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Gas Turbines: Technological Limits and Future Directions

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Gas Turbines: Technological Limits and Future Directions Cranfield University Alexander David Nind A Technoeconomic Risk Assessment of Conventional Aero- Gas Turbines: Technological Limits and Future Directions School of Aerospace, Transport and Manufacturing PhD Thesis July 2016 Supervisors: Dr Vishal Sethi Dr Devaiah Nalianda Karumbaiah © Cranfield University, 2016 All rights reserved. No part of this publication may be reproduced without the written permission of the copyright holder Abstract Increasing environmental awareness, uncertain economic climates and fluctuating fuel prices have led to airlines investigating the means to lower aircraft fuel burn, emissions and noise, while maintaining the highest possible safety standards. This is done in order to reduce operating costs as well as a desire to offer customers more environmentally responsible transport options. The jet engine has been a fundamental part of passenger aircraft travel and has evolved to become more efficient and quiet. With an aim to improve the overall efficiency of the gas turbine, the industry has consistently sought to improve thermal and propulsive efficiency. Higher thermal efficiencies have been achieved through increased overall pressure ratios and the turbine entry temperatures, while higher propulsive efficiencies has been achieved through increase in bypass ratios. Conventional technology is however reaching the limits of any further improvements. This study seeks to investigate these design limits for the conventional aero gas turbine and focusses on the propulsion system of short to medium range jet aircraft, specifically catering to low cost airline operations in Europe. A techno-economic risk analysis approach was followed through the utilisation of a flexible multi-disciplinary framework. This allows a multitude of critical parameters and factors to be investigated and their effects established. Some of the key parameters investigated include the effect of design optimisation on SFC, mission fuel burn, engine sizes and weights. By first quantifying the current design parameters and associated constraints for the selected conventional propulsion system, an optimisation study is carried out to identify the possible design limits to which the conventional technology may be pushed. It is therefore possible to then quantify the maximum benefit available to this mature technology and also to further identify which future technologies may offer the most benefits for a particular airline market strategy. The key contribution to knowledge from this study is to therefore provide a techno-economic risk assessment of an optimised conventional high bypass ratio turbofan and establish the design limits that may be needed to achieve further benefits from conventional designs. The study is undertaken from an operator/airline perspective and further quantifies the point at which the investment opportunity of a novel technology justifies the risks associated with it. This study has shown that there is still potential for fuel burn improvement from the evolution of the conventional turbofan. This improvement could be up to 15-20% when compared to technology of the year 2000. This is shown to be achieved through improvement material and design of the high pressure compressor spool, aimed at essentially reducing weight and diameters. The study also includes a qualitative discussion on novel, disruptive technologies, and the risks associated with their introduction as future propulsion systems. i ii Acknowledgments Firstly I would like to express my thanks to easyJet, as well as the Engineering and Physical Sciences Research Council (EPSRC) for providing the funding for this PhD. At Cranfield University I would firstly like to thank Professor Pericles Pilidis for offering the opportunity of studying for a PhD, and particular thanks to my two supervisors: Dr Vishal Sethi and Dr Devaiah Nalianda for their help, understanding and patience. Thanks also goes to Fran Radcliffe and Teresa Townsend, part of the University's support network, for their help in getting me through a difficult last few months. There are many friends, office mates and colleagues who I have shared many experiences over the years, offering insights and assistance, including Wanis Mohammed, Peter Zhang, Lefteris Giakoumakis, Hasani Azamar Aguirre, Emmanuel Osigwe, Alejandro Block, Joshua Sebastiampillai, Diana Guiomar San Benito Pastor and Tala El Samad My final acknowledgement is to my wife, Andrea, for her unconditional support and understanding. I can now repay you by looking after the kids and giving you a break! iii iv Contents Abstract .............................................................................................................................. i Acknowledgments ........................................................................................................... iii Contents ............................................................................................................................ v List of Figures ................................................................................................................. vii List of Tables ................................................................................................................... ix Nomenclature.................................................................................................................... x Acronyms and Abbreviations ........................................................................................ x Letters and Symbols ..................................................................................................... xi 1.0 Introduction ................................................................................................................ 1 1.1 Objectives ............................................................................................................... 2 1.2 Contribution to Knowledge .................................................................................... 2 1.3 Thesis Structure ...................................................................................................... 4 2.0 Literature Review ....................................................................................................... 5 2.1 Aero-Engine Trends ............................................................................................... 5 2.2 Improving Fuel Consumption ................................................................................. 9 2.3 Recent Engine Research ....................................................................................... 11 2.4 The Gap ................................................................................................................ 16 2.5 TERA Overview ................................................................................................... 18 2.5.1 History of TERA ........................................................................................... 18 2.5.2 What is TERA? .............................................................................................. 20 2.6 Other Multi-Disciplinary Optimisation Tools ...................................................... 24 2.7 Environmental Policy and Targets Context .......................................................... 25 2.7.1 Global Policies ............................................................................................... 26 2.7.2 European Environmental Goals and Legislation ........................................... 26 2.8 Alternative Aircraft Engine Technologies ............................................................ 29 2.8.1 Pulse Detonation Engines (PDE) ................................................................... 29 2.8.2 Wave Rotor .................................................................................................... 34 2.8.3 Intercooled, Recuperated and Intercooled & Recuperated Cores ................. 39 2.8.4 Open Rotors/High Speed Propellers .............................................................. 44 2.8.5 Turboprops/Conventional Propellers ............................................................. 48 3.0 TERA Methodology and Models ............................................................................. 52 3.1 General TERA Methodology ............................................................................... 52 3.2 Engine Performance Module ................................................................................ 53 3.3 Aircraft Performance Module ............................................................................... 57 3.4 Engine Sizing Module - TETHYS ....................................................................... 63 3.4.1 Fan ................................................................................................................. 66 3.4.2 Compressors .................................................................................................. 68 3.4.3 Turbines ......................................................................................................... 72 3.4.5 Nacelle ........................................................................................................... 74 3.4.6 Ducts .............................................................................................................. 80 3.4.7 Combustor ..................................................................................................... 81 3.4.8 Verification ...................................................................................................
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