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Compressors for ultra-high-pressure-ratio aero-engines

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Abstract

A highly efficient, robust compression system is a key part of any high-performance core engine that is to be developed for meeting future low emission requirements, i.e., for significant reductions in CO2, NOx, and other gaseous emissions. Not only does the compression system has to deliver the increased OPR demanded by the thermal cycle. It has to do so more efficiently to avoid excessive increases in cycle temperatures and weight to avoid reducing the benefit from the new cycle. This challenge is made harder, as OPR is increased up to 70:1, as core-engine size will reduce introducing greater threats to efficiency and compressor stability margin through: (1) lower Reynolds numbers that will result in higher blade losses; (2) tip and shroud/seal clearances increasing due to physical size limitations; (3) if manufacturing tolerances are maintained, blade and vane leading edges, maximum thickness, and fillets radii will be relatively larger; (4) the threat of inclement weather, deterioration, and foreign object damage (FOD) will be greater as compressors get smaller; (5) high aspect ratio blade design will be applied to limit the relative weight and length increase due to required pressure ratio increase of the compression system; (6) higher OPR compression systems will require more stability improvement features, such as VSVs, bleeds, and rotor tip treatments. This paper gives an overview of the above issues and how the FP7 integrated project LEMCOTEC is addressing them through CFD simulations, low- and high-speed rig tests, and innovative designs.

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Abbreviations

ACARE:

Advisory Council for Aeronautics Research in Europe

ASME:

American Society of Mechanical Engineers

BLISK:

Blade integrated disk

CAEP:

Committee on Aviation Environmental Protection

CEC:

Carbon emissions calculator (ICAO)

CFD:

Computational fluid dynamics

CO:

Carbon monoxide

CO2 :

Carbon dioxide

CRTF:

Counter-rotating turbofan

DDTF:

Direct drive turbofan

DLR:

Deutsches Zentrum für Luft-und Raumfahrt e.V

DP:

Mass of species

EC:

European Commission

EDP:

Engine Development Programme

F:

Force (thrust)

FB:

Fuel burn

FCC:

Flow controlled core

FOD:

Foreign objective damage

FP:

Framework Programme

GTF:

Geared turbofan

HAR:

High aspect ratio

HP:

High pressure

HPC:

High-pressure compressor

IATA:

International Air Transport Association

IC:

Inter-cooling

ICC:

Inter-compressor case

ICAO:

International Civil Aviation Organization

INTA:

Instituto Nacional de Técnica Aeroespacial

IP:

Intermediate-pressure

IP:

Integrated project

IPC:

Intermediate-pressure compressor

IRA:

Inter-cooled and recuperated aero-engine

IRC:

Internal re-circulation

ISA:

International Standard Atmosphere

ISABE:

International Society for Air Breathing Engines

ITP:

Industria de Turbo Propulsores S.A

LCC:

Life cycle costs

LDI:

Lean direct injection

LP(P):

Lean premixed (prevaporised)

LR:

Long range

LSRC:

Low-speed research compressor

LTF:

Large turbo fan

LTO:

Landing and take-off

M:

Month

MOR:

Mid-size open rotor

MSFI:

Multi-stage fuel injection

NASA:

National Aeronautics and Space Administration

NOx:

Nitrogen oxides (NO + NO2)

OGV:

Outlet guide vanes

ONERA:

Office National d’Études et de Recherches Aérospatiales

OPR:

Overall pressure ratio

P:

Pressure

PAX:

Passenger

PBS:

PRVNI BRNENSKA STROJIRNA VELKA BITES A.S

PR:

Pressure ratio

PERM:

Partially evaporating rapid mixing

R:

Rotor

RRD:

Rolls-Royce Deutschland Ltd

RTF:

Regional turbo fan

RWTH:

Rheinisch-Westfälische Technische Hochschule

SFC:

Specific fuel consumption

SLS:

Sea level static

SOx:

Sulphur oxides

SR:

Short range

T:

Temperature

TF:

Turbofan

T/O:

Take-off

TRL:

Technology readiness level

TUD:

Technische Universität Dresden

UHC:

Unburnt hydro-carbons

UV:

Ultra-violet

VKI:

von Kármán Institute

VSV:

Variable stator vanes

VZLU:

VÝZKUMNÝ A ZKUŠEBNÍ LETECKÝ ÚSTAV, A.S

WEMM:

Whole engine mechanical model

Y:

Year

AIDA:

aggressive intermediate duct aerodynam

ANTLE:

Affordable near-term low emissions

E-BREAK:

Engine breakthrough components and subsystems

NEWAC:

New aero-engines core concepts

LEMCOTEC:

Low emissions core-engine technology

POA:

Power optimised aircraft

BRU:

Brussels

FRA:

Frankfurt

JFK:

John F. Kennedy (New York)

TXL:

Tegel (Berlin)

References

  1. ICAO Aircraft Engine Emissions Databank, Issue 20B, 7 March 2014. EASA, Cologne

  2. von der Bank, R., Donnerhack, S., Rae, A., Poutriquet, F., Lundbladh, A., Peschiulli, A.: Technologies for high thermal efficiency aero-engines. AVT-230/RSM-033 Specialists Meeting, 20–24 April 2015, Rzeszów, Poland

  3. Peacock, N.: ANTLE—an integration of European and National Research Programmes. Aerodays 2006, 19–20 June 2006, Vienna, Austria

  4. Rolt, A., Kyprianidis, K.: Assessment of new aero engine core concepts and technologies in the EC Framework 6 NEWAC project. ICAS2010-4.6.3, 19–24 September 2010, Nice, France

  5. Sieber, J.: Overview of the NEWAC programme, greening of aircraft propulsion—progress and prospects. Royal Aeronautical Society, 20 October 2010, London, UK

  6. Sturm, W.: Countering the environmental penalties of a growing air traffic by means of active core technologies. ISABE2011-1401, 12–16 September 2011, Gothenburg, Sweden

  7. Bock, S., Horn, G., Wilfert, G., Sieber, J.: Active core technology within the NEWAC Research program for cleaner and more efficient aero engines. CEAS2007-055, 10–13 September 2007, Berlin, Germany

  8. von der Bank, R., Donnerhack, S., Rae, A., Cazalens, M., Lundbladh, A., Dietz, M.: LEMCOTEC—improving the core-engine thermal efficiency. ASME, GT2014-25040, 16–20 June 2014, Düsseldorf, Germany

  9. von der Bank, R., Donnerhack, S., Rae, A., Poutriquet, F., Lundbladh, A., Schweinberger, A.: Advanced core engine technologies—assessment and validation. In: European Turbomachinery Conference, Universidad Politécnica de Madrid, ETC2015, 23–26 March 2015, Madrid, Spain

  10. ICAO Annex 16, Environmental protection, vol. II. Aircraft engine emissions, 3rd edn (2008)

  11. Walker, A.D., Barker, A.G., Mariah, I., Peacock, G.L., Carrotte, J.F., Northall, R.M.: An aggressive S-shaped compressor transition duct with swirling flow and aerodynamic Lifting struts. ASME, GT2014-25844, 16–20 June 2014, Düsseldorf, Germany

  12. Wallin, F., Bergstedt, R., Walker, A.D., Peacock, G.L.: Aerodesign and validation of turning struts for an intermediate compressor duct. ISABE2015-22143, 25–30 October 2015, Phoenix, Arizona, USA

  13. Poledno, M.: Rozsireni oblasti stabilni prace odstredivych kompresoru. Thesis, University of Defence, Brno, 2013, Czech Republic

  14. Klauke, T., Söhner, D., Drees, B., Winkelmann, P., Klomp-de Boer, R.: Development of a hybrid-unison ring for VSV-systems for new high-OPR aero engines. 64. Deutscher Luft-und Raumfahrtkongress, 22–24 September 2015, Rostock, Germany

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Acknowledgments

The authors wish to gratefully thank Wolfgang Sturm (MTU), Sandro Nitschke (TUD), Thomas Klauke, Henner Schrapp (RRD), Dario Bruna (RR), and Fredrik Wallin (GKN) for their valuable contributions. The research in LEMCOTEC (Low Emissions Core-Engine Technologies) leading to these results has received funding from the European Union’s Seventh Framework Programme (FP7/2007-2013) under Grant Agreement No. 283216.

Author information

Authors and Affiliations

  1. Rolls-Royce Deutschland, Blankenfelde-Mahlow, Germany

    R. von der Bank

  2. MTU Aero-Engines, Munich, Germany

    S. Donnerhack

  3. Rolls-Royce, Derby, United Kingdom

    A. Rae

  4. Safran Aircraft Engines, Moissy Cramayel, France

    F. Poutriquet

  5. GKN Aerospace, Trollhättan, Sweden

    A. Lundbladh

  6. ITP, San Fernando de Henares (Madrid), Spain

    A. Antoranz

  7. Safran Helicopter Engines, Bordes, France

    L. Tarnowski

  8. PBS, Velká Bíteš, Czech Republic

    M. Ruzicka

Authors
  1. R. von der Bank
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  2. S. Donnerhack
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  3. A. Rae
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  4. F. Poutriquet
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  5. A. Lundbladh
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  6. A. Antoranz
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  7. L. Tarnowski
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  8. M. Ruzicka
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Corresponding author

Correspondence to R. von der Bank.

Additional information

This paper is based on a presentation at the German Aerospace Congress, September 22–24, 2015, Rostock, Germany.

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von der Bank, R., Donnerhack, S., Rae, A. et al. Compressors for ultra-high-pressure-ratio aero-engines. CEAS Aeronaut J 7, 455–470 (2016). https://doi.org/10.1007/s13272-016-0200-9

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  • DOI: https://doi.org/10.1007/s13272-016-0200-9

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