Conversion from Jet Engines to Carbonless Electrified Propulsion for Commercial Airlines, Boeing 737 Max

This paper aims to introduce the design flow and components of a developed “conversion” tool that can suggest feasible solutions for seamless conversions of conventional aircraft into electrified configurations for commercial operation. The electrified propulsion system is anticipated to be essential for the future aviation industry to accomplish zero emissions by 2050. However, designing a new commercial aircraft for an entire operation is a highly complex and time-consuming process, typically undertaken by a limited number of manufacturing companies. The targeted commercial aircraft used as the baseline is the Boeing 737 Max 800, which accommodates around 150 passengers and has a maximum range (R) of approximately 3,500 nautical miles. New propulsion systems, such as hydrogen-based fuel cells and solid oxide fuel cells (SOFCs), are typically heavier and more volumetric, but they have higher energy efficiency. The primary objective of the developed tool in this paper is to provide feasible solutions for new design or operation modifications when a new propulsion system is introduced to the baseline while maintaining the same performance, particularly in terms of flight range. The need for conversion is based on using existing commercial airliner resources without substantial structural design modifications. Unlike most aircraft design concepts, which offer high aerodynamic performances but exist only on “paper” and lack practical operational aspects, the approach in this paper maintains an already existing, verified aircraft model, providing a sense of continuity and familiarity. It focuses on one of the most common commercial airliners to ensure aeroelasticity and operational feasibility. Moreover, a significant contribution of this tool development is that most aircraft design tools overlook the characteristics of propulsion systems, which play a critical role in understanding aerodynamic performance and operational conditions. To address this problem more practically and effectively, the authors begin by analyzing the baseline. The actual field data of the Boeing 737 Max 800 with internal combustion engines (ICE) have been established through in-depth pilot interviews, providing a basis for performance analysis. This analysis details changes in aerodynamic parameters under specific operational conditions. Subsequently, the tool was developed to simulate the matching aerodynamic performances when the same operational conditions and new propulsion systems were newly adopted. This tool suggests precise aerodynamic performance evaluation and feasible design and operation modification criteria for design solutions when new propulsion systems are considered for use with conventional aircraft structures.