PERFORATED PLATES FOR ENHANCED COMBUSTION IN GAS TURBINES

Abstract

The present invention relates to an innovative design for enhancing combustion efficiency in gas turbine engines through the use of multiple perforated plates strategically placed within the combustion chamber, feature varying thicknesses and geometries, including circular and square perforations, which promote improved fuel-air mixing and increased turbulence generation. The design positions the plates at specific distances from the fuel and air injectors so that it is inherently adaptive to different operational conditions through tunable flow control. Advanced techniques of Computational Fluid Dynamics and CAD are adapted to optimize iteratively against flame instability and improper mixing. Improvements in combustion efficiency are estimated to be around 1-2%, and there will be more efficient fuel utilization along with reduced emissions. The overall contribution of the current invention is toward more effective and sustainable usage of gas turbines, given concentration to prime performance and environmental concerns.

Specification

Description:The present invention relates to an innovative combustion chamber design for gas turbine engines, specifically aimed at enhancing combustion efficiency and improving fuel-air mixing through the strategic incorporation of multiple perforated plates. When conventional combustion chamber designs are employed, there is usually an inefficient generation of turbulence which adversely affects the fuel-air mixing, causes unstable flames, and increases emissions. This invention provides a multi-layer approach through varying geometries and thicknesses in the perforated plates, bettering the challenges that lead to a significant improvement in combustion stability and performance parameters. Such design achieves an optimized flow dynamic that enhances the operational efficiency of gas turbine engines.
The invention introduces two perforated plates in strategic locations relative to the fuel and air injectors; the first causes an initial swirl of introduction into the mix, and the second enhances the mixing downstream. This sequential arrangement allows for maximum fuel-air interaction through enhanced homogeneity contributing to stable combustion. Specific geometric shapes of perforations-round and square, in particular-were selected to configure the plates, so that the turbulence produced is maximized while retaining pressure loss within very low ranges in the combustion chamber.
Utilizing advanced Computational Fluid Dynamics (CFD) and Computer-Aided Design (CAD) techniques, the design process allows for precise optimization of plate shapes and arrangements to address specific challenges in flame stability and fuel-air mixing. The iterative simulations enable engineers to analyze key performance parameters, such as turbulence intensity, velocity distribution, and temperature profiles. By considering these factors, the invention achieves a significant improvement in combustion efficiency, estimated to be between 1.5% and 2%. This improvement not only enhances fuel consumption rates but also results in lower emissions, making the design more environmentally friendly.
The versatility of the invention is further underscored by its compatibility with existing gas turbine systems. The multi-layered perforated plates are being seamlessly integrated into conventional combustion chambers and utilized alongside existing components, thereby offering an adaptable solution that requires minimal modification. This feature simplifies installation and maintenance processes, reducing operational downtime and costs. Additionally, the durable design reduces wear and tear on critical components, contributing to extended service life and improved reliability.
This invention addresses the existing limitations in gas turbine combustion chamber designs besides being a platform for the next-generation engines that consider efficiency and sustainability. It is most definitely focusing on the critical aspects of fuel-air mixing and combustion stability presented by the invention, which has much to do with modern engineering challenges and their requirements for both the aerospace and energy sectors.
Key aspects of the Invention
1. Perforated Plates
The core component of the invention consists of multiple perforated plates designed with varying thicknesses and geometric shapes. These plates increase turbulence which results in fuel-to-air mixing through swirl flows causing even interaction between fuel and air. The drop in pressure losses occur due to stable combustion design, which again adds to improved overall performance of an engine.
2. Injectors
The injector system comprises strategically placed fuel and air injectors that work in tandem with the perforated plates. The system ensures a very precise mixture of fuel and air into the combustion chamber; further mixing is promoted in this chamber by the plates. The result implies a better fuel-air mixture that improves the efficiency of combustion and lower emissions. In particular, air injectors consist of 6 circles with a diameter of 20 mm, roundly arranged at a radius of 200 mm from the center. Fuel injectors have 4 circles with a diameter of 35 mm for an arrangement to be set at 100 mm. With this configuration, the mixture of fuel and air being well delivered directly into the combustion chamber.
The injector face consists of a 700 mm diameter circle extruded to 200 mm, with a 600 mm circle cut to 150 mm depth. The mid-section is formed by extruding a solid 700 mm diameter circle to 48 mm. Two perforated plates are designed: the first with a 700 mm diameter base extruded to 1 mm, containing 13 squares of 75 mm side spaced 120 mm apart, and a second with 13 squares of 40 mm side similarly spaced. Additionally, two circular perforated plates are included, one featuring 25 circles of 60 mm diameter and the other with 44 circles of 50 mm diameter, each patterned and spaced evenly. Finally, a cylindrical chamber is created by extruding a 700 mm diameter circle to a height of 1750 mm, integrating all components into a cohesive design.
3. Combustion Chamber
The combustion chamber serves as the primary housing where the combustion reaction occurs. Integrated with the innovative perforated plates, it enhances mixing and stability during combustion. The system ensures a very precise mixture of fuel and air into the combustion chamber; further mixing is promoted in this chamber by the plates. The result implies a better fuel-air mixture that improves the efficiency of combustion and lower emissions. In particular, air injectors consist of 6 circles with a diameter of 20 mm, roundly arranged at a radius of 200 mm from the center. Fuel injectors have 4 circles with a diameter of 35 mm for an arrangement to be set at 100 mm. With this configuration, the mixture of fuel and air is being well delivered directly into the combustion chamber.
4. Exhaust Outlet
The exhaust outlet is designed to efficiently channel combustion gases away from the combustion chamber. By improving the mixing process through the perforated plates, the exhaust flow becomes more stable and uniform, reducing backpressure and enhancing the engine's overall performance. This feature plays a vital role in ensuring that emissions are minimized and that the system operates efficiently.
Steps and Functionality
I. Design Phase
During the design phase, CAD software is utilized to model the perforated plates, allowing for customization of shape, thickness, and perforation pattern. This phase is crucial for establishing the baseline geometry of the plates, which directly affects the turbulence and mixing characteristics within the combustion chamber. Engineers create various configurations to explore the most effective designs for different operational conditions. The first square plate features a circular outline of 700 mm, extruded to a thickness of 1 mm, with 13 squares of side 75 mm uniformly arranged 120 mm apart. The second square plate is similar but features 13 squares of side 40 mm. The circular plates include one with 25 circular holes of 60 mm diameter and another with 44 holes of 50 mm diameter, each designed to optimize flow dynamics for effective fuel-air mixing.
II. Simulation Phase
Following the design phase, CFD software simulates airflow and fuel-air mixing dynamics within the combustion chamber. A judgement of the effect of perforated plates on turbulence intensity, velocity distribution, and pressure drops follows. Thus, engineers compare which configurations lead to better mixing and stable combustion and solve the problems at the design stage only.
III. Optimization
This design is therefore iteratively refined using the data generated from CFD simulations so that maximum performance is achieved. The perforation shapes, thicknesses, and placements of the perforated plates are adjusted according to performance metrics to increase combustion efficiency by a minimum of 1.5 to 2%. Optimization ensures that the desirable operational criteria for which the final design is supposed to meet is minimized for possible drawbacks.
IV. Integration with Control Systems
In a real-world application, the invention is equipped with embedded control software that monitors the combustion process in real-time. It controls such parameters as injection rates of fuels and air intake for optimal performance. Analyzing data from sensors located inside the combustion chamber, the control system ensures stability and efficiency throughout the operational range of the gas turbine engine.
The functionality of the software is integral to the invention, ensuring precise geometry, flow analysis, and design improvements. Here's a brief explanation of the steps and functionality:
I. Design Specifications (Circular and Square Perforated Plates)
The invention features two types of perforated plates-circular and square-each crafted to enhance turbulence and fuel-air mixing. The circular plates have varying diameters of perforations, promoting uniform swirling flows, while the square plates introduce more aggressive flow disruptions. Each plate has been designed with specific thicknesses of a combination that results in a balance between turbulence generation and pressure loss for maximum performance.
II. Sequential Arrangement
The perforated plates are placed in step-wise fashion inside the combustion chamber at carefully calculated distances from the fuel and air injectors. Hence, the first plate causes mixing via swirl formation, and the subsequent plate improves mixing further downstream. Therefore, this step-wise placement ensures sufficient interaction between the fuel and the air, thus encouraging both combustion stability and efficiency. Parameters like: Turbulence intensity, Pressure drops, Velocity distribution, Temperature profiles, and Combustion efficiency are assessed.
III. Flow Dynamics
As the fuel-air mixture travels through perforated plates, it develops an induced swirl that results in velocity and direction variations. Due to intensified turbulence, the fuel-air mixture is made more uniform and stable enough to support combustion. The flow dynamics brought about by plates advance improved mixing patterns that lead to better fuel intake and lower exhaust emissions during an operation.
IV. Functional Benefits
The invention significantly increases turbulence intensity, which correlates with improved combustion stability and efficiency. The design is multi-layered; hence, an optimization of combustion for various operational conditions is achieved in a rather fine-tuned way. In this regard, there is improvement in combustion efficiency by 1.5-2%, which means better fuel usage and reduced emissions, and thus provides a cost-effective solution for modern gas turbine engines.
Figure 1 illustrates the combustion chamber with circular perforated plates depicting fuel injectors (1) i.e., six fuel injectors positioned to introduce fuel into the combustion chamber, enabling efficient mixing with the incoming air for combustion, air injectors (2) with four air injectors are used to introduce air into the chamber. The air mixes with the fuel to form a combustible mixture, circular perforated plate (60 mm diameter holes) (3) contains 25 circular holes, each with a diameter of 60 mm. It is designed to enhance the air-fuel mixing by allowing the air to pass through these openings, promoting turbulence and improving combustion efficiency, circular perforated plate (50 mm diameter holes) (4), the second perforated plate has 44 circular holes, each with a diameter of 50 mm. Similar to the first plate, this configuration aims to further enhance the mixing process by generating turbulence and optimizing the fuel-air mixture, and exhaust outlet (5) which is the is the chamber's exit point where the combustion products are expelled, ensuring continuous flow through the combustion chamber according to various embodiments of the present invention.
Figure 2 illustrates injector face showing the front view, left view, and right view, where in the front view (1) shows the layout of the fuel injectors and (2) represent air injector. In the front view, display the injector face, which contains both fuel and air injectors. There are 6 fuel injectors and 4 air injectors according to various embodiments of the present invention.
Figure 3 illustrates circular perforated plate showing the front view, back view, and left view depicting first plate (3) and second plate (4). In the front view, first plate, which contains 25 circular holes, each with a diameter of 60 mm. In the back view, the second plate consists of 44 circular holes, each with a diameter of 50 mm according to various embodiments of the present invention
Figure 4 illustrates cylindrical section of the combustion chamber, showing the front view, and left view. The front view and left view display the cylindrical chamber, which connects the injector face to the exhaust outlet where in left view (5) represents the exhaust outlet, indicating its position relative to the cylindrical chamber according to various embodiments of the present invention.
Figure 5 illustrates the combustion chamber with square perforated plates depicting fuel injectors (1) with six fuel injectors positioned to introduce fuel into the combustion chamber, enabling efficient mixing with the incoming air for combustion, air injectors (2) with four air injectors are used to introduce air into the chamber. The air mixes with the fuel to form a combustible mixture, circular plate with square perforation (75mm) (3) which contains 13 square holes, each with a side length of 75 mm. It is designed to enhance the air-fuel mixing by allowing the air to pass through these openings, promoting turbulence and improving combustion efficiency, circular plate with square perforation (40 mm) (4) which consists of 13 square holes, each with a side length of 40 mm and exhaust outlet (5) which is the chamber's exit point where the combustion products are expelled, ensuring continuous flow through the combustion chamber according to various embodiments of the present invention.
Fig. 6 illustrates the square perforated plates, showing the front view, back view, and right view depicting first plate (3) which contains 13 square holes, each with a side length of 75 mm. In the back view, and second plate (4) which consists of 13 square holes, each with a side length of 40 mm according to various embodiments of the present invention.
The present invention provides a ground-breaking solution to the challenges faced by conventional gas turbine combustion chambers. Through the innovative design of multiple perforated plates, this invention significantly enhances fuel-air mixing and combustion efficiency while addressing issues related to flame instability and emissions.
The flexibility of the design allows assimilation into current systems with minimal alteration and hence is applicable to a large scope of gas turbine applications. It constitutes an important step in the advancement of combustion processes for optimizing performance and sustainability in aerospace and energy sectors through the use of advanced design and simulation techniques.
, Claims:1. A gas turbine combustion chamber comprising:
multiple perforated plate featuring with different shapes circular, triangular, and hexagonal perforations; and at least one perforated plate featuring circular perforation and one perforated plate featuring square perforations;
wherein said perforated plates have different thicknesses to enhance turbulence generation and optimize fuel-air mixing;
wherein the perforated plates are positioned at varying distances from the fuel and strategically relative to air injectors, allowing for tunable flow control to adapt to various operational needs;
utilizing Computational Fluid Dynamics (CFD) and Computer-Aided Design (CAD) for iterative refinement of the plate designs, ensuring enhanced performance and addressing issues of flame instability and improper mixing;
configured to improve combustion efficiency by 1-2%, contributing to better fuel utilization and lower emissions.
2. The gas turbine combustion chamber of claim 1, wherein the multiple perforated plates are arranged in a layered configuration that maximizes interaction between the fuel-air mixture and the plates to enhance the mixing process.
3. The gas turbine combustion chamber of claim 1, wherein the varying thicknesses of the perforated plates are designed to create optimal turbulence while minimizing pressure loss within the combustion chamber.
4. The gas turbine combustion chamber of claim 1, wherein the specific arrangements and geometries of the perforations on each plate are optimized to control flow dynamics and increase the turbulence intensity of the fuel-air mixture.
5. The gas turbine combustion chamber of claim 1, wherein the design of the perforated plates facilitates improved flame stability, reducing the risk of flame oscillations during operation.
6. The gas turbine combustion chamber of claim 1, wherein the perforated plates are constructed from materials that provide durability and resistance to wear, minimizing the need for frequent replacements.
7. The gas turbine combustion chamber of claim 1, wherein the design of the perforated plates is adaptable for integration with existing combustion systems or for replacement without extensive modifications.
8. The gas turbine combustion chamber of claim 1, further comprising a monitoring system that utilizes real-time data from sensors within the combustion chamber to adjust fuel and air injection rates for optimal performance.
9. The gas turbine combustion chamber of claim 1, wherein the design incorporates maintenance features that simplify the inspection and replacement processes, reducing operational downtime.
10. The gas turbine combustion chamber of claim 1, wherein the computational design optimization process includes simulations to evaluate the effects of varying plate configurations on combustion efficiency and emissions reduction.

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