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An Innovative Cryogenic Heat Exchanger Design for Sustainable Aviation

Author

Listed:
  • Francesco Sciatti

    (Department of Mechanics, Mathematics and Management (DMMM), Polytechnic University of Bari, 70125 Bari, Italy)

  • Vincenzo Di Domenico

    (Department of Mechanics, Mathematics and Management (DMMM), Polytechnic University of Bari, 70125 Bari, Italy)

  • Paolo Tamburrano

    (Department of Mechanics, Mathematics and Management (DMMM), Polytechnic University of Bari, 70125 Bari, Italy)

  • Elia Distaso

    (Department of Mechanics, Mathematics and Management (DMMM), Polytechnic University of Bari, 70125 Bari, Italy)

  • Riccardo Amirante

    (Department of Mechanics, Mathematics and Management (DMMM), Polytechnic University of Bari, 70125 Bari, Italy)

Abstract

Aviation is one of the most important industries in the current global scenario, but it has a significant impact on climate change due to the large quantities of carbon dioxide emitted daily from the use of fossil kerosene-based fuels (jet fuels). Although technological advancements in aircraft design have enhanced efficiency and reduced emissions over the years, the rapid growth of the aviation industry presents challenges in meeting the environmental targets outlined in the “Flightpath 2050” report. This highlights the urgent need for effective decarbonisation strategies. Hydrogen propulsion, via fuel cells or combustion, offers a promising solution, with the combustion route currently being more practical for a wider range of aircraft due to the limited power density of fuel cells. In this context, this paper designs and models a nitrogen–hydrogen heat exchanger architecture for use in an innovative hydrogen-propelled aircraft fuel system, where the layout was recently proposed by the same authors to advance sustainable aviation. This system stores hydrogen in liquid form and injects it into the combustion chamber as a gas, making the cryogenic heat exchanger essential for its operation. In particular, the heat exchanger enables the vaporisation and superheating of liquid hydrogen by recovering heat from turbine exhaust gases and utilising nitrogen as a carrier fluid. A pipe-in-pipe design is employed for this purpose, which, to the authors’ knowledge, is not yet available on the market. Specifically, the paper first introduces the proposed heat exchanger architecture, then evaluates its feasibility with a detailed thermodynamic model, and finally presents the calculation results. By addressing challenges in hydrogen storage and usage, this work contributes to advancing sustainable aviation technologies and reducing the environmental footprint of air travel.

Suggested Citation

  • Francesco Sciatti & Vincenzo Di Domenico & Paolo Tamburrano & Elia Distaso & Riccardo Amirante, 2025. "An Innovative Cryogenic Heat Exchanger Design for Sustainable Aviation," Energies, MDPI, vol. 18(5), pages 1-22, March.
    • Handle: RePEc:gam:jeners:v:18:y:2025:i:5:p:1261-:d:1605324
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    References listed on IDEAS

    as
    1. Paolo Tamburrano & Francesco Sciatti & Elia Distaso & Riccardo Amirante, 2023. "Comprehensive Numerical Analysis of a Four-Way Two-Position (4/2) High-Frequency Switching Digital Hydraulic Valve Driven by a Ring Stack Actuator," Energies, MDPI, vol. 16(21), pages 1-20, October.
    2. Christopher Winnefeld & Thomas Kadyk & Boris Bensmann & Ulrike Krewer & Richard Hanke-Rauschenbach, 2018. "Modelling and Designing Cryogenic Hydrogen Tanks for Future Aircraft Applications," Energies, MDPI, vol. 11(1), pages 1-23, January.
    3. Akshay Nag Srinath & Álvaro Pena López & Seyed Alireza Miran Fashandi & Sylvain Lechat & Giampiero di Legge & Seyed Ali Nabavi & Theoklis Nikolaidis & Soheil Jafari, 2022. "Thermal Management System Architecture for Hydrogen-Powered Propulsion Technologies: Practices, Thematic Clusters, System Architectures, Future Challenges, and Opportunities," Energies, MDPI, vol. 15(1), pages 1-45, January.
    4. Teresa Donateo & Andrea Graziano Bonatesta & Antonio Ficarella & Leonardo Lecce, 2024. "Energy Consumption and Saved Emissions of a Hydrogen Power System for Ultralight Aviation: A Case Study," Energies, MDPI, vol. 17(13), pages 1-24, July.
    5. Rosa Maria Arnaldo Valdés & Serhat Burmaoglu & Vincenzo Tucci & Luiz Manuel Braga da Costa Campos & Lucia Mattera & Víctor Fernando Gomez Comendador, 2019. "Flight Path 2050 and ACARE Goals for Maintaining and Extending Industrial Leadership in Aviation: A Map of the Aviation Technology Space," Sustainability, MDPI, vol. 11(7), pages 1-24, April.
    6. Olumayegun, Olumide & Wang, Meihong & Kelsall, Greg, 2017. "Thermodynamic analysis and preliminary design of closed Brayton cycle using nitrogen as working fluid and coupled to small modular Sodium-cooled fast reactor (SM-SFR)," Applied Energy, Elsevier, vol. 191(C), pages 436-453.
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