This project lays the foundation for one of the most promising propulsion systems in the regional market segment: HYLENA (HYdrogen eLectrical Engine Novel Architecture). The analyzed cycle-integrated solid oxide fuel cell gas turbine (SOFC-GT) hybrid engine was identified as promising high potential improvement in overall efficiency by synergistically utilizing the electric power produced by the SOFC as well as the high-temperature heat and water vapor generated during SOFC operation.

During the conceptual design space exploration, a variety of conceptual ideas were generated and aggregated, resulting in a concept cloud representing multiple design options. The SOFC integration into the gas turbine nacelle, which will be enabled by advancements in manufacturing capabilities that allow fabrication of more compact microtubular SOFCs, was identified as one of the main challenges. Therefore, potential SOFC integration options such as the circumferential as well as the box-shaped integration were introduced and discussed. Ultimately, five SOFC-GT integration concept candidates were pre-selected, discussed and preliminarily evaluated. The successful concept candidate that was downselected during HYLENA offers the best compromise between efficiency, weight, and operational implications. It is characterized by its cross-counterflow recuperator for SOFC inlet air preheating, as well as the non-axial box-shaped integration of the microtubular SOFC and the heat exchanger. The SOFC electrical power is directly integrated onto the output shaft via an electric motor, and the concept allows the core nozzle to contribute to thrust generation.

Nacelle integration sketch of SOFC-GT hybrid

The downselected concept is shown integrated in the nacelle, including the detailed geometric component arrangement.

Microtubular SOFC stack

A schematic of a microtubular single repeating unit (SRU) within an exploded view of a stack is shown, including the SRU components cathode, electrolyte, anode, and interconnector.

Glossary:
SOFC-GT solid oxide fuel cell gas turbine,
HEX heat exchanger,
PMAD power management and distribution,
EM electric motor,
GBX gear-box,
SRU single repeating unit