Validation of a High Efficient Low NOx core, a High Speed Turbine ...

EEFAECLEAN“New” Engine ConceptsGear Turbofan (GTF)Intercooled RecuperativeAero Engine (IRA)© 2005 MTU Aero Engines GmbH. The information in this document is the property of MTU Aero Engines GmbH, itmay not be copied or communicated to a third party, or used for any purpose other than for which it is suppliedwithout the express written consent of the MTU Aero Engines GmbH.Dr. Günter Wilfert20.06.2006

EEFAECLEANLimits of a Conventional Engine ConceptBlade tip speed limited byAerodynamics and noise, max. 430 m/s, target 300 m/sGear Turbofan (GTF):FanLPCHP-Comp.LP ShaftComb.HPTLPT Low tip speed for low fannoise High speed booster andhigh speed low pressureturbine for low stagenumber and low noise(Fan) (Fan) Shaft Shaft diameter diameter limited limited by by the the HPT HPT bore bore diameter diameterSolution: Solution: Gearing Gearing between between Fan Fan and and LP LP Shaft Shaft© 2005 MTU Aero Engines GmbH. The information in this document is the property of MTU Aero Engines GmbH, itmay not be copied or communicated to a third party, or used for any purpose other than for which it is suppliedwithout the express written consent of the MTU Aero Engines GmbH.Dr. Günter Wilfert20.06.2006

EEFAECLEANIntercooled Recuperative Aero Engine concept to further increasethermal efficiency and minimize NOx and CO2IRA ConceptIntercoolerRecuperatorFanLPCHPCHPTIPTLPTGearBPR =18OPR =25-30Variable CycleLong range aircraft, 2020-2025 EISTarget: 20% CO2 reduction80% NOx reduction-30 dB cumulated© 2005 MTU Aero Engines GmbH. The information in this document is the property of MTU Aero Engines GmbH, itmay not be copied or communicated to a third party, or used for any purpose other than for which it is suppliedwithout the express written consent of the MTU Aero Engines GmbH.Dr. Günter Wilfert20.06.2006

EEFAECLEANThe Technology Platform EEFAE partly funded by the EU (3/2000-2/2005)consists of two Validation VehiclesEEFAEEfficient and Environmentally Friendly Aero-Engine50 MEURO 50 MEUROVehicle I - ANTLEAffordable Near Term Low Emission engineConventional Cycle EngineCo-ordinator: Rolls RoyceVehicle II - CLEANComponent vaLidator forEnvironmentally friendly Aero-eNgineAdvanced Cycle EngineCo-ordinator: MTU/SnecmaEIMG Partners: ITP, Volvo, RRD, TA, AVIOEIMG Partners: Volvo, AVIOAssociated Partners: Aerospatiale, Lucas, Hispano-Suiza, Eldim, Esil, CEPr© 2005 MTU Aero Engines GmbH. The information in this document is the property of MTU Aero Engines GmbH, itmay not be copied or communicated to a third party, or used for any purpose other than for which it is suppliedwithout the express written consent of the MTU Aero Engines GmbH.Dr. Günter Wilfert20.06.2006

EEFAECLEANCLEAN – Partner ResponsibilityTurbine Center FrameMTU Aero EnginesHigh Speed LP TurbineMTU Aero Engines, Volvo AeroHP TurbineSnecma MoteursTurbine Exhaust CaseVolvo AeroCombustorAVIO, Snecma MoteursHP CompressorSnecma MoteursTESTMTU Aero EnginesRecuperatorMTU Aero Engines© 2005 MTU Aero Engines GmbH. The information in this document is the property of MTU Aero Engines GmbH, itmay not be copied or communicated to a third party, or used for any purpose other than for which it is suppliedwithout the express written consent of the MTU Aero Engines GmbH.Dr. Günter Wilfert20.06.2006

EEFAECLEANActive Surge Control System Technology6 « kulites » / stageACTUATORSHPC HPC fast fastopeningbleed bleedvalvesVSV VSV fast fastclosureLIDIADiagnostic Diagnostic :: flow flowprecursor precursordetection (« (« kulites kulites »» signals signalsspatial spatial and andspectral analysis) analysis)DecisionDecision::surgesurgeriskriskanalysisanalysisbasedbasedononprecursorprecursortypologytypology//magnitudemagnitude//evolutionevolution© 2005 MTU Aero Engines GmbH. The information in this document is the property of MTU Aero Engines GmbH, itmay not be copied or communicated to a third party, or used for any purpose other than for which it is suppliedwithout the express written consent of the MTU Aero Engines GmbH.Dr. Günter Wilfert20.06.2006

EEFAECLEANCombustor Design and Verification• Double annular combustor design• Atmospheric combustor tests at AVIO• Full annular high pressure tests at CEPr(LowNOx III)• Engine validation in CLEANPilot runmodeStage burning runningmodeFull runningmode© 2005 MTU Aero Engines GmbH. The information in this document is the property of MTU Aero Engines GmbH, itmay not be copied or communicated to a third party, or used for any purpose other than for which it is suppliedwithout the express written consent of the MTU Aero Engines GmbH.Dr. Günter Wilfert20.06.2006

EEFAECLEANCLEAN Turbine Center Frame & Low Pressure TurbineTCFLPT© 2005 MTU Aero Engines GmbH. The information in this document is the property of MTU Aero Engines GmbH, itmay not be copied or communicated to a third party, or used for any purpose other than for which it is suppliedwithout the express written consent of the MTU Aero Engines GmbH.Dr. Günter Wilfert20.06.2006

EEFAECLEANHeat exchanger integrated in the Exhaust Casing1 2© 2005 MTU Aero Engines GmbH. The information in this document is the property of MTU Aero Engines GmbH, itmay not be copied or communicated to a third party, or used for any purpose other than for which it is suppliedwithout the express written consent of the MTU Aero Engines GmbH.Dr. Günter Wilfert20.06.2006

EEFAECLEANAltitude Test Facility at Stuttgart was prepared for the CLEAN Test© 2005 MTU Aero Engines GmbH. The information in this document is the property of MTU Aero Engines GmbH, itmay not be copied or communicated to a third party, or used for any purpose other than for which it is suppliedwithout the express written consent of the MTU Aero Engines GmbH.Dr. Günter Wilfert20.06.2006

EEFAECLEANCLEAN vehicle installed in the test bed© 2005 MTU Aero Engines GmbH. The information in this document is the property of MTU Aero Engines GmbH, itmay not be copied or communicated to a third party, or used for any purpose other than for which it is suppliedwithout the express written consent of the MTU Aero Engines GmbH.Dr. Günter Wilfert20.06.2006

EEFAECLEANTest Facility prepared for TestsHEX Hot Gas PipeVehicleSASSupply & Bleed TubesATF Facility© 2005 MTU Aero Engines GmbH. The information in this document is the property of MTU Aero Engines GmbH, itmay not be copied or communicated to a third party, or used for any purpose other than for which it is suppliedwithout the express written consent of the MTU Aero Engines GmbH.Dr. Günter Wilfert20.06.2006

EEFAECLEANCLEAN - Test Results© 2005 MTU Aero Engines GmbH. The information in this document is the property of MTU Aero Engines GmbH, itmay not be copied or communicated to a third party, or used for any purpose other than for which it is suppliedwithout the express written consent of the MTU Aero Engines GmbH.Dr. Günter Wilfert20.06.2006

EEFAECLEANResult of the Active Surge Control SystemA typical acceleration with activated control was performed and a surgesuccessfully avoided• No surge• Successful surgeavoidance withactuator M4HPC pressure rateSurge lineOperating lineM4 Valves closureM4 Valves openingHPC inlet flow rate© 2005 MTU Aero Engines GmbH. The information in this document is the property of MTU Aero Engines GmbH, itmay not be copied or communicated to a third party, or used for any purpose other than for which it is suppliedwithout the express written consent of the MTU Aero Engines GmbH.Dr. Günter Wilfert20.06.2006

EEFAECLEANResult of the LPP combustor: NOx emissions• The emissions of the LPP combustor was higher than expected• The analysis of the gas emissions results shows an aerodynamic problemregarding the air feeding of the main injection systems.• The emissions model matches the results obtainedduring the CLEAN campaign and predictsthat NOx emissions with adapted air splitmeets nearly the target.© 2005 MTU Aero Engines GmbH. The information in this document is the property of MTU Aero Engines GmbH, itmay not be copied or communicated to a third party, or used for any purpose other than for which it is suppliedwithout the express written consent of the MTU Aero Engines GmbH.Dr. Günter Wilfert20.06.2006

EEFAECLEANResults of the High Speed LPT and the TCF:• High Speed Low Pressure Turbine: Technology readiness of thehigh speed LPT achieved LPT efficiency higher than expected• Turbine Center Frame: Verification of new design solutions forthe turbine center frame successful© 2005 MTU Aero Engines GmbH. The information in this document is the property of MTU Aero Engines GmbH, itmay not be copied or communicated to a third party, or used for any purpose other than for which it is suppliedwithout the express written consent of the MTU Aero Engines GmbH.Dr. Günter Wilfert20.06.2006

EEFAECLEANResults of the High Speed LPT and the TCF:• New materials and coatings behave asexpected• New brush seals and outer air sealssuccessfully testedNew coatingNew blade materialBrush sealsOuter air seal materialS14seeTCF S11 S12Sstat,© 2005 MTU Aero Engines GmbH. The information in this document is the property of MTU Aero Engines GmbH, itmay not be copied or communicated to a third party, or used for any purpose other than for which it is suppliedwithout the express written consent of the MTU Aero Engines GmbH.Dr. Günter Wilfert20.06.2006

EEFAECLEANTest results of the Recuperator:• Mechanical behaviour of the heat exchanger as expected• Pressure losses on the cold side achieved• Pressure losses on the hot side slightly higher than expected• Flow distribution not uniform enough© 2005 MTU Aero Engines GmbH. The information in this document is the property of MTU Aero Engines GmbH, itmay not be copied or communicated to a third party, or used for any purpose other than for which it is suppliedwithout the express written consent of the MTU Aero Engines GmbH.Dr. Günter Wilfert20.06.2006

EEFAECLEANSummary (1)• The Technology Platform in the 5th EU frame work program was a verysuccessful program to verify existing or emerging technologies in one vehicle.• The technology demonstrator was successful developed with an internationalteam• The complex test was performed under the lead of MTU at the altitude facilityof the University of Stuttgart• All test sequences have delivered valuable test data.• A lot of technologies are still to be developed before a launch of an IntercooledRecuperated Aero-engine. CLEAN was the first step.© 2005 MTU Aero Engines GmbH. The information in this document is the property of MTU Aero Engines GmbH, itmay not be copied or communicated to a third party, or used for any purpose other than for which it is suppliedwithout the express written consent of the MTU Aero Engines GmbH.Dr. Günter Wilfert20.06.2006

EEFAECLEAN© 2005 MTU Aero Engines GmbH. The information in this document is the property of MTU Aero Engines GmbH, itmay not be copied or communicated to a third party, or used for any purpose other than for which it is suppliedwithout the express written consent of the MTU Aero Engines GmbH.Dr. Günter Wilfert20.06.2006