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BOEING is a trademark of Boeing Management Company.
Copyright © 2013 Boeing. All rights reserved.
Consideration of Fuel Cells for Future Airplanes
Al Carlo
Pressurized Compartment Fire Marshal
Payloads Engineering
October 29, 2014
Copyright © 2013 Boeing. All rights reserved.
Addressing CO2 as a Priority
Renewable fuel and energy
solutions
Operational efficiency
Environmentally progressive
products and services
Through innovative research and development
Copyright © 2013 Boeing. All rights reserved.
Building on a Strong Track Record
Rel
ativ
e fu
el u
se
Early Jet Airplanes
New Generation Jet Airplanes
Noise dB
MORE FUEL
LESS FUEL
HIGHER
DECIBELS
LOWER
DECIBELS
70% Fuel Improvement and Reduced CO2
90% Reduction in Noise Footprint
EVEN
LOWER EVEN LESS
Noise footprint based on 85 dBa.
1950s 1990s
Copyright © 2013 Boeing. All rights reserved.
Power
Source
Bleed No Bleed + MEA
Electrical Cabin Lighting
Avionics,
Fuel Pumps,
etc.
Engine start, De-
Ice
ECS &
Pressurization,
Cabin Lighting,
Avionics,
Fuel Pumps,
Brakes,
Flight Controls,
etc.
Hydraulic Brakes,
Flight Controls,
Landing Gear,
etc.
Flight Controls,
Landing Gear
Pneumatic Engine start,
De-Ice
ECS &
Pressurization
Cowl De-Ice
More Electric Airplane (MEA) Background
Efficiency changes in 787 due to:
Composite airframe
Efficient no-bleed engines
Transition in power sources in the MEA
Increase in electric power to ~1.5 MW
Efficient No-Bleed Engines
Copyright © 2013 Boeing. All rights reserved.
Distributed - More Electric Architecture Solid State Power Controllers and Contactors
Generator
2 x 250 kVA
Loads
Forward E/E
Bay
115 Vac
External Power
115 Vac
APU Generator
Aft E/E Bay
External Power
Remote Power
Distribution Unit
230 Vac Feeder
Centralized Distribution (Traditional) Circuit Breakers, Relays and Contactors
Generator
1 x 120 kVA
Loads
E/E Bay
External Power
115 Vac
APU Generator
115 Vac Feeder
115 Vac or 28
Vdc Wire
Pre-787 787
The More Electric Airplane Is Moving Toward A More Distributed System
Copyright © 2013 Boeing. All rights reserved.
Electrical Power Technologies Integration
Copyright © 2013 Boeing. All rights reserved.
Potential Future Grid-Like Power Systems
Benefits:
Power System Flexibility and Utility
Maintainability
Reliability/Redundancy
Efficiency
Availability
Power Management
Utility
Reduced Power Extraction
Reduced Operational (Life Cycle) Cost
Environment (less emissions and noise)
Copyright © 2013 Boeing. All rights reserved.
POWER
ELECTRONICS
(Si, SiC, FUTURE)
SEMICONDUCTOR
SWITCHES
CAPACITORS
CIRCUITRY
OTHER COMPONENTS
ENERGY STORAGE
BATTERIES
SUPERCAPACITORS
MAINTENANCE
FREE
LITHIUM
RECHARGEABLE
THERMAL
MANAGEMENT
ACTIVE VS. PASSIVE
SPRAY COOLING
“ELECTRIC” AIR
CONDITIONING
POWER GENERATION /
UTILIZATION
MOTOR TYPES
INDUCTION
COOLING
MAG BEARINGS
CONTROLLERS
POWER DISTRIBUTION /
SYSTEM INTEGRATION
VOLTAGE TYPE
HIGH VOLTAGES,
FREQUENCY
QUALITY / STABILITY
EMI
SWITCHED
RELUCTANCE
STARTER /
GENERATORS
MODELING
DEMONSTRATIONS
ELECTRIC
ACTUATION
SIGNAL CONTROLS
ELECTRIC PHOTONIC
COMMERCIAL
AIRCRAFT
More Electric
Platforms
Solid State
Thermal Engine
“More Electric” Is Industry Trend
Copyright © 2013 Boeing. All rights reserved.
Fuel Cells Can Support Optimized Power Management
Lower power margin during
idle descent
Energy storage & load
management opportunities
Potential to improve airplane
efficiency & reduce power
system rating
Copyright © 2013 Boeing. All rights reserved.
APU Engine
Large
Airplane NOx
Emissions at
Airport
Fuel Cell APU Can Cut Airplane NOx Emissions At The Airport
Fuel Cell
Copyright © 2013 Boeing. All rights reserved.
Demonstrators Are A Means To Get Familiar With Integration And Operational Issues
Battery Pack
Electric Motor
5,000 psi Gaseous
Hydrogen
20kW PEM Fuel Cell
(from Intelligent Energy)
Motor
Controller
Fuel Cell
Controller
Boeing Fuel Cell Airplane Demonstrator
Copyright © 2013 Boeing. All rights reserved.
The Architecture Is Key To Understanding Fuel Cell Application In Airplanes
Need to develop and evaluate optimum fuel cell architectures including type and size of fuel cells, operation, infrastructure, fuels, etc.
Some of these architectures can begin to be evaluated on the ground
Supporting infrastructure and airplane interface can also be addressed with ground networks
FUEL CELL APU’S IN COMMERCIAL AIRCRAFT –
AN ASSESSMENT OF SOFC AND PEMFC CONCEPTS,
ICAS 2004, 24TH INTERNATIONAL CONGRESS OF T
HE AERONAUTICAL SCIENCES
Copyright © 2013 Boeing. All rights reserved.
Fuel Cells For Non-Essential Loads
Fuel cells can be used to power non-critical loads like galleys and In-Flight Entertainment systems
Potential to remove these loads from the power system
Decreases the size of the generating system
Decreases the engine power extraction
Provides improved operational efficiency for airlines
Micro-grid approach provides increased configuration flexibility
Copyright © 2013 Boeing. All rights reserved.
Variable Area Fan Nozzle
Adaptive Trailing Edges (FAA CLEEN)
Advanced Air Traffic Management Flight
Trajectory Optimization And Information
Management
Copyright © 2012 Boeing. All rights reserved.
Active Engine Vibration Reduction (EVRN- AVC)
2012 ecoDemonstrator Program
Regenerative Fuel Cell with IHI and IHI
Aerospace
Copyright © 2013 Boeing. All rights reserved.
RFC System Configuration
- Five(5) modules were located in B737-800 aft cargo area
- Control switches/power converters were located in cabin
ecoDemonstrator 2012
Main Unit
(fuel cell, electrolyzer,
water tank and pumps)
H2 Tank Unit
(hydrogen gas tanks) O2 Tank Unit
(oxygen gas tanks)
RFC Controller
Radiator Fan Unit
(heat exchanger)
Copyright © 2013 Boeing. All rights reserved.
RFC System Was Fully Checked In The Lab In Seattle Prior
To Installation In The Airplane
Copyright © 2013 Boeing. All rights reserved.
RFC System Installed In The Aft Cargo Bay Of
ecoDemonstrator 2012
Copyright © 2012 Boeing. All rights reserved.
Copyright © 2013 Boeing. All rights reserved.
Summary
• The More Electric Airplane (MEA) is expected to play a significant role in the future of overall airplane system design, operation and performance
• The MEA is a technology enabler for energy generation, storage and conversion systems
• Some of the MEA-associated technologies (such as fuel cells) require significant R&D to bring them to the level of development so that industry can then make them commercially viable for airplane application
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