FUEL TANK INERTING SYSTEMS FOR AIRCRAFT

Abstract

Aircraft air separation systems having a compressed air source arranged to supply compressed air, an air separation module arranged to receive air from the compressed air source, the air separation module arranged to separate air into nitrogen enriched air and oxygen enriched air, wherein the nitrogen enriched air is supplied to a fuel tank of the aircraft, and a source of mixing air arranged to fluidly supply the mixing air at a location between the compressed air source and the air separation module such that the mixing air is selectively mixed with the compressed air to generate treated air that is supplied to the air separation module.

Claims

1. An aircraft air separation system, the air separation system comprising: a compressed air source arranged to supply compressed air; an air separation module arranged to receive air from the compressed air source, the air separation module arranged to separate air into nitrogen enriched air and oxygen enriched air, wherein the nitrogen enriched air is supplied to a fuel tank of the aircraft; and a source of mixing air arranged to fluidly supply the mixing air at a location between the compressed air source and the air separation module such that the mixing air is selectively mixed with the compressed air to generate treated air that is supplied to the air separation module.

2. The air separation system of claim 1, further comprising an aircraft environmental control system having a primary heat exchanger, wherein the source of mixing air is an cooling air extraction element arranged to extract air that exits the primary heat exchanger.

3. The air separation system of claim 2, wherein the cooling air extraction element is a cold corner tap.

4. The air separation system of claim 3, wherein the cold corner tap is part of the primary heat exchanger and located at an outlet of the primary heat exchanger.

5. The air separation system of claim 1, further comprising a dedicated air separation module heat exchanger, wherein the source of the mixing air is the dedicated air separation module heat exchanger.

6. The air separation system of claim 5, wherein the dedicated air separation module heat exchanger receives air from the compressed air source to be treated within the dedicated air separation module heat exchanger by air from a cold air source operating as a heat sink.

7. The air separation system of claim 6, wherein the cold air source operating as a heat sink is cabin recirculation air.

8. The air separation system of claim 6, wherein the cold air source operating as a heat sink is cabin exhaust air.

9. The air separation system of claim 6, wherein the cold air source operating as a heat sink is outlet air of an environmental control system.

10. The air separation system of claim 1, wherein treated air is maintained at temperatures below 215° F. (102° C.).

11. The air separation system of claim 10, wherein treated air is maintained at temperatures in a range of 150° F. (65° C.) to 200° F. (93° C.).

12. The air separation system of claim 1, further comprising a filter arranged upstream of the air separation module and configured to filter the treated air.

13. The air separation system of claim 1, wherein the treated air is supplied completely from the source of the mixing air.

14. The air separation system of claim 1, further comprising a controller configured to control one or more valves to maintain the treated air at or below a predetermined temperature.

15. The air separation system of claim 1, wherein the compressed air source is one of (i) bleed air, (ii) an electric compressor, or (iii) a turbine driven compressor.

16. An aircraft comprising: a pressurized zone; and an air separation system, the air separation system comprising: a compressed air source arranged to supply compressed air; an air separation module arranged to receive air from the compressed air source, the air separation module arranged to separate air into nitrogen enriched air and oxygen enriched air, wherein the nitrogen enriched air is supplied to a fuel tank of the aircraft; and a dedicated air separation module heat exchanger forming in part a source of mixing air arranged to fluidly supply the mixing air at a location between the compressed air source and the air separation module such that the mixing air is selectively mixed with the compressed air to generate treated air that is supplied to the air separation module, wherein air in the pressurized zone cools the mixing air.

17. The aircraft of claim 16, wherein the air in the pressurized zone is at least one of cabin exhaust air and cabin recirculation air.

18. A method of separating air into oxygen enriched air and nitrogen enriched air on an aircraft, the method comprising: supplying compressed air from a compressed air source to an air separation module; supplying mixing air at a location between the compressed air source and the air separation module such that the mixing air is selectively mixed with the compressed air to generate treated air that is supplied to the air separation module to be separated into oxygen enriched air and nitrogen enriched air; separating air received from the compressed air source at the air separation module; and supplying nitrogen enriched air to a fuel tank of the aircraft.

19. The method of claim 18, wherein the compressed air source is one of (i) bleed air, (ii) an electric compressor, or (iii) a turbine driven compressor.

20. The method of claim 18, further comprising cooling the compressed air with a cold air source to generate the mixing air.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

[0031] The subject matter which is regarded as the invention is particularly pointed out and distinctly claimed in the claims at the conclusion of the specification. The foregoing and other features and advantages of the invention are apparent from the following detailed description taken in conjunction with the accompanying drawings in which:

[0032] FIG. 1A is a schematic illustration of an aircraft that can incorporate various embodiments of the present disclosure;

[0033] FIG. 1B is a schematic illustration of a bay section of the aircraft of FIG. 1A;

[0034] FIG. 2 is a schematic illustration an environmental control system and fuel tank inerting system in accordance with an embodiment of the present disclosure;

[0035] FIG. 3 is a schematic illustration of a fuel tank inerting system in accordance with another embodiment of the present disclosure;

[0036] FIG. 4 is a schematic illustration of a fuel tank inerting system in accordance with another embodiment of the present disclosure; and

[0037] FIG. 5 is a schematic illustration of a fuel tank inerting system in accordance with another embodiment of the present disclosure.

DETAILED DESCRIPTION OF THE INVENTION

[0038] As shown in FIGS. 1A-1B, an aircraft 101 can include one or more bays 103 beneath a center wing box. The bay 103 can contain and/or support one or more components of the aircraft 101. For example, in some configurations, the aircraft 101 can include environmental control systems and/or fuel inerting systems within the bay 103. As shown in FIG. 1B, the bay 103 includes bay doors 105 that enable installation and access to one or more components (e.g., environmental control systems, fuel inerting systems, etc.). During operation of environmental control systems and/or fuel inerting systems of the aircraft 101, air that is external to the aircraft 101 can flow into one or more environmental control systems within the bay doors 105 through one or more ram air inlets 107. The air may then flow through the environmental control systems to be processed and supplied to various components or locations within the aircraft 101 (e.g., passenger cabin, fuel inerting systems, etc.). Some air may be exhaust through one or more ram air exhaust outlets 109.

[0039] Also shown in FIG. 1A, the aircraft 101 includes one or more engines 111. The engines 111 are typically mounted on wings of the aircraft 101, but may be located at other locations depending on the specific aircraft configuration. In some aircraft configurations, air can be bled from the engines 111 and supplied to environmental control systems and/or fuel inerting systems, as will be appreciated by those of skill in the art.

[0040] As discussed above, a dedicated heat exchange in environmental control systems and/or fuel inerting systems may be undesirable due to the increased space and/or weight on the aircraft. Accordingly, embodiments of the present disclosure are directed to systems that may eliminate the need for a dedicated heat exchanger in the ram circuit. Instead, embodiments of the present disclosure make use of another cold air source as a heat sink. Various example cold air sources are described herein. These sources include, but are not limited to, conditioned environmental control system outlet air, cabin recirculation air, and cabin exhaust air. Bleed air can be taken downstream of the engine bleed system and upstream of the environmental control system primary heat exchanger and heat can be transferred into the any individual or combination of the cold air sources in the various embodiments of the present disclosure or variations thereon.

[0041] Turning now to FIG. 2, a schematic illustration of an environmental control system 200 and fuel inerting system 202 in accordance with a non-limiting embodiment of the present disclosure is shown. The environmental control system 200 is arranged to supply compressed air (e.g., bleed air) to the fuel inerting system 202 and thus the two systems 200, 202 are fluidly connected at connector 204. Although shown and described herein with respect to bleed air, various other embodiments may be employed without departing from the scope of the present disclosure. For example, compressed air can be employed that is sourced from an electric compressor, a turbine driven compressor, a bleed air driven compressor, etc.

[0042] The environmental control system 200 includes a ram portion having a ram air inlet 206, a primary heat exchanger 208, a secondary heat exchange 210, and a ram air outlet 212, as will be appreciated by those of skill in the art. A compressed air source 214 (e.g., an engine, a compressor, etc.) is arranged to provide compressed air 215 to a compressed air inlet 216 that passes through the primary heat exchanger 208 to be conditioned therein. The compressed air 215 is then passed through and/or interacts with various components of environmental control system 200, including, but not limited to, a compressor 218, a turbine 220 that drives the compressor 218, a condenser 222, a water collector 224, and a reheater 226. Although schematically shown with an air flow through the environmental control system 200, those of skill in the art will appreciate the functions and fluid connections therein, and thus no further discussion will be provided herein.

[0043] As shown, after the compressed air 215 from the compressed air source 214 passes through the primary heat exchanger 208 a cooling air extraction element 228 is arranged to extract cold mixing air 217 from the compressed air 215 flow to be provided to the fuel inerting system 202 through the connector 204 as mixing air 217. In some non-limiting embodiments, the cooling air extraction element 228 is a cold corner tap that is arranged at, on, or downstream from the primary heat exchanger 208. In other embodiments, the cooling air extraction element 228 is any type of tap, port, flow line, valve, etc. that is arranged to extract air downstream of the primary heat exchanger 208. The cooling air extraction element 228 is arranged such that cold air from the compressed air source 214 is removed at a desired temperature. In some embodiments, the cooling air extraction element 228 is arranged relative to the primary heat exchanger 208 such that the air supplied to the fuel inerting system 202 is maintained below approximately 215° F. (102° C.).

[0044] As shown in FIG. 2, the fuel inerting system 202 receives the mixing air 217 from the cooling air extraction element 228 at the connector 204. The mixing air 217 can be mixed with compressed air 215 provided from the compressed air source 214 (through a separate supply line from the environmental control system 200), as schematically shown. One or more valves 230 are arranged to control the flow and mixing of both the mixing air 217 from the cooling air extraction element 228 and the compressed air 215 from the compressed air source 214 within the fuel inerting system 202. The valves 230 can be arranged as check valves, trim valves, flow metering vales, etc. as will be appreciated by those of skill in the art. In some embodiments, some or all of the valves 230 may be actively controlled (e.g., electronically, mechanically, etc.), or some or all of the valves 230 may be passive valves (e.g., check valves, ball valves, etc.). The air mixes within a feed line 232 to generate treated air 219 (treated air that is to be separated within an air separation module 236) and is supplied a filter 234 of the fuel inerting system 202. After being filtered within the filter 234, the treated air 219 enters the air separation module (“ASM”) 236 where nitrogen enriched air 221 and oxygen enriched air 223 are separated at first outlet 238 and second outlet 240, respectively, as schematically shown. The air separation module 236 includes, in some embodiments and as will be appreciated by those of skill in the art, a membrane for separating nitrogen and oxygen of the treated air 219 supplied through the feed line 232. The nitrogen enriched air 221 can then be supplied to a fuel tank 242 to provide a volume of inert gas (e.g., the nitrogen enriched air 221) into the fuel tank 242, as will be appreciated by those of skill in the art. As shown, the fuel inerting system 202 includes a controller 244 that is arranged to control metering of air within the feed line 232 and the supply of nitrogen enriched air 221 to the fuel tank 242.

[0045] The controller 244 can be a dedicated controller that is part of the fuel inerting system 202, can be part of the environmental control system 200, and/or other controller that is part of systems of an aircraft in which the fuel inerting system 202 is installed. Thus, the controller 244 is not intended to be limiting in connection, structure, and/or function. The controller 244 can include various electronic components, including, but not limited to, processors, memory, electronic busses, communication components, etc. as will be appreciated by those of skill in the art.

[0046] In accordance with the embodiment shown in FIG. 2, the need for a dedicated heat exchange in the ram circuit can be limited and/or completely eliminated. The cold air function to provide air conditioning to air within the air separation module (used to optimize the separation function) is integrated into the environmental control system 200. As shown in FIG. 2, the primary heat exchanger 208 is arranged with the cooling air extraction element 228 downstream of the outlet of the primary heat exchanger 208, through which the mixing air 217 flows. In another non-limiting embodiment, an independent bypass or tap can be arranged in or on the primary heat exchanger 208, which may require additional headers or a cold corner tap directly on or integrated into the primary heat exchanger 208. The cooling air extraction element 228 shown in FIG. 2 is achieved through use of a splitting partition in an outlet header of the primary heat exchanger 208 with the cold corner air (mixing air 217) being extracted from the ram air inlet 206 and bleed outlet corner of the primary heat exchanger 208.

[0047] The primary heat exchanger 208 of the environmental control system 200 is designed such that the outlet air (through cooling air extraction element 228) can cool the compressed air within the feed line 232 enough to maintain a safe and optimal temperature for the air separation module 236, the fuel tank 242, and other downstream components. In one non-limiting example, the arrangement of the environmental control system 200 and feed line 232 (or other features) are arranged to generally limit the supply temperature to about 200° F. (about 93° C.), and in some embodiments limited to a range of about 150° F. (about 65° C.) to about 200° F. (about 93° C.). However, in some configurations and/or systems, particularly based on the air separation module configuration, the supply temperature may be higher or lower, to thus optimize the air separation achieved within the air separation module 236.

[0048] The controller 244 can be arranged to control the valves 230 to achieved desired temperatures of air supplied to the air separation module 236. Various sensors can be positioned along the feed line 232 upstream and/or downstream of the filter 234 to enable desired valve control. For example, in operation, when the temperature from the outlet of the primary heat exchanger 208 is lower than optimal, compressed air from compressed air source 214 can be mixed through the use of a temperature control valve (e.g., one of the valves 23) with the outlet air of the primary heat exchanger 208 to bring the temperature back up to optimal (e.g., mixing within the feed line 232).

[0049] In an alternative embodiment, a way to integrate into environmental control systems having existing primary heat exchangers, air tapped off downstream of the primary heat exchanger is used to partially cool the air. A second, additional small dedicated air separation module heat exchanger can be positioned at the connector 204. Various other configurations are possible without departing from the scope of the present disclosure.

[0050] For example, instead of using ram air as the heat sink (e.g., ram air passing through the primary and secondary heat exchangers 208, 210 in the environmental control system 200 shown in FIG. 2) as current systems do, an alternate source of cold air can be employed. For example, various sources of cold air within systems can include, but is not limited to, environmental control system pack outlets, cabin recirculation air, or cabin exhaust air that is expelled overboard as fresh air from the environmental control system replaces the exhaust air. The required compressed air flow for air separation modules is significantly less than that required or employed in environmental control systems. For example, an air separation module may require less than 10% of environmental control system flow. As such, a dedicated air separation module heat exchanger may be relatively small (in terms of weight, size, volume, etc.).

[0051] Further, in such arrangements, the amount of heat transfer that is needed may be reduced because the primary heat exchanger of the environmental control system may already reduce the temperature to desired temperatures, or at least close to desired temperatures. As such, a dedicated air separation module heat exchanger can be relatively small as a low heat transfer rate may be sufficient to achieve desired air temperatures for the air separation module. That is, the dedicated air separation module heat exchanger in accordance with various embodiments of the present disclosure may only need to be sized to reduce air temperatures a small amount to achieve desired or optimal temperatures for operation of the air separation module.

[0052] Although shown and described with the compressed air source 214 supplying compressed air 215 into both the air inlet 216 of the primary heat exchanger 208 and the feed line 232 of the fuel inerting system 202, such arrangement is not to be limiting. For example, in some embodiments, the compressed air that is supplied to the primary heat exchanger 208 can be sourced from a different supply than that of the compressed air that is supplied to the fuel inerting system 202. For example, in one non-limiting embodiment, bleed air can be the compressed air source for the primary heat exchanger 208 and an electric compressor can be the compressed air source for the fuel inerting system 202.

[0053] Turning now to FIG. 3, an embodiment of an air separation system 302 having a supply of mixing air 317 treated by cabin recirculation air 346 in accordance with an embodiment of the present disclosure is shown. In this embodiment, the need for a dedicated heat exchanger in the ram circuit may be eliminated. In this embodiment, the cabin recirculation air 346 can be employed as a cold air source to treat compressed air 315, and thus operate as a cold air source as a heat sink to reduce temperatures of the compressed air 315 from a compressed air source 314. As schematically shown, compressed air 315 from the compressed air source 314 can be directed to a dedicated air separation module heat exchanger 348 that is positioned such that the cabin recirculation air 346 can extract heat from the compressed air 315 from the compressed air source 314. As shown, a controllable valve 325 can be employed to direct some or all compressed air 315 toward the dedicated air separation module heat exchanger 348.

[0054] As schematically shown, cabin recirculation air 346 can be extracted from a cabin 350 of the aircraft. The cabin recirculation air 346 is fed into a mix manifold 352 that is fluidly connected to an environmental control system 300, as will be appreciated by those of skill in the art. The mix manifold 352 can be located within a pressurized zone 354 of the aircraft (e.g., cargo, etc.) that includes a cabin outflow valve 356. As shown, the dedicated air separation module heat exchanger 348 can be positioned upstream of the mix manifold 352 and the cabin recirculation air 346 can operate as a heat sink to extract heat from the compressed air 315 directed from the compressed air source 314 and thus lower the temperature thereof. After passing through the dedicated air separation module heat exchanger 348, the mixing air 317 may be supplied directly through a filter 344 and into an air separation module 336 of the air separation system 302. Nitrogen enriched air may then be supplied to a fuel tank 342 to provide an inert volume within the fuel tank 342. In some embodiments, the mixing air 317 can be mixed with a portion of the compressed air 315 to generate treated air 319. However, in some embodiments, the mixing air 317 can be the sole source of “treated air 319” when the controlled valve 325 is arranged to prevent any compressed air 315 from bypassing the dedicated air separation module heat exchanger 348.

[0055] Turning now to FIG. 4, an embodiment of an air separation system 402 having a supply of mixing air 417 treated by outlet air 458 of an environmental control system 400 in accordance with an embodiment of the present disclosure is shown. In this embodiment, the need for a dedicated heat exchanger in the ram circuit may be eliminated. In this embodiment, the environmental control system outlet air 458 can be employed as a cold air source, and thus operate as a cold air source as a heat sink to reduce temperatures of air from a compressed air source 414. As schematically shown, air from the compressed air source 414 can be directed to a dedicated air separation module heat exchanger 460 that is positioned such that the environmental control system outlet air 458 can extract heat from the air from the compressed air source 414.

[0056] As schematically shown, cabin recirculation air 446 is extracted from a cabin 450 of the aircraft. The cabin recirculation air 446 is fed into a mix manifold 452 that is fluidly connected to the environmental control system 400, as will be appreciated by those of skill in the art. The mix manifold 452, as shown, is located within a pressurized zone 454 of the aircraft (e.g., cargo, etc.) that includes a cabin outflow valve 456. As shown, the dedicated air separation module heat exchanger 460 can be positioned upstream of the mix manifold 452 on a flow path from the environmental control system 400. The environmental control system outlet air 458 can operate as a heat sink to extract heat from the air directed from the compressed air source 414 and thus lower the temperature thereof. After passing through the dedicated air separation module heat exchanger 460, the treated air may be supplied through a filter 444 and into an air separation module 436 of the air separation system 402. Nitrogen enriched air may then be supplied to a fuel tank 442 to provide an inert volume within the fuel tank 442. In some embodiments, the mixing air 417 can be mixed with a portion of the compressed air 415 to generate treated air 419. However, in some embodiments, the mixing air 417 can be the sole source of “treated air 419” when the controlled valve 425 is arranged to prevent any compressed air 415 from bypassing the dedicated air separation module heat exchanger 460.

[0057] Turning now to FIG. 5, an embodiment of an air separation system 502 having a supply of mixing air 517 treated by cabin exhaust air 562 in accordance with an embodiment of the present disclosure is shown. In this embodiment, the need for a dedicated heat exchanger in the ram circuit may be eliminated. In this embodiment, the cabin exhaust air 562 can be employed as a cold air source, and thus operate as a cold air source as a heat sink to reduce temperatures of air from a compressed air source 514. As schematically shown, air from the compressed air source 514 can be directed to a dedicated air separation module heat exchanger 564 that is positioned such that the cabin exhaust air can extract heat from the air from the compressed air source 514.

[0058] As schematically shown, cabin recirculation air 546 is extracted from a cabin 550 of the aircraft. The cabin recirculation air 546 is fed into a mix manifold 552 that is fluidly connected to the environmental control system 500, as will be appreciated by those of skill in the art. The mix manifold 552, as shown, is located within a pressurized zone 554 of the aircraft (e.g., cargo, etc.) that includes a cabin outflow valve 556. As shown, the dedicated air separation module heat exchanger 564 is positioned at the cabin outflow valve 556 such that the cabin exhaust air 562 passes through the dedicated air separation module heat exchanger 564. The cabin exhaust air 562 can operate as a heat sink to extract heat from the air directed from the compressed air source 514 and thus lower the temperature thereof. After passing through the dedicated air separation module heat exchanger 564, the treated air may be supplied through a filter 544 and into an air separation module 536 of the air separation system 502. Nitrogen enriched air may then be supplied to a fuel tank 542 to provide an inert volume within the fuel tank 542. In some embodiments, the mixing air 517 can be mixed with a portion of the compressed air 515 to generate treated air 519. However, in some embodiments, the mixing air 517 can be the sole source of “treated air 519” when the controlled valve 525 is arranged to prevent any compressed air 515 from bypassing the dedicated air separation module heat exchanger 564.

[0059] The three example cold air sources described herein (e.g., FIGS. 3-5) include the conditioned environmental control system outlet air, cabin recirculation air, and cabin exhaust air. In some embodiments, bleed air can be taken downstream of an engine bleed system and upstream of the environmental control system primary heat exchanger (e.g., to the left of the primary heat exchanger 208 in FIG. 2) and heat can be transferred into the any individual or combination of the cold air sources described herein (e.g., combinations of the embodiments of FIGS. 3-5). A heat exchanger bypass line (labeled 315a, 415a, 515a in FIGS. 3-5, respectively) and control valve can be used to maintain a steady temperature and/or the cooled compressed air downstream of the respective heat exchanger (labeled 348, 460, 564 in FIGS. 3-5, respectively), air can be mixed further downstream with warm compressed air which may be employed based on physical limitations and/or restraints (e.g., space, location, etc.). In some embodiments, air tapped off down-stream of the primary heat exchanger of the environmental control system can be employed to partially cool the air and an additional, small dedicated air separation module heat exchanger can be installed elsewhere within the system (e.g., at locations shown in the embodiments of FIGS. 3-5).

[0060] In various embodiments of the present disclosure, the dedicated air separation module heat exchanger can be sized and positioned to reduce the temperature under all conditions to a desired temperature, with the cooler primary air, received from, for example, cooling air extraction element 228 shown in FIG. 2, as a starting point. That is, in some embodiments, a combination of features as described herein can be employed to enable an efficient cooling scheme (e.g., combining the downstream cool air (from a primary heat exchanger) with a small dedicated air separation module heat exchanger). For example, in such arrangements, and with reference to the embodiment shown in FIG. 3, the dedicated air separation module heat exchanger 348 may only be required to reduce the temperature a small amount, as compared to a typically large reduction in temperature, e.g., from about 450° F. (about 232° C.) to about 200° F. (about 93° C.) (approximately a 200° F. (about 93° C.) temperature change). With the combination approach, the temperature difference is significantly lower for the reduction to be achieved by the small dedicated air separation module heat exchanger, e.g., in one case the required temperature change was 70° F. or less (21° C. or less).

[0061] While the invention has been described in detail in connection with only a limited number of embodiments, it should be readily understood that the invention is not limited to such disclosed embodiments. Rather, the invention can be modified to incorporate any number of variations, alterations, substitutions, combinations, sub-combinations, or equivalent arrangements not heretofore described, but which are commensurate with the spirit and scope of the invention. Additionally, while various embodiments of the invention have been described, it is to be understood that aspects of the invention may include only some of the described embodiments.

[0062] For example, although certain configurations are shown in FIGS. 2-5, those of skill in the art will appreciate that other configurations may be used without departing from the scope of the invention. For example, other sources of air may be used for either supplying air to an inerting module and/or for supplying air to drive a turbine and compressor. Further, although there are valves and junctions illustratively shown at certain locations within the system(s), those of skill in the art will appreciate that these locations are merely for example only and other configurations may be used. Moreover, the order of components shown and described herein, in terms of the flow line and direction of air flow through the system may be changed without departing from the scope of the invention. For example, the location of the heat exchangers, compressors, turbines, valves, etc. may be adjusted based on the specific systems and efficiencies therein.

[0063] Accordingly, the present disclosure is not to be seen as limited by the foregoing description, but is only limited by the scope of the appended claims.