CRYOGENIC AIRCRAFT

DEVELOPMENT OF CRYOGENIC FUEL AIRCRAFT

In mid-1970-s of previous century energy strategic dominated in the USSR according
to which all atomic energy was supposed to be utilized first while oil and gas should
have been considered of minor importance in view of small resources as they
erroneously believed at that time.

Realization of Hydrogen Energy Program started. Tupolev’s specialists were involved

in the Program. As it used to happen many times in the background of our company –
Alexey Tupolev took a courageous decision - to build “Hydrogen” aircraft. Such
aircraft was built and successfully tested without any serious incidents. It was
preceded by a long-term Program of bench and ground tests intended for testing
functioning of new systems (such systems were more than 30 on the aircraft) and
mainly for providing safe operation.

Unfortunately mentioned above energy strategy turned to be not very correct. Atomic
energy has not become dominating. It was natural gas that turned to be of
paramount importance in the Energetic Program of our country. The content of
natural gas exceeds 50% of energy balance. That’s why our flying laboratory having
status of experimental TU-155 a/c was modified to use not only liquid hydrogen but
also to use Liquefied Natural Gas (LNG). This is how the first in the world Cryogenic
Aircraft was built.

Remarkable properties of liquid hydrogen as aviation fuel and first of all its high
ecological cleanliness, high heat of combustion and high cooling capacity attracted
attention of aviation specialists to this type of fuel. Liquid hydrogen allows to improve
aircraft performance significantly, to build aircraft operating at speeds of M>6.
Therefore our activities on liquid hydrogen served as a scientific and technological
work done which will be used in near-term outlook. However extremely high price of
liquid hydrogen makes its commercial use impossible for a long time.

If to speak about near future tomorrow task is to introduce LNG as aviation fuel which
was reflected in “Program on development of Russian civil aviation for the period
from 2002 to 2010 and for the period till 2015”.Oil shortage is growing. During
previous 25 years specific weight of oil in worlds energy balance decreased by more
than 10%.

Currently price of kerosene is 8000 rubles per tone, LNG price is 3000 rubles per
tone. Benefit makes 5000 rubles per each tone of replaced kerosene. The benefit is
likely to grow constantly according to opinion of many specialists.

Recently some special scientific “explosion” happened in the world and especially in
Russia that provoked a vision that traditional and non-traditional resources of natural
gas can be increased by an order magnitude greater and exceed total amount of
traditional fossil fuel on earth.

Natural gas is supplied to substantially each airfield via pipelines i.e. transportation
issues have been practically solved now. Its high energy capacity, huge cooling
capacity make it possible to build aircraft with significantly high performance in
comparison with aircraft using kerosene. Fuel efficiency of flight using LNG can make
10 g/pass, km.

When using LNG potential emission of toxic agents will be decreased as follows:
carbon monoxide – 1 – 10 times, hydrocarbons – 2.5 – 3 times, nitrogen oxides – 1.5 –
2 times, polycyclic aromatic hydrocarbons including benzapyrene – 10 times.

TU-155 a/c was built on the basis of serial TU-154B a/c. To use cryogenic fuel airframe
and some standard systems were modified, cryogenic fuel charging, storage and
feeding systems were installed that ensured fire/explosion safety, and data
acquisition and recording system as well.In safety purpose experimental cryogenic
fuel complex was disposed within special compartment isolated from adjacent
fuselage compartments by buffer areas provided with ventilation system.
Experimental LNG- or Hydrogen – powered NK-88 engine is located in the rightside
nacelle. Cryogenic fuel resource is kept in fuel tank of 17.5 m3 capacity installed in
special compartment in rear portion of passenger cabin.

To charge the aircraft with cryogenic fuels special charging complex was made which
in view of safety was located on separated site that was also used for a/c parking and
maintenance. Cryogenic fuel is delivered to the site by filling truck. Some issues
concerning components and systems of experimental cryogenic TU-155 a/c were
studied on ground rigs.

Creation of the aircraft was accompanied by serious scientific and research works and
elaboration of large amount of regulatory documentation. 15 April, 1988 the aircraft
performed its maiden flight using liquid hydrogen. Upon flight testing and
development 18 January, 1989 TU-155 a/c performed its first flight on liquefied
natural gas. Large flight testing Program was fulfilled, several international flight
demonstrations were made including those to Bratislava (Czhekoslovakia), Nice
(France), Berlin and Ganover (Germany).

Appearance of TU-155a/c changed dramatically scope of tasks for creation of

cryogenic aviation. It was demonstrated in reality that using existing technical aids
power plant has been built which allowed to operate Hydrogen- or LNG-powered
aircraft with the same safety level than those working on kerosene.

Main result of the works on TU-155 aircraft represented creation of following:

• collectives of specialists skilled in aviation cryogenics in a number of companies;

• ground infrastructure to support cryogenic aircraft;

• complex of ground cryogenic rigs.

A real possibility appeared to turn to creation of LNG-powered aircraft.

In the course of the aircraft building several pioneering technical approaches were
developed that were embodied on the aircraft and on rigs.

Experience of ensuring fire/explosion safety of cryogenic aircraft is unique. Principles

and technical approaches that were developed when solving this problem (for
example gas test system newly applied) will be used on all future cryogenic aircraft.

The same is about power plant of the aircraft which main technical approaches are
quite new. Engine scheme and cryogenic components, fuel pumps, pressure
maintenance system and cryogenic fuel tanks - all od these could be utilized in future
developments.

Tupolev” PSC elaborated Cryogenic Aircraft Manufacturing Program. On the first

phase of this Program TU-156 a/c was built.

Cargo-passenger TU-156 a/c was designed for optimization of airborne cryogenic fuel
system during long-term operation and its certification and also for optimization of
ground infra-structure. Cryogenic components of the aircraft will be installed on
consequent serial Tupolev’s cryogenic aircraft.

The aircraft uses two fuels: aviation kerosene and liquefied natural gas which makes
it possible to operate the aircraft from usual airfields and from airfields provided with
LNG fueling systems. Use of two fuels improves flight safety level significantly.

TU-156 a/c is capable to carry 14 t of payload for distance 2600 km using LNG and for
distance of 3300 km using LNG and kerosene. In rear portion of passenger cabin
there is a ventilated compartment to receive a main cryogenic tank of 13 t capacity.
Nose baggage compartment is provided with ventilated bay wherein trim cryogenic
fuel tank is installed composed of two horizontal communicating vessels capable to
receive 3.8 tones of LNG.

Substantially all technical publication and records have been issued for TU-156 a/c.
NK-89 prototype engine and a number of other cryogenic components have been
manufactured and are being tested on benches.

To support activities on TU-156 a/c manufacturing a ground cryogenic power plant rig
is now being prepared. On the basis of certified mid-range passenger TU-204 a/c
powered by PS-90A engines a mid-range TU-204K a/c powered by PS-92 engines is
currently under development. Kerosene is located in wing fuel tanks, LNG tanks are
disposed on fuselage within fairing which shape is of minimum aerodynamic drag.
TU-204K a/c fuel efficiency makes 19.6 g/pass, km. This aircraft is capable to carry
210 passengers for distance of 5200 km. The aircraft tanks can receive 22.5 t of LNG
and 5.5 t of kerosene as fuel reserve. Being developed to the level of technical
proposals TU-204K uses main elements of cryogenic system installed on TU-156 a/c.

Works have been launched on manufacturing a new regional cargo/passenger TU-136

a/c powered by two TB7-117SF engines which has optimal layout in view of LNG
properties. This aircraft is intended for passenger and cargo transportation. It can be
operated from airfields of any class including unpaved ones. It will be operated on
routes that connect regional centers of Russia and for cargo/passenger transportation
for servicing centers of mineral industry and also to function as flying laboratory for
inspection of gas lines in Northern areas and in Siberia. After being certified the
aircraft can be used by foreign airlines in the countries with developed infra-
structures of natural gas consumers.

This aircraft having takeoff weight of 20 t will carry 53 passengers and up to 5 t of

cargo for 2200 km at the speed of 550 km/h and at the altitude of about 72 km. Fuel
efficiency (about 20 g/pass, km) corresponds to that of the best aircraft in the world
of this class while use of LNG will allow to cut down direct operational expenses by
near 30%.

The aircraft was designed in view of special properties of cryogenic fuel. It is of

biplane aerodynamic configuration logically interfaced with cryogenic fuel tanks.
Structure of the aircraft was made with maximal wing and fuselage load relief.
Cryogenic fuel tanks receiving 3680 kg of LNG are located in two nacelles installed
behind power plant. Alignment of tank mid-section with engine nacelle mid-section
and also supporting pylons agreement with general aerodynamic configuration made
it possible to locate cryogenic fuel tank out of fuselage substantially without
increasing aerodynamic drag and wing force. Short cryogenic paths are of small
weight and do not require superheat insulation. Power plant spaced from passenger
cabin increases passenger and crew members safety significantly and facilitates its
experimental optimization. Kerosene is filled in wing tanks as in ordinary aircraft.

TU-330 transport a/c powered by LNG NK-94 engine is now under development. The
aircraft is designed to carry military and civil cargo of 35 t weight. Aviation kerosene
is located in wing fuel tanks, tanks with LNG are disposed on upper fuselage within
fairing which shape is of minimal aerodynamic drag and receive 22.6 t of LNG. Engine
NK-94 for this aircraft is developed by “SNTK named after N.Kuznetsov” PSC. It
represents a cryogenic version of NK-93. Landing on unpaved airfield is provided.
Currently the aircraft has been developed to the level of technical proposals. The
aircraft includes all main elements of cryogenic system installed on TU-156 a/c and
can use both LNG and kerosene. Design works have started to build on the basis of
TU-334 a/c a short-range passenger TU-334K a/c powered by BR-710C engines. It will
carry 102 passengers for the distance up to 2000 km at the altitude up to 10.6 km.
The aircraft is fuelled with 7 t of LNG and 2 t of kerosene as fuel reserve. Main
elements of cryogenic system can be taken from TU-156 a/c.