AIRCRAFT ENVIRONMENTAL CONTROL SYSTEM

Abstract

An aircraft environmental control system (20) comprises a first heat exchanger (24) configured to exchange heat between air provided by a pressurised air source (13) and a working fluid of a closed cycle refrigeration system, and an air turbine (32) configured to receive cooled air from the first heat exchanger (24). The closed cycle refrigeration system comprises a closed cycle refrigeration system compressor (35) driven by the air turbine (32), a closed cycle refrigeration system expander (36), and a second heat exchanger (33) configured to exchange heat between working fluid of the closed cycle refrigeration system and air downstream of the air turbine (32). The air turbine drives a further load (39).

Claims

1. An aircraft environmental control system comprising: a first heat exchanger configured to exchange heat between air provided by a pressurised air source, and a working fluid of a closed cycle refrigeration system; an air turbine configured to receive cooled air from the first heat exchanger; wherein the closed cycle refrigeration system comprises: a closed cycle refrigeration system compressor driven by the air turbine, a closed cycle refrigeration system expander, and a second heat exchanger configured to exchange heat between working fluid of the closed cycle refrigeration system and a coolant; and wherein the air turbine drives a further load.

2. A system according to claim 1, wherein the environmental control system further comprises an air cycle machine comprising an air cycle machine compressor coupled to an air cycle machine turbine by an air cycle machine shaft.

3. A system according to claim 2, wherein the air cycle machine compressor is configured to receive pressurised air from the pressurised air source, and is configured to air to the first heat exchanger.

4. A system according to claim 3, wherein the air cycle machine turbine is configured to receive cooled bleed air downstream of the first heat exchanger, and is configured to deliver bleed air to the air turbine.

5. A system according to claim 1, wherein pressurised the air source comprises one or more of a main gas turbine engine core compressor, an electrically driven compressor, and a gas turbine engine shaft driven auxiliary compressor.

6. A system according to claim 1, wherein the working fluid of the closed cycle refrigeration system comprises carbon dioxide.

7. A system according to claim 1, wherein the closed cycle refrigeration system is configured such that the working fluid is heated to a critical or supercritical state by the first heat exchanger.

8. A system according to claim 1 wherein the coolant comprises one of air provided from a ram air duct, and aircraft fuel.

9. A system according to claim 1, wherein the second heat exchanger is configured to exchange heat between working fluid of the closed cycle refrigeration system and air downstream of the air turbine.

10. A system according to claim 9, wherein the closed cycle refrigeration system comprises a third heat exchanger provided downstream in working fluid flow of the second heat exchanger, and configured to exchange heat between the closed cycle refrigeration system working fluid and a heat sink working fluid comprising one of air provided from a ram air duct, and aircraft fuel.

11. A system according to claim 1, wherein the further load driven by the air turbine comprises an electrical generator.

12. A system according to claim 1, wherein the closed cycle refrigeration system compressor is provided downstream in working fluid flow of the first heat exchanger, the second heat exchanger is provided downstream of the closed cycle refrigeration compressor, the expander is provided downstream in working fluid flow of the second heat exchanger, and the first heat exchanger provided downstream in working fluid flow of the expander) to form a closed cycle.

13. A system according to claim 1, wherein the expander comprises one of an expansion valve and a closed cycle refrigeration turbine.

14. A system according to claim 13, wherein the closed cycle refrigeration turbine is configured to drive the closed cycle refrigeration cycle compressor.

15. A system according to claim 2, wherein the environmental control system comprise a bypass passage) configured to bypass air from an output of the air cycle machine compressor to an input of a heater configured to heat air within the air turbine.

16. An aircraft comprising a gas turbine engine and an environmental control system in accordance with claim 1, the gas turbine engine being configured to provide a source of compressed air to the environmental control system.

Description

[0025] Embodiments will now be described by way of example only, with reference to the Figures, in which:

[0026] FIG. 1 is a schematic drawing of a prior environmental control system for an aircraft;

[0027] FIG. 2 is a plan view of an aircraft including an environmental control system;

[0028] FIG. 3 is a schematic side view of a gas turbine engine of the aircraft of FIG. 2;

[0029] FIG. 4 is a schematic side view of first alternative gas turbine engine of the aircraft of FIG. 2;

[0030] FIG. 5 is a schematic side view of second alternative gas turbine engine of the aircraft of FIG. 2;

[0031] FIG. 6 is a schematic drawing of an environmental control system of the aircraft of FIG. 2;

[0032] FIG. 7 is a schematic drawing of an alternative environmental control system of the aircraft of FIG. 2; and

[0033] FIG. 8 is a schematic drawing of a further alternative environmental control system of the aircraft of FIG. 2.

[0034] With reference to FIG. 2, an aircraft 1 in the form of a passenger aircraft is shown. The aircraft 1 is powered by a pair of gas turbine engines 10, suitable examples of which are shown schematically in FIGS. 3, 4 and 5. The gas turbine engine of FIG. 3 is generally indicated at 10 and comprises, in axial flow series, an air intake 11, a propulsive fan 12, a compressor 13, combustion equipment 14, a turbine 15, and an exhaust nozzle 16. A nacelle 17 generally surrounds the engine 10 and defines the intake 11.

[0035] The gas turbine engine 10 works in the conventional manner so that air entering the intake 11 is accelerated by the fan 12 to produce two air flows: a first air flow into the compressor 13 and a second air flow which passes through the nacelle 17 to provide propulsive thrust. The compressor 13 compresses the air flow directed into it before delivering that air to the combustion equipment 14.

[0036] In the combustion equipment 14 the air flow is mixed with fuel and the mixture combusted. The resultant hot combustion products then expand through, and thereby drive the turbine 15 before being exhausted through the nozzle 16 to provide additional propulsive thrust. The turbine 15 drives the compressor 13 and the fan 12, by an interconnecting shaft.

[0037] The compressor 13 comprises an environmental control system bleed port 18 configured to provide pressurised bleed air to an environmental control system (ECS) 20.

[0038] A first alternative gas turbine engine 110 is shown in FIG. 4. The engine 110 is similar to the engine 10, and comprises a fan 112, main engine core compressor 113, combustor 114 and turbine 115. The compressor 113 and turbine 115 are interconnected by a main engine shaft 119. However, instead of a bleed port, the gas turbine engine 110 comprises an engine shaft driven auxiliary compressor 118. The auxiliary compressor 118 is configured to ingest air, and compress it to provide a source of pressurised air to an environmental control system (ECS) 20.

[0039] Similarly, a second alternative gas turbine engine 210 is shown in FIG. 5. The engine 210 is similar to the engine 10, and comprises a fan 212, main engine core compressor 213, combustor 214 and turbine 215. The compressor 213 and turbine 215 are interconnected by a main engine shaft 219. However, instead of a bleed port, the gas turbine engine 110 comprises an engine shaft driven electrical generator 245. The electrical generator 245 is coupled to an electric motor 247 via an electrical interconnector 246. The motor 247 in turn drives an auxiliary compressor 218. The auxiliary compressor 218 is again configured to ingest air, and compress it to provide a source of pressurised air to an environmental control system (ECS) 20.

[0040] A schematic drawing of a first environmental control system 20 is shown in FIG. 6. The system comprises an air inlet 21, which is configured to receive air from the bleed port 18 of the gas turbine engine 10 or other pressurised air source. The air inlet 21 communicates with a temperature control valve in the form of a two way switching valve 22, which is configured to provide air to an air conditioning system downstream, and/or provide air to a bypass line 27. The temperature control valve 22 is controlled by an electronic controller (not shown) in accordance with a schedule.

[0041] Downstream in ECS flow of the valve 22 is an air cycle machine in the form of an air conditioning unit. The air conditioning unit comprises an air compressor 23, which is configured to compress bleed air downstream of the valve 22 to increase its pressure. The air compressor is of conventional configuration, and typically comprises a centrifugal compressor.

[0042] Downstream of the compressor 23 is a heat recovery unit in the form of the first heat exchanger 24. The first heat exchanger 24 comprises first passages which carry compressed air, and second passages which carry a second working fluid in the form of a refrigerant, which does not consist of air. Typically, the refrigerant is carbon dioxide, though other refrigerants may be used. The air passage and refrigerant passage are in thermal contact, such that heat is transferred from the compressed air to the relatively cool refrigerant in operation.

[0043] An air turbine 25 is provided downstream in the bleed air flow of the first heat exchanger 24. The air turbine 25 is configured to expand the bleed air to provide rotary power. The air turbine 25 is coupled to the compressor 23 by a bleed air cycle machine shaft 26, such that rotation of the turbine 25 drives the compressor 23. It will be understood that the air cycle machine may be omitted. In such a case, the air from the inlet 21 would be transmitted directly to the heat exchanger 24.

[0044] A mixing valve 28 is provided downstream in bleed air flow of the turbine 25, and is configured to recombine bleed air flow that has passed through the air conditioning machine (i.e. the compressor 23, heat exchanger 24 and turbine 25), with air that has passed through the bypass line 27. Consequently, the temperature and pressure of the air can be adjusted by control of the valve 28.

[0045] Further downstream is a re-heater 29. The re-heater is also in the form of a heat exchanger, and is configured to exchange heat with bleed air further downstream in the cycle. The operation of this reheat will be described in further detail below. It will be understood that, in versions that omit the air cycle machine, the re-heater 29 would be directly downstream of the first heat exchanger 24.

[0046] A water extraction loop comprising a condenser 30 and a water extractor 31 are provided downstream of the reheater 29. These are configured to remove excess water from the bleed air to both dehumidify the air, and prevent condensation in downstream components.

[0047] The bleed air line once again passes through the reheater 29 downstream of the water extractor 31.

[0048] Downstream of the re-heater 29 is an air turbine 32. The air turbine 32 is similar to the air cycle machine turbine 25, and is again configured to expand the air within the air line to rotate the turbine 32. The air turbine 32 is coupled to a shaft 37 and also to a load in the form of an electrical generator 39. The air turbine 32 comprises an inlet which receives relatively low pressure, relatively low temperature air downstream of the re-heater 29. The turbine 32 also comprises a heater 41, which surrounds a turbine outlet and is configured to heat air within the air turbine 32. The heater 41 can optionally be supplied with warm air from an outlet of the air cycle machine compressor 23 via a bypass line 50. This warmed air prevents ice from building up within the turbine 32. Spent air is then returned to an inlet of the air cycle machine compressor 23 via a return line 51. Flow from the through the lines 50, 51 may be controlled by suitable valves.

[0049] Downstream of the air turbine 32 is a second heat exchanger 33. The second heat exchanger 33 is configured to exchange heat between air and refrigerant. However, in this case, the heat flows from the refrigerant to the air, for reasons that will be explained below.

[0050] The air once again passes through the condenser 30 to re-humidify the air, before it is passed to the cabin via an outlet 34. A further mixer valve 44 is provided, which allows a proportion of air to bypass the air conditioning machine, such that hot, high pressure air can be provided to the cabin if necessary.

[0051] The environmental control system further comprises a closed cycle refrigeration system. The closed cycle refrigeration system exchanges heat with the air to further cool the air.

[0052] The closed cycle refrigeration system comprises a refrigerant compressor 35 downstream in refrigerant flow of the first heat exchanger 24, and is configured to compress refrigerant that has been heated by the first heat exchanger 24. The refrigerant compressor 35 is driven by a refrigeration cycle shaft 37, which couples the air turbine 32 to the refrigerant compressor 35. Consequently, the refrigerant compressor 35 is driven by the air turbine 32.

[0053] The second heat exchanger 33 is provided downstream of the refrigerant compressor 35 in refrigerant flow, such that heat is exchanged between the air and refrigerant once more. As previously mentioned, heat is rejected from the refrigerant to the air in this second heat exchanger 33.

[0054] A further heat exchanger 38 is optionally provided downstream of the second heat exchanger 33, which is configured to exchange heat between the cooled (though still warmer than ambient) refrigerant and a cooling medium, such as aircraft fuel or ambient temperature airflow, such as fan air flow. Where the cooling medium is air, a water injection line 43 is optionally provided, which is configured to provide water to the ambient temperature air prior to entry to the further heat exchanger, to thereby cool the ambient air, and increase the heat exchange efficiency.

[0055] A refrigerant expander is provided downstream in refrigerant flow of the second heat exchanger 33. The expander is in the form of a throttle valve 36, and is configured to expand and thereby cool the compressed refrigerant.

[0056] The first heat exchanger 24 is then provided downstream of the throttle valve 36 in refrigerant flow, to thereby provide a closed loop.

[0057] In operation, the environmental control system operates as follows.

[0058] Air is introduced to the air inlet 21 from the compressor 13 of the gas turbine engine 10. The air is then directed through one or both of the bypass line 27 or the air conditioning machine compressor 23 via the switching valve 22. Air which is passed to the air compressor 23 is compressed, which increases both the temperature and the pressure of the bleed air. This air is then cooled a first time by exchanging heat with the refrigerant in the first heat exchanger 24, thereby reducing the temperature of the bleed air, and increasing the temperature of the refrigerant.

[0059] Following the air again, the air is then cooled and expanded by the air cycle machine turbine 25, which rotates to drive the air cycle machine compressor 23 via the shaft 26. This cooled, expanded air is then mixed with the bypassed air at valve 28, before being cooled by the reheater 29. The air then passes through the condenser 30 and water extractor 31, to remove water from the air.

[0060] The dehumidified air is then passed back through the re-heater 29 again, to re-warm the air. This re-warmed air is then passed to the air turbine 32, where the air is once again expanded, to reduce the pressure and temperature of the air, and to also drive the shaft 37, refrigerant compressor 35 and generator 39.

[0061] The cooled air is now passed to the second heat exchanger 33, which transfers heat from the refrigerant to the air, to thereby increase the temperature of the air, and reduce the temperature of the refrigerant.

[0062] This air is now passed through the condenser once more to re-humidify the air, before being passed to the cabin.

[0063] Turning now to the closed cycle refrigeration system, heat is input to the cycle at the first heat exchanger 24. In the case where the refrigerant is carbon dioxide, the temperatures and pressures within the system may be regulated such that the carbon dioxide is heated to a super critical or trans-critical state by the first heat exchanger 24, and may be maintained in the critical or trans-critical state throughout the closed cycle. It will be understood that carbon dioxide is generally regarded as being supercritical where the temperature is above 31.1 degrees Celsius, and 7.38 mega-pascals (MPa). Under these conditions, CO.sub.2 will generally expand to fill its container in a similar manner to a gas, but will have a density similar to a liquid. In view of the supercritical state of the CO.sub.2 throughout the cycle, the refrigerant generally does not undergo phase changes during compression, heating and expansion.

[0064] The heated refrigerant is then passed to the refrigerant compressor 35, where it is compressed, thereby raising both the temperature and pressure of the refrigerant. The compressed and heated refrigerant is then passed to the second heat exchanger 33, where the now hot refrigerant exchanges heat with the relatively cool bleed air in the second heat exchanger 33, such that the temperature of the refrigerant is lowered, and the temperature of the bleed air is raised. The cooled refrigerant is then passed to the further heat exchanger 38, where the refrigerant is cooled further.

[0065] The refrigerant then passes to the throttle valve 36, where the pressure of the refrigerant is reduced, thereby again, lowering its temperature, before the refrigerant is passed once again to the first heat exchanger, thereby closing the cycle.

[0066] Advantageously, the cycle of the present disclosure is more efficient than a conventional cycle because part of the excess bleed enthalpy is converted into mechanical work, instead of being completely rejected to the ram air. The closed refrigeration cycle acts as a heat pump, lifting part of the excess enthalpy of the bleed air to higher temperatures. The presence of the second heat exchanger 33 in the refrigeration cycle allows the air turbine 32 to extract the maximum work from the compressed air, and at the same time meet the required target temperature. Indeed, the air turbine 32 can operate with a discharge temperature much lower than in a conventional cycle (resulting in maximum power extraction), and recover the required outlet temperature using part of the heat discharged from the refrigeration cycle. The system has been modelled by the inventors based on typical temperatures and pressure delivery for a modern gas turbine engine, as well as typical cabin air demand in terms of pressure, mass flow and temperature. In models, efficiency gains approaching 1% of overall fuel burn have been achieved, for a relatively small increase in overall system weight, or in some cases a reduction is system weight. Aerodynamic drag is also decreased, since the further heat exchanger can be reduced in size or eliminated entirely.

[0067] In order to further illustrate the operation of this embodiment, the following table shows the pressure, (in kilo-Pascals), temperature (in degrees Celcius) and mass flow (in kilograms per second) at various points in the cycle in an example embodiment, which has been modelled by the inventors. It will be appreciated that these numbers are merely illustrative, and not limiting. The position of each point in the cycle is illustrated in FIG. 6, with air parameters being prefaced by the letter A, and refrigerant parameters being prefaced with the letter R.

TABLE-US-00001 TABLE 1 Station Pressure (kPa) Temperature ( C.) Mass Flow (kg/s) A1 241.3 200.0 1.016 A5 241.3 200.0 1.016 A6 311.2 241.3 1.016 A9 301.9 53.8 1.016 A10 171.5 11.6 1.016 A12 171.5 11.6 1.016 A13 166.4 10.0 1.016 A14 161.4 6.1 1.016 A16 161.4 6.1 1.016 A17 156.5 7.8 1.016 A18 87.1 29.7 1.016 A19 85.4 2.9 1.016 A20 82.8 1.0 1.016 R21 7750.0 32.9 3.890 R22 7700.0 57.2 3.890 R23 11550.0 57.2 3.890 R24 11550.0 55.5 3.890 R25 11400.0 45.0 3.890 A26 38.0 22.9 3.307 A28 37.8 38.0 3.307

[0068] In this example, the power produced by the air turbine 32 is 39.65 kW, and the power consumed by the refrigerant compressor 35 is 38.13 kW. Consequently, in this example, net power of 1.52 kW is input to the generator 39 for the production of electrical power.

[0069] FIG. 7 shows an alternative arrangement. Features having functions equivalent to those of the embodiment of FIG. 6 have equivalent reference numerals, incremented by 100. For the sake of brevity, only those features that differ from the first embodiment are described in detail.

[0070] The system includes a first heat exchanger 124, refrigerant compressor 135, second and further heat exchanger 133, 138, shaft 137 and air turbine 132 driving a further load 139, which are each similar to their equivalent components of the first embodiment. However, the throttle valve 36 is replaced by a refrigerant turbine 136. The refrigerant turbine is configured to expand the refrigerant cooled by the second and further heat exchangers 133, 138, and drive the shaft 137, such that the load on the air turbine required to drive the refrigerant compressor 135 is reduced. Consequently, efficiency of the refrigerant cycle is increased, and overall system efficiency is further increased, since more air turbine power is available to drive the further load 139. Optionally, the air turbine 132 and refrigerant turbine 136 may be coupled via a gearbox (not shown), which may reduce or increase the rotational speed of the turbine 132 relative to the turbine 136, in order to match their speeds in operation. In some cases, a gearbox having multiple ratios or a continuously variable ratio (CVT) gearbox may be used.

[0071] Other gas turbine engines to which the present disclosure may be applied may have alternative configurations. By way of example such engines may have an alternative number of interconnecting shafts (e.g. three) and/or an alternative number of compressors and/or turbines. Further the engine may comprise a gearbox provided in the drive train from a turbine to a compressor and/or fan.

[0072] FIG. 8 shows a further alternative arrangement. Again, features having functions equivalent to those of the embodiment of FIG. 6 have equivalent reference numerals, incremented by 200. For the sake of brevity, only those features that differ from the first embodiment are described in detail. This embodiment primarily differs from the previous embodiments, in that the refrigerant coolant is ambient ram air, rather than air provided downstream of the power air turbine.

[0073] Referring to FIG. 8, the system includes a first heat exchanger 224, refrigerant compressor 235, second heat exchanger 238, shaft 237, throttle valve 236, power air turbine heater 241 and air turbine 232 driving a further load 239, which are each similar to their equivalent components of the first embodiment. Again, the air cycle machine is omitted.

[0074] In this embodiment, the second heat exchanger is configured to exchange heat with ambient air in a similar manner to the third heat exchanger of the first embodiment. Consequently, no heat is exchanged between the air downstream of the air turbine 232. Instead, air flows from the air turbine 232 directly to the condenser 230, and then to the cabin. A further difference in this embodiment is the provision of a bleed offtake line 252, which bleeds off air to ambient downstream of the power air turbine heater 241.

[0075] In order to better illustrate the advantages of this embodiment, the below table 2 provides flow parameters at various points in the cycle in an example embodiment, which has been modelled by the inventors. It will be appreciated that these numbers are merely illustrative, and not limiting. The position of each point in the cycle is illustrated in FIG. 8, with air parameters being prefaced by the letter A, and refrigerant parameters being prefaced with the letter R.

TABLE-US-00002 TABLE 2 Station Pressure (kPa) Temperature ( C.) Mass Flow (kg/s) A1 241.3 200.0 1.016 A5 241.3 200.0 0.975 A6 241.3 200 0.975 A9 228.3 56.5 0.975 A10 228.3 56.5 0.975 A12 228.3 62.3 1.016 A13 221.5 52.8 1.016 A14 214.8 30.7 1.016 A16 214.8 30.7 1.016 A17 208.4 40.2 1.016 A18 85.4 21.2 1.016 A19 85.4 21.2 1.016 A20 82.8 1.0 1.016 R21 7750.0 32.9 2.850 R22 7700.0 33.8 2.850 R23 11550.0 57.2 2.850 R24 11550.0 57.2 2.850 R25 11400.0 45.0 2.850 A26 38.0 22.9 2.300 A28 37.8 51.0 2.300

[0076] In this example, the power produced by the air turbine 232 is 62.43 kW, and the power consumed by the refrigerant compressor 235 is 29.05 kW. Consequently, in this example, net power of 33.39 kW is input to the generator 39 for the production of electrical power. As can be seen, more excess power is generated by this embodiment. However, it should be understood that the parameters of these systems have not been fully optimised. Consequently, further efficiency improvements of each of these systems may be realised.

[0077] Other refrigerants may be used, such as R12, R11, R134a, R410a, R744 or equivalents. In some cases, the heat exchangers may act as evaporators or condensers where these refrigerants are used. The electrical generator could be replaced with a different load, such as a pneumatic or hydraulic pump. Elements of the embodiments could be combined. For example, the throttle valve of the first embodiment could be replaced by the refrigerant turbine of the second embodiment.

[0078] It will be understood that the invention is not limited to the embodiments above-described and various modifications and improvements can be made without departing from the concepts described herein. Except where mutually exclusive, any of the features may be employed separately or in combination with any other features and the disclosure extends to and includes all combinations and sub-combinations of one or more features described herein.