System and method for cooling hydrocarbon-fueled rocket engines

Information

  • Patent Application
  • 20080016846
  • Publication Number
    20080016846
  • Date Filed
    July 18, 2006
    18 years ago
  • Date Published
    January 24, 2008
    16 years ago
Abstract
A rocket engine combustion chamber wall operates as a heat exchange section through which the fuel passes in a heat exchange relationship. By first passing the fuel through a deoxygenator system fuel stabilization unit (FSU), oxygen is selectively removed such that the heat sink capacity of the fuel is increased which translates into an increased impulse power rocket engine.
Description

BRIEF DESCRIPTION OF THE DRAWINGS

The various features and advantages of this invention will become apparent to those skilled in the art from the following detailed description of the currently preferred embodiment. The drawings that accompany the detailed description can be briefly described as follows:



FIG. 1A is a schematic view of a rocket engine embodiment for use with the present invention;



FIG. 1B is a schematic view of a rocket engine fuel system with a deoxygenator system;



FIG. 2A is an expanded perspective view of a deoxygenator system; and



FIG. 2B is an expanded sectional view of a flow plate assembly illustrating a fuel channel and an oxygen-receiving vacuum or sweep gas channel.





DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT


FIG. 1A illustrates a schematic view of a rocket engine 10. The engine 10 generally includes a nozzle assembly 12, a fuel system 14, an oxidizer system 16 and an ignition system 18. The fuel system 14 and the oxidizer system 16 preferably provide a gaseous propellant system of the rocket engine 10, however, other propellant systems such as liquid will also be usable with the present invention. It should be further understood that although an expanded cycle type rocket engine is illustrated in the disclosed embodiment other rocket engine power cycle types including but not limited to Gas-generator cycle, Staged combustion cycle, and Pressure-fed cycle will also benefit from the present invention.


A combustion chamber wall 20 about a thrust axis A defines the nozzle assembly 12. The combustion chamber wall 20 defines a thrust chamber 22, a combustion chamber 24 upstream of the thrust chamber 22, and a combustion chamber throat 26 therebetween. The nozzle assembly 12 includes an injector face 28 with a multitude of fuel/oxidizer injector elements 30 (shown schematically) which receive fuel which passes first through the fuel cooled combustion chamber wall 20 fed via fuel supply line 14a of the fuel system 14 and an oxidizer such as Gaseous Oxygen (GOx) through an oxidizer supply line 16a of the oxidizer system 16.


Heat in the fuel cooled combustion chamber wall 20 serves to superheat and/or at least partially vaporize the fuel. The fuel vapor is then passed through a turbine 32 and injected into the combustion chamber 24 to burn with the oxidizer as generally understood. Preferably, all the propellants are burned at the optimal mixture ratio in the combustion chamber 24, and typically no flow is dumped overboard; however, heat transfer to the fuel is typically the limiting factor of the power available to the turbine 32.


Referring to FIG. 1B, the rocket engine 10 of the present invention utilizes a deoxygenator system 34 within the fuel system 14 upstream of the fuel cooled combustion chamber wall 20. The combustion chamber wall 20 operates as a heat exchange section through which the fuel passes in a heat exchange relationship. By first passing all or a portion of the fuel through the deoxygenator system 34, oxygen is selectively removed such that the heat sink capacity of the fuel is increased which translates into increased power available to the turbine 32 and thus an increase impulse power rocket engine 10. Typically, lowering the oxygen concentration to approximately 5 ppm is sufficient to overcome the coking problem and allows the fuel to be heated to approximately 650° F. during heat exchange, for example. It should be understood that even a relatively low reduction of the oxygen concentration will provide significant benefits in liner lifer as deoxygenated fuel will primarily be utilized to the nozzle throat and areas where the heat fluxes and coke deposits would otherwise be relatively high.


As the fuel passes through the deoxygenator system 34, oxygen is selectively removed into a vacuum or sweep-gas system 36. The sweep gas may be any gas that is essentially free of oxygen. The deoxygenated fuel flows from a fuel outlet of the deoxygenation system 34 via a deoxygenated fuel conduit, to the fuel cooled combustion chamber wall 20. It should be understood that although a particular component arrangement is disclosed in the illustrated embodiment, other arrangements will benefit from the instant invention.


Referring to FIG. 2A, the deoxygenator system 14 preferably includes a multiplicity of gas/fuel flow-channel assemblies 38 (FIG. 2B). The assemblies 38 include a oxygen permeable membrane 40 between a fuel channel 44 and an oxygen receiving vacuum or sweep-gas channel 42 which can be formed by a supporting mesh which permits the flow of nitrogen and/or another oxygen-free gas. It should be understood that the channels may be of various shapes and arrangements to provide a oxygen partial pressure differential, which maintains an oxygen concentration differential across the membrane to deoxygenate the fuel.


The oxygen permeable membrane 40 allows dissolved oxygen (and other gases) to diffuse through angstrom-size voids but excludes the larger fuel molecules. Alternatively, or in conjunction with the voids, the oxygen permeable membrane 40 utilizes a solution-diffusion mechanism to dissolve and diffuse oxygen (and/or other gases) through the membrane while excluding the fuel. The family of Teflon AF which is an amorphous copolymer of perfluoro-2,2-dimethyl-1,3-dioxole (PDD) often identified under the trademark “Teflon AF” registered to E. I. DuPont de Nemours of Wilmington, Del., USA, and the family of Hyflon AD which is a copolymer of 2,2,4-trifluoro-5-trifluoromethoxy-1,3-dioxole (TDD) registered to Solvay Solexis, Milan, Italy have proven to provide effective results for fuel deoxygenation.


Fuel flowing through the fuel channel 44 is in contact with the oxygen permeable membrane 40. Vacuum creates an oxygen partial pressure differential between the inner walls of the fuel channel 44 and the oxygen permeable membrane 40 which causes diffusion of oxygen dissolved within the fuel to migrate through the porous support 46 which supports the membrane 40 and out of the deoxygenator system 34 through the oxygen receiving channel 42.


The specific quantity of assemblies 38 are determined by application-specific requirements, such as fuel type, fuel temperature, and mass flow demand from the engine. Further, different fuels containing differing amounts of dissolved oxygen may require differing amounts of deoxygenation to remove a desired amount of dissolved oxygen. For further understanding of other aspects of one membrane based fuel deoxygenator system and associated components thereof which are capable of processing high flow rates characteristic of rocket engines in a compact and lightweight assembly, and lowering dissolved oxygen concentration sufficiently to suppress coke formation, attention is directed to U.S. Pat. No. 6,315,815 entitled MEMBRANE BASED FUEL DEOXYGENATOR; U.S. Pat. No. 6,939,392 entitled SYSTEM AND METHOD FOR THERMAL MANAGEMENT and U.S. Pat. No. 6,709,492 entitled PLANAR MEMBRANE DEOXYGENATOR which are assigned to the assignee of the instant invention and which are hereby incorporated herein in their entirety.


It should be understood that relative positional terms such as “forward,” “aft,” “upper,” “lower,” “above,” “below,” and the like are with reference to the normal operational attitude of the vehicle and should not be considered otherwise limiting.


It should be understood that although a particular component arrangement is disclosed in the illustrated embodiment, other arrangements will benefit from the instant invention.


For further understanding of other aspects of the airflow distribution networks and associated components thereof, attention is directed to U.S. Pat. No. 5,327,744 which is assigned to the assignee of the instant invention and which is hereby incorporated herein in its entirety.


Although particular step sequences are shown, described, and claimed, it should be understood that steps may be performed in any order, separated or combined unless otherwise indicated and will still benefit from the present invention.


The foregoing description is exemplary rather than defined by the limitations within. Many modifications and variations of the present invention are possible in light of the above teachings. The preferred embodiments of this invention have been disclosed, however, one of ordinary skill in the art would recognize that certain modifications would come within the scope of this invention. It is, therefore, to be understood that within the scope of the appended claims, the invention may be practiced otherwise than as specifically described. For that reason the following claims should be studied to determine the true scope and content of this invention.

Claims
  • 1. A rocket engine comprising: a fuel deoxygenator system; anda fuel cooled combustion chamber wall in fluid communication with said deoxygenator system.
  • 2. The rocket engine as recited in claim 1, wherein said fuel cooled combustion chamber wall defines a thrust chamber, a combustion chamber upstream of the thrust chamber, and a combustion chamber throat therebetween.
  • 3. The rocket engine as recited in claim 1, further comprising a turbine in fluid communication with a fuel system through said fuel cooled combustion chamber wall.
  • 4. A rocket engine comprising: a thrust chamber assembly having a fuel cooled combustion chamber wall;a fuel system in communication with said thrust chamber assembly through said fuel cooled combustion chamber wall;an oxidizer system in communication with said thrust chamber assembly; anda deoxygenator system in fluid communication with said fuel cooled combustion chamber wall.
  • 5. The rocket engine as recited in claim 4, wherein said thrust chamber wall assembly defines a thrust chamber, a combustion chamber upstream of the thrust chamber, and a combustion chamber throat therebetween.
  • 6. The rocket engine as recited in claim 4, wherein said deoxygenator system is upstream of said fuel cooled combustion chamber wall
  • 7. A method of increasing a thrust impulse of a rocket engine comprising the steps of: (A) deoxygenating a fuel;(B) communicating the deoxygenated fuel through a fuel cooled combustion chamber wall; and(C) communicating the deoxygenated fuel from the fuel cooled combustion chamber wall into a thrust chamber assembly.
  • 8. A method as recited in claim 7, wherein said step (C) further comprises: (a) communicating the deoxygenated fuel from the fuel cooled combustion chamber wall to a turbine prior to communication into the thrust chamber assembly.
  • 9. A method as recited in claim 7, wherein said step (C) further comprises: (a) partially vaporizing the deoxygenated fuel within the fuel cooled combustion chamber wall;(b) communicating the partially vaporized deoxygenated fuel from said step (a) to a turbine; and(c) communicating the partially vaporized deoxygenated fuel from said step (b) to the thrust chamber assembly.
  • 10. A method as recited in claim 7, wherein said step (C) further comprises: (a) superheating the deoxygenated fuel within the fuel cooled combustion chamber wall;(b) communicating the superheated deoxygenated fuel from said step (a) to a turbine; and(c) communicating the superheated vaporized deoxygenated fuel from said step (b) to the thrust chamber assembly.