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Fuel Cell APU for Commercial AircraftFuel Cell APU for Commercial Aircraft
Joe BreitSystems Concept Center
Boeing Commercial Airplanes(In Conjunction with NASA)
AgendaAgenda
• Background
• NASA
• SOFCo
• Integration Options
• Boeing
Turbine APU Engine
LargeAirplane (777-sized)
NOx Emissions atAirport
Replacing APU with fuel cell will reduce airport emissions
Replacing APU with fuel cell will reduce airport emissions
Fuel Cell
Boeing 777-sized “More Electric Airplane”
Future “More Electric Airplane” is ideally suited for fuel cell APU
Future “More Electric Airplane” is ideally suited for fuel cell APU
Present APU
Future 440 kW Fuel Cell APU Concept
EnvironmentControlSystem
Motor
EnvironmentControlSystem
Motor
Engine
GearLift
Motor
GearLift Motor
DC
AC
DC
AC Starter/Generator
Engine
Starter/Generator
Air
craf
tSy
stem
sA
ircr
aft
Syst
ems AC
DC
Battery
Working with fuel cell industry to obtain future SOFC performance
Working with fuel cell industry to obtain future SOFC performance
- Tech. U. of Munich (i.e. Europeans) 2-year SOFC APU design completed
- SOFCo 1st contract completed, 2nd contract issued
- US & Canadian National Labs- NASA Glenn Feasibility study to Boeing
- GE Contract issued
- University of California, IrvineSOFC model completed
- Delphi Contract issued
- UTRC NASA to issue contract
- Turbine Co. Future Contract?
- Fuel Cell Energy In discussions
AgendaAgenda
• Background
• NASA
• SOFCo
• Integration Options
• Boeing
Concept 440 kW Solid Oxide Fuel Cell in Boeing 777 Airplane Tail Cone
2015 AerospaceSame as industrial plus:• Weight & Size• Altitude Operation• Jet-A fuel• Safety• Vibration & shock
2003 Industrial
Industrial Solid Oxide Fuel Cell Installations
NASA to leverage SOFC R&D for aerospaceNASA to leverage SOFC R&D for aerospace
• Cost• Efficiency• Commercialization• Reliability
2003 2004 2005 2006 2007 2008 2009 2010
NASA/Boeing fuel cell APU timelineNASA/Boeing fuel cell APU timeline
Boeing Fuel Cell Powered AirplaneDemonstrator
NASA FC APUPhase I (feasibility)
NASA FC APUProposed Phase II (proof of concept)
Current 5kW SOFC
Power Current Electrical System
with 5kW unit Hybrid aircraft unit
development
NASA FC APUProposed Phase III (scaled demo)
Boe
ing
IR&
D
N
ASA
/Ind
ustr
y C
olla
bora
tion DOE SECA program
AgendaAgenda
• Background
• NASA
• SOFCo
• Integration Options
• Boeing
SOFCo 1st System Configuration SOFCo 1st System Configuration
Cabin Air
Cathode
Anode
405 kW
36 kW
Comp. TurbineStarter/Generator
JetFuel
Waterto
Filter
Exh.
OutsideAir
Reformer
Recuperator
TrimHeat
Exchanger
FuelHeater
SteamGenerator
SOFCo System Advantages SOFCo System Advantages
Cabin Air
Cathode
Anode
405 kW
36 kW
Comp. TurbineStarter/Generator
JetFuel
Waterto
Filter
Exh.
OutsideAir
Reformer
Recuperator
TrimHeat
Exchanger
FuelHeater
SteamGenerator
SOFC operates near ambient pressure for low vessel weight
Trim Hx for low thermal gradients
Simple, single-stage 2.5 PR impellers
SOFCo System DisadvantagesSOFCo System Disadvantages
Cabin Air
Cathode
Anode
405 kW
36 kW
Comp. TurbineStarter/Generator
JetFuel
Waterto
Filter
Exh.
OutsideAir
Reformer
Recuperator
TrimHeat
Exchanger
FuelHeater
SteamGenerator
Efficiency loss at low pressure
High cost for low weight, reliable recouperator
Waste sulfur results in acidic water, needs filter prior to steam generator
480kW cooling air needed … Yikes!
Gas doesn’t fully expand to atmospheric pressure – lost power potential
Fuel CellHot Box
Recuperator
ATR
TrimHXTurbo/Comp
Burner
ExhaustOut
SOFCo APU concept fits within tail coneSOFCo APU concept fits within tail cone
APU compartment firewall
777 APU Cavity(aft end of airplane)
Future 2015 Hybrid Solid Oxide Fuel Cell APU
SOFCo says airplane APU achievable but challenging
SOFCo says airplane APU achievable but challenging
Old 2002 Study New 2003 Study
• Pressure/Temperature stack optimization
• Desulfurization & water extraction schemes
• Fuel processing alternatives
• Single (440kW) vs. two (2 ea. 250kw) units?
• 2nd iteration to optimize system
• 0.45kW/kg system density almost met goals
• 58% efficiency
• Fits within space
• Fuel sulfur a problem
• Aspen model identified 1st configuration needs to change
Air In
DepletedAir Out
Stacks (4)
Depleted Fuel Manifolds
Fuel Supply Manifolds
Air In
DepletedAir Out
Stacks (4)
Depleted Fuel Manifolds
Fuel Supply Manifolds
Fuel Cell Hot Box
AgendaAgenda
• Background
• NASA
• SOFCo
• Integration Options
• Boeing
Integration into airplane affects performance Integration into airplane affects performance
Exhaust Cabin airHybrid SOFC Fuel Cell
APU
Airplanetail cone
Option “A”(basic design with POX)
Option #Fuel eff.WeightDragThrust
A
#1 = Best Rating Fuel in
Sulfur Tolerant
Poorest Fuel Efficiency
3
LowestSystemWeight
1
No Drag Impact1
Best ThrustRecovery
1
Integration into airplane affects performance Integration into airplane affects performance
HeatExchanger
Hybrid SOFC Fuel Cell
APU
CathodeExhaust
H20
Cabin air
Anode Exh.
Option #Fuel eff.WeightDragThrustWater
A31113
#1 = Best
B Option “B”(recovers water and has ATR)
Fuel in
Lowest Sulfur
Fuel Req.
2
HighestUnit
Weight
3
High InletDrag3
LowestThrust
3
Recovers H2O to offset weight
1
Integration into airplane affects performance Integration into airplane affects performance
Separator
Hybrid SOFC Fuel Cell
APU
CathodeExhaust Cabin air
Anode Exh.
Fuel in
A31113
#1 = Best
CB23331
Option “C”(recycles water)
H2 & H20
Low Sulfur
Fuel Req. Air, N2, Sulfur, CO2
Option #Fuel eff.WeightDragThrustWater
Best Fuel Efficiency
12
Low Drag122
FuelSavedA
irpla
ne F
uel S
avin
gs
A B CDesign
Trading-Off: Weight, Drag, Thrust & Efficiency
Best Airplane Performance
Design “C” has best airplane value due to lowest drag & highest efficiency
Design “C” has best airplane value due to lowest drag & highest efficiency
Syst
em E
ffici
ency
(%)
Syst
em E
ffici
ency
(%)APU Fuel Efficiency
0.20
0.30
0.40
0.50
0.60
0.70
AgendaAgenda
• Background
• NASA
• SOFCo
• Integration Options
• Boeing
Future 2015SOFC APU
≈75% Efficient(Overall system at cruise)
0.6 litre
=Jet-A
40% less fuel used
40-45% Efficient(Jet-A to electrical
during cruise)
Jet-A
1 litre
=
In-flight fuel saving opportunityIn-flight fuel saving opportunity
Fuel saving opportunity on the ground is very attractive
Fuel saving opportunity on the ground is very attractive
Future 2015SOFC APU
60% Efficient(at std. sea-level conditions)
0.25 litre
=Jet-A
75% less fuel used
15% Efficient(over average operating cycle)
Typical Turbine-powered APU
Jet-A
1 litre
=
?
Cost Pollution(at altitude)
Power Output
DLD
02-3
1
Startup time0
100
200
300
400
500
Fuel
Cel
l Per
form
ance
(% o
f tur
bine
) 4000
Weight Fuel efficiency
Cruise
Ground
Overall, FCAPU looks to be beneficialOverall, FCAPU looks to be beneficial
Turbine APU Baseline
Top 4 aerospace SOFC APU challengesTop 4 aerospace SOFC APU challenges
• Technology ready by 2010 (enables a 2015 entry into service date)
• High system power density (0.5 kW/kg system goal)
• Ability to reform Jet-A fuel (1,000 PPM fuel sulfur level tolerance goal)
• 40,000 hour life in airplane environment
Forever New FrontiersForever New Frontiers
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