The example technology herein relates to aircraft design, and more particularly to aircraft operations, aircraft performance, aircraft fuel systems, and aircraft propulsion systems. Still more particularly, the example technology herein relates to aircraft designs for using alternative, environmentally friendly fuels such as hydrogen.
The aviation industry is searching for alternatives to decrease the environmental footprint of its products. One goal is to operate commercial aircraft in a way that provides no or only very low greenhouse gas emissions. Among the several potential options, hydrogen-based propulsion is one of the most promising for regional and narrow body aircraft.
Hydrogen provides advantages as an aviation fuel, such as high heating value (specific energy or energy to mass ratio) and specific heat (resulting in potentially greater engine efficiency). Additionally, its combustion does not produce carbon-based gases, which addresses the referenced environmental challenge. However, some important challenges arise from hydrogen usage: it has a very low energy density (energy to volume ratio), so it must be stored compressed or cryogenically liquified in order to decrease the installation burden, in terms of weight and drag, on the aircraft. Additionally, hydrogen tanks are heavy, and currently hydrogen cost per energy content is 3-4 times higher than the cost of standard fossil-based Jet Fuel. Therefore, different approaches must be taken in order to balance hydrogen benefits with its downsides.
Aircraft should be sized taking into account mission fuel reserves, which are important to provide contingency plans for pilots, if the destination airport is not able to authorize the landing of the aircraft and an alternate must be sought. Typically, reserves are translated to a diversion mission, with a fixed distance (100-200 nmi) plus loiter time (30-45 minutes). In the vast majority of the missions, the reserve fuel is not used.
For short range regional aircraft, the typical sector energy requirement is of similar order of magnitude to the reserve sector. Therefore, if hydrogen tanks were to be sized considering the typical mission plus reserves, they would have twice the volume and weight of hydrogen tanks sized only for the main mission. Given this fact, a strategy that minimizes the need of carrying hydrogen in case the aircraft needs to alternate to the very infrequent sector, is of interest.
In addition to the challenges discussed above, hydrogen production and infrastructure are also important points that need to be addressed. Hydrogen may be produced by different means, but in order to have net (“well to wake”) emissions reductions, so-called “blue” or “green” hydrogen should be employed. Hydrogen is commonly produced from natural gas with a process of steam methane reforming, where natural gas is mixed with very hot steam and a catalyst. The result is H2 and a CO2 byproduct. Unfortunately, producing one part hydrogen causes a release of nine parts of CO2. If the CO2 byproduct is released to the atmosphere, the hydrogen produced is sometimes called “grey hydrogen”. “Blue” hydrogen may be produced the same way but the CO2 byproduct is stored and contained or sold, instead of being released into the atmosphere. Hydrogen can also be produced by electrolysis of water, which produces O2 and H2 but no CO2 byproduct. When the electricity used to power electrolysis comes from renewable sources like wind, water or solar, the resulting hydrogen gas is said to be “green.” Producing green hydrogen is currently much more expensive than producing blue hydrogen (because renewable sources of electricity are more expensive), but costs of green hydrogen are projected to come down substantially in the future. It is very likely that the blue/green hydrogen infrastructure will be built gradually in the future. See e.g., “Questions and answers: A Hydrogen Strategy for a climate neutral Europe”, (European Commission 8 Jul. 2020 Brussels)
An aircraft that runs only on hydrogen will only be able to fly routes where both airports of the flight terminus city pair have hydrogen refueling stations. Or alternatively, it will need hydrogen tanks large enough to carry hydrogen to use on the return flight, rendering its economic viability even more challenging. This lack of infrastructure risks retarding the adoption of hydrogen until it is available in the majority of airports.
Moreover, the hydrogen infrastructure will probably develop unevenly around the world. Specifically, more developed countries will likely be able to invest greater sums in economical, environmentally-friendly hydrogen production infrastructure as compared with underdeveloped countries. Therefore, an aircraft that is only able to operate with hydrogen as a fuel will not be able to operate globally after its certification and entry into service, which is an additional drawback to its economic feasibility.
Another challenge that needs to be addressed is the delivery process of a hydrogen aircraft, from its manufacturing plant to its operational hubs. An aircraft manufactured in a location A must have enough hydrogen refueling stations en route to reach its operating hub B. This may be a major challenge since a hydrogen aircraft will likely have smaller ranges than its fossil-based counterparts.
Finally, it is worth pointing out that although hydrogen combustion does not produce CO2, it does emit other potentially greenhouse gases, such as water vapor, contrails (condensation trails) and NOx. Contrails are human-made clouds. They form in air above about 25,000 feet, when that air is moist and colder than −40 degrees Celsius. Like regular clouds, they arise when water vapor, in this case from the engine exhausts, forms into droplets by condensing onto particles in the air. Within a second, the water droplets freeze to make tiny ice crystals that show up visually as contrails. Some claim contrails contribute to global warming. See e.g., Pearce, “How Airplane Contrails Are Helping Make the Planet Warmer” Yale School of the Environment (Jul. 18, 2019).
Engine technologies such as combustion chamber optimization will likely be able to minimize NOx, and the impact of water vapor/contrails is greatly minimized if flight altitudes below a certain threshold (25-30 kft) are used. These lower flight altitudes are more compatible with regional aircraft, so this aircraft category may be the best fit for hydrogen propulsion, at least in the shorter term.
Arguably, aircraft with higher payload range capabilities may not be able to use Fuel Cell systems since they typically are much heavier than gas turbines. In the last decades, a number of system concepts have been attempted in order to support the use of hydrogen in Gas Turbines. However, further improvements are possible and desirable.
Example Non-Limiting Embodiments Provide the following combinations of features:
An aircraft that has dual fuel engines, where one of the fuels consumed is a non-cryogenic (liquid at ambient temperature) fuel (Jet Fuel, Jet A, Jet A-1, Jet B, SAF, Avgas, Ethanol, etc.) and another fuel consumed is a cryogenic fuel such as liquid hydrogen or methane. In one embodiment, the cryogenic fuel could be fossil-based or non-fossil based but preferably comprises hydrogen. At temperatures typically encountered on board an aircraft, the cryogenic fuel is in the gaseous state which ordinarily would require large, heavy, high pressure storage vessels capable of withstanding 5000-10,000 psi. Such tanks may be too heavy and bulky for many or most aircraft. Therefore, in one embodiment, the cryogenic fuel is cooled to a liquid state before being loaded onto the aircraft so it can be stored compactly at low pressure.
For example, storage of hydrogen as a liquid requires cryogenic temperatures because the boiling point of hydrogen at one atmosphere pressure is −252.8° C. Similarly, the boiling point of methane is −161.6° C. But if these fuels can be maintained at such cryogenic temperatures, they can be stored in low pressure, lighter weight vessels when compared to high pressure gaseous hydrogen tanks.
The cryogenic fuel is stored in one or more tanks inside the aircraft fuselage or at other appropriate positions (e.g. wing pods), and the non-cryogenic fuel is stored in two or more fuel tanks, located in standard positions, usually inside the left and right aircraft wings. See
In one embodiment, the cryogenic fuel can be employed as the reserve fuel, extending the range of the aircraft when it is certain that successive destinations will not be able to resupply the aircraft with hydrogen, as will occur while the hydrogen infrastructure is being progressively expanded across the globe.
The non-cryogenic and cryogenic fuels can be used independently or in conjunction to provide energy for the engine.
The non-cryogenic fuel may be used as a motive fuel (e.g. engine variable inlet guide vanes actuation) or cooling fuel (e.g. engine and/or electric generator and/or electric motor oil cooler) at all flight phases, even when the cryogenic fuel is the only fuel being consumed by the engines. propelling the aircraft.
The cryogenic fuel can be used to cool or keep the non-cryogenic fuel temperatures down in order to reduce fuel vapors flammability inside the non-cryogenic fuel tank. The non-cryogenic fuel can be used to heat the cryogenic fuel before it enters the engines.
The control of the fuel mix is performed preferentially by the aircraft, considering, but not limited to:
1) A lighter and more economical aircraft is obtained, when compared to an aircraft that is able to operate only with hydrogen:
2) Reduced environmental footprint aircraft:
3) Increased operational flexibility for aircraft:
4) Potential aircraft safety increase
Example Non-Limiting More Detailed Description of an Aircraft
A schematic layout of an example embodiment aircraft is shown in
In one embodiment, the core engine (2) is modified or specifically designed to be able to operate with non-cryogenic fuels such as Jet A, Jet A-1, Jet B, SAF, etc. and cryogenic fuels in gaseous or liquid forms (e.g., hydrogen or methane). The consumption of each fuel type may be concurrent or independent, depending on the mixing fuel strategy of each mission.
Here, we use the term “non-cryogenic fuel” to refer to a fuel that is naturally in the liquid state when stored at typical aircraft environment temperatures and reasonable pressures (e.g., 1 atmosphere); and we use the term “cryogenic fuel” to refer to a fuel that requires storage at extremely low (cryogenic) temperatures in order to maintain it in a liquid state. Cryogenic temperatures are typically considered to be temperatures below −150 degrees centigrade. Hydrogen is an example of a cryogenic fuel because at ambient sea-level pressures such as 1 atmosphere it becomes a liquid only at cryogenic temperatures such as below −250 degrees centigrade. Conventional jet fuel (aviation turbine fuel or ATF) is an example of a non-cryogenic fuel because it is a liquid at typical ambient temperatures and pressures an aircraft encounters during fueling, taxiing and operation. See e.g., DEF STAN 91-91 and ASTM specification D1655. Common jet fuel freezes at around −40 to −53 degrees Centigrade depending on type, and has a boiling point that is about 176 degrees Centigrade, It is thus in the liquid state at all typical ambient temperatures a typical commercial jet aircraft encounters.
As
Additionally, the cryogenic fuel lines that feed the engines may be directed through the non-cryogenic fuel tanks in order to keep the non-cryogenic fuel temperature within acceptable flammability limits for its fuel vapors and eliminating or minimizing the need of a tank inertization system, saving aircraft weight and further improving fuel savings and minimizing emissions. Thus, the introduction of cryogenic fuel to the system permits the cryogenic fuel to be used to replace prior non-cryogenic fuel cooling systems that might otherwise be necessary, reducing the costs of safely maintaining non-cryogenic fuel on board the aircraft.
As
An Aircraft fuel control system (7) is responsible to operate and optimize fuel source mixing strategies at any flight phase, enabling different mixing strategies objectives, as outlined in the provided mission profiles and in the Protection Focus Section below. The aircraft fuel control system (7) is also responsible to set the fuel source mixing strategy in exceptional conditions, like aircraft or engine component failures (in-flight or to allow dispatch with failed components), adverse weather conditions (e.g., Rain and hail), etc.; or in conditions demanded by the engine (e.g., In-flight starting, in sub-idle conditions, when detecting operability issues, etc.). The fuel mixing strategy may involve both engines consuming the same fuel or even a first engine consuming the non-cryogenic fuel and a second engine consuming the cryogenic fuel. An engine control system (8) is responsible for implementing the aircraft fuel control system-defined fuel mixing strategy in the most suitable manner in terms of engine steady state and transient performance and operability characteristics, as well as accommodating failures. Some functions of the Aircraft Fuel Control System may be embedded in the Engine Control System if bringing benefits in terms of robustness, safety or cost.
Each of these control systems (7), (8) may be implemented by a combination of hardware and software, for example one or more controllers or systems on chips (SOCs) connected to data buses and executing software instructions shown in
The proposed environmentally friendly aircraft architecture allows a more fuel efficient aircraft, provides fuel flexibility for the aircraft operator, allowing it to use a fuel(s) that has/have lower environmental impact, letting the operator adopt an environmentally friendly aircraft before the cryogenic refueling infrastructure is fully available at its route network. It also allows the operator to choose between Jet Fuel, SAF or hydrogen based on mission requirements (range, payload), airport fuel availability and fuel costs. Among the possible fuel mixing possibilities, a few are briefly discussed below:
Typical range mission (
Additionally to the representation of
Extended range mission (
Pure SAF/Jet Fuel missions (
Contrails avoidance strategy (
Design range mission (
All patents and publications cited above are incorporated herein by reference.
While the invention has been described in connection with what is presently considered to be the most practical and preferred embodiment, it is to be understood that the invention is not to be limited to the disclosed embodiment, but on the contrary, is intended to cover various modifications and equivalent arrangements included within the spirit and scope of the appended claims.
Priority is claimed from Provisional Application No. 63/223,417 filed Jul. 19, 2021, incorporated herein by reference in its entirety and for all purposes.
Number | Date | Country | |
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63223417 | Jul 2021 | US |