An Innovative Cryogenic Heat Exchanger Design for Sustainable Aviation

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.