VITAL - Environmentally Friendly Aero-Engine
Overview
Background & policy context:
At the time of this project air traffic growth (5% growth rate per annum according to ICAO) was greatly impeded by the noise generated by aircraft as well as the harmful effects of aircraft pollutants on the environment (3% growth in CO2 emissions per annum). Aircraft engines are a large source of CO2 and NOx emissions and contributors of noise. The quantity of these gases emitted into the atmosphere is controlled by operational factors as well as engine and aircraft design technologies. This is why the engine is judged to require a further 20% CO2 reduction when the ACARE SRA requires a 50% reduction by 2020.
Consequently, Europe's aviation industry faces a massive challenge to satisfy the demand whilst ensuring economic, safe and environmentally friendly air travel. Radical and innovative engine structures and architectures werre investigated in order to meet these extremely challenging targets for acoustics and pollution. Such reductions could only be achieved by reconsidering completely, in a first step, the different components of an engine with innovative breakthrough designs, and in a second step, by assembling and optimising these components in new engines.
VITAL provided a major advance in developing the next generation commercial aircraft engine technologies, enabling the European aero-engine industry to produce high-performance, low-noise and low-emission engines at an affordable cost for the benefit of their customers, air passengers and society at large.
Objectives:
The main objective of VITAL was to develop and validate engine technologies that provide:
- 6 dB noise reduction per aircraft operation and equivalent to a cumulative margin of 15-18 EPNdB on the three certification measurement points and
- 7% reduction in CO2 emissions.
This is with regard to engines in service prior to 2000.
VITAL integrated the benefits and the results of ongoing research projects with regard to weight reduction (EEFAE) and noise reduction (SILENCE(R)) technologies, assessed at a whole engine level their benefits and combined their outcomes with those of VITAL to enable, by the end of the project in 2008, the following:
- 8 dB Noise reduction per aircraft operation (cumulative ~24 EPNdB on the 3 certification measurement points) and
- 18% reduction in CO2 emissions.
Methodology:
The objective of VITAL was achieved through the design, manufacture and rig-scale testing of the following innovative technologies and architectures:
- two innovative low-speed fan architectures for (1) Direct Drive Turbo Fan (DDTF) and Geared Turbo Fan (GTF) and (2) Contra-Rotating Turbo Fan (CRTF). This included intensive use of lightweight materials to minimise the weight penalty of Very High Bypass Ratio (VHBR) engines;
- new high-speed and low-speed low-pressure compressor concepts and technologies for weight and size reduction;
- new lightweight structures using new materials as well as innovative structural design and manufacturing techniques;
- new shaft technologies enabling the high torque needed by the new fan concepts through the development of innovative materials and concepts;
- new low-pressure turbine technologies for weight and noise reduction, suited to any of the new fan concepts;
- optimal installation of VHBR engines related to nozzle, nacelle, reverser and positioning to optimise weight, noise and fuel burn reductions.
All these technologies were evaluated through preliminary engine studies for the three architectures, DDTF, GTF and CRTF.
To achieve the VITAL objectives, different modules of an engine were considered, some generic and usable in all three engine types, while some others were specific. Consequently, the work in VITAL was organised into seven technical sub-projects and one sub-project (Sub-Project 0) for management and dissemination activities. The technical sub-projects were split according to each part of the engine. A transversal sub-project (Sub Project 1) ensures that the module is well integrated by:
- defining module requirements and
- assessing the three main engine architectures: DDTF, GTF and CRTF.
VITAL researched, designed and developed technologies regarding:
- innovative fan design (lightweight fan and contra fan technologies) - Sub Project 2;
- high-load booster design and technologies - Sub Project 3;
- lightweight hot and cold structures - Sub Project 4;
- novel materials and concept for low-pressure engine shafts - Sub Project 5;
- high-loaded and high-lift low noise and lightweight, low-pressure turbines - Sub Project 6;
- nacelle design and aircraft installation - Sub Project 7.
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