© 2011 Rolls-Royce Corporation The information in this document is the property of Rolls-Royce Corporation and may not be copied or communicated to a third party, or used for any purpose other than that for which it is supplied without the express written consent of Rolls-Royce Corporation. This information is given in good faith based upon the latest information available to Rolls-Royce Corporation, no warranty or representation is given concerning such information, which must not be taken as establishing any contractual or other commitment binding upon Rolls-Royce Corporation or any of its subsidiary or associated companies.

FAA Continuous Lower Energy, Emissions & Noise (CLEEN) Technologies

Rolls-Royce Program Overview

2 November 2011

Approved for Public Release

Rolls-Royce CLEEN Technologies Program

Approved for Public Release

Fuel BurnReduction

Alternative FuelsFeasibility

Dual-Wall Turbine BladesDesign, Fabricate, Engine Test

Ceramic Matrix Composite (CMC)Turbine Blade TracksDesign, Fabricate, Engine Test

US Alt Fuels ProgramLab & Rig Test; AE 3007 Engine & Flight Demo

UK Alt Fuels ProgramLab & Rig Test; RB211-524 Engine Demo

Rolls-Royce CLEEN Technologies ProgramDual-Wall Turbine Blades

Highly-efficiency turbine cooling is a key technology for Reduced Fuel Burn in NextGen product applications Reduction in cooling flow in current engine cycles Enables progression toward more advanced engine cycles

Rolls-Royce has developed and patented high effectiveness, dual-wall turbine airfoil cooling systems

Approved for Public Release

Cooling Airflow

Cooling Airflow Parameter

Rel

ativ

e C

oolin

g

Ideal TranspirationTranspiration

Serpentine

Advanced Film-Convention

Rolls-Royce CLEEN Technologies ProgramDual-Wall Turbine Blades

Affordability is key challenge to production readiness Traditional casting methods

require significant investments in tooling and pattern development

Approved for Public Release

Make Core Die

Make Wax Die

Make Cores

Remove Wax

Fire/Sinter

Make Wax

Make Mold

Pour Casting

Remove Ceramic

Heat Treat Casting

Finish Casting

Inspect Casting

Design Tools

Rolls-Royce CLEEN Technologies ProgramDual-Wall Turbine Blades

Affordability is key challenge to production readiness Traditional casting methods

require significant investments in tooling and pattern development

Process innovations provide a significant opportunity Advanced casting

technologies use e-tools to enable major reductions in lead time and cost

Approved for Public Release

Fire/Sinter

Make Mold

Pour Casting

Remove Ceramic

Heat Treat Casting

Finish Casting

Inspect Casting

Design Tools

Rolls-Royce CLEEN Technologies ProgramDual-Wall Turbine Blades

Rolls-Royce LeanCoolTM blade technology combines these advanced cooling and casting technologies Achieves reduced fuel burn with low weight, long life, and greater

affordability

LeanCool blades for engine testing are nearing completion Blade design and analysis complete Casting process has been progressively developed/improved Machining and inspection of blades on-going

Technology demonstration will be conducted as part of the UK Environmentally Friendly Engine (EFE) program Planned testing to acquire thermal effectiveness and vibratory data

Approved for Public Release

Rolls-Royce CLEEN Technologies ProgramCMC Turbine Blade Tracks

Application of advanced CMC turbine materials enables Reduced Fuel Burn in NextGen product applications Reduction in cooling flow and weight savings in current engine cycles Enables progression toward more advanced engine cycles

Approved for Public Release

Combustion linersIncreased wall temperatureReduced emissions

Blade tracks/shroudsIncreased temperatureReduced weightImproved SFC

Airfoils (blades/vanes)Increased temperatureReduced weightImproved SFC

Large Civil 3-Shaft Engine

Rolls-Royce CLEEN Technologies ProgramCMC Turbine Blade Tracks

Rolls-Royce SiCf-SiCm CMC turbine blade tracks will demonstrate these substantial benefits Significant reduction in required cooling flow Substantial weight savings compared to metallics

Blade tracks for engine testing are nearing completion Blade track design and analysis complete CMC hardware manufacturing and inspection is complete Validation (bench) testing of blade tracks is underway

Technology demonstration will be conducted as part of the UK Environmentally Friendly Engine (EFE) program Planned testing will provide design validation and demonstrate

durability.

Approved for Public Release

Rolls-Royce CLEEN Technologies ProgramEnvironmentally Friendly Engine (EFE) Program

Demonstration program will validate new technologies aimed at reducing noise, fuel burn and emissions

5 builds, first run start 2010

Key Technology Areas High temperature materials High efficiency turbines Low emissions combustion Advanced manufacturing Engine control and actuation

Targets enabling technologies to deliver 2020 ACARE goals

Approved for Public Release

Rolls-Royce CLEEN Technologies ProgramFuel Burn Reduction Projects

Approved for Public Release

WE1 – Program Management

WE2 – Technology Maturity (Design, Fabrication)

WE1 – Program Management

2010 2011 2012 2013

Dual-Wall Turbine Blades

CMC Turbine Blade Tracks

WE2 – Technology Maturity (Design, Fabrication)

WE3 – Sys Eng & Intgr

WE4 – Technology Demo

WE5 – Tech Assess

WE4 – Technology Demonstration

WE3 – Sys Eng & Integration

WE5 – Tech Assess

Rolls-Royce CLEEN Technologies ProgramAlternative Fuels Objectives

Approved for Public Release

Energy density CO2 benefit Mass productionFuel specification Low agricultural impact Global distribution

Operability Renewable feedstocksAircraft compatibility

Energy density CO2 benefit Mass productionFuel specification Low agricultural impact Global distribution

Operability Renewable feedstocksAircraft compatibility

Suitability Sustainability Industrialization

Rolls-Royce CLEEN Technologies ProgramUS Alternative Fuels Program

Comprehensive evaluation of single HEFA* fuel blend Dynamic Fuels R-8; 50:50 blend

Establish correlation between rig/engine data Sequential and methodical

progression

Approved for Public Release

Lab Evaluations /Material Compatibility

Spray DiagnosticsRig

FlametubeCombustion Rig

3-Cup Sector Combustion Rig

Full Annular Combustor Rig

Material Endurance Rig

AE 3007 Ground Test

Cessna Model 750 Flight Test

* HEFA - HydroprocessedEsters and Fatty Acids

Rolls-Royce CLEEN Technologies ProgramUS Alternative Fuels Program

Comprehensive evaluation of single HEFA* fuel blend Dynamic Fuels R-8; 50:50 blend

Establish correlation between rig/engine data Sequential and methodical

progression

Approved for Public Release

Lab Evaluations /Material Compatibility

Spray DiagnosticsRig

FlametubeCombustion Rig

3-Cup Sector Combustion Rig

Full Annular Combustor Rig

Material Endurance Rig

AE 3007 Ground Test

Cessna Model 750 Flight Test

HEFA blends approved by ASTM;

Program truncated

* HEFA - HydroprocessedEsters and Fatty Acids

Rolls-Royce CLEEN Technologies ProgramUS Alternative Fuels Program

Fuel Properties / Spray Testing Thermo-physical properties

50:50 HEFA properties bounded by limits of petroleum fuels

Spray visualization and drop size measurements Testing conducted using 50:50

HEFA, JP-8, JP-TS, and JP-5 Simulated relight conditions Spray characteristics at relight

conditions are similar for all fuelsPure AirBlast Nozzle

Combustor Reference Velocity

Dro

p Si

ze

JP-8JP-TSJP-550% HRJWindmilling

Assisted

Ground Idle

Approved for Public Release

Rolls-Royce CLEEN Technologies ProgramUS Alternative Fuels Program

Flametube Rig Relight and LBO

-23≤BIT≤76°F; 4≤BIP≤13 psia; 50:50 HEFA chilled to -40°F

No differences among 50:50 HEFA, JP-8, JP-TS, and JP-5

Gaseous Emissions NOx, CO, and UHC @ At 7, 30,

45, 60, 75, 85, and 100% power and 45K 0.8Mn conditions

NOx performance bounded by limits of petroleum fuels

CO and UHC performances appear to be weaker

Approved for Public Release

NOx CO UHC

CA

EP 6

Mar

gins

JP-850% HRJJP-TSJP-5

Ignition

Combustor Reference Velocity

FAR

JP-8JP-TSJP-550% HRJ

Rolls-Royce CLEEN Technologies ProgramUS Alternative Fuels Program

Material Endurance Rig 6 types of hot section materials

exposed to combustion gas of 50:50 HEFA blend

400 hour (1600 cycle) test 1 cycle = 14 min exposure + 1

min cooling

Initial results found no difference from prior testing of conventional fuels and other bio fuels Weight loss patterns of the test

pin qualitatively agree Awaiting results of lab analysis

Approved for Public Release

Rolls-Royce CLEEN Technologies ProgramUK Alternative Fuels Program

Approved for Public Release

Q2 2011

Q2/3 2010

Q2 2012

Q1 2013

Reducingnumber of fuels

Increasingvolume of fuels

Lab tests

11 fuels

RFI / RFP

To fuel suppliers

Rig

~5 fuels

Engine ReportFuel A

Fuel B

Rolls-Royce CLEEN Technologies ProgramUK Alternative Fuels Program

Candidate Fuel Summary SPK Type Materials - range

of raw materials and processes including: Hydro-treatment of varying

severity Typical plant oils and algae

Fully Formulated - range of raw materials and processes including: Fermentation, Bio-forming,

Catalytic, and Hydrogenation based processes

Cellulosic, Glucose/Sugars, Plant Oils ,and/or Alcohols

Participating Fuel Suppliers Advanced Bio-energy

Technologies Inc. Applied Research

Associates Inc. Algaeon Inc and Swift

Enterprises Ltd. Byogy Renewable Inc. Logos Technologies Inc. Shell Research Ltd. and

Virent Energy Systems Inc. Solazyme Inc, UOP, a Honeywell Company

Approved for Public Release

Rolls-Royce CLEEN Technologies ProgramUK Alternative Fuels Program

Laboratory Testing Lab testing phase of the

program is complete Detailed Composition/Purity Selected Specification Tests

Fuels have been assessed relative to reference specifications Conventional Fuel: ASTM

D1655 Jet A/A-1 Synthetic Blends: ASTM

D7566-11 (FT-SPK and HEFA)

Compilation of test report is underway

Approved for Public Release

Rolls-Royce CLEEN Technologies ProgramUK Alternative Fuels Program

Planned Rig Testing A broad range of products meeting program criteria have been

received from participating suppliers Lab results have identified good potential and novel aspects for the

submitted fuels Candidate fuels have been identified for next phase of test program

Rig test program will assess selected fuels for a broad range of characteristics Combustion Performance Emissions Elastomer Compatibility Thermal Stability

Rig test program will also investigate aromatic risk/benefits optimization Combustion v. Elastomer Compatibility over range of 0%-16% aromatics

Approved for Public Release

Rolls-Royce CLEEN Technologies ProgramAlternative Fuels Projects

WE1 – Program Management

WE5 – Tech Assess

WE1 – Program Management

WE3 – Sys Eng & Integration

WE4 – Tech Demo

WE5 – Tech Assess

2010 2011 2012 2013

US Alt Fuels Program

UK Alt Fuels Program

WE2 – Technology Maturity (Lab / Rig Testing)

WE2 – Technology Maturity (Lab / Rig Testing)

Approved for Public Release

Final Report – Q1 2012

Lab Report – Q1 2012

Rolls-Royce CLEEN Technologies ProgramSummary

Rolls-Royce has made substantial progress during 2011 Design and fabrication of turbine components Lab and rig tests of alternative fuels

Effort planned for 2012-13 will provide valuable data and validation of selected technologies Engine demonstration of turbine components (TRL6) Rig and engine testing of selected alternative fuels

Technologies and approaches selected will provide a significant contribution to the FAA CLEEN program goals Reduced Fuel Burn Alternative Fuels Feasibility

Approved for Public Release