Coke Deposition and Smoke Formation in Turbojet Engines
In the early development of jet engines, it was occasionally found that excessive amounts of coke or other carbonaceous deposits were formed in the combustion chamber. Sometimes a considerable amount of smoke was noted in the-exhaust gases. Excessive coke deposits may adversely affect jet-engine performance in several ways. The formation of excessive amounts of coke on or just downstream of a fuel nozzle (figs. 116(a) and (b)) changes the fuel-spray pattern and possibly affects combustor life and performance. Similar effects on performance can result from the deposition of coke on primary-air entry ports (fig. 116(c)). Sea-level or altitude starting may be impaired by the deposition of coke on spark-plug electrodes (fig. 116(b)), deposits either grounding the electrodes completely or causing the spark to occur at positions other than the intended gap. For some time it was thought that large deposits of coke in turbojet combustion chambers (fig. 116(a)) might break away and damage turbine blades; however, experience has indicated that for metal blades this problem is insignificant. (Cermet turbine blades may be damaged by loose coke deposits.) Finally, the deposition of coke may cause high-temperature areas, which promote liner warping and cracking (fig. 116(d)) from excessive temperature gradients and variations in thermal-expansion rates. Smoke in the exhaust gases does not generally impair engine performance but may be undesirable from a tactical or a nuisance standpoint. Appendix B of reference 1 and references 2 to 4 present data obtained from full-scale engines operated on test stands and from flight tests that indicate some effects on performance caused by coke deposits and smoke. Some information about the mechanism of coke formation is given in reference 5 and chapter IX. The data indicate that (1) high-boiling fuel residuals and partly polymerized products may be mixed with a large amount of smoke formed in the gas phase to account for the consistency, structure, and chemical composition of the soft coke in the dome and (2) the hard deposits on the liner are similar to petroleum coke and may result from the liquid-phase thermal cracking of the fuel. During the early development period of jet engines, it was noted that the excessive coke deposits and exhaust smoke were generally obtained when fuel-oil-type fuels were used. Engines using gasoline-type fuels were relatively free from the deposits and smoke. These results indicated that some type of quality control would be needed in fuel specifications. Also noted was the effect of engine operating conditions on coke deposition. It is possible that, even with a clean-burning fuel, an excessive amount of coke could be formed at some operating conditions. In this case, combustor redesign could possibly reduce the coke to a tolerable level. This chapter is a summary of the various coke-deposition and exhaust-smoke problems connected- with the turbojet combustor. Included are (1) the effect of coke deposition on combustor life or durability and performance; (2) the effect of combustor design, operating conditions, inlet variables, and fuel characteristics on coke deposition; (3) elimination of coke deposits; (4) the effect of operating conditions and fuel characteristics on formation of exhaust smoke; and (5) various bench test methods proposed for determining and controlling fuel quality.