Cryogenic and Superconducting Technologies for 3.2 MW Hybrid-Electric Aircraft Propulsion T.J. Haugan1, G.Y. Panasyuk2 1Air Force Research Laboratory, AFRL/RQQM, Wright-Patterson AFB, OH 45433 2UES Inc., Dayton OH 45432 3.2 MW Aircraft deHavilland Dash 8 3.2 MW Drivetrains 70 kW Chevy-Volt Style Drivetrain, Siemens DA36 E-Star de Havilland Bombadier Dash 8: DHC-8-100 series (Canada) DHC-8-100 Capacity 37-39 passengers Typical Payload 7511 lbs Range 1174 miles Motors 2 PW121 Motor Weight 1874 lbs Max. Fuel Size 1003 U.S. gal Max. Fuel Weight 6039 lbs Maximum Weight 36661 lbs 70 kW Electric Motor and Drivetrain “Similar to General Motors' Chevy Volt drive train, the DA36 E-Star uses a serial hybrid electric drive train…” - “Siemens scientists …are currently working on a new electric motor that is expected to be five times lighter than conventional drives. In two years, another aircraft is expected to be equipped with an ultra-light electric drive.” http://www.siemens.com/ 3.2 MW Prius-Style Drivetrain DHC-8-100B Hybrid Cu-Wire Hybrid Cryo 3.2 MW Engine (2 PW121) 1874 lb 1.83 MW Electric Motor/Generator 1010 lb* 101 lb 2.6 MW Electric Motor 1439 lb* 144 lb 227 MJ Li Battery 413 lb** Extra Machine Weight (w battery) 2862 lb 658 lb Fuel Weight (Max.) 6039 lbs 3446 lb 5381 lb (3.2 MW) (1.8 MW) (2.6 MW) Pratt-Whitney PW110, 1.4 MW continuous - PW121 Mass = 425 kg - Power = 1.603 MW continuous - Power density = 3.77 kW/kg http://en.wikipedia.org/wiki/Pratt_%26_Whitney_Canada_PW100 http://en.wikipedia.org/wiki/Turbo http://en.wikipedia.org/wiki/Bombardier_Dash_8 prop 3 MW Components 3 MW Generators (227 MJ) Cu-Wire 1/2- Supercond HTS @ 77K Full- Supercondu ctor @20K* Weight Device (lb) 1554 753 132 Power Density (cont.) 4.1 kW/kg 8.8 kW/kg 50 kW/kg Machine Efficiency (%) 95 97 99.97 Waste Heat (cont.) 150 kW 90 kW 0.9 kW Waste Heat / Mass ( per hr) 540 MJ 324 MJ 3.3 MJ Waste Heat / Mass (MJ/kg*h) 0.37 0.32 0.03 CryoCooler Mass @ 3 MW (option) 66 lb cryo ? Non-cryo 238 lb* Liquid Cooling @ 3 MW (option) 23.7 lbs/h Liquid H2 Cryo 4x lighter 0.2 MW Cu-Wire (Tesla Inc.) www.motortrend.com GOTCHA: Weight reduced > 10x * Assume power density = 4 kW/kg ** Energy density = 400 Wh/kg GOTCHA: Heat loss reduced > 100x Cryo 60% longer range 1-35 MW ½-Superconductor (General Electric-MEPS) 1-30 MW Full- Superconducting (NASA-Glenn) 3.2 MW Chevy-Volt-Style Drivetrain (1.8 MW) (1.55 MW) (3.2 MW) (2.8 GJ) DHC-8-100B Hybrid Cu-Wire* Cryo Combustion Engines 1874 lb (3.2 MW) 1054 lb (1.8 MW) 1.55 MW Electric Motor/Generator 833 lb* 83 lb 3.2 MW Elec- Motor 1721 lb* 172 lb Cooling ? 38 lb H2-liq/hr or 88 lb N2-liq/hr Machine Weight 1,874 lb 3,608 lb 1,310 lb Fuel Mix Max. 6,039 lb gas 772 lb gas 3,533 lb battery 5,831 lb battery Machine+Fuel Max. 7,913 lb Range @ Poweravg 1,174 miles gas 150 milesgas 69 mileselec** 126 mileselec ** Fuel Cost @ Poweravg (per 100 miles*passenger) $6.51 $1.27 $1.14 GOTCHA: Risk factor low for Cryo Machines * Assume Turbo-Brayton cryocooler 30% efficient, and power density = 3 kw/Kg *J. Felder, et al, NASA-Glenn, ISABE_ 2011_1340 3 MW Li-Batteries Energy densities = 400 Wh/kg achieved ! Cryo 3x lighter www.motortrend.com Rangeelec = [Range-Maxgas]/Fuel-Maxgas]*FuelBattery*[ƞelec/ Ƞgas]; where Ƞ = drivetrain efificiency http://enviasystems.com * Assume power density = 4 kW/kg ** Battery energy density = 400 Wh/kg - Electric Cu-wire drivetrain efficiency = 90% (Tesla motors = 88%) - Combustion efficiency = 29% - HTS drivetrain efficiency = 99% - Electric cost = $1.8 per gal equiv. ($0.054/kW-h, Dayton Sept 2013) - JP-8 Fuel = $3.12 per gal (2012 avg) Rangecryo-elec ~10% Rangegas Fuel Cost 6x lower Summary The major components of 3.2 MW drivetrains were considered for both cryogenic and Cu-wire, however the associated power electronics and mechanical gearing were not estimated yet. A Prius style drive-train is 4x lighter for cryogenic than Cu-wire. A Chevy-volt style drive-train with cryogenic components is estimated to be 3x lighter, increasing the range for cruise in electric drive 2x and reducing fuel cost 3x. Calculations Cruise speed = 500 km/hr Electric-drivetrain efficiency = 90% (Tesla Motors = 88%) Power use = 22% of 3.2 MW DISTRIBUTION A. Approved for public release. Distribution unlimited.