlers as shown, or they may have other shapes, such as the non-swirling vane 47D of
In any of the embodiments of the invention herein, the first and second fuels 26A, 26B may be supplied from two or more independent supply facilities, such as storage tanks, supply lines, or an on-site integrated gasification facility. For example, the first fuel 26A may be natural gas supplied from a storage tank or supply line, while the second fuel 26B may be a synthetic gas supplied from on-site gasification of coal or other carbon-containing material. The first and second fuels 26A, 26B are selectively supplied alternately to the first main fuel supply channel 19A or to the second main fuel supply channel 19B respectively. The same first and second fuels 26A, 26B may also be selectively supplied alternately to the first pilot fuel supply channel 35A or to the second pilot fuel supply channel 35B respectively. The selection and switching between alternate fuels may be done by valves, including electronically controllable valves. Embodiments where more than two (such as three for example) radial passages may be fed by a central fuel supply channel may be envisioned.
The present invention provides alternate fuel capability in a fuel/air mixing apparatus, and allows the fuel/air mixing apparatus to maintain a predetermined and proven performance for a first fuel while adding an optimized alternate fuel capability for a second fuel having a widely different energy density from the first fuel.
While various embodiments of the present invention have been shown and described herein, it will be obvious that such embodiments are provided by way of example only. Numerous variations, changes and substitutions may be made without departing from the invention herein. For example, while exemplary embodiments having two radial passages for a lower BTU fuel are discussed, other embodiments may have more than two radial fuel passages fed by a single fuel supply, such as three radial passages in one embodiment. Accordingly, it is intended that the invention be limited only by the spirit and scope of the appended claims.
This application claims benefit of the 26 Sep. 2008 filing date of U.S. provisional application No. 61/100,448.
Development for this invention was supported in part by Contract No. DE-FC26-05NT42644, awarded by the United States Department of Energy. Accordingly, the United States Government may have certain rights in this invention.
Number | Date | Country | |
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61100448 | Sep 2008 | US |