The present disclosure relates to a fuel mixer for a gas turbine engine. In particular, the present disclosure relates to a fuel mixer configured to blend hydrogen fuels.
Current mixers for natural gas-powered turbine engines blend fuel with air to create a fuel-air mixture for providing to a combustor of the engine. The conventional mixers mix inlet air and inlet fuel to create the fuel-air mixture. The inlet air may be introduced to the combustor without imparting a swirl.
According to an embodiment, a mixer configured to provide a fuel-air mixture to a combustor of an engine, the mixer comprising: a mixer body having an interior passage with a central axis; a fuel flow parallel to the central axis; a first air flow parallel to the central axis and to the fuel flow; a second air flow inclined with respect to the first air flow and the fuel flow; and a third air flow tangential to the mixer body, wherein the first air flow is configured to pull the fuel flow along the central axis and through the interior passage, wherein the second air flow is configured as a forward swirling jet to prevent low-velocity flow on a conical surface within the mixer body, and wherein the third air flow is configured to prevent the fuel flow from approaching an inner wall of the mixer body.
According to an embodiment, a mixer configured to provide a fuel-air mixture to a combustor of an engine, the mixer comprising: a mixer body having an outer surface, an interior passage, and a central axis; a fuel inlet located parallel to the central axis, the fuel inlet configured to introduce a fuel flow to the interior passage of the mixer body; a central air jet located parallel to the central axis; a first set of openings inclined with respect to the central axis; and a second set of openings having an inlet surface tangential to the mixer body, wherein the central air jet, the first set of openings, and the second set of openings are each configured to introduce an air flow to the interior passage of the mixer body, wherein the first set of openings and the second set of openings are configured to prevent the fuel flow from approaching a boundary layer flow near an interior surface of the mixer body, and wherein the fuel flow comprises H2 fuel in a range of 0% to 100%.
According to an embodiment, a mixer array comprising one or more mixers according to any of the embodiments disclosed herein.
Additional features, advantages, and embodiments of the disclosure are set forth or apparent from consideration of the following detailed description, drawings and claims. Moreover, it is to be understood that both the foregoing summary of the disclosure and the following detailed description are exemplary and intended to provide further explanation without limiting the scope of the disclosure as claimed.
The foregoing and other features and advantages will be apparent from the following, more particular, description of various exemplary embodiments, as illustrated in the accompanying drawings, wherein like reference numbers generally indicate identical, functionally similar, and/or structurally similar elements.
Various embodiments of the mixer are discussed in detail below. While specific embodiments are discussed, this is done for illustration purposes only. A person skilled in the relevant art will recognize that other components and configurations may be used without departing from the spirit and scope of the present disclosure.
Current mixers present low-velocity pockets and fuel-air mixture in low velocity pocket on the wall of mixer part that may create flashback/flame-holding within mixer and may result in high temperatures that may damage the structure of the mixer and/or combustor. Thus, conventional mixers are not well suited for hydrogen and blends of hydrogen fuel due to the increased risk in flame-holding and high temperatures on mixer parts. A need exists for a mixer that may blend hydrogen fuels, at any percentage, and air to present safely to the combustor of an engine.
The mixer of the present disclosure may allow for fuel to be injected from a central (e.g., along a central axis extending longitudinally through a center point in the mixer) or radially offset distance relative to the mixer tube center line. The mixer may include three air flows that may be injected into the mixer tube. A central air flow may be injected along a passage that is parallel to the fuel flow. A first air flow may be introduced through aft, D-shaped forward swirling jet holes. A second air flow may be introduced through tangential circular or shaped air jets closer to the outer diameter of the mixer. The first air flow may generate a high velocity on a conic surface within the mixer tube. The second air flow may generate a high near wall velocity and may avoid fuel approaching the wall and the boundary layer flow. The mixer tube may generate a desired fuel/air distribution that may reduce flame-holding, reduce NOx and CO emissions, and allow for the burn of varying blends of hydrogen (H2) fuels.
The mixer of the present disclosure avoids low-velocity pockets and provide uniform mixing of the fuel and air. The mixer may be arranged such that the premixing length and residence time of the mixture within the mixer is lower, as compared to prior art mixers. The mixer of the present disclosure may provide enhanced mixing while maintaining the fuel, and thus the fuel-air mixture, away from the wall and boundary layer. The mixer of the present disclosure may allow for burn of any percentage of H2 fuel, including high percentage or 100% H2 fuel.
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The mixers described herein (e.g., mixers 200, 300, 400 and 500) may be the mixer 102 provided in the mixer array 100 of
The mixers described herein may include a third set of openings for introducing air to the central passage. Three or more sets of openings may be contemplated. The third set of openings may be located axially farther away from the fuel inlet. The third set of openings may include a separate passage and opening. The third set of openings may include a passage that branches from the passage of the second set of openings and extends to a third outlet.
In the mixer, the number of sets of openings may be based on the desired amount of air flow to be mixed into the fuel. The number of sets of openings, the number of openings within a set, the size of the openings, the location of the openings, the inclination of the openings, or any combination thereof may depend on how much air is available to the system and what is the desired fuel-air mixture at the output of the mixer.
As described herein, the mixers of the present disclosure may reduce the flashback/flame-holding risk.. In conventional mixer a recirculation zone exists on the center body where high H2 fuel may become trapped due to a low-velocity zone, resulting in flame-holding. The conventional mixer of
The high velocity central jets of air may create a low pressure driving the fuel toward the center. The flame is stabilized due to the swirl and flow dynamics presented by the mixer of the present disclosure. There is little or no fuel exists close to the mixer wall. The mixer of present disclosure creates compact flame structure and low and uniform downstream temperature. The mixer of the present disclosure thus allows for no low-velocity region in the mixer and instead provides higher velocity near the outer mixer wall to prevent fuel from approaching the boundary layer. The fuel may be distributed in the center, away from the mixer outer diameter. The mixer of the present disclosure may have a short mixing length (as compared to the prior art mixers) resulting in smaller residence time.
The hydrogen fuel percentage may vary from a volume percentage of the fuel blend between 0% to 100%. The hydrogen fuel percentage may vary from a volume percentage of the fuel blend between 10% to 100%. The hydrogen fuel percentage may vary from a volume percentage of the fuel blend between 20% to 100%. The hydrogen fuel percentage may vary from a volume percentage of the fuel blend between 30% to 100%. The hydrogen fuel percentage may vary from a volume percentage of the fuel blend between 40% to 100%. The hydrogen fuel percentage may vary from a volume percentage of the fuel blend between 50% to 100%. The hydrogen fuel percentage may vary from a volume percentage of the fuel blend between 60% to 100%. The hydrogen fuel percentage may vary from a volume percentage of the fuel blend between 70% to 100%. The hydrogen fuel percentage may vary from a volume percentage of the fuel blend between 80% to 100%. The hydrogen fuel percentage may vary from a volume percentage of the fuel blend between 90% to 100%. The hydrogen fuel percentage may vary from a volume percentage of the fuel blend between 55% to 95%. The hydrogen fuel percentage may vary from a volume percentage of the fuel blend between 60% to 90%. The hydrogen fuel percentage may vary from a volume percentage of the fuel blend between 65% to 85%. The hydrogen fuel percentage may vary from a volume percentage of the fuel blend between 70% to 80%. The hydrogen fuel percentage may vary from a volume percentage of the fuel blend between 85% to 100%. The hydrogen fuel percentage may vary from a volume percentage of the fuel blend between 95% to 100%. The hydrogen fuel percentage may vary from a volume percentage of the fuel blend of about 55%, 65%, 70%, 75%, 80%, 85%, 90%, 95%, or 100%. The mixer of the present disclosure may allow for burning of 100% hydrogen fuel in an engine.
Enhanced mixing (as compared to prior art mixing), such as provided by the mixers disclosed herein, may keep NOx emissions down. The mixers of the present disclosure keep the fuel flow away from the inner wall of the mixer, that is, away from the boundary layer air flow. By maintaining the fuel flow away from the inner wall, flash-back/flame holding risk is reduced, different stages of air helps to achieve uniform fuel-air mixing within mixer passage that helps keep NOx emissions low.
Of particular note with respect to the mixers of the present disclosure is the ability to 1) inject the fuel near the center of the mixer and have no or very little fuel near the inner wall of the mixer; 2) introduce air at a high velocity and momentum to maintain the fuel toward the center of the mixer; and 3) provide swirling jets of air near the inner wall to prevent the fuel from approaching the inner wall of the mixer. A mixer with the aforementioned principles may achieve lower emissions and lower flash-back/flame-holding risk, allowing for higher content hydrogen fuels to be burned.
The mixer of the present disclosure may reduce or eliminate carbon emission by achieving burning of varying blends of H2 fuel. The percentage of H2 in the fuel may vary from 0% to 100% H2 and any incremental value therebetween. The percentage of H2 fuel may be blended to achieve lower NOx and CO emissions. The percentage of H2 fuels may be selected or predetermined based on emissions requirements of a jurisdiction or system and/or based on a desired performance of the engine. The burning of H2 fuel may ensure the lowering of NOx emissions. The mixer of the present disclosure may provide a distribution of air and fuel mixture that removes auto-ignition, flash-back, flame-holding risk of a pure premixed burner/mixer design with high H2 fuel blends.
The mixer of the present disclosure may include a central high velocity axial air jet. The central jet may create a low pressure in the center of the mixer tubes. This central low pressure may allow for blends of H2 fuel to remain at the center of the mixer tube and away from the premixer outer wall. This may avoid flame-holding risk within the mixer tube. The central air jet may have a low swirl to improve radial spread of the fuel-air mixture.
The H2 fuel, or blends thereof, may be injected from a conic surface at an angle (e.g., any increment of 0 degrees to 90 degrees with respect to the central mixer axis). The mixer of the present disclosure may attain smaller compact flames due to the array of tubes. The system of the present disclosure may be employed with fuel mixtures, that is multiple fuels may be injected through different mixers. For example, one or more of the mixer tubes in zones A and C (
A primary air flow, either swirling or non-swirling, may be introduced on a conic surface that creates high velocity flow on the conic tip. The air introduced at this angle may keep the fuel in the center line of the mixer. The primary air flow may include aft swirling holes that may have an angle relative to the central mixer axis. This may streamline the flow closer to the outer wall of the mixer.
The mixer of the present disclosure may include a second set of vanes that may introduce a secondary, low swirling air either in the same direction (e.g., co-swirling) or in a counter direction to the aforementioned air. This may create a sheet of high velocity air closer to the outer wall of the mix that may prevent the fuel from approaching the outer wall boundary layer. The combination of the central non-swirling jet and the co-swirled stream from the conic surface and outer mixer wall may create unique flow structure that maintains high velocity and higher fuel concentration in the core of the mixer which may lower flame-holding and generate lesser emissions.
Accordingly, the present disclosure presents a mixer that allows for circumferential staging of air (by making some of the air inlet holes smaller than the remaining air inlet holes). This may allow for a particular fuel distribution pattern to be achieved at the mixer exit that may create changes in heat release and assist in dynamics. A shear between the compounded impinged swirling air (e.g., the primary and secondary air flows) and the strong core jet (e.g., the fuel flow) may create a desired fuel:air ratio at the exit of the mixer. Further mixing of the fuel-air mixture may take place after the mixer exit before the flame front surface due to the swirl induced by the flow structures. The mixer of the present disclosure provides an array of compact and swirled flames.
The mixer of the present disclosure has applications in aero-derivative engines, other gas turbine engines, and applications outside of the gas turbine application. The mixer of the present disclosure may allow for burning of 100% hydrogen fuel in an engine (e.g., a DLE engine). The burning of up to 100% hydrogen fuel capability may allow for zero carbon footprint, which may allow for merging with renewables while requiring little or no water for achieving a lower NOx emission.
Further aspects of the present disclosure are provided by the subject matter of the following clauses.
1. A mixer configured to provide a fuel-air mixture to a combustor of an engine, the mixer comprising: a mixer body having an interior passage with a central axis; a fuel flow parallel to the central axis; a first air flow parallel to the central axis and to the fuel flow; a second air flow inclined with respect to the first air flow and the fuel flow; and a third air flow tangential to the mixer body, wherein the first air flow is configured to pull the fuel flow along the central axis and through the interior passage, wherein the second air flow is configured as a forward swirling jet to prevent low-velocity flow on a conical surface within the mixer body, and wherein the third air flow is configured to prevent the fuel flow from approaching an inner wall of the mixer body.
2. The mixer of any preceding clause, wherein the fuel flow, the first air flow, the second air flow, and the third air flow are separate flows prior to entering the interior passage of the mixer body.
3. The mixer of any preceding clause, wherein the fuel flow or the first air flow is coincident with the central axis of the mixer.
4. The mixer of any preceding clause, wherein the first air flow is configured to pull the fuel flow into the interior passage of the mixer.
5. The mixer of any preceding clause, wherein the second air flow and the third air flow are configured to move the fuel flow toward the central axis.
6. The mixer of any preceding clause, wherein the third air flow prevents the fuel flow from reaching a boundary layer air flow.
7. The mixer of any preceding clause, wherein the fuel flow comprises H2 in a range of 0% to 100%.
8. The mixer of any preceding clause, wherein the fuel flow comprises H2 in a range of 10% to 100%.
9. A mixer configured to provide a fuel-air mixture to a combustor of an engine, the mixer comprising: a mixer body having an outer surface, an interior passage, and a central axis; a fuel inlet located parallel to the central axis, the fuel inlet configured to introduce a fuel flow to the interior passage of the mixer body; a central air jet located parallel to the central axis; a first set of openings inclined with respect to the central axis; and a second set of openings having an inlet surface tangential to the mixer body, wherein the central air jet, the first set of openings, and the second set of openings are each configured to introduce an air flow to the interior passage of the mixer body, wherein the first set of openings and the second set of openings are configured to prevent the fuel flow from approaching a boundary layer flow near an interior surface of the mixer body, and wherein the fuel flow comprises H2 fuel in a range of 0% to 100%.
10. The mixer of any preceding clause, wherein the fuel inlet or the central air jet has a central axis coincident with the central axis of the mixer body.
11. The mixer of any preceding clause, wherein the central air jet, the first set of openings, and the second set of openings are separate entry points into the interior passage.
12. The mixer of any preceding clause, wherein the first set of openings and the second set of openings are located circumferentially around the outer surface of the mixer body.
13. The mixer of any preceding clause, wherein the second set of openings includes one or more first openings and one or more second openings, the one or more second openings being larger than the one or more first openings, and wherein the second set of openings are located circumferentially around the outer surface of the mixer body.
14. The mixer of any preceding clause, further comprising a stationary vane within the central air jet, the stationary vane configured to swirl an air flow through the central air jet.
15. The mixer of any preceding clause, wherein the fuel flow comprises H2 in a range of 10% to 100%.
16. The mixer of any preceding clause, wherein the fuel flow comprises H2 in a range of 50% to 100%.
17. A mixer array comprising one or more mixers according to any preceding clause.
Although the foregoing description is directed to the preferred embodiments, it is noted that other variations and modifications will be apparent to those skilled in the art, and may be made without departing from the spirit or scope of the disclosure. Moreover, features described in connection with one embodiment may be used in conjunction with other embodiments, even if not explicitly stated above.