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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
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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
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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
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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
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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
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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
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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
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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
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2019 Program Schedule
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2020 Program Schedule
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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
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Compact Combustor
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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
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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
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