The subject matter disclosed herein generally relates to hydrocarbon fuel processing and delivery, and more particularly to removal of dissolved gases from a hydrocarbon fuel stream.
Hydrocarbon fuels can be thermodynamically characterized as high-energy, low-entropy materials, and are utilized for their characteristic of being chemically unstable under certain conditions so that the fuel readily reacts with atmospheric oxygen in a highly exothermic combustion reaction. Liquid hydrocarbon fuels are typically prepared through the chemical refining of crude oil. However, liquid hydrocarbon fuels can contain substances other than the moderately short-chain hydrocarbons that make up the bulk of the liquid fuel. For example, they can contain dissolved contaminants or by-products from the refining process. Other contaminants such as dissolved gases can be introduced to the liquid fuel through contact with gases (e.g. the surrounding atmosphere) during storage or transportation. Contaminants such as dissolved gases can cause performance problems for fuel system or engine operation and components, and although various technologies have been proposed for removing gases from fuels, new approaches continue to be sought.
Disclosed is a fuel system comprising a fuel tank containing hydrocarbon fuel, a hydrocarbon fuel flow path in fluid communication with the fuel tank, and a gas separation pump disposed on the flow path. The gas separation pump comprises a pump housing comprising an inner wall defining a cylindrical internal cavity. The pump housing comprises an inlet at a first axial position along the cylindrical cavity outer circumference, an outlet at a second axial position along the cylindrical cavity outer circumference, and a vacuum connection in fluid communication with the cylindrical cavity axis. A first impeller comprising an outer edge configured to sweep along the inner wall is axially disposed between the inlet and the outlet. A second impeller configured to eject liquid through the fluid outlet is axially disposed between the first impeller and the outlet.
In some embodiments, the vacuum connection can be disposed at a radially central location along a first end of the inner cylindrical cavity closer to the axial position of the inlet than to the axial position of the outlet.
In some embodiments, the gas separation pump can further comprise a third impeller at an axial position between the inlet and the first end of the inner cylindrical cavity.
In some embodiments, the vacuum connection can be disposed at a second end of the inner cylindrical cavity closer to the axial position of the outlet than the axial position of the fluid inlet.
In some embodiments, the vacuum connection can be in fluid communication with a vacuum device, either integrated with or external to the gas separation pump, on a common rotor with the first and second impellers.
In some embodiments, the vacuum device can comprise a vacuum ejector.
In some embodiments, the first impeller, or the pump housing inner wall, or both the first impeller or the pump housing inner wall, can include an uneven surface in a region where the first impeller is configured to sweep during operation.
In some embodiments, the uneven surface can be configured to form eddy or vortex currents in pumped fluid during operation.
In some embodiments, the gas separation pump inlet can further comprise an orifice or Venturi tube.
In some embodiments, the fuel system can further comprise an inert gas source in fluid communication with an ullage space in the fuel tank.
In some embodiments, the inert gas source can comprise a catalytic reactor that combusts fuel vapor to form carbon dioxide and water.
In some embodiments, the fuel system can be configured to control a vacuum pressure at the vacuum connection based on temperature of the liquid hydrocarbon fuel.
Also disclosed is an engine fueling system comprising the fuel system of any one or combination of the above embodiments and an engine that receives fuel from the hydrocarbon fuel flow path.
In some embodiments, the engine fueling system can further comprise a scavenge pump on the hydrocarbon fluid flow path between the fuel tank and the gas separation pump inlet, wherein fuel flow output from the gas separation pump or a boost pump provides motive force to the scavenge pump.
In some embodiments, the engine fueling system can further comprise a heat exchanger comprising a heat absorption side on the hydrocarbon fuel flow path and a heat rejection side in thermal communication with a heat source.
In some embodiments, the engine can comprise a gas turbine aircraft engine, and the heat source comprises engine lubricating oil.
Also disclosed is a method of assembling a fuel system comprising fluidly connecting a fuel tank containing a hydrocarbon fuel to an inlet of a gas separation pump, and fluidly connecting the gas separation pump outlet to a fuel delivery outlet. The gas separation pump comprises a pump housing comprising an inner wall defining a cylindrical internal cavity. The pump housing comprises an inlet at a first axial position along the cylindrical cavity outer circumference, an outlet at a second axial position along the cylindrical cavity outer circumference, and a vacuum connection in fluid communication with the cylindrical cavity axis. A first impeller comprising an outer edge configured to sweep along the inner wall is axially disposed between the inlet and the outlet. A second impeller configured to eject liquid through the fluid outlet is axially disposed between the first impeller and the outlet.
Also disclosed is a gas separation pump comprising a pump housing comprising an inner wall defining a cylindrical internal cavity. The pump housing comprises an inlet at a first axial position along the cylindrical cavity outer circumference, an outlet at a second axial position along the cylindrical cavity outer circumference, and a vacuum connection in fluid communication with the cylindrical cavity axis. A first impeller comprising an outer edge configured to sweep along the inner wall is axially disposed between the inlet and the outlet. The first impeller, or the pump housing inner wall, or both the first impeller or the pump housing inner wall, includes an uneven surface in a region where the first impeller is configured to sweep during operation. A second impeller configured to eject liquid through the fluid outlet is axially disposed between the first impeller and the outlet.
The following descriptions should not be considered limiting in any way. With reference to the accompanying drawings, like elements are numbered alike:
A detailed description of one or more embodiments of the disclosed apparatus and method are presented herein by way of exemplification and not limitation with reference to the Figures.
Various embodiments of the present disclosure are related to the removal of dissolved gaseous species (e.g. oxygen, carbon dioxide, water vapor, etc.) from fuel. In some embodiments, for example, hydrocarbon fuel can serve as a heat sink on aircraft or other vehicles by absorbing heat from an engine, engine accessories, and other heat loads. At high temperature, however, the fuel can react with dissolved oxygen to form solid carbonaceous deposits (“varnish” or “lacquering”) in fuel passages. The deposits can foul surfaces for heat exchange and clog fuel system components. When fuel is heated above approximately 250° F., the increased rate of these auto-oxidation reactions can shorten typical fuel system maintenance intervals. Further, water in fuel can also be problematic because water degrades the heating value of fuel. Water can also freeze in the fuel system and block fuel flow. Water can also allow microorganisms to grow in fuel that can occlude flow of fuel and whose metabolic byproducts contribute to corrosion of fuel system components. Additionally, carbon dioxide in fuel may also be problematic. Carbon dioxide in fuel can cause vapor lock or fuel pump cavitation under certain conditions. Vapor lock is the undesired presence of gases and vapors in the fuel system that can adversely affect delivery of fuel to the engine. Carbon dioxide and water can get into fuel through exposure to the environment, or in some embodiments through fuel tank inerting systems that provide a nonflammable gas by catalytic combustion to form carbon dioxide and water, which can present a risk of vapor lock or cavitation when dissolved in fuel. Many approaches for removing dissolved gases from hydrocarbon fuels have utilized selective membranes that can have high bulk and weight and limited durability. This disclosure seeks to address the issue of dissolved gases in fuel with embodiments that can be used as an alternative to or in combination with other gas removal technologies such as selective membranes.
With reference now to the Figures,
An example embodiment of an on-board aircraft fuel system is schematically shown in
With reference now to
Various types of vacuum devices can be used as the vacuum pump 26. For example, in some embodiments a rotary vane vacuum pump can be used as vacuum pump 26. In some embodiments, a vacuum can be generated by a vacuum generation device as described in U.S. patent application Ser. No. 15/587,669 entitled “Vacuum Systems for Degassing of Liquid Hydrocarbon Fuels”, the disclosure of which is incorporated herein by reference in its entirety. In some embodiments, the vacuum pump 26 can be integrated with the gas separation pump 20, and in some embodiments, the vacuum pump 26 can be external to the gas separation pump 20. In some embodiments, the vacuum pump can be on or powered by the same rotor as the impellers of the gas separation pump 20.
As mentioned above, some embodiments can provide a technical effect of removing dissolved gases from liquid hydrocarbon fuel. In some embodiments, the processing of liquid hydrocarbon fuel for removal of dissolved gases can be promoted in various ways. For example, in some embodiments, features can be included in the gas separation pump 20 to enhance mass transfer for the evolution of gases such as oxygen, nitrogen, and carbon dioxide in the region where the inducer impeller sweeps along the inner wall of the pump housing 102. In some embodiments, such features can include an uneven surface on the pump housing inner wall or on the blade edge of the inducer impeller. Example embodiments of such features are is shown in
In some embodiments, the level of vacuum can be varied. A deep vacuum can generally promote evolution of gas from the liquid fuel, but increased levels of vacuum can also promote evaporation of lighter fractions (lower molecular weight hydrocarbons) in the fuel and can lead to pump cavitation. Although any fuel lost to the vacuum exhaust can be recaptured downstream by a condenser or a reverse selective membrane, it can be beneficial in some embodiments to control the vacuum level to inhibit fuel loss. A vacuum level of about 50 torr absolute pressure can removed dissolve gases in liquid hydrocarbon fuel at 50° C. without excessive fuel evaporation, but may be less effective at lower temperatures. However, the vapor pressures of the liquid hydrocarbon fractions are also reduced at lower temperatures, so that a deeper vacuum can be drawn at lower temperatures without excessive fuel evaporation. In some embodiments, the fuel system is configured to operate (e.g., includes a controller configured to operate the system) to vary the vacuum pressure based on the fuel temperature. In some embodiments, the fuel system is configured to operate (e.g., includes a controller configured to operate the system) to reduce the vacuum pressure with reduced temperature and to increase the vacuum pressure with increased temperature. Increasing the residence time of the liquid hydrocarbon fuel in the pump can promote evolution of dissolved gases from the liquid fuel. In some embodiments, the pump can be configured and operated to provide a minimum residence time of at least 5 milliseconds (ms), or at least 25 ms, or at least 250 ms for fuel at room temperature. These range endpoints can be independently combined to form a number of ranges, and each possible range is hereby explicitly disclosed.
In some embodiments, the gas separation pump can be outfitted with seals and other materials that are compatible with hydrocarbon fuels. For example, seal materials can be a fluoropolymer elastomer or a fluorosilicone rubber. Aluminum for the pump housing and rotors is compatible with kerosene-based fuels such as aviation fuel Jet A-1. In some embodiments, copper conduits should be avoided, as should brass fittings because they can catalyze the auto-oxidation reactions of dissolved oxygen in the fuel. Seals and materials should not only be chemically compatible with fuel, they should also be compatible with temperature in which in which the gas separation pump is subjected to subfreezing temperatures during the cold soak condition. For example, some commercially available fluoroelastomer materials are compatible with a wide range of temperatures from −50° C. to +200° C.
The terminology used herein is for the purpose of describing particular embodiments only and is not intended to be limiting of the present disclosure. As used herein, the term “about” is intended to include the degree of error associated with measurement of the particular quantity based upon the equipment available at the time of filing the application. For example, “about” can include a range of ±8% or 5%, or 2% of a given value. As used herein, the singular forms “a”, “an” and “the” are intended to include the plural forms as well, unless the context clearly indicates otherwise. It will be further understood that the terms “comprises” and/or “comprising,” when used in this specification, specify the presence of stated features, integers, steps, operations, elements, and/or components, but do not preclude the presence or addition of one or more other features, integers, steps, operations, element components, and/or groups thereof.
While the present disclosure has been described with reference to an exemplary embodiment or embodiments, it will be understood by those skilled in the art that various changes may be made and equivalents may be substituted for elements thereof without departing from the scope of the present disclosure. In addition, many modifications may be made to adapt a particular situation or material to the teachings of the present disclosure without departing from the essential scope thereof. Therefore, it is intended that the present disclosure not be limited to the particular embodiment disclosed as the best mode contemplated for carrying out this present disclosure, but that the present disclosure will include all embodiments falling within the scope of the claims.