Scientists at the University of Stuttgart in Germany have developed a 3D printed fuel injection system designed to help compact gas turbines operate on a variety of fuels, including hydrogen, kerosene, methanol, natural gas and synthetic e-fuels.
The new injector adapts technology originally developed for aircraft turbine engines. Its design aims to produce a fine and evenly distributed fuel spray helping improve combustion while limiting emissions such as soot and nitrogen oxides.
Using additive manufacturing, researchers were able to create complex internal passages in the injector. Although metal 3D printing can leave rough surfaces that affect fuel flow through small openings laboratory tests showed that the new design could still achieve clean combustion.
The technology could be particularly useful for gas turbines used as backup power sources when renewable generation from solar and wind falls. It may also offer a way to adapt existing turbines to alternative fuels without replacing the entire system.
Researchers now plan to refine the nozzle’s geometry and manufacturing process before developing a full prototype. The system will then be tested with different fuels under real-world operating conditions.