Efforts to improve aero engine performance through the optimal design of heat recuperation systems targeting fuel consumption and pollutant emissions reduction

Abstract

The present work is focused on the conceptual development and numerical assessment of various new heat recuperation system configurations, specifically designed and optimized for a state-of-the-art turbofan application developed by MTU Aero Engines AG. The optimization efforts were performed through CFD computations, experimental measurements and aero engine thermodynamic cycle analysis. A critical part of the optimization phase was conducted using a customizable numerical tool modelling the recuperation system heat transfer and pressure loss characteristics and including the effect of important heat exchanger design decisions. The numerical tool was based on an advanced porosity model approach in which the heat exchangers macroscopic behaviour was included through the integration of predefined heat transfer and pressure loss correlations, calibrated through CFD computations and experimental measurements. The optimization led to two new recuperation configurations with significant improvements regarding the aero engine fuel consumption and pollutant emissions reduction providing direct environmental and economic benefits.