Thermal performance of three-wheel and split-wheel air cycle systems for a civil aircraft environmental control system (ECS)

The conventional approach of regulating cabin temperature and pressure on aircraft is to utilize engine-bleed air through an environmental control system (ECS). The extraction of bleed air from the engine leads to a decrease in thrust and an increase in drag on the ECS ram air duct, resulting in higher fuel consumption. Consequently, the ECS transitioned from being engine-powered to being electrically powered. In this study, the thermodynamic characteristics of three-wheel and split-wheel air cycle systems (ACSs) with a high-pressure water separation system (HPWS) were investigated by developing a parameter decomposition model and an iterative algorithm using MATLAB for a state-of-the-art electrically driven ECS (EECS) on the Boeing 787 Dreamliner. The efficiency of the ACS was assessed by establishing analytical correlations for the coefficient of performance (COP) using relevant literature on endo-reversible thermodynamic model (ETM). By employing these analytical correlations, the thermal performance of both ACSs can be accurately predicted without the need for system modeling and simulation, considering variations in the input variables and operating conditions, such as the temperatures of fresh air and ram air, the ratio of the mass flow rates of ram air and fresh air, and component parameters, including the efficiencies of the primary and secondary heat exchangers and the pressure ratios of the fan and compressor. The implementation of a split-wheel ACS instead of three-wheel ACS in the Boeing 787 EECS led to an improvement in the COP from 0.31 to 0.43, and also resulted in a reduction of 14.35 % in the input power.