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Consortium Presentation – Open Discussion HONEYWELL CLEEN II Dan Frias 05/07/2019 UNLIMITED RIGHTS Agreement Number: DTFAWA-15-A-80017 Contractor Name: Honeywell International Inc. Address: 111 S. 34 th Street Phoenix, Arizona 85072-2181 21-15790(07)-2
Transcript

Consortium Presentation – Open Discussion HONEYWELL CLEEN IIDan Frias

05/07/2019

UNLIMITED RIGHTSAgreement Number: DTFAWA-15-A-80017 Contractor Name: Honeywell International Inc.Address: 111 S. 34th StreetPhoenix, Arizona 85072-2181

21-15790(07)-2

21-15790(07)-2 Use or disclosure of information contained on this page is subject to the restrictions on the cover.

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Agenda

• Elevator Speech• Honeywell’s Products and CLEEN II• CLEEN II Technologies• Technology Maturation Approach and Program Schedule

• Engine and Aircraft Systems Analysis Status• Technologies Status – Compact Combustor• Technologies Status – Blade Outer Air Seal (BOAS)• Future Plans• Summary

21-15790(07)-2 Use or disclosure of information contained on this page is subject to the restrictions on the cover.

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CLEEN II Elevator Speech• Honeywell’s CLEEN II program is maturing advanced

turbine and combustor technologies to reduce weight for improved fuel burn and reduced emissions

21-15790(07)-2 Use or disclosure of information contained on this page is subject to the restrictions on the cover.

3

CLEEN Technologies Enhance Future Product Capabilities

• State-of-the-art (SOA) performance• Industry leading dispatch reliability• Quantum leap in value: cost and durability• Versatile technology: 7000-10000 lbs thrust• Five aircraft applications to date

- > 1000 engines in service- > 2 million flight hours

Next Generation Turbofan Can Benefit from CLEEN Technologies to Reduce Fuel Burn and Emissions

HTF7000 SeriesEngine Platform

HTF7000 Bombardier Challenger 300

HTF7350B Bombardier Challenger 350

HTF7250G Gulfstream G280

HTF7500E Embraer Legacy 450/500

HTF7700L Cessna Citation Longitude

21-15790(07)-2 Use or disclosure of information contained on this page is subject to the restrictions on the cover.

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Honeywell CLEEN II Technologies• Under CLEEN II Honeywell is developing and demonstrating

advanced Combustor and Turbine technologies

The advanced Turbine BOASincreases high pressure turbine efficiency, resulting in reduced fuel burn.

Compact Low Emissions Combustor integrates advanced aerodynamics and fuel injection technologies to reduce engine NOX emissions and weight, contributing to reducing fuel burn.

Blade Outer Air Seal

Compact Combustor

RICH

LEAN

QUENCH

21-15790(07)-2 Use or disclosure of information contained on this page is subject to the restrictions on the cover.

5

CLEEN II Technology SummaryCLEEN

Technology Name

Goal Impact Benefits, Applications and Collateral Benefits

Compact Combustor System

Emissions • Goal - Reduce NOx emissions to >50% margin (CAEP/8),for next generation super mid-sized class business jet turbofan engines for 2025 entry into service (EIS)

Advanced Turbine BOAS System

Compact Combustor

Fuel Burn • Goal - Enable turbofan engine fuel burn reduction >22%relative to the baseline engine for next generation turbofan, turboshaft, turboprop engines for 2025 EIS

Collateral Benefits• FAA CLEEN programs support validation of Low-k thermal

barrier coating (TBC) and Alloy 10 powder metal super-alloy• Currently being evaluated by major aerospace and industrial engine original equipment manufacturer (OEMs)

• Applied to current and future turbine propulsion and industrial engines should increase fuel efficiency and lower operating costs

21-15790(07)-2 Use or disclosure of information contained on this page is subject to the restrictions on the cover.

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CLEEN II Value and Opportunity Cost

Technology CLEEN II Value Opportunity Cost(If FAA had not funded…)

Fuel Burn Enables >22% fuel burn improvement over baseline engine through an advanced engine architecture with high efficiency turbine technologies

Likely delays technology development and implementation of advanced fuel burn technologies impacting near term reductions in fuel burn and CO2emissions.

Emissions Enables > 2x improvement in NOx margin over Honeywell SOA combustor through integration of advanced combustor aerodynamics, fuel placement and materials

Achieving ultra-low emissions is very challenging and requires major investment. Without FAA support, level of internal investment reduced and level of current customer/regulatory requirements, will result in delayed implementation of ultra low emissions technologies.

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Technology Maturation Approach

Progressive Approach to Validate Technology and Reduce Risk

Analysis and Technology Demonstration Testing

Component / SystemDevelopment Testing

Engine Demonstration and Validation Testing

RICH

LEAN

QUENCH

May 2019 Status

TRL 6TRL 5TRL 4TRL 3

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Progress and Achievements• Systems Engineering

- Engine detailed design review (DDR) complete- Gulfstream assessment complete- Provide assessment information to Georgia Tech upon test completion

• BOAS Development- Coupon material characterization testing complete- Structural test of engine attachment design complete- Thermal characterization test complete- Shroud engine hardware inspection complete (Engine Test Q3 2019)- Air plasma spray (APS) TBC process down-select complete

• Combustor Development- Initial rig testing complete- Second Phoenix rig test underway (Q2 2019)- Preliminary NASA rig design nearing completion

Next Steps to Validate Technology Designs

21-15790(07)-2 Use or disclosure of information contained on this page is subject to the restrictions on the cover.

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2019 Program Schedule

21-15790(07)-2 Use or disclosure of information contained on this page is subject to the restrictions on the cover.

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2020 Program Schedule

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11

Engine and Aircraft SystemsAnalysis Status

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Systems Progress and Achievements

• DDR Complete- Engine system architecture and cycle defined- Reference aircraft and engine analysis complete- >22% aircraft mission fuel burn reduction over baseline

engine achieved with CLEEN II and Honeywell technologies

- Ground engine test configuration layout complete - Linkage with Honeywell’s marketing plans for near- and

long-term potential platforms complete

Next Steps to Refine and Validate Technology Designs

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CLEEN II Aircraft Fuel Benefits• CLEEN II aircraft mission fuel burn reduction goal of 22% from baseline engine• Fuel burn reduction includes CLEEN and Honeywell technologies

CLEEN II Continues to Contribute to Fuel Burn Reduction

CLEEN IITechnologies

2.1%Fuel Burn

Benefit

CLEEN ITechnologies

5.0%Fuel Burn

Benefit

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Benefits• Improved power-to-weight ratio• Reduced engine thrust specific fuel

consumption (TSFC)• Reduced fuel burn and NOx emissions

Engine and Aircraft Systems Analysis

Objectives• Define a ‘CLEEN II’ engine with

advanced technologies that enable reduction in fuel burn and NOx emissions

Work Statement• Perform engine preliminary and detail

engine concept reviews along with independent assessments of the technology benefits

Technology Schedule

Risks/Mitigations• Insufficient aircraft fuel burn

assessment/work with Gulfstream and Georgia Tech

Accomplishments/Milestones• Engine DDR complete• Gulfstream assessment complete

Task 2 - DDR

Task 1 - PDR

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CLEEN II Technologies StatusCompact Combustor

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16Compact Combustor Technology

Combustor Technology to Reduce NOx to >50% Margin to CAEP/8

is an advanced combustor design that integrates SOA aerodynamic design, advanced material selection and coatings and improved fuel control.

Compact Combustor Attributes• Improved aerodynamic design• Advanced cooling and materials• Improved durability enabling higher

temperature cycle to reduce fuel burn• Reduced weight

RICH

LEAN

QUENCH

Compact Combustor

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17

Compact Combustor Accomplishments

Combustor Technology Progressing to TRL 4 in Q2 2019

• Combustor technology demonstration testing progressing to enable refinements to combustor system to meet program goals- Evaluated multiple fuel injector and combustor aerodynamic design

configurations designed using advanced computational fluid dynamics (CFD) large eddy simulation (LES) analysis to optimize performance, emissions and wall cooling

• Currently rig testing latest CLEEN II combustor in Phoenix Combustor Test Laboratory with results expected in June

• Completed design review with NASA and FAA of CLEEN II annular combustor rig to be tested in the NASA Glenn Advanced Subsonic Combustor Rig (ASCR) facility in mid-2020

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Compact Combustor Next Steps

• Continue technology demonstration and annular combustor system development rig testing through Q4 2019

• Complete fabrication and build NASA rig (adaptive rig hardware) to support validation testing at NASA ASCR test facility in Q2 2020 to:- Validate combustor NOx emissions and

performance - Measure combustor nvPM- Validate Liner wall temperatures for

durability assessment• Complete Honeywell engine validation

testing in Q3 2020

Technology Maturation Plan to Demonstrate TRL 6

Honeywell Rig Testing

Honeywell Engine Testing

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Benefits• Lower engine emissions• Reduction in fuel burnRisks/Mitigations• Operability - Rig test validation at altitude cond.• Emissions - Test validation at full engine cycle

operating conditions in NASA facility• Combustor Durability - Demo engine cyclic test

Combustor System Technology

Objectives• Reduce NOx emissions• Reduce combustor weight

Work Statement• Develop and demonstrate a low

emission compact combustor for improved NOx and fuel burn in a an engine

Technology Schedule

Accomplishments/Milestones• Completed initial Compact Combustor design• Rig testing annular combustor technologies and

full system to demonstrate program goals • Completed design of CLEEN-II NASA combustor

rig. Testing planned in ASCR facility in 2020

RICH

LEAN

QUENCH

21-15790(07)-2 Use or disclosure of information contained on this page is subject to the restrictions on the cover.

20

CLEEN II Technologies StatusBlade Outer Air Seal (BOAS)

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Blade Outer Air Seal (BOAS) Technology

BOAS Technology to Reduce Turbofan Engine Fuel Burn 2.1%

is an advanced turbine system design that addresses blade-to-shroud interaction, high temperature capability and durability.

BOAS Attributes• Increased Temperature Capability• Reduced Leakage • Effective Tip Clearance• Improved Durability• Reduced Weight

Blade Outer Air Seal

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Honeywell’s Next Gen APS TBC Technology

Air Plasma Spray Technology Progressing to TRL 4 in Q3 2019

is a protective ceramic coatingapplied to the external surfaceof engine components for insulation and to inhibit oxidation and hotcorrosion.

Lower Thermal Conductivity TBC

Low-k APS TBC Attributes• 15-20% lower conductivity• 10-20% improved erosion rate• Equivalent spallation life• Phase stable above 3,000°F• Ready to test, 2019

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Advanced BOAS System Accomplishments

• Turbine Blade/Shroud- Advanced blade material oxidation characterization complete- Advanced blade/shroud rub testing well underway- Engine shroud design complete and hardware received- Shroud material mechanical testing complete- Shroud material thermal characterization testing complete

• APS Low-k TBC- Identified most promising powder and processing route for

APS Low-k TBC - Initial thermal conductivity testing complete- Thermal phase stability testing complete

BOAS to Achieve System TRL 4 in Q3 2019

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Benefits• Fuel burn reduction• Improved power-to-weight ratioRisks/Mitigations• Insufficient material durability/rig and

engine test• Insufficient performance/alternate

BOAS design

Advanced Turbine BOAS System Technology

Objectives• Improve high pressure turbine (HPT)

efficiency

Project Schedule

Blade Outer Air Seal

Low Thermal Conductivity TBC

Work Statement• Develop and demonstrate a BOAS

system that improves HPT efficiency in an engine

Accomplishments/Milestones• HPT shroud design complete and hardware

received for 2019 development engine testing• APS Low-k TBC processing down-selected

and shows good results

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Technology Readiness Level(TRL) Maturation and Summary

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Future Plans – TRL Maturation• TRL 4 – 2019

- Blade Tip Mechanical Testing – Q2 2019- Annular Compact Combustor Testing – Q2 2019- APS Low-k TBC Process Optimization – Q3 2019

• TRL 5 – 2019-2020- Development Test(1) – Q3 2019

HPT Shroud Technology Assessment

- Development Test(2) – Q1 2020 HPT BOAS Technology assessment

• TRL 6 – 2020- NASA Combustor System Testing – Q2 2020- Endurance Engine Test – Q3 2020

Engine emissions assessment Endurance engine test to support TRL 6 validation of

Compact Combustor and BOAS Technologies

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Summary• Honeywell CLEEN II program is progressing well to mature the

compact combustor and the advanced turbine BOAS to reduce fuel burn and NOx emissions

- Engines and Aircraft Systems Analysis Engine DDR complete Gulfstream aircraft/engine assessment complete

- Compact Combustor Initial compact combustor design complete Rig testing annular combustor technologies and full system to

demonstrate program goals well underway Completed design of CLEEN II NASA combustor rig. Testing

planned in ASCR facility in 2020- Turbine BOAS

HPT shroud design complete and hardware received for 2019/2020 development engine testing

APS Low-k TBC processing down-selected and shows good results

21-15790(07)-2 Use or disclosure of information contained on this page is subject to the restrictions on the cover.

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