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UNCLASSIFIED 
Electric Flight – Potential and Limitations 
Martin Hepperle 
German Aerospace Center 
Institute of Aerodynamics and Flow Technology 
Lilienthalplatz 7, D-38108 Braunschweig, Germany 
Martin.Hepperle@dlr.de 
ABSTRACT 
During the last years, the development of electric propulsion systems is pushed strongly, most notably for 
automotive applications. For ground based transportation, the system mass is relevant, but of relatively 
low importance. This paper addresses the application of electric propulsion systems in aeronautics, where 
all systems are much more constrained by their mass. After comparing different propulsion system 
architectures the focus is cast on the energy storage problem and here especially on battery storage 
systems. Using first order principles the limitations and required technology developments are 
demonstrated by introducing battery powered electric propulsion systems to small and medium sized 
aircraft. 
9 - 1 STO-MP-AVT-209 
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Abbreviations and Symbols 
b = wing span [m] 
C = capacity [Wh] 
D = drag force [N] 
E* = mass specific energy content [Wh/kg] 
e f = empty mass fraction e m /m 
g = gravity acceleration [m/s2] 
L = lift force [N] 
m = mass [kg] 
initial m = initial mass at takeoff [kg] 
e m = empty mass without fuel and payload [kg] 
final m = final mass at landing [kg] 
battery m = battery mass [kg] 
payload m = payload mass [kg] 
pax m = mass per passenger [kg] 
PAX = number of passengers 
P = power [W] 
battery P = electric power provided by battery [W] 
R = range [m] 
t = time [s] 
T = thrust [N] 
V* = volume specific energy content [Wh/m3] 
v¥ = flight speed [m/s] 
h = efficiency 
¥ r = density of air [kg/m3]
UNCLASSIFIED 
1.0 INTRODUCTION 
Stimulated by the progress in technology developments in the entertainment, toy and car industries, the 
interest in electric propulsion systems for aircraft has grown considerably during the last years. According 
to many scientific and general publications the storage of electric energy in battery systems promises a 
clean new world with fantastic new opportunities. This paper highlights the differences between 
conventional aircraft propulsion systems, burning fossil fuel and aircraft propelled by electric motors. It 
tries to show the potential but also the limitations of electric propulsion technology for aircraft. This paper 
contains assumptions about specific weights, energy densities and efficiencies which are sometimes 
subject to large uncertainties. Therefore all results must be considered with care but the author believes 
that the main trends and relations are well represented. The numerical data should not be used to derive 
final conclusions about the performance of any specific product which is mentioned in this paper. 
2.0 MOTIVATION 
There are several reasons to study alternative propulsion systems and especially electric systems. The 
observed growth of air transport is clearly visible despite any temporary drawbacks (Figure 1). This 
growth leads to increased fuel burn and a stronger impact of aviation on the environment. The aviation 
industry (manufacturers as well as operators) are currently introducing new technologies and operating 
schemes to achieving a strong reduction in fuel consumption per flight in the order of 15-20%. However it 
will take many years until all aircraft are replaced with new generation vehicles and on the other hand the 
growth of air traffic will to lead to increasing overall fuel consumption and hence emissions from air 
traffic. 
Besides the problem of emissions and pollution the amount of oil is limited (Figure 2). Even if it is not 
clear when the oil resources will be depleted, the price of oil has been steadily climbing for many years 
following a rather unsteady but clearly visible trend. 
Attractive features of electric propulsion systems are that they benefit from better efficiency in the energy 
conversion chain and that they can be considered as locally zero-emission – albeit depending on how the 
electric energy is produced. 
However, introducing electric propulsion systems into ground transportation seems to be relatively simple 
compared to the implementation in aviation. While ground based vehicles can easier cope with additional 
mass due to not fully developed electric storage and propulsion systems, aircraft are much more sensible 
to mass. Furthermore typical trip distances as flown by aircraft are much larger that trips in ground 
vehicles (cars, buses, trains) and safety standards in aviation are extremely high. Finally one must 
acknowledge the fact that current aircraft are already very efficient in terms of fuel burn per payload and 
distance. 
All these facts make it no easy task to develop electric propulsion system concepts for aviation, but it is of 
strong interest and necessary to determine the physical limitations of using electric energy for aircraft 
propulsion and to work out the requirements and guidelines for future development. 
9 - 2 STO-MP-AVT-209 
UNCLASSIFIED
UNCLASSIFIED 
Electric Flight – Potential and Limitations 
Figure 1 Expected growth of air traffic according to Airbus [1]. 
120 
100 
80 
60 
40 
Middle East 
120 
100 
80 
60 
40 
1940 1950 1960 1970 1980 1990 2000 2010 2020 2030 
STO-MP-AVT-209 9 - 3 
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Oil Production [Mbarrel/day] 
20 
Middle East 
Africa 
Latin America 
South Asia 
East Asia 
China 
Transition Economies 
OECD Pacific 
OECD Europe 
OECD North America 
Demand [35] 
OECD Europe 
OECD North America 
Africa 
Latin America 
Transition Economies 
20 
Year 
Figure 2 Daily oil production versus time. Extrapolation of oil required by the world [34].
UNCLASSIFIED 
Electric Flight – Potential and Limitations 
3.0 THERE IS NOTHING NEW UNDER THE SUN 
Electric flight is no new technology. Due to the sensitivity of aircraft to their mass, it was not really 
feasible for many years. Here only one of the many ancestral lines of electric flight shall be mentioned 
because it shows a remarkably long development path. Already in 1940 Fred Militky toyed with electric 
motors to propel model aircraft, but due to heavy brushed motors and lead batteries he was unsuccessful to 
obtain good results. Nevertheless he followed his idea until he finally was able to introduce a small model 
airplane into the hobby market in 1960. This free flight model was using a highly efficient electric motor 
and still small lead batteries. Later in 1972, when Ni-Cd batteries with higher power densities became 
available he developed the first radio-controlled model which was commercially produced. Finally using 
the same Ni-Cd batteries he helped to prepare the first electric flight of a manned aircraft. This aircraft was 
the modified motor-glider MB-E1 which was finally flown in October 1973 by pilot H. Brditschka in 
Austria. The technology available in these years allowed only for short flights of up to 15 minutes but 
nevertheless showed the feasibility of electric propulsion for man carrying aircraft. Lack of better battery 
systems prevented further development. It should be noted that in contrast to some pioneering ultra-light 
experimental demonstrator aircraft the MB-E1 was a variant of the fully certified airframe HB-3 with 
minor modifications to carry batteries and electric motor. 
Figure 3 Development steps as performed by Fred Militky leading to man-carrying electric aircraft. 
3.1.CONVENTIONAL PROPULSION SYSTEMS 
Today’s propulsion systems are storing energy in liquid form. This fuel is usually based on oil and is 
thermally decomposed, i.e. burnt. Technically, with small modifications, these systems are also capable of 
also using gaseous fuels like hydrogen or natural gas. The fuel is burnt in either piston engines or in gas 
turbines to produce mechanical power. These machines are connected to a shaft which is linked to an 
aerodynamic propulsion device, either a propeller (piston-propeller or turbo-propeller) or a fan (turbo-fan). 
All systems accelerate an incoming mass flow of air to produce thrust. An additional part of the thrust may 
be created by recovering part of the thermodynamic energy in the exhaust, i.e. by passing the hot gasses 
through suitable nozzles. In case of propulsion by propellers it is often necessary to use a gearbox to adapt 
the performance characteristics of the core engine to the characteristics of the propulsion device so that the 
overall efficiency is maximized. Gearboxes are now also introduced to decouple the fan from the turbine 
of turbofan engines, thus increasing their total efficiency considerably. 
A notable feature of these propulsion systems is that they burn the fuel and the exhaust is emitted into the 
atmosphere. Besides affecting the environment, this also reduces the mass of the airplane during the flight 
and therefore affects the performance. 
9 - 4 STO-MP-AVT-209 
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Electric Flight – Potential and Limitations 
Propeller 
STO-MP-AVT-209 9 - 5 
UNCLASSIFIED 
Kerosene 
Bio Fuel 
liquid fuel 
Turboshaft 
Piston Engine 
Gearbox 
H2 
H gas 2 
Turbine 
H2 
H gas 2 
Turboshaft 
Piston Engine 
Gearbox 
Fan 
Propeller 
Kerosene 
Bio Fuel 
liquid fuel 
Turbine 
Fan 
Kerosene 
Bio Fuel 
liquid fuel 
Turbine 
Fan 
Gearbox 
Figure 4 Different propulsion systems exploiting the energy in the fuel by burning it. 
3.2.ELECTRIC PROPULSION SYSTEMS 
In case of electric propulsion systems there are a large number of possible concepts. They differ in energy 
storage and conversion. Today mainly two systems are of interest: battery based systems and fuel cell 
based systems. Both systems are under constant development, driven by automotive and other mobile 
applications. Most of these developments are currently aiming at power consumptions below 100 kW. 
3.2.1 Fuel Cell Systems 
These systems store energy in liquid or gaseous form and convert it to electric power by fuel cells. These 
perform a more or less cold decomposition of the fuel with relatively high efficiency and low emissions. 
Fuel cell systems have been built for many years for specific applications and a range of power 
requirements. Still these systems are quite complex and heavy. When the by-products are exhausted to the 
atmosphere, they lead to a mass reduction during flight like on classical combustion engines. When 
hydrogen is used for fuel, the emissions contain more water vapor then the emissions of kerosene based 
fuels and may create more severe contrails in the atmosphere.
UNCLASSIFIED 
Electric Flight – Potential and Limitations 
3.2.2 Turbo-Electric Systems 
In [3] one of the main motivations to used turbo-electric drive systems is given by the fact that such a 
system allows to decouple turbine speed and fan speed and thus may be the enabler for distributed multi-fan 
propulsion systems. The first argument is weakened by recent developments of highly efficient geared 
turbofan engines (decoupling turbine and fan allows to increase the overall efficiency by 10-20%). 
However the second argument still holds some opportunities for the development of distributed propulsion 
systems to improve the propulsive efficiency. These systems can either be driven by conventional fuel or 
by hydrogen, which still leads to high emission levels and contrail formation. 
3.2.3 Battery Systems 
Here the energy is stored in batteries which allows for a direct extraction of electric power. The efficiency 
is limited by the chemical processes occurring during charging and discharging. In most cases the mass of 
the system is usually not changing, except for some specific air breathing cells like Li-O2. 
Figure 5 Components of different electric propulsion systems. 
9 - 6 STO-MP-AVT-209 
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Electric Flight – Potential and Limitations 
3.2.4 Energy Storage 
The energy required for a flight must be stored on-board. For application in aircraft the most important 
parameters are the energy per mass E* and to a lesser extent the energy per volume V* . These specific 
values are shown in Figure 6 for various energy storage systems. It can be seen that even the most 
advanced current battery storage systems fall short of the parameters of Kerosene. While the factor in 
specific volume is only about 18, the factor in mass specific energy density is in the order of 60. This is a 
core problem for application in aviation and imposes strict limits for battery powered systems. The lower 
volume specific energy content is less critical as long as the aircraft design is not limited by internal 
volume. Otherwise the vehicle would require larger wings or fuselages or additional external “energy 
pods” which would lead to losses in overall aircraft efficiency due to larger wetted surface. Of course 
there are ideas to incorporate batteries and other storage systems into the primary structure, but these are 
still rather far from practical application. In case of fuel cells hydrogen can e.g. be stored in porous metal, 
but the weight of these foams is very high and appears unsuitable for aeronautical application. However, 
such systems have been used in marine applications, where the additional mass is less critical. Table 1 lists 
some characteristics, advantages and disadvantages of energy storage systems. 
As a side-note it is interesting to note that some “bio-fuels”, like milk or cream have rather high energy 
densities – unfortunately efficient high power conversion technology is still lacking. 
10000 
1000 
100 
10 
LiOH Battery 
Methanol 
TNT 
Kerosene 
LPG Propane 
STO-MP-AVT-209 9 - 7 
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1 
1 10 100 1000 10000 100000 
mass specifc energy E* [Wh/kg] 
NiCd-Battery 
Pb-Battery 
300 bar compressed air 
volume specifc energy V* [Wh/liter] 
NiMH Battery 
HO2 2 
Ethanol 
H liquid 2 
H 1 bar 2 
factor 60 
factor 18 
H 700 bar 2 
LiOH Nano-Wire Battery 
3.5% Milk 
Cream 
Flywheels 
Figure 6 Volume and mass specific energy characteristics of different energy storage systems.
UNCLASSIFIED 
Electric Flight – Potential and Limitations 
Kerosene, AVGAS Can be stored in wing and fuselage tanks. These are often part of the 
structure and therefore of low mass. 
Hydrogen (gas) Requires high pressure tanks (typically 350 to 700 bars). Tanks are much 
heavier than the actual fuel and are also a safety risk. If the pressure is 
reduced, tanks of large volume are required, which affect weight and drag 
and therefore aircraft performance. Could partially be stored in metallic 
structures, but practical application in aeronautics is rather limited so far. 
Hydrogen (liquid) Requires cryogenic tanks with insulation to keep the fuel at about -250°C. 
Tanks are heavy and also require considerable volume with the drawbacks 
similar to gaseous hydrogen. 
Battery Requires casings with temperature control systems. 
Fuel Cell Requires liquid or gaseous fuel with all the aspects mentioned above. 
Additional infrastructure like air pumps, water supply or reformer devices 
is necessary. 
Table 1 Characteristics of energy storage systems. 
3.2.5 Efficiency Chains 
The conversion of energy stored on-board to propulsive power involves several conversion steps. Each of 
them is affected by losses, which are expressed by individual efficiencies. For the comparison of different 
systems, the on-board conversion chain must be considered. For a complete picture one could extend this 
view to the complete energy chain e.g. from “well-to-wheel” in case of fossil fuel, but such an analysis is 
beyond the scope of this paper and very difficult. Figure 7 shows four typical conversion chains: 
9 - 8 STO-MP-AVT-209 
UNCLASSIFIED 
• a conventional turboprop 
• a conventional turbofan, 
• a battery powered system, and 
• a fuel cell powered system. 
Typical values for the efficiency of the individual components have been assumed1. It is clearly visible 
that all electric systems exhibit high overall system efficiency. Especially battery systems which avoid the 
conversion of fuel to electricity in the airplane offer the highest efficiency of more than 70%, compared 
with the efficiency of the classical combustion systems reaching efficiencies of up to 40%. Of course these 
on-board chains do not contain the generation of electricity on the ground nor do they include the 
generation and distribution of fuel or electricity. For example the charging and discharging cycle of 
chemical batteries causes energy losses in the order of 15-20%. Nevertheless in terms of efficient usage of 
on-board energy the battery systems are very attractive. The important aspect of the system mass is 
examined in the next section. 
1 When looking up these efficiency values one has to be careful, as in some cases (e.g. fuel cells) efficiencies may include the 
exploitation of thermal power which may not be of interest. For a more refined picture one must consider how to exploit these 
additional capabilities e.g. for air conditioning purposes or thermal thrust generation. Also note that the latest turbofan engines 
claim to achieve thermal efficiencies of almost 60%, which would raise the chain efficiencies for turboprop and turbofan to 
47% resp. 39%, bringing them closer to the value of the fuel cell chain.
UNCLASSIFIED 
Electric Flight – Potential and Limitations 
Turbofan 
Kerosene 
100% 
Thermodynamic Cycle 
Turboprop 
Kerosene 
100% 
Propeller 
η=80% 
Battery 
Battery 
100% 
Gearbox 
η=98% 
Fuel Cell 
Hydrogen 
100% 
Fuel Cell 
η=60% 
Gearbox 
η=98% 
STO-MP-AVT-209 9 - 9 
UNCLASSIFIED 
η=50% 
Fan and Nozzles 
η=65% 
33% 
Thermodynamic Cycle 
η=50% 
Gearbox 
η=98% 
39% 
Controller 
η=98% 
Electric Motor 
η=95% 
Propeller 
η=80% 
73% 
Controller 
η=98% 
Electric Motor 
η=95% 
Propeller 
η=80% 
44% 
Figure 7 Typical on-board conversion chains with typical component efficiencies and total chain efficiency. 
3.2.6 Equivalent Energy Density of Electric Power Sources 
In order to compare different electric power sources with a battery system it is necessary to transform their 
parameters into an equivalent mass specific energy E* of the complete system. First, we compare the 
systems as electric power sources, i.e. the chain up to the electric connector where the motor controller 
would be plugged in. Figure 8 relates the stored energy to the mass of the electric power source. 
The example assumes identical flight performance of a general aviation airplane requiring a propulsive 
power of 50 kW for fast cruise. The required energy is determined from the respective efficiency chains so 
that 100 kWh are finally available for the mission. As the airplane has not been adapted to the mass of the 
propulsion system, this is yields an optimistic view for the heavier systems. 
The mass given below the fuel tanks are for the fuel and the additional mass of the tank with its fuel 
systems. It can be seen that a high pressure tank for hydrogen outweighs the fuel mass almost by a factor 
of 20. 
In Figure 9 we can add the motor controller and the electric motor so that the chain extends up to the 
propeller shaft. This allows comparing the chain with an internal combustion engine. 
The results show that the classical internal combustion engine offers the lowest mass and hence an 
effective specific energy of almost 1600 Wh/kg, which is about 14% of the specific energy content of the 
raw kerosene fuel. This propulsion system is followed by the hybrid electric system which adds a 
generator and an electric motor to the drive train.
UNCLASSIFIED 
Electric Flight – Potential and Limitations 
2 
Battery E* = 180 Wh/kg 
Hydrogen 
Fuel Cell 
50 
kW 
E* = 701 Wh/kg 
(Kerosene: 211 800 Wh/kg) 
2 
9 - 10 STO-MP-AVT-209 
UNCLASSIFIED 
Hydrogen 
Fuel Cell 
FC 
=55% 
(50 kg) 
H2 gas 
Reformer 
=75% 
(33.3 kg) 
liquid fuel 
Kerosene 
(20.5 kg + 12 kg) 
Battery 
(556 kg) 
50 
kW 
0 100 200 300 400 500 600 
m [kg] 
H2 gas 
FC 
=55% 
(50 kg) 
H 
(5.5 kg + 95.5 kg) 
E* = 862 Wh/kg 
(Kerosene: 211 800 Wh/kg) 
Kerosene 
Reformer 
Fuel Cell 
700 
bar 
50 
kW 
E* = 662 Wh/kg 
(H : 33 306 Wh/kg) 2 
50 
kW 
E* = 1105 Wh/kg 
(Kerosene: 211 800 Wh/kg) 
Kerosene 
I/C engine 
Generator Generator 
=95% 
(25 kg) 
shaft 
I/C engine 
=35% 
(25 kg) 
liquid fuel 
Kerosene 
(25.5 kg + 15 kg) 
Fuel Cell 
Reformer 
Tank 
Fuel 
I/C engine 
Generator 
Figure 8 Mass and equivalent energy density of electric power generation systems delivering an electric 
power of 50 kW for 2 hours. 
Battery E* = 172 Wh/kg 
0 100 200 300 400 500 600 
m [kg] 
Kerosene 
Reformer 
Fuel Cell 
700 
bar 
50 
kW 
E* = 551 Wh/kg 
(H : 33 306 Wh/kg) 2 
E* = 850 Wh/kg 
(Kerosene: 211 800 Wh/kg) 
Kerosene 
I/C engine 
Generator 
Hybrid 
50 
kW 
Fuel Cell 
Reformer 
Tank 
Fuel/Battery 
I/C engine 
Generator 
Electric Motor 
E* = 1575 Wh/kg 
(Kerosene: 211 800 Wh/kg) 
Kerosene 
I/C engine shaft 
I/C engine 
=35% 
(25 kg) 
liquid fuel 
Kerosene 
(25.5 kg + 15 kg) 
Motor 
=95% 
(25 kg) 
Generator 
=95% 
(25 kg) 
shaft 
I/C engine 
=35% 
(25 kg) 
liquid fuel 
Kerosene 
(25.5 kg + 15 kg) 
shaft 
Motor 
=95% 
(25 kg) 
Battery 
(556 kg) 
shaft 
Motor 
=95% 
(25 kg) 
H2 gas 
FC 
=55% 
(50 kg) 
H 
(5.5 kg + 95.5 kg) 
shaft 
Motor 
=95% 
(25 kg) 
FC 
=55% 
(50 kg) 
H2 gas 
Reformer 
=75% 
(33.3 kg) 
liquid fuel 
Kerosene 
(20.5 kg + 12 kg) 
shaft 
Figure 9 Mass and equivalent energy density of propulsion systems providing a shaft power of 50 kW for 2 
hours.
UNCLASSIFIED 
Electric Flight – Potential and Limitations 
3.2.7 Battery Technology 
Today, most electric powered aircraft are using battery systems of the Lithium-Ion type. These are mass 
produced mainly as power sources for mobile devices and are readily available. Such batteries can be 
produced relatively cheap and can be scaled to build larger systems of several hundred kWh energy 
capacity. Currently available systems provide a mass specific energy content of up to 200 Wh/kg (see 
Figure 10). Further developments may lead to values in the order of 250 Wh/kg, which is insufficient for 
automotive and larger aerial applications. Today, the development of other Lithium based battery systems 
is pushed forward. Lithium-Sulfur and Lithium-Oxygen are two systems on which research and 
development are focused. While sulfur-based systems have reached practical prototype status (after more 
than 50 years of development), oxygen based systems are still in their infancy. All these systems offer 
energy densities which are larger by a factor of about 3 to 10. A very complete survey of Lithium based 
battery technology is given in [3]. Table 2 contains values taken from this publication and shows the 
expected development of these systems. Concerning the possible application of the air breathing, oxygen 
based battery systems in aviation many questions are still open and cannot be expected to be answered 
within the next 10 years. Therefore it seems to be more realistic to expect the application of sulfur based 
systems within the next 20 years in mobile applications as well as in unmanned and possibly manned air 
vehicles. 
Figure 10 Specific energy density of current Lithium Ion battery systems. 
System theoretical specific energy expected in 2025 
Li-Ion (2012) 390 Wh/kg 250 Wh/kg 
Zn-air 1090 Wh/kg 400-500 Wh/kg 
Li-S 2570 Wh/kg 500-1250 Wh/kg 
Li-O2 3500 Wh/kg 800-1750 Wh/kg 
Table 2 Specific energy density of current and future chemical battery systems. 
STO-MP-AVT-209 9 - 11 
UNCLASSIFIED
UNCLASSIFIED 
Electric Flight – Potential and Limitations 
today and within next 5 years 
expected within next 10-20 years 
theorectically possible 
0 500 1000 1500 2000 2500 3000 3500 4000 
Li-Ion (1/2C Li + Li CoO  3C + LiCoO ) 6 0.5 2 2 
Zn-air (Zn + 1/2O  ZnO) 2 
Li-S (2Li + S  Li S) 2 
Li-O (non aqueuous) 2 (2Li + O  Li O ) 2 2 2 
Li-O (aqueuous) 2 (2Li + 1/2O + H O  2 LiOH) 2 2 
14 
12 
10 
8 
6 
4 
2 
electric motors 
piston engines 
Honda FCX 
e-Genius 
Antares 
Tesla 
NASA 
(AIAA-2010-276) 
GE-90 Turbofan 
9 - 12 STO-MP-AVT-209 
UNCLASSIFIED 
specific energy [Wh / kg] 
Figure 11 Current battery technology and expected development. 
3.2.8 Electric Motor Technology 
Electric motors for application in aviation must be designed for continuous operation at cruise power. 
Motors for hybrid automotive applications or for model aircraft are often designed for short power boost 
applications so that one must be careful when comparing data. Figure 12 plots the power specific mass of 
various piston engines and electric motors. The few electric motors available today for aircraft propulsion 
have a power output of less than 100 kW. Large electric motors are also used in trains, ships and 
submarines, but here the mass is less important. Today it seems to be possible to build electric motors 
having a specific mass of about 2 to 4 kW/kg. This compares favorably with the specific mass of larger 
turboshaft and turbofan engines at cruise power (see Figure 13 and Figure 14). Future developments may 
extend the range of electric motors to values of up to 8 kW/kg, but there is a strong need for the 
development of lightweight electric motors, specifically designed for application in aircraft. In the 
literature assumptions of up to 14 (e.g. in [5]) can be found, but assume superconducting motors with 
cryogenic cooling systems. 
0 
1 10 100 1000 10000 100000 
P [kW] 
P/m [kW/kg] 
BMW V10 F1 
GE Marine Turboshaft 
turbine engines 
Figure 12 Specific power density of current piston engines (squares) and electric motors (circles).
UNCLASSIFIED 
Electric Flight – Potential and Limitations 
Figure 13 Specific power density of turboshaft engines. 
Figure 14 Specific power density of turbofan engines, derived from cruise thrust. 
STO-MP-AVT-209 9 - 13 
UNCLASSIFIED
UNCLASSIFIED 
Electric Flight – Potential and Limitations 
4.0 RANGE EQUATIONS 
The range of an aircraft depends on the available energy, the propulsion system, the mass of the aircraft 
and the aerodynamic properties of the aircraft. The range equations for classical, fuel burning aircraft with 
variable mass are well known and have been derived for various cruise flight conditions. In case of battery 
powered electric aircraft the mass of the aircraft stays constant and hence the range equation is simplified. 
The range of an aircraft is defined by flight speed and flight time 
R v t ¥ = ⋅. (1) 
In case of a battery powered aircraft, the flight time is equal to the time to drain the battery, which, under 
ideal conditions, is 
* 
m E 
battery 
battery 
m E 
⋅ 
= ⋅ = ⋅ . (5) 
⋅ 
= ⋅ 
m E 
= ⋅h ⋅ ⋅ ⋅ . (8) 
9 - 14 STO-MP-AVT-209 
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t 
P 
⋅ 
= . (2) 
Inserting this flight time into the definition of the range (1) yields 
* 
battery 
battery 
R v 
¥ P 
⋅ 
= ⋅ . (3) 
The power drawn from the battery is related to the propulsive power required by the aircraft 
aircraft 
battery 
total 
P 
P = 
h 
(4) 
where the power required by the aircraft is linked to its weight, lift over drag ratio and flight speed: 
aircraft aircraft 
m g 
P D v v 
¥ L / D ¥ 
With (5), the battery power (4) finally becomes 
battery 
total 
m g 
P v 
L /D ⋅ h 
¥ 
(6) 
and can be inserted into equation (3) 
* 
battery 
total 
R v 
m g 
v 
L /D 
¥ 
¥ 
⋅ 
= ⋅ 
⋅ 
⋅ 
⋅ h 
. (7) 
This equation can be simplified to the range equation for battery electric flight 
* battery 
total 
1 L m 
R E 
g D m 
Interestingly the range is independent of the flight speed v¥ which is only indirectly affecting the result 
via lift to drag ratio and the total efficiency total h . 
This equation clearly shows that for maximum range the following parameters should be maximized:
UNCLASSIFIED 
Electric Flight – Potential and Limitations 
• the ratio of battery mass to total mass battery m /m, 
• the specific energy capacity E* of the battery, 
• the lift over drag ratio L/D, and 
• the total system efficiency total h (from battery to propulsive power). 
3000 
2500 
2000 
1500 
1000 
500 
total = 0.75, R for powered level flight 
R [km] 
6000 
5000 
4000 
3000 
2000 
1000 
12000 
10000 
8000 
6000 
4000 
2000 
      
ö÷= ⋅ h ⋅ 1 æç ⋅ L ⋅ çç 1 
÷÷÷÷ 
çè - ø 
STO-MP-AVT-209 9 - 15 
UNCLASSIFIED 
On the other hand 
• the aircraft mass m 
should be minimized. 
0 
100 200 300 400 500 600 700 800 900 1000 
E* [Wh/kg] 
0 
10 
L/D 
0 
40 20 
m /m=1.0 battery 
m /m=0.8 battery 
m /m=0.6 battery 
m /m=0.4 battery 
m /m=0.2 battery 
battery * 
total 
m L 1 
R E 
m D g 
Status 
2012 
Figure 15 Range versus specific energy for different battery mass fractions. The vertical axes are for three 
different ratios of lift over drag, ranging from small General Aviation aircraft to sailplanes. 
The range obtained from this equation is plotted in Figure 15 versus the specific energy of the battery 
system E* . The shaded triangle indicates the range of technically feasible battery mass fractions. It can be 
seen that for larger ranges the battery technology must be improved to at least five-fold values compared 
to the state in 2012. 
Comparing the range equation for battery powered aircraft with one form of the classical range equation 
for kerosene burning jet engines 
* 
total 
fuel 
R E ln 
g D 1 m /m 
. (9) 
shows that the two equations only differ in the last term. Figure 16 compares this term for aircraft having 
different fuel mass fractions respectively ranges. It can be seen that the drawback of maintaining constant 
mass increases with range and may grow to more than 20% for long range flights. This drawback is 
inherent in battery powered aircraft and must be compensated by additional energy respectively efficiency.
UNCLASSIFIED 
Electric Flight – Potential and Limitations 
0.7 
0.6 
0.5 
0.4 
0.3 
0.2 
0.1 
ln(1/(1-m /m)) f 
m/m f 
23% low 
Boeing 747 SP 
  		  	       	 
     
Cessna 182
6% low 
æç ö÷= ⋅ h ⋅ ⋅ ⋅ çç - - ÷÷÷ ç ÷÷ çè 
çè 
ö÷= 1 L æç m 
⋅ ⋅ h ⋅ ⋅ çç - ÷÷÷ ç ÷÷ R E 1 
⋅ 
PAX m 
9 - 16 STO-MP-AVT-209 
UNCLASSIFIED 
0 
0 0.05 0.1 0.15 0.2 0.25 0.3 0.35 0.4 0.45 0.5 
m/m f 
* battery 
total 
1 L m 
R E 
g D m 
* 
total 
fuel 
1 L 1 
R E ln m g D 1 
m 
ln(1/(1-m /m))f m/m f 
Figure 16 Range terms versus fuel respectively battery mass fraction. 
4.1.MAXIMUM RANGE 
To gain more insight into typical aircraft design parameters we replace the battery mass 
battery empty payload m = m-m -m (10) 
to obtain 
* empty payload 
total 
1 L m m 
R E 1 
g D m m 
ø 
. (11) 
Reducing the payload mass to zero allows finding the ultimate range 
* empty 
ultimate total 
g D m 
ø 
. (12) 
For the given technology parameters, this range can never be exceeded. Also note that for this hypothetical 
range the aircraft mass would grow to infinity. Therefore the practical range must be lower that this hard 
limit. 
Equation (11) can be solved for the airplane mass which is required for a desired range and payload using 
a given technology level in structures, aerodynamics and propulsion system: 
payload 
e * 
total 
m 
g 
1 f R 
E L/ D 
= 
- - ⋅ 
⋅ h ⋅ 
. (13)
UNCLASSIFIED 
Electric Flight – Potential and Limitations 
Equation (13) can be used for a very quick first order assessment of the required size of an airplane, using 
only a few basic technology parameters. The structural design of the aircraft is represented by the empty 
mass fraction fe = mempty /m; for a given structural technology and typical design parameters, like 
aspect ratio and wing thickness, one can assume a certain value for e f (which is typically between 0.4 and 
0.7, see Figure 17). Of course, this ratio should be as low as possible to obtain the lowest aircraft mass. 
The aerodynamics is represented by the lift over drag ratio, which should as large as possible to minimize 
the mass. 
In order to obtain a valid solution of (13) with a finite and positive aircraft mass the following conditions 
must be fulfilled: 
The lift over drag ratio must be at least 
⋅ 
L Rg 
D 1 f E 
( ) * 
e total 
⋅ 
R g 
⋅ 
R g 
1 
0.8 
0.6 
0.4 
0.2 
light airplanes 
Airbus 
Boeing 
STO-MP-AVT-209 9 - 17 
UNCLASSIFIED 
 
- ⋅ ⋅h 
, (14) 
the specific energy of the battery must be larger than 
( ) 
* 
e total 
E 
1 f L/D 
 
- ⋅h ⋅ 
, (15) 
and the empty mass fraction of the aircraft must be lower than 
e * 
total 
f 1 
E L/ D 
 - 
⋅ h ⋅ 
. (16) 
These limits are independent of the payload and can be used to define the required technology level in 
each discipline or to judge the feasibility of a proposed concept. If a design does not fulfill these 
constraints, it is unfeasible with the given the technology. 
0 
1000 10000 100000 1000000 
takeoff mass [kg] 
empty mass / takeoff mass 
propeller 
turbofan 
approximation 
Figure 17 Empty mass fraction of aircraft versus take-off mass.
UNCLASSIFIED 
Electric Flight – Potential and Limitations 
A more realistic range limit can be found by monitoring the mass growth per range increase. 
Differentiating (13) with respect to the range yields the mass growth per distance for a design for a given 
range 
¶ ⋅ ⋅ 
m PAX m g 
pax 
R 2 
g R 
1 f E L/D 
E L/ D 
⋅ 
L 1 PAX m 1 L 
* pax * 
= ⋅h ⋅ ⋅ ⋅ - - ⋅ ⋅ ⋅h ⋅ 
R E 1 f E 
max total e * total 
D g m g D 
çæ¶ ÷öçç ÷÷çè¶ ÷ø 
çæ¶ ÷ö é ù ç ÷÷ = ⋅ ê ú ççè¶ ÷ø ê ú ë û 
9 - 18 STO-MP-AVT-209 
UNCLASSIFIED 
* 
e * total 
total 
= 
¶ æ ⋅ ö÷ çç - - ÷÷ ⋅ ⋅ h ⋅ çç ⋅ h ⋅ ÷÷ è ø 
, (17) 
where the payload mass has been replaced by payload pax m = PAX ⋅m . 
If we limit the mass growth per distance to a certain limit value ( )* ¶m/¶R , we can solve (17) for the 
limit range max R 
( ) 
ultimate 
R 
R 
 
. (18) 
The first term in this equation equals equation (12), the second term corresponds to the range reduction 
imposed by the mass growth limit. 
A more complete analysis of existing and prospective electric aircraft showed that the acceptable mass 
growth depends on aircraft mass: for heavier aircraft a higher limit can be accepted. Based on the 
numerical results, the following empirical relation has been developed: 
* 
m 1 1.27 kg 
m 
R 4200 km 
. (19) 
For lightweight single seat aircraft (m = 1000 kg) this equation yields limit values in the order of 1 kg/km, 
while the limit for heavy regional aircraft (m = 15 tons) reaches values of 50 kg/km. 
Numerical values for a hypothetical 30 seat regional aircraft are shown in Figure 18. The realistic range 
limit is indicated by symbols. Two ways of exploiting an increase of the specific energy E* from 200 to 
400 Wh/kg are shown. First one can maintain the aircraft mass and move horizontally to double the range 
from 325 to 650 km. At this point (hollow symbol) the mass growth limit is not yet reached so that the 
practical range can be extended further to about 820 km. Alternatively one could move vertically down, 
maintaining the range but reducing the aircraft mass from about 14 tons to 8.5 tons.
UNCLASSIFIED 
Electric Flight – Potential and Limitations 
Figure 18 Total mass and battery mass for two values of the specific energy E* versus range. The solid sym-bols 
indicate the range limit imposed by a prescribed mass growth gradient dm/dR. 
4.2.RANGE SENSITIVITIES 
Equation 11 shows that in order to achieve maximum range for a given aircraft mass one should of course 
minimize the empty mass fraction fe = mempty /m as well as the payload mass fraction 
p payload f = m /m so that the battery mass is maximized. At the same time one should also maximize the 
lift over drag ratio L/D. The sensitivities of equation 11 with respect to the mass parameters e f and p f 
R R 1 L 
* 
total 
f f g D 
e p 
E 
R 1 L 1 
= - ⋅ E ⋅ h ⋅ ⋅ m 
⋅ 
¶ 
R 1 
= 1 - f - f ⋅ ⋅ E 
⋅h 
¶ 
R 1 
¶ 
= - - ⋅ ⋅h ⋅ 
STO-MP-AVT-209 9 - 19 
UNCLASSIFIED 
¶ ¶ 
= =- ⋅ ⋅h ⋅ 
¶ ¶ 
. (20) 
show that a change in empty weight or payload weight fraction is more critical when the ratio L/D and 
the system efficiency total h are high. The sensitivity with respect to the total mass 
* 
total battery 2 
m g D m 
¶ 
(21) 
shows a strong dependency on the inverse of the mass. A lightweight aircraft is more sensible to a change 
in mass than a heavy aircraft. 
The impact of the lift to drag ratio can be assessed from 
( ) * 
e p total 
L/D g 
¶ 
, (22) 
which demonstrates that a lightweight aircraft is more sensitive to changes in L/D. Concerning the 
effect of the battery technology, the derivative is similar: 
( ) * e p total 
1 f f L/D 
E g 
¶ 
. (23)
UNCLASSIFIED 
Electric Flight – Potential and Limitations 
These sensitivities can be used to assess the robustness of a design with respect to changes in operating 
parameters. A numerical example is shown in Table 3 to demonstrate these sensitivities. The right hand 
side of the table shows the effect on range of increasing a parameter by 10% respectively of increasing the 
number of passengers by one. Additionally, derived sensitivities can be used to “trade” one discipline for 
another discipline; for example the derivative * 
¶E / ¶fe shows that an increase of 10% of the empty mass 
fraction ( e Df = 0.053) is has the same impact on range as a decrease of the specific energy of the battery 
system by DE* = -31.9 Wh/kg. 
assumptions results 
E* 200 Wh/kg max R 173.1 km 
L / D 16.35 - ¶R / ¶E* ⋅10%⋅E* 28.2 km 
e f 0.53 - e e ¶R / ¶f ⋅10%⋅ f -44.9 km 
total h 0.7 - ¶R / ¶L / D⋅10%⋅ L / D 28.2 km 
PAX 32 - ¶R / ¶PAX -3.4 km 
pax m 90 kg derived sensitivity 
( )* 
e e ¶E / ¶f ⋅10%⋅ f -31.9 Wh/kg 
¶m / ¶R 52 kg/km * 
Table 3 Set of parameters (left) for an electric powered aircraft and its range sensitivities (right). Note 
that the assumed L/D ratio is lower than in Figure 18, therefore the range is lower. 
9 - 20 STO-MP-AVT-209 
UNCLASSIFIED
UNCLASSIFIED 
Electric Flight – Potential and Limitations 
5.0 ELECTRIC PROPULSION FOR REGIONAL AIRCRAFT 
In order to assess the potential of an electric propulsion system in larger aircraft a more complete mission 
simulation tool was developed. Here the mission consists of a climb, a cruise and a descent segment. For 
each segment the aircraft is flown at minimum energy consumption. The simulation performs the time 
integration over the three segments for a given aircraft and propulsion system model. 
climb 
z Range 
20 
15 
10 
5 
energy required by aircraft 
STO-MP-AVT-209 9 - 21 
UNCLASSIFIED 

 
cruise 
descent 
x 
time 

 
no reserves! 
Figure 19 Simplified mission profile. 
5.1.CLIMB SEGMENT 
This segment is defined by either climb angle or climb rate. The simulation then determines the optimum 
flight speed for each altitude so that the energy drawn from the battery per altitude battery dE / dz is 
minimized. It is important to include the efficiency of the propulsion system to avoid the trivial solution of 
a vertical climb which provides minimum energy consumption of the airframe alone (Figure 20). 
0 
0 20 40 60 80 100 
dE/dz [Wh/m] 
 [°] 
energy drawn from battery 
min 
min 
90 
Figure 20 Energy consumed per altitude for the aircraft and for the aircraft with propulsion system chain. 
The trivial optimum for the airframe would be to climb vertically and as slow as possible to 
minimize total drag. Including the efficiency of the propulsion system yields a realistic minimum.
UNCLASSIFIED 
Electric Flight – Potential and Limitations 
5.2.CRUISE SEGMENT 
During cruise, the optimum flight speed is determined so that dE / dx is minimized. Again, the 
efficiency of the propulsion system chain including the propeller is taken into account, so that the 
optimum speed is not identical to the optimum of the aircraft alone. 
5.3.DESCENT SEGMENT 
The descent segment is flown with a given descent angle, which is steeper than the maximum of lift over 
drag ratio of the airframe to minimize the energy consumption. During this flight phase only auxiliary 
power for the aircraft systems has to be provided by the battery. No recuperation is considered here due to 
the high drag and low efficiency of the windmilling propellers, which would allow to recover about 5% of 
the total energy (in case of a 500 km flight of a regional aircraft at H = 3000 m the potential energy 
m⋅ g ⋅H is about 20% of the total energy consumed during the flight). 
5.4.APPLICATION 
Applying this simulation model to a specific aircraft allows determining the possible performance and the 
technology improvements required to achieve the desired results. As a test case a regional aircraft similar 
to the Dornier Do 328 turboprop aircraft was modeled. Step by step several modifications were performed 
to optimize the aircraft for the electric propulsion system. 
The range of the original aircraft with 32 
passengers is about 1200 km. With a reduced 
payload of 28 passengers the maximum range is 
approximately 2200 km, while the lift-to-drag ratio 
is around 16. 
The first modification consists of simply replacing 
the conventional fuel system and the turboprop 
engines with a battery electric system having the 
same mass. Using current (2012) technology this 
aircraft would reach a range of 202 km. The flight 
time would be about 40 minutes. Cruise speed 
would be about 300 km/h. 
If an additional reserve of 30 minutes for holding at 
the destination airport would have to be considered, 
the practical range would drop to 50 km. 
Figure 21 Modified baseline aircraft with drop-in electric propulsion system. 
9 - 22 STO-MP-AVT-209 
UNCLASSIFIED
UNCLASSIFIED 
Electric Flight – Potential and Limitations 
The next step tries to improve the aerodynamic 
performance by reducing the zero lift drag 
coefficient by 20%. 
This could be achieved by optimizing the 
installation of the propulsion system (smaller 
nacelles or fully integrated motors, less cooling air 
flow) as well as many other detail improvements. 
Part of these improvements could be achieved by 
introducing laminar flow on the wing and on the 
tailplanes. This is feasible as the wing is unswept 
and may be produced in composite material with 
the required smoothness. 
Due to the lower drag, the optimum cruise speed 
would increase to 330 km/h. However, as the zero 
lift drag is only about half the total drag, this 
modification would increase the range by only 10% 
to 221 km. 
Figure 22 Modified aircraft with reduced zero lift drag. 
Next the induced drag is reduced through an 
increase in wing span of 50% without increasing 
the wing mass and the wing area. The new wing 
span is now 31.5 m compared to the initial 21.0 m. 
This change would require substantial changes to 
the structure, possibly the introduction of a strut 
braced wing concept (while maintaining zero lift 
drag) and an optimized composite structure. 
This modification would increase the range by 
about 40% to 302 km. 
The higher aspect ratio would move the energy 
minimum to a lower cruise speed of 275 km/h. 
Figure 23 Modified aircraft with increased wing span. 
STO-MP-AVT-209 9 - 23 
UNCLASSIFIED
UNCLASSIFIED 
Electric Flight – Potential and Limitations 
The next modification would reduce the empty 
mass of the aircraft by 20%. This would require 
introducing extreme lightweight design features. As 
many components are unlikely to be reduced in 
mass the main structural components would have to 
be reduced by probably 30%. 
This modification would increase the range by 
another 10% to 339 km. Due to the lower mass, the 
optimum flight speed would be about 255 km/h. 
Figure 24 Modified aircraft with reduced mass. 
This step improves the battery technology by 
doubling the mass specific energy E* . Such an 
improvement is quite well possible with future 
development of Li-S battery systems within the 
next 15 years. 
This modification would double the range to 
711 km so that it at least comes into the order of the 
kerosene based aircraft. 
Nevertheless, there is still a factor of 3 in range 
missing. In order to achieve the range of the 
original aircraft, the battery technology would have 
to be improved by this factor, i.e. a factor of 6 
compared to todays (2012) technology. 
Figure 25 Modified aircraft with improved battery technology. 
9 - 24 STO-MP-AVT-209 
UNCLASSIFIED
UNCLASSIFIED 
Electric Flight – Potential and Limitations 
The last modification doubles the mass specific 
energy density of the battery system again. Such an 
improvement may be possible with future 
development of Li-S battery systems in the next 30 
years. 
This modification would double the range again to 
1455 km so that it is almost identical to the 
kerosene based aircraft. Such an aircraft could be 
operated profitable if the technology would be 
available at reasonable costs. Furthermore new 
infrastructure to replace and recharge the batteries 
on each airport would be required to make such an 
aircraft feasible. 
However one must consider that this improvement 
also includes many very optimistic assumptions and 
improvements in structures and aerodynamics. Just 
using the improved batteries in the electrified 
baseline aircraft 328 E would lead to a range of 
800 km at the same specific energy consumption of 
124 Wh/PAX/km. 
Figure 26 Modified aircraft with further improved battery technology. 
Rult. Rult. Rult. 
3500 
3000 
2500 
2000 
1500 
1000 
500 
STO-MP-AVT-209 9 - 25 
UNCLASSIFIED 
0 
0 500 1000 1500 2000 2500 3000 3500 4000 
Range [km] 
Payload [kg] 
328 E 
E* = 180 360 720 
328 TP 
Rult. 
1980 Wh/kg 
Rult. 
1620 
Figure 27 Payload-range chart of the baseline and the electrified aircraft. 
Comparing the payload-range characteristics of the baseline turboprop aircraft and the battery powered 
electric aircraft shows that trading payload for fuel respectively battery has a very beneficial effect in case 
of kerosene because of its high specific energy. The gain in case of the electric aircraft is smaller, even if 
the design range and payload are similar. As can be seen, the gradient depends on the specific energy
UNCLASSIFIED 
Electric Flight – Potential and Limitations 
content E* of the battery system, which is always lower than that of kerosene. This means that the range 
flexibility of the battery powered aircraft is more limited than that of the kerosene powered turboprop 
variant. Similar payload range capability is obtained when the specific energy of the battery system 
exceeds about 1500 Wh/kg. 
If, on the other hand, the final extremely modified aircraft 328-LBME2 would be equipped with a current 
turbo-prop engine, its fuel consumption would be as low as 1.5 liters per passenger per 100 km, which is 
about half that of the baseline aircraft. 
6.0 CONCLUSIONS 
Practical battery electric powered airplanes are today limited to small vehicles up to 2 passengers and by 
rather short ranges and endurance. Neglecting costs, the current technology is suitable for small Ultra- 
Light aircraft, but not for commercial aviation. In order to power larger aircraft a dramatic improvement in 
battery technology would be required. Comparing with today’s technology with specific energy values of 
150 to 200 Wh/kg, the mass specific energy density would have to be increased at least by a factor of 5 to 
become useful. More realistic this factor would have to be in the order of 10 to attract commercial interest 
for larger (regional) aircraft. In this context we must note that all numerical studies presented in this paper 
did not consider reserves as required for commercial aircraft. These would add 30 to 45 minutes of flight 
time for holding at the destination airport and deviations. 
Currently there is a lot of development in battery technology, mostly driven by mobile devices and by 
automotive applications. Development history hints that the required improvements may take about 20-40 
years until they may become available. 
Besides these basic considerations, there are still many questions which have to be and which are currently 
addressed: 
• how does the total energy balance and the environmental footprint including manufacturing look 
9 - 26 STO-MP-AVT-209 
UNCLASSIFIED 
like? 
• are there enough raw materials for battery production (automotive plus aviation) available? 
• how to achieve the required level of safety and how to adapt certification rules? 
• which infrastructure and investment is required at the airport for battery replacement and 
recharging? 
• how can the low noise features of electric propulsion systems be exploited better? 
• how does the battery technology compare to future fuel cell technology developments? 
• how do fuel cell powered aircraft compare to aircraft burning synthetic fuels or hydrogen? 
Returning to the historic flight of the MB-E1 we can apply the same numeric analysis to study the option 
of repeating the experiment with the technology readily available in 2012. We can replace the Ni-Cd 
batteries (E* = 20 Wh/kg) with Li-OH cells (E* =180 Wh/kg) of the same mass and the brushed electric 
forklift motor ( h = 66%) with a specifically designed brushless motor ( h = 90%). This simple 
modification would extend the powered flight time of the MB-E1 from 7 minutes to 2 hours and 33 
minutes. The range of the aircraft would grow from 17 km to 261 km. Mainly due to the improved 
efficiency of the electric motor the energy consumption of the single passenger (the pilot) per distance 
would be almost halved from E* = 135 Wh/PAX/km to E* = 80.8 Wh/PAX/km.
UNCLASSIFIED 
Electric Flight – Potential and Limitations 
7.0 REFERENCES 
[1] Airbus Global Market Forecast 2012 – 2031. http://www.airbus.com/company/market/forecast/, 
[retrieved 25 September 2012]. 
[2] World Economic Outlook April 2011, International Monetary Fund, ISBN 978-1-61635-059-8, 
http://www.imf.org/external/pubs/ft/weo/2011/01/, [retrieved 25 September 2012]. 
[3] C. A. Luongo, P. J. Masson, T. Nam, D. Mavris, H. D. Kim, G. V. Brown, M. Waters, D. Hall, 
“Next Generation More-Electric Aircraft: A Potential Application for HTS Superconductors”, IEEE 
Transactions on Applied Superconductivity, Vol 19, No. 3, pp. 1055-1068, 2009. 
[4] P. G. Bruce, S. A. Freunberger, J. J. Hardwick, J.-M. Tarascon, “Li-O2 and Li-S batteries with high 
energy storage”, nature materials, Vol. 11, January 2012, Macmillan Publishers, 2012. 
[5] A. R. Gibson, D. Hall, M. Waters, B. Schiltgen, T. Foster, J. Keuth, P. Masson, “The Potential and 
Challenge of TurboElectric Propulsion for Subsonic Transport Aircraft”, AIAA 2010-276, 48th AIAA 
Aerospace Sciences Meeting, 4-7 January 2010, Orlando, USA, 2010. 
[6] A. S. Gohardani, G. Doulgeris, R. Singh, “Challenges of future aircraft propulsion: A review of 
distributed propulsion technology and its potential application for the all-electric commercial aircraft”, 
Progress in Aerospace Sciences, Vol. 47, pp.369-391, 2011. 
[7] B. Sørensen, “Energy Storage”, Annual Review of Energy, Vol. 9, pp. 1-29, 1984. 
[8] C. M. Shepherd, “Theoretical Design of Primary and Secondary Cells – Part III – Battery Discharge 
Equation”, U. S. Navy Research Laboratory Report 5908, .1963 
[9] L. M. Nicolai, “Fundamentals of Aircraft Design”, METS Inc., 1984. 
[10] D. P. Raymer, “Aircraft Design, A Conceptual Approach”, American Institute of Aeronautics and 
STO-MP-AVT-209 9 - 27 
UNCLASSIFIED 
Astronautics, AIAA, 2nd edition, 1992. 
[11] J. D. Anderson, “Aircraft Performance and Design”, McGraw-Hill, 1999. 
[12] “Jane's All the World's Aircraft 2004-2005”, Jane’s Information Group Ltd., 2004. 
[13] J. B. Heywood, “Internal Combustion Engines Fundamentals”, McGraw-Hill, 1988. 
[14] Pipistel Taurus technical data, http://www.pipistrel.si/plane/taurus-electro/technical-data, [retrieved 
12 October 2011]. 
[15] “Electric powered glider Lange Antares 20E”, http://www.lange-flugzeugbau.com/ [retrieved 27 
June 2010]. 
[16] “Solar powered airplane Solar Impulse”, http://www.solarimpulse.com/ [retrieved 27 June 2010]. 
[17] R. Eppler, M. Hepperle, “A procedure for Propeller Design by Inverse Methods”, proceedings of 
the “International Conference on Inverse Design Concepts in Engineering Sciences” (ICIDES), pp. 
445-460, Austin, October 17-18, 1984. 
[18] E. Obert, “Aerodynamic Design of Transport Aircraft”, IOS Press, 2009. 
[19] Nuvera Fuel Cells, http://www.nuvera.com/, [retrieved 1 November 2011].
UNCLASSIFIED 
Electric Flight – Potential and Limitations 
[20] Anonymous, “Hydrogen, new energy technologies”, Commissariat à l'Énergie Atomique et aux 
Énergies Alternatives, Clefs CEA n°50/51, 
http://www.cea.fr/var/cea/storage/static/gb/library/Clefs50/contents.htm, [retrieved 11 November 
2011]. 
[21] L. Chick, “Assessment of Solid Oxide Fuel Cell Power System for Greener Commercial Aircraft, 
Pacific Northwest National Laboratory, 
http://www.hydrogen.energy.gov/pdfs/review11/mt001_chick_2011_o.pdf, [retrieved 8 November 
2011]. 
[22] C. Svoboda, “Turbofan engine database as a preliminary design tool”, Aircraft Design, Volume 3, 
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UNCLASSIFIED 
2000, pp.17-31. 
[23] K. Hayashi, M. Yokoo, Y. Yoshida, H. Arai, “Solid Oxide Fuel Cell Stack with High Electrical 
Efficiency”, NTT Technical Review, NTT Energy and Environment Systems Laboratories, Japan, 
https://www.ntt-review.jp/archive/ntttechnical.php?contents=ntr200910sf3.pdfmode=show_pdf, 
[retrieved 11 November 2011]. 
[24] The Green Box Systems Group, “Combined Heat and Power Systems”, University of Strathclyde, 
Glasgow, http://www.esru.strath.ac.uk/EandE/Web_sites/99- 
00/bio_fuel_cells/groupproject/library/chp/text.htm, [retrieved 9 October 2012]. 
[25] Anonymous, „328 Turboprop Fact Sheet“, 328 Support Services GmbH, www.328support.de, 2006. 
[26] O. Tremblay1, L.-A. Dessaint, „Experimental Validation of a Battery Dynamic Model for EV 
Applications“, World Electric Vehicle Journal Vol. 3, 2009. 
[27] K. M. Abraham, „A Brief History of Non-aqueous Metal-Air Batteries“, ECS Transactions, 3 (42) 
67-71, The Electrochemical Society, 2008. 
[28] European Aviation Safety Agency, EASA Type-Certificate for Lange Flugzeugbau EA 42 series 
engines, E.015, 2006. 
[29] European Aviation Safety Agency, EASA Type-Certificate for Lange Flugzeugbau E1 Antares, 
TCDS No. A.092, 2006. 
[30] C. Chiang, C. Herwerth, M. Mirmirani, A. Ko, S. Matsuyama, S. B. Choi, N. Nomnawee, „Systems 
Integration of a Hybrid PEM Fuel Cell/Battery Powered Endurance UAV“, AIAA 2008-151, 46th 
AIAA Aerospace Sciences Meeting and Exhibit, 7 - 10 January 2008, Reno, 2008 
[31] K. A. Burke, „Fuel Cells for Space Science Applications“, AIAA-2003-5938, NASA TM-2003- 
212730, 2003. 
[32] I. Moysan, „Onboard Storage of Hydrogen“, CLEFS CEA, No 50/51, Winter 2004-2005, 2005. 
[33] H. W. Brandhorst, P. R. K. Chettyt, M. J. Doherty, G. L. Bennett, „Technologies for Spacecraft 
Electric Power Systems“, Journal of Propulsion and Power, Vol. 12, No. 5, 1996. 
[34] J. Schindler, W. Zittel, “Zukunft der weltweiten Erdölversorgung”, 2008, 
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[35] International Energy Agency, “World Energy Outlook 2006”, Paris, 2006
UNCLASSIFIED 
Electric Flight – Potential and Limitations 
8.0 APPENDIX – RESULTS FOR BASELINE AIRCRAFT “328 E” 
Aircraft: 
Name Do 328 E 
Wing span b = 20.98 m 
Wing area S = 40.00 m^2 
Aspect ratio AR = 11.00 
k-Factor k = 1.060 
L/D max L/D = 16.16 
v_EAS(L/D max) v = 79.8 m/s = 287.1 km/h 
v_stall v stall = 53.7 m/s = 193.5 km/h 
climb CD0 = 0.0321 
cruise CD0 = 0.0312 
descent CD0 = 0.0306 
passenger+crew load PAX = 32 @ 90.0 kg 
Mass total m = 15880.0 kg 
Mass empty me = 8500.0 kg 
Mass payload mp = 2880.0 kg (32 PAX) 
wing box volume Vw = 3260.1 liters 
empty weight fraction me/m = 0.535 
payload weight fraction mp/m = 0.181 
battery weight fraction mb/m = 0.283 
wing loading m/S = 397.00 kg/m^2 
span loading m/b^2 = 36.08 kg/m^2 
range factor (m/b^2)/(m/S) = 0.091 
ultimate range R ult = 347.4 km 
Range sensitivities for 51.5 kg/km, eta_total = 0.700: 
max. powered range R max = 143.0 km 
specific energy dR/dE* = 24.5 km/10% 
empty mass fraction dR/dfe = -40.0 km/10% 
lift over drag dR/d(L/D) = 24.5 km/10% 
passenger count dR/dPAX = -3.2 km/PAX 
payload distance E/(R*mp) = 119.5 - 138.0 Wh/km/PAX (range - endurance 
specific energy dE*/dfe = -29.4 Wh/kg/10% 
STO-MP-AVT-209 9 - 29 
UNCLASSIFIED 
Battery: 
Energy E = 793.80 kWh 
Mass mb = 4500.0 kg 
Volume V = 793.8 liters 
Voltage U = 1800.0 V 
Capacity C = 441.0 Ah 
C spec. E* = 180.0 Wh/kg 
Limit I I max = 2205.0 A (5*C/h) 
Limit P P max = 3969.0 kW (5*C/h) 
Climb Segment: 
prescribed climb angle theta = 7.5 degrees. 
Altitude H = 0.0 ... 3000.0 m 
Time t = 0.1 h 
Distance R = 22.8 km 
Speed avg v = 333.7 km/h (mean) 
Climb rate vz = 12.1 m/s (mean) 
Energy E = 296.26 kWh (from battery) 
Power, a/c P = 2798.55 kW (mean, for aircraft) 
Thrust, a/c T = 30189.1 N (mean, for aircraft) 
CL avg CL = 0.8 (mean) 
CD avg CD = 0.054 (mean) 
L/D avg L/D = 15.655 (mean) 
eta, prop avg eta = 74.88 % (mean) 
eta total avg eta t = 65.44 % (mean) 
Power, batt P = 4296.77 kW (mean, from battery) 
Voltage, batt U = 1812.3 V (mean) 
Current, batt I = 2389.9 A (mean)

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Electric flight – Potential and Limitations (2012)

  • 1. UNCLASSIFIED Electric Flight – Potential and Limitations Martin Hepperle German Aerospace Center Institute of Aerodynamics and Flow Technology Lilienthalplatz 7, D-38108 Braunschweig, Germany Martin.Hepperle@dlr.de ABSTRACT During the last years, the development of electric propulsion systems is pushed strongly, most notably for automotive applications. For ground based transportation, the system mass is relevant, but of relatively low importance. This paper addresses the application of electric propulsion systems in aeronautics, where all systems are much more constrained by their mass. After comparing different propulsion system architectures the focus is cast on the energy storage problem and here especially on battery storage systems. Using first order principles the limitations and required technology developments are demonstrated by introducing battery powered electric propulsion systems to small and medium sized aircraft. 9 - 1 STO-MP-AVT-209 UNCLASSIFIED Abbreviations and Symbols b = wing span [m] C = capacity [Wh] D = drag force [N] E* = mass specific energy content [Wh/kg] e f = empty mass fraction e m /m g = gravity acceleration [m/s2] L = lift force [N] m = mass [kg] initial m = initial mass at takeoff [kg] e m = empty mass without fuel and payload [kg] final m = final mass at landing [kg] battery m = battery mass [kg] payload m = payload mass [kg] pax m = mass per passenger [kg] PAX = number of passengers P = power [W] battery P = electric power provided by battery [W] R = range [m] t = time [s] T = thrust [N] V* = volume specific energy content [Wh/m3] v¥ = flight speed [m/s] h = efficiency ¥ r = density of air [kg/m3]
  • 2. UNCLASSIFIED 1.0 INTRODUCTION Stimulated by the progress in technology developments in the entertainment, toy and car industries, the interest in electric propulsion systems for aircraft has grown considerably during the last years. According to many scientific and general publications the storage of electric energy in battery systems promises a clean new world with fantastic new opportunities. This paper highlights the differences between conventional aircraft propulsion systems, burning fossil fuel and aircraft propelled by electric motors. It tries to show the potential but also the limitations of electric propulsion technology for aircraft. This paper contains assumptions about specific weights, energy densities and efficiencies which are sometimes subject to large uncertainties. Therefore all results must be considered with care but the author believes that the main trends and relations are well represented. The numerical data should not be used to derive final conclusions about the performance of any specific product which is mentioned in this paper. 2.0 MOTIVATION There are several reasons to study alternative propulsion systems and especially electric systems. The observed growth of air transport is clearly visible despite any temporary drawbacks (Figure 1). This growth leads to increased fuel burn and a stronger impact of aviation on the environment. The aviation industry (manufacturers as well as operators) are currently introducing new technologies and operating schemes to achieving a strong reduction in fuel consumption per flight in the order of 15-20%. However it will take many years until all aircraft are replaced with new generation vehicles and on the other hand the growth of air traffic will to lead to increasing overall fuel consumption and hence emissions from air traffic. Besides the problem of emissions and pollution the amount of oil is limited (Figure 2). Even if it is not clear when the oil resources will be depleted, the price of oil has been steadily climbing for many years following a rather unsteady but clearly visible trend. Attractive features of electric propulsion systems are that they benefit from better efficiency in the energy conversion chain and that they can be considered as locally zero-emission – albeit depending on how the electric energy is produced. However, introducing electric propulsion systems into ground transportation seems to be relatively simple compared to the implementation in aviation. While ground based vehicles can easier cope with additional mass due to not fully developed electric storage and propulsion systems, aircraft are much more sensible to mass. Furthermore typical trip distances as flown by aircraft are much larger that trips in ground vehicles (cars, buses, trains) and safety standards in aviation are extremely high. Finally one must acknowledge the fact that current aircraft are already very efficient in terms of fuel burn per payload and distance. All these facts make it no easy task to develop electric propulsion system concepts for aviation, but it is of strong interest and necessary to determine the physical limitations of using electric energy for aircraft propulsion and to work out the requirements and guidelines for future development. 9 - 2 STO-MP-AVT-209 UNCLASSIFIED
  • 3. UNCLASSIFIED Electric Flight – Potential and Limitations Figure 1 Expected growth of air traffic according to Airbus [1]. 120 100 80 60 40 Middle East 120 100 80 60 40 1940 1950 1960 1970 1980 1990 2000 2010 2020 2030 STO-MP-AVT-209 9 - 3 UNCLASSIFIED Oil Production [Mbarrel/day] 20 Middle East Africa Latin America South Asia East Asia China Transition Economies OECD Pacific OECD Europe OECD North America Demand [35] OECD Europe OECD North America Africa Latin America Transition Economies 20 Year Figure 2 Daily oil production versus time. Extrapolation of oil required by the world [34].
  • 4. UNCLASSIFIED Electric Flight – Potential and Limitations 3.0 THERE IS NOTHING NEW UNDER THE SUN Electric flight is no new technology. Due to the sensitivity of aircraft to their mass, it was not really feasible for many years. Here only one of the many ancestral lines of electric flight shall be mentioned because it shows a remarkably long development path. Already in 1940 Fred Militky toyed with electric motors to propel model aircraft, but due to heavy brushed motors and lead batteries he was unsuccessful to obtain good results. Nevertheless he followed his idea until he finally was able to introduce a small model airplane into the hobby market in 1960. This free flight model was using a highly efficient electric motor and still small lead batteries. Later in 1972, when Ni-Cd batteries with higher power densities became available he developed the first radio-controlled model which was commercially produced. Finally using the same Ni-Cd batteries he helped to prepare the first electric flight of a manned aircraft. This aircraft was the modified motor-glider MB-E1 which was finally flown in October 1973 by pilot H. Brditschka in Austria. The technology available in these years allowed only for short flights of up to 15 minutes but nevertheless showed the feasibility of electric propulsion for man carrying aircraft. Lack of better battery systems prevented further development. It should be noted that in contrast to some pioneering ultra-light experimental demonstrator aircraft the MB-E1 was a variant of the fully certified airframe HB-3 with minor modifications to carry batteries and electric motor. Figure 3 Development steps as performed by Fred Militky leading to man-carrying electric aircraft. 3.1.CONVENTIONAL PROPULSION SYSTEMS Today’s propulsion systems are storing energy in liquid form. This fuel is usually based on oil and is thermally decomposed, i.e. burnt. Technically, with small modifications, these systems are also capable of also using gaseous fuels like hydrogen or natural gas. The fuel is burnt in either piston engines or in gas turbines to produce mechanical power. These machines are connected to a shaft which is linked to an aerodynamic propulsion device, either a propeller (piston-propeller or turbo-propeller) or a fan (turbo-fan). All systems accelerate an incoming mass flow of air to produce thrust. An additional part of the thrust may be created by recovering part of the thermodynamic energy in the exhaust, i.e. by passing the hot gasses through suitable nozzles. In case of propulsion by propellers it is often necessary to use a gearbox to adapt the performance characteristics of the core engine to the characteristics of the propulsion device so that the overall efficiency is maximized. Gearboxes are now also introduced to decouple the fan from the turbine of turbofan engines, thus increasing their total efficiency considerably. A notable feature of these propulsion systems is that they burn the fuel and the exhaust is emitted into the atmosphere. Besides affecting the environment, this also reduces the mass of the airplane during the flight and therefore affects the performance. 9 - 4 STO-MP-AVT-209 UNCLASSIFIED
  • 5. UNCLASSIFIED Electric Flight – Potential and Limitations Propeller STO-MP-AVT-209 9 - 5 UNCLASSIFIED Kerosene Bio Fuel liquid fuel Turboshaft Piston Engine Gearbox H2 H gas 2 Turbine H2 H gas 2 Turboshaft Piston Engine Gearbox Fan Propeller Kerosene Bio Fuel liquid fuel Turbine Fan Kerosene Bio Fuel liquid fuel Turbine Fan Gearbox Figure 4 Different propulsion systems exploiting the energy in the fuel by burning it. 3.2.ELECTRIC PROPULSION SYSTEMS In case of electric propulsion systems there are a large number of possible concepts. They differ in energy storage and conversion. Today mainly two systems are of interest: battery based systems and fuel cell based systems. Both systems are under constant development, driven by automotive and other mobile applications. Most of these developments are currently aiming at power consumptions below 100 kW. 3.2.1 Fuel Cell Systems These systems store energy in liquid or gaseous form and convert it to electric power by fuel cells. These perform a more or less cold decomposition of the fuel with relatively high efficiency and low emissions. Fuel cell systems have been built for many years for specific applications and a range of power requirements. Still these systems are quite complex and heavy. When the by-products are exhausted to the atmosphere, they lead to a mass reduction during flight like on classical combustion engines. When hydrogen is used for fuel, the emissions contain more water vapor then the emissions of kerosene based fuels and may create more severe contrails in the atmosphere.
  • 6. UNCLASSIFIED Electric Flight – Potential and Limitations 3.2.2 Turbo-Electric Systems In [3] one of the main motivations to used turbo-electric drive systems is given by the fact that such a system allows to decouple turbine speed and fan speed and thus may be the enabler for distributed multi-fan propulsion systems. The first argument is weakened by recent developments of highly efficient geared turbofan engines (decoupling turbine and fan allows to increase the overall efficiency by 10-20%). However the second argument still holds some opportunities for the development of distributed propulsion systems to improve the propulsive efficiency. These systems can either be driven by conventional fuel or by hydrogen, which still leads to high emission levels and contrail formation. 3.2.3 Battery Systems Here the energy is stored in batteries which allows for a direct extraction of electric power. The efficiency is limited by the chemical processes occurring during charging and discharging. In most cases the mass of the system is usually not changing, except for some specific air breathing cells like Li-O2. Figure 5 Components of different electric propulsion systems. 9 - 6 STO-MP-AVT-209 UNCLASSIFIED
  • 7. UNCLASSIFIED Electric Flight – Potential and Limitations 3.2.4 Energy Storage The energy required for a flight must be stored on-board. For application in aircraft the most important parameters are the energy per mass E* and to a lesser extent the energy per volume V* . These specific values are shown in Figure 6 for various energy storage systems. It can be seen that even the most advanced current battery storage systems fall short of the parameters of Kerosene. While the factor in specific volume is only about 18, the factor in mass specific energy density is in the order of 60. This is a core problem for application in aviation and imposes strict limits for battery powered systems. The lower volume specific energy content is less critical as long as the aircraft design is not limited by internal volume. Otherwise the vehicle would require larger wings or fuselages or additional external “energy pods” which would lead to losses in overall aircraft efficiency due to larger wetted surface. Of course there are ideas to incorporate batteries and other storage systems into the primary structure, but these are still rather far from practical application. In case of fuel cells hydrogen can e.g. be stored in porous metal, but the weight of these foams is very high and appears unsuitable for aeronautical application. However, such systems have been used in marine applications, where the additional mass is less critical. Table 1 lists some characteristics, advantages and disadvantages of energy storage systems. As a side-note it is interesting to note that some “bio-fuels”, like milk or cream have rather high energy densities – unfortunately efficient high power conversion technology is still lacking. 10000 1000 100 10 LiOH Battery Methanol TNT Kerosene LPG Propane STO-MP-AVT-209 9 - 7 UNCLASSIFIED 1 1 10 100 1000 10000 100000 mass specifc energy E* [Wh/kg] NiCd-Battery Pb-Battery 300 bar compressed air volume specifc energy V* [Wh/liter] NiMH Battery HO2 2 Ethanol H liquid 2 H 1 bar 2 factor 60 factor 18 H 700 bar 2 LiOH Nano-Wire Battery 3.5% Milk Cream Flywheels Figure 6 Volume and mass specific energy characteristics of different energy storage systems.
  • 8. UNCLASSIFIED Electric Flight – Potential and Limitations Kerosene, AVGAS Can be stored in wing and fuselage tanks. These are often part of the structure and therefore of low mass. Hydrogen (gas) Requires high pressure tanks (typically 350 to 700 bars). Tanks are much heavier than the actual fuel and are also a safety risk. If the pressure is reduced, tanks of large volume are required, which affect weight and drag and therefore aircraft performance. Could partially be stored in metallic structures, but practical application in aeronautics is rather limited so far. Hydrogen (liquid) Requires cryogenic tanks with insulation to keep the fuel at about -250°C. Tanks are heavy and also require considerable volume with the drawbacks similar to gaseous hydrogen. Battery Requires casings with temperature control systems. Fuel Cell Requires liquid or gaseous fuel with all the aspects mentioned above. Additional infrastructure like air pumps, water supply or reformer devices is necessary. Table 1 Characteristics of energy storage systems. 3.2.5 Efficiency Chains The conversion of energy stored on-board to propulsive power involves several conversion steps. Each of them is affected by losses, which are expressed by individual efficiencies. For the comparison of different systems, the on-board conversion chain must be considered. For a complete picture one could extend this view to the complete energy chain e.g. from “well-to-wheel” in case of fossil fuel, but such an analysis is beyond the scope of this paper and very difficult. Figure 7 shows four typical conversion chains: 9 - 8 STO-MP-AVT-209 UNCLASSIFIED • a conventional turboprop • a conventional turbofan, • a battery powered system, and • a fuel cell powered system. Typical values for the efficiency of the individual components have been assumed1. It is clearly visible that all electric systems exhibit high overall system efficiency. Especially battery systems which avoid the conversion of fuel to electricity in the airplane offer the highest efficiency of more than 70%, compared with the efficiency of the classical combustion systems reaching efficiencies of up to 40%. Of course these on-board chains do not contain the generation of electricity on the ground nor do they include the generation and distribution of fuel or electricity. For example the charging and discharging cycle of chemical batteries causes energy losses in the order of 15-20%. Nevertheless in terms of efficient usage of on-board energy the battery systems are very attractive. The important aspect of the system mass is examined in the next section. 1 When looking up these efficiency values one has to be careful, as in some cases (e.g. fuel cells) efficiencies may include the exploitation of thermal power which may not be of interest. For a more refined picture one must consider how to exploit these additional capabilities e.g. for air conditioning purposes or thermal thrust generation. Also note that the latest turbofan engines claim to achieve thermal efficiencies of almost 60%, which would raise the chain efficiencies for turboprop and turbofan to 47% resp. 39%, bringing them closer to the value of the fuel cell chain.
  • 9. UNCLASSIFIED Electric Flight – Potential and Limitations Turbofan Kerosene 100% Thermodynamic Cycle Turboprop Kerosene 100% Propeller η=80% Battery Battery 100% Gearbox η=98% Fuel Cell Hydrogen 100% Fuel Cell η=60% Gearbox η=98% STO-MP-AVT-209 9 - 9 UNCLASSIFIED η=50% Fan and Nozzles η=65% 33% Thermodynamic Cycle η=50% Gearbox η=98% 39% Controller η=98% Electric Motor η=95% Propeller η=80% 73% Controller η=98% Electric Motor η=95% Propeller η=80% 44% Figure 7 Typical on-board conversion chains with typical component efficiencies and total chain efficiency. 3.2.6 Equivalent Energy Density of Electric Power Sources In order to compare different electric power sources with a battery system it is necessary to transform their parameters into an equivalent mass specific energy E* of the complete system. First, we compare the systems as electric power sources, i.e. the chain up to the electric connector where the motor controller would be plugged in. Figure 8 relates the stored energy to the mass of the electric power source. The example assumes identical flight performance of a general aviation airplane requiring a propulsive power of 50 kW for fast cruise. The required energy is determined from the respective efficiency chains so that 100 kWh are finally available for the mission. As the airplane has not been adapted to the mass of the propulsion system, this is yields an optimistic view for the heavier systems. The mass given below the fuel tanks are for the fuel and the additional mass of the tank with its fuel systems. It can be seen that a high pressure tank for hydrogen outweighs the fuel mass almost by a factor of 20. In Figure 9 we can add the motor controller and the electric motor so that the chain extends up to the propeller shaft. This allows comparing the chain with an internal combustion engine. The results show that the classical internal combustion engine offers the lowest mass and hence an effective specific energy of almost 1600 Wh/kg, which is about 14% of the specific energy content of the raw kerosene fuel. This propulsion system is followed by the hybrid electric system which adds a generator and an electric motor to the drive train.
  • 10. UNCLASSIFIED Electric Flight – Potential and Limitations 2 Battery E* = 180 Wh/kg Hydrogen Fuel Cell 50 kW E* = 701 Wh/kg (Kerosene: 211 800 Wh/kg) 2 9 - 10 STO-MP-AVT-209 UNCLASSIFIED Hydrogen Fuel Cell FC =55% (50 kg) H2 gas Reformer =75% (33.3 kg) liquid fuel Kerosene (20.5 kg + 12 kg) Battery (556 kg) 50 kW 0 100 200 300 400 500 600 m [kg] H2 gas FC =55% (50 kg) H (5.5 kg + 95.5 kg) E* = 862 Wh/kg (Kerosene: 211 800 Wh/kg) Kerosene Reformer Fuel Cell 700 bar 50 kW E* = 662 Wh/kg (H : 33 306 Wh/kg) 2 50 kW E* = 1105 Wh/kg (Kerosene: 211 800 Wh/kg) Kerosene I/C engine Generator Generator =95% (25 kg) shaft I/C engine =35% (25 kg) liquid fuel Kerosene (25.5 kg + 15 kg) Fuel Cell Reformer Tank Fuel I/C engine Generator Figure 8 Mass and equivalent energy density of electric power generation systems delivering an electric power of 50 kW for 2 hours. Battery E* = 172 Wh/kg 0 100 200 300 400 500 600 m [kg] Kerosene Reformer Fuel Cell 700 bar 50 kW E* = 551 Wh/kg (H : 33 306 Wh/kg) 2 E* = 850 Wh/kg (Kerosene: 211 800 Wh/kg) Kerosene I/C engine Generator Hybrid 50 kW Fuel Cell Reformer Tank Fuel/Battery I/C engine Generator Electric Motor E* = 1575 Wh/kg (Kerosene: 211 800 Wh/kg) Kerosene I/C engine shaft I/C engine =35% (25 kg) liquid fuel Kerosene (25.5 kg + 15 kg) Motor =95% (25 kg) Generator =95% (25 kg) shaft I/C engine =35% (25 kg) liquid fuel Kerosene (25.5 kg + 15 kg) shaft Motor =95% (25 kg) Battery (556 kg) shaft Motor =95% (25 kg) H2 gas FC =55% (50 kg) H (5.5 kg + 95.5 kg) shaft Motor =95% (25 kg) FC =55% (50 kg) H2 gas Reformer =75% (33.3 kg) liquid fuel Kerosene (20.5 kg + 12 kg) shaft Figure 9 Mass and equivalent energy density of propulsion systems providing a shaft power of 50 kW for 2 hours.
  • 11. UNCLASSIFIED Electric Flight – Potential and Limitations 3.2.7 Battery Technology Today, most electric powered aircraft are using battery systems of the Lithium-Ion type. These are mass produced mainly as power sources for mobile devices and are readily available. Such batteries can be produced relatively cheap and can be scaled to build larger systems of several hundred kWh energy capacity. Currently available systems provide a mass specific energy content of up to 200 Wh/kg (see Figure 10). Further developments may lead to values in the order of 250 Wh/kg, which is insufficient for automotive and larger aerial applications. Today, the development of other Lithium based battery systems is pushed forward. Lithium-Sulfur and Lithium-Oxygen are two systems on which research and development are focused. While sulfur-based systems have reached practical prototype status (after more than 50 years of development), oxygen based systems are still in their infancy. All these systems offer energy densities which are larger by a factor of about 3 to 10. A very complete survey of Lithium based battery technology is given in [3]. Table 2 contains values taken from this publication and shows the expected development of these systems. Concerning the possible application of the air breathing, oxygen based battery systems in aviation many questions are still open and cannot be expected to be answered within the next 10 years. Therefore it seems to be more realistic to expect the application of sulfur based systems within the next 20 years in mobile applications as well as in unmanned and possibly manned air vehicles. Figure 10 Specific energy density of current Lithium Ion battery systems. System theoretical specific energy expected in 2025 Li-Ion (2012) 390 Wh/kg 250 Wh/kg Zn-air 1090 Wh/kg 400-500 Wh/kg Li-S 2570 Wh/kg 500-1250 Wh/kg Li-O2 3500 Wh/kg 800-1750 Wh/kg Table 2 Specific energy density of current and future chemical battery systems. STO-MP-AVT-209 9 - 11 UNCLASSIFIED
  • 12. UNCLASSIFIED Electric Flight – Potential and Limitations today and within next 5 years expected within next 10-20 years theorectically possible 0 500 1000 1500 2000 2500 3000 3500 4000 Li-Ion (1/2C Li + Li CoO 3C + LiCoO ) 6 0.5 2 2 Zn-air (Zn + 1/2O ZnO) 2 Li-S (2Li + S Li S) 2 Li-O (non aqueuous) 2 (2Li + O Li O ) 2 2 2 Li-O (aqueuous) 2 (2Li + 1/2O + H O 2 LiOH) 2 2 14 12 10 8 6 4 2 electric motors piston engines Honda FCX e-Genius Antares Tesla NASA (AIAA-2010-276) GE-90 Turbofan 9 - 12 STO-MP-AVT-209 UNCLASSIFIED specific energy [Wh / kg] Figure 11 Current battery technology and expected development. 3.2.8 Electric Motor Technology Electric motors for application in aviation must be designed for continuous operation at cruise power. Motors for hybrid automotive applications or for model aircraft are often designed for short power boost applications so that one must be careful when comparing data. Figure 12 plots the power specific mass of various piston engines and electric motors. The few electric motors available today for aircraft propulsion have a power output of less than 100 kW. Large electric motors are also used in trains, ships and submarines, but here the mass is less important. Today it seems to be possible to build electric motors having a specific mass of about 2 to 4 kW/kg. This compares favorably with the specific mass of larger turboshaft and turbofan engines at cruise power (see Figure 13 and Figure 14). Future developments may extend the range of electric motors to values of up to 8 kW/kg, but there is a strong need for the development of lightweight electric motors, specifically designed for application in aircraft. In the literature assumptions of up to 14 (e.g. in [5]) can be found, but assume superconducting motors with cryogenic cooling systems. 0 1 10 100 1000 10000 100000 P [kW] P/m [kW/kg] BMW V10 F1 GE Marine Turboshaft turbine engines Figure 12 Specific power density of current piston engines (squares) and electric motors (circles).
  • 13. UNCLASSIFIED Electric Flight – Potential and Limitations Figure 13 Specific power density of turboshaft engines. Figure 14 Specific power density of turbofan engines, derived from cruise thrust. STO-MP-AVT-209 9 - 13 UNCLASSIFIED
  • 14. UNCLASSIFIED Electric Flight – Potential and Limitations 4.0 RANGE EQUATIONS The range of an aircraft depends on the available energy, the propulsion system, the mass of the aircraft and the aerodynamic properties of the aircraft. The range equations for classical, fuel burning aircraft with variable mass are well known and have been derived for various cruise flight conditions. In case of battery powered electric aircraft the mass of the aircraft stays constant and hence the range equation is simplified. The range of an aircraft is defined by flight speed and flight time R v t ¥ = ⋅. (1) In case of a battery powered aircraft, the flight time is equal to the time to drain the battery, which, under ideal conditions, is * m E battery battery m E ⋅ = ⋅ = ⋅ . (5) ⋅ = ⋅ m E = ⋅h ⋅ ⋅ ⋅ . (8) 9 - 14 STO-MP-AVT-209 UNCLASSIFIED t P ⋅ = . (2) Inserting this flight time into the definition of the range (1) yields * battery battery R v ¥ P ⋅ = ⋅ . (3) The power drawn from the battery is related to the propulsive power required by the aircraft aircraft battery total P P = h (4) where the power required by the aircraft is linked to its weight, lift over drag ratio and flight speed: aircraft aircraft m g P D v v ¥ L / D ¥ With (5), the battery power (4) finally becomes battery total m g P v L /D ⋅ h ¥ (6) and can be inserted into equation (3) * battery total R v m g v L /D ¥ ¥ ⋅ = ⋅ ⋅ ⋅ ⋅ h . (7) This equation can be simplified to the range equation for battery electric flight * battery total 1 L m R E g D m Interestingly the range is independent of the flight speed v¥ which is only indirectly affecting the result via lift to drag ratio and the total efficiency total h . This equation clearly shows that for maximum range the following parameters should be maximized:
  • 15. UNCLASSIFIED Electric Flight – Potential and Limitations • the ratio of battery mass to total mass battery m /m, • the specific energy capacity E* of the battery, • the lift over drag ratio L/D, and • the total system efficiency total h (from battery to propulsive power). 3000 2500 2000 1500 1000 500 total = 0.75, R for powered level flight R [km] 6000 5000 4000 3000 2000 1000 12000 10000 8000 6000 4000 2000 ö÷= ⋅ h ⋅ 1 æç ⋅ L ⋅ çç 1 ÷÷÷÷ çè - ø STO-MP-AVT-209 9 - 15 UNCLASSIFIED On the other hand • the aircraft mass m should be minimized. 0 100 200 300 400 500 600 700 800 900 1000 E* [Wh/kg] 0 10 L/D 0 40 20 m /m=1.0 battery m /m=0.8 battery m /m=0.6 battery m /m=0.4 battery m /m=0.2 battery battery * total m L 1 R E m D g Status 2012 Figure 15 Range versus specific energy for different battery mass fractions. The vertical axes are for three different ratios of lift over drag, ranging from small General Aviation aircraft to sailplanes. The range obtained from this equation is plotted in Figure 15 versus the specific energy of the battery system E* . The shaded triangle indicates the range of technically feasible battery mass fractions. It can be seen that for larger ranges the battery technology must be improved to at least five-fold values compared to the state in 2012. Comparing the range equation for battery powered aircraft with one form of the classical range equation for kerosene burning jet engines * total fuel R E ln g D 1 m /m . (9) shows that the two equations only differ in the last term. Figure 16 compares this term for aircraft having different fuel mass fractions respectively ranges. It can be seen that the drawback of maintaining constant mass increases with range and may grow to more than 20% for long range flights. This drawback is inherent in battery powered aircraft and must be compensated by additional energy respectively efficiency.
  • 16. UNCLASSIFIED Electric Flight – Potential and Limitations 0.7 0.6 0.5 0.4 0.3 0.2 0.1 ln(1/(1-m /m)) f m/m f 23% low Boeing 747 SP Cessna 182
  • 17. 6% low æç ö÷= ⋅ h ⋅ ⋅ ⋅ çç - - ÷÷÷ ç ÷÷ çè çè ö÷= 1 L æç m ⋅ ⋅ h ⋅ ⋅ çç - ÷÷÷ ç ÷÷ R E 1 ⋅ PAX m 9 - 16 STO-MP-AVT-209 UNCLASSIFIED 0 0 0.05 0.1 0.15 0.2 0.25 0.3 0.35 0.4 0.45 0.5 m/m f * battery total 1 L m R E g D m * total fuel 1 L 1 R E ln m g D 1 m ln(1/(1-m /m))f m/m f Figure 16 Range terms versus fuel respectively battery mass fraction. 4.1.MAXIMUM RANGE To gain more insight into typical aircraft design parameters we replace the battery mass battery empty payload m = m-m -m (10) to obtain * empty payload total 1 L m m R E 1 g D m m ø . (11) Reducing the payload mass to zero allows finding the ultimate range * empty ultimate total g D m ø . (12) For the given technology parameters, this range can never be exceeded. Also note that for this hypothetical range the aircraft mass would grow to infinity. Therefore the practical range must be lower that this hard limit. Equation (11) can be solved for the airplane mass which is required for a desired range and payload using a given technology level in structures, aerodynamics and propulsion system: payload e * total m g 1 f R E L/ D = - - ⋅ ⋅ h ⋅ . (13)
  • 18. UNCLASSIFIED Electric Flight – Potential and Limitations Equation (13) can be used for a very quick first order assessment of the required size of an airplane, using only a few basic technology parameters. The structural design of the aircraft is represented by the empty mass fraction fe = mempty /m; for a given structural technology and typical design parameters, like aspect ratio and wing thickness, one can assume a certain value for e f (which is typically between 0.4 and 0.7, see Figure 17). Of course, this ratio should be as low as possible to obtain the lowest aircraft mass. The aerodynamics is represented by the lift over drag ratio, which should as large as possible to minimize the mass. In order to obtain a valid solution of (13) with a finite and positive aircraft mass the following conditions must be fulfilled: The lift over drag ratio must be at least ⋅ L Rg D 1 f E ( ) * e total ⋅ R g ⋅ R g 1 0.8 0.6 0.4 0.2 light airplanes Airbus Boeing STO-MP-AVT-209 9 - 17 UNCLASSIFIED - ⋅ ⋅h , (14) the specific energy of the battery must be larger than ( ) * e total E 1 f L/D - ⋅h ⋅ , (15) and the empty mass fraction of the aircraft must be lower than e * total f 1 E L/ D - ⋅ h ⋅ . (16) These limits are independent of the payload and can be used to define the required technology level in each discipline or to judge the feasibility of a proposed concept. If a design does not fulfill these constraints, it is unfeasible with the given the technology. 0 1000 10000 100000 1000000 takeoff mass [kg] empty mass / takeoff mass propeller turbofan approximation Figure 17 Empty mass fraction of aircraft versus take-off mass.
  • 19. UNCLASSIFIED Electric Flight – Potential and Limitations A more realistic range limit can be found by monitoring the mass growth per range increase. Differentiating (13) with respect to the range yields the mass growth per distance for a design for a given range ¶ ⋅ ⋅ m PAX m g pax R 2 g R 1 f E L/D E L/ D ⋅ L 1 PAX m 1 L * pax * = ⋅h ⋅ ⋅ ⋅ - - ⋅ ⋅ ⋅h ⋅ R E 1 f E max total e * total D g m g D çæ¶ ÷öçç ÷÷çè¶ ÷ø çæ¶ ÷ö é ù ç ÷÷ = ⋅ ê ú ççè¶ ÷ø ê ú ë û 9 - 18 STO-MP-AVT-209 UNCLASSIFIED * e * total total = ¶ æ ⋅ ö÷ çç - - ÷÷ ⋅ ⋅ h ⋅ çç ⋅ h ⋅ ÷÷ è ø , (17) where the payload mass has been replaced by payload pax m = PAX ⋅m . If we limit the mass growth per distance to a certain limit value ( )* ¶m/¶R , we can solve (17) for the limit range max R ( ) ultimate R R  . (18) The first term in this equation equals equation (12), the second term corresponds to the range reduction imposed by the mass growth limit. A more complete analysis of existing and prospective electric aircraft showed that the acceptable mass growth depends on aircraft mass: for heavier aircraft a higher limit can be accepted. Based on the numerical results, the following empirical relation has been developed: * m 1 1.27 kg m R 4200 km . (19) For lightweight single seat aircraft (m = 1000 kg) this equation yields limit values in the order of 1 kg/km, while the limit for heavy regional aircraft (m = 15 tons) reaches values of 50 kg/km. Numerical values for a hypothetical 30 seat regional aircraft are shown in Figure 18. The realistic range limit is indicated by symbols. Two ways of exploiting an increase of the specific energy E* from 200 to 400 Wh/kg are shown. First one can maintain the aircraft mass and move horizontally to double the range from 325 to 650 km. At this point (hollow symbol) the mass growth limit is not yet reached so that the practical range can be extended further to about 820 km. Alternatively one could move vertically down, maintaining the range but reducing the aircraft mass from about 14 tons to 8.5 tons.
  • 20. UNCLASSIFIED Electric Flight – Potential and Limitations Figure 18 Total mass and battery mass for two values of the specific energy E* versus range. The solid sym-bols indicate the range limit imposed by a prescribed mass growth gradient dm/dR. 4.2.RANGE SENSITIVITIES Equation 11 shows that in order to achieve maximum range for a given aircraft mass one should of course minimize the empty mass fraction fe = mempty /m as well as the payload mass fraction p payload f = m /m so that the battery mass is maximized. At the same time one should also maximize the lift over drag ratio L/D. The sensitivities of equation 11 with respect to the mass parameters e f and p f R R 1 L * total f f g D e p E R 1 L 1 = - ⋅ E ⋅ h ⋅ ⋅ m ⋅ ¶ R 1 = 1 - f - f ⋅ ⋅ E ⋅h ¶ R 1 ¶ = - - ⋅ ⋅h ⋅ STO-MP-AVT-209 9 - 19 UNCLASSIFIED ¶ ¶ = =- ⋅ ⋅h ⋅ ¶ ¶ . (20) show that a change in empty weight or payload weight fraction is more critical when the ratio L/D and the system efficiency total h are high. The sensitivity with respect to the total mass * total battery 2 m g D m ¶ (21) shows a strong dependency on the inverse of the mass. A lightweight aircraft is more sensible to a change in mass than a heavy aircraft. The impact of the lift to drag ratio can be assessed from ( ) * e p total L/D g ¶ , (22) which demonstrates that a lightweight aircraft is more sensitive to changes in L/D. Concerning the effect of the battery technology, the derivative is similar: ( ) * e p total 1 f f L/D E g ¶ . (23)
  • 21. UNCLASSIFIED Electric Flight – Potential and Limitations These sensitivities can be used to assess the robustness of a design with respect to changes in operating parameters. A numerical example is shown in Table 3 to demonstrate these sensitivities. The right hand side of the table shows the effect on range of increasing a parameter by 10% respectively of increasing the number of passengers by one. Additionally, derived sensitivities can be used to “trade” one discipline for another discipline; for example the derivative * ¶E / ¶fe shows that an increase of 10% of the empty mass fraction ( e Df = 0.053) is has the same impact on range as a decrease of the specific energy of the battery system by DE* = -31.9 Wh/kg. assumptions results E* 200 Wh/kg max R 173.1 km L / D 16.35 - ¶R / ¶E* ⋅10%⋅E* 28.2 km e f 0.53 - e e ¶R / ¶f ⋅10%⋅ f -44.9 km total h 0.7 - ¶R / ¶L / D⋅10%⋅ L / D 28.2 km PAX 32 - ¶R / ¶PAX -3.4 km pax m 90 kg derived sensitivity ( )* e e ¶E / ¶f ⋅10%⋅ f -31.9 Wh/kg ¶m / ¶R 52 kg/km * Table 3 Set of parameters (left) for an electric powered aircraft and its range sensitivities (right). Note that the assumed L/D ratio is lower than in Figure 18, therefore the range is lower. 9 - 20 STO-MP-AVT-209 UNCLASSIFIED
  • 22. UNCLASSIFIED Electric Flight – Potential and Limitations 5.0 ELECTRIC PROPULSION FOR REGIONAL AIRCRAFT In order to assess the potential of an electric propulsion system in larger aircraft a more complete mission simulation tool was developed. Here the mission consists of a climb, a cruise and a descent segment. For each segment the aircraft is flown at minimum energy consumption. The simulation performs the time integration over the three segments for a given aircraft and propulsion system model. climb z Range 20 15 10 5 energy required by aircraft STO-MP-AVT-209 9 - 21 UNCLASSIFIED cruise descent x time no reserves! Figure 19 Simplified mission profile. 5.1.CLIMB SEGMENT This segment is defined by either climb angle or climb rate. The simulation then determines the optimum flight speed for each altitude so that the energy drawn from the battery per altitude battery dE / dz is minimized. It is important to include the efficiency of the propulsion system to avoid the trivial solution of a vertical climb which provides minimum energy consumption of the airframe alone (Figure 20). 0 0 20 40 60 80 100 dE/dz [Wh/m] [°] energy drawn from battery min min 90 Figure 20 Energy consumed per altitude for the aircraft and for the aircraft with propulsion system chain. The trivial optimum for the airframe would be to climb vertically and as slow as possible to minimize total drag. Including the efficiency of the propulsion system yields a realistic minimum.
  • 23. UNCLASSIFIED Electric Flight – Potential and Limitations 5.2.CRUISE SEGMENT During cruise, the optimum flight speed is determined so that dE / dx is minimized. Again, the efficiency of the propulsion system chain including the propeller is taken into account, so that the optimum speed is not identical to the optimum of the aircraft alone. 5.3.DESCENT SEGMENT The descent segment is flown with a given descent angle, which is steeper than the maximum of lift over drag ratio of the airframe to minimize the energy consumption. During this flight phase only auxiliary power for the aircraft systems has to be provided by the battery. No recuperation is considered here due to the high drag and low efficiency of the windmilling propellers, which would allow to recover about 5% of the total energy (in case of a 500 km flight of a regional aircraft at H = 3000 m the potential energy m⋅ g ⋅H is about 20% of the total energy consumed during the flight). 5.4.APPLICATION Applying this simulation model to a specific aircraft allows determining the possible performance and the technology improvements required to achieve the desired results. As a test case a regional aircraft similar to the Dornier Do 328 turboprop aircraft was modeled. Step by step several modifications were performed to optimize the aircraft for the electric propulsion system. The range of the original aircraft with 32 passengers is about 1200 km. With a reduced payload of 28 passengers the maximum range is approximately 2200 km, while the lift-to-drag ratio is around 16. The first modification consists of simply replacing the conventional fuel system and the turboprop engines with a battery electric system having the same mass. Using current (2012) technology this aircraft would reach a range of 202 km. The flight time would be about 40 minutes. Cruise speed would be about 300 km/h. If an additional reserve of 30 minutes for holding at the destination airport would have to be considered, the practical range would drop to 50 km. Figure 21 Modified baseline aircraft with drop-in electric propulsion system. 9 - 22 STO-MP-AVT-209 UNCLASSIFIED
  • 24. UNCLASSIFIED Electric Flight – Potential and Limitations The next step tries to improve the aerodynamic performance by reducing the zero lift drag coefficient by 20%. This could be achieved by optimizing the installation of the propulsion system (smaller nacelles or fully integrated motors, less cooling air flow) as well as many other detail improvements. Part of these improvements could be achieved by introducing laminar flow on the wing and on the tailplanes. This is feasible as the wing is unswept and may be produced in composite material with the required smoothness. Due to the lower drag, the optimum cruise speed would increase to 330 km/h. However, as the zero lift drag is only about half the total drag, this modification would increase the range by only 10% to 221 km. Figure 22 Modified aircraft with reduced zero lift drag. Next the induced drag is reduced through an increase in wing span of 50% without increasing the wing mass and the wing area. The new wing span is now 31.5 m compared to the initial 21.0 m. This change would require substantial changes to the structure, possibly the introduction of a strut braced wing concept (while maintaining zero lift drag) and an optimized composite structure. This modification would increase the range by about 40% to 302 km. The higher aspect ratio would move the energy minimum to a lower cruise speed of 275 km/h. Figure 23 Modified aircraft with increased wing span. STO-MP-AVT-209 9 - 23 UNCLASSIFIED
  • 25. UNCLASSIFIED Electric Flight – Potential and Limitations The next modification would reduce the empty mass of the aircraft by 20%. This would require introducing extreme lightweight design features. As many components are unlikely to be reduced in mass the main structural components would have to be reduced by probably 30%. This modification would increase the range by another 10% to 339 km. Due to the lower mass, the optimum flight speed would be about 255 km/h. Figure 24 Modified aircraft with reduced mass. This step improves the battery technology by doubling the mass specific energy E* . Such an improvement is quite well possible with future development of Li-S battery systems within the next 15 years. This modification would double the range to 711 km so that it at least comes into the order of the kerosene based aircraft. Nevertheless, there is still a factor of 3 in range missing. In order to achieve the range of the original aircraft, the battery technology would have to be improved by this factor, i.e. a factor of 6 compared to todays (2012) technology. Figure 25 Modified aircraft with improved battery technology. 9 - 24 STO-MP-AVT-209 UNCLASSIFIED
  • 26. UNCLASSIFIED Electric Flight – Potential and Limitations The last modification doubles the mass specific energy density of the battery system again. Such an improvement may be possible with future development of Li-S battery systems in the next 30 years. This modification would double the range again to 1455 km so that it is almost identical to the kerosene based aircraft. Such an aircraft could be operated profitable if the technology would be available at reasonable costs. Furthermore new infrastructure to replace and recharge the batteries on each airport would be required to make such an aircraft feasible. However one must consider that this improvement also includes many very optimistic assumptions and improvements in structures and aerodynamics. Just using the improved batteries in the electrified baseline aircraft 328 E would lead to a range of 800 km at the same specific energy consumption of 124 Wh/PAX/km. Figure 26 Modified aircraft with further improved battery technology. Rult. Rult. Rult. 3500 3000 2500 2000 1500 1000 500 STO-MP-AVT-209 9 - 25 UNCLASSIFIED 0 0 500 1000 1500 2000 2500 3000 3500 4000 Range [km] Payload [kg] 328 E E* = 180 360 720 328 TP Rult. 1980 Wh/kg Rult. 1620 Figure 27 Payload-range chart of the baseline and the electrified aircraft. Comparing the payload-range characteristics of the baseline turboprop aircraft and the battery powered electric aircraft shows that trading payload for fuel respectively battery has a very beneficial effect in case of kerosene because of its high specific energy. The gain in case of the electric aircraft is smaller, even if the design range and payload are similar. As can be seen, the gradient depends on the specific energy
  • 27. UNCLASSIFIED Electric Flight – Potential and Limitations content E* of the battery system, which is always lower than that of kerosene. This means that the range flexibility of the battery powered aircraft is more limited than that of the kerosene powered turboprop variant. Similar payload range capability is obtained when the specific energy of the battery system exceeds about 1500 Wh/kg. If, on the other hand, the final extremely modified aircraft 328-LBME2 would be equipped with a current turbo-prop engine, its fuel consumption would be as low as 1.5 liters per passenger per 100 km, which is about half that of the baseline aircraft. 6.0 CONCLUSIONS Practical battery electric powered airplanes are today limited to small vehicles up to 2 passengers and by rather short ranges and endurance. Neglecting costs, the current technology is suitable for small Ultra- Light aircraft, but not for commercial aviation. In order to power larger aircraft a dramatic improvement in battery technology would be required. Comparing with today’s technology with specific energy values of 150 to 200 Wh/kg, the mass specific energy density would have to be increased at least by a factor of 5 to become useful. More realistic this factor would have to be in the order of 10 to attract commercial interest for larger (regional) aircraft. In this context we must note that all numerical studies presented in this paper did not consider reserves as required for commercial aircraft. These would add 30 to 45 minutes of flight time for holding at the destination airport and deviations. Currently there is a lot of development in battery technology, mostly driven by mobile devices and by automotive applications. Development history hints that the required improvements may take about 20-40 years until they may become available. Besides these basic considerations, there are still many questions which have to be and which are currently addressed: • how does the total energy balance and the environmental footprint including manufacturing look 9 - 26 STO-MP-AVT-209 UNCLASSIFIED like? • are there enough raw materials for battery production (automotive plus aviation) available? • how to achieve the required level of safety and how to adapt certification rules? • which infrastructure and investment is required at the airport for battery replacement and recharging? • how can the low noise features of electric propulsion systems be exploited better? • how does the battery technology compare to future fuel cell technology developments? • how do fuel cell powered aircraft compare to aircraft burning synthetic fuels or hydrogen? Returning to the historic flight of the MB-E1 we can apply the same numeric analysis to study the option of repeating the experiment with the technology readily available in 2012. We can replace the Ni-Cd batteries (E* = 20 Wh/kg) with Li-OH cells (E* =180 Wh/kg) of the same mass and the brushed electric forklift motor ( h = 66%) with a specifically designed brushless motor ( h = 90%). This simple modification would extend the powered flight time of the MB-E1 from 7 minutes to 2 hours and 33 minutes. The range of the aircraft would grow from 17 km to 261 km. Mainly due to the improved efficiency of the electric motor the energy consumption of the single passenger (the pilot) per distance would be almost halved from E* = 135 Wh/PAX/km to E* = 80.8 Wh/PAX/km.
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  • 30. UNCLASSIFIED Electric Flight – Potential and Limitations 8.0 APPENDIX – RESULTS FOR BASELINE AIRCRAFT “328 E” Aircraft: Name Do 328 E Wing span b = 20.98 m Wing area S = 40.00 m^2 Aspect ratio AR = 11.00 k-Factor k = 1.060 L/D max L/D = 16.16 v_EAS(L/D max) v = 79.8 m/s = 287.1 km/h v_stall v stall = 53.7 m/s = 193.5 km/h climb CD0 = 0.0321 cruise CD0 = 0.0312 descent CD0 = 0.0306 passenger+crew load PAX = 32 @ 90.0 kg Mass total m = 15880.0 kg Mass empty me = 8500.0 kg Mass payload mp = 2880.0 kg (32 PAX) wing box volume Vw = 3260.1 liters empty weight fraction me/m = 0.535 payload weight fraction mp/m = 0.181 battery weight fraction mb/m = 0.283 wing loading m/S = 397.00 kg/m^2 span loading m/b^2 = 36.08 kg/m^2 range factor (m/b^2)/(m/S) = 0.091 ultimate range R ult = 347.4 km Range sensitivities for 51.5 kg/km, eta_total = 0.700: max. powered range R max = 143.0 km specific energy dR/dE* = 24.5 km/10% empty mass fraction dR/dfe = -40.0 km/10% lift over drag dR/d(L/D) = 24.5 km/10% passenger count dR/dPAX = -3.2 km/PAX payload distance E/(R*mp) = 119.5 - 138.0 Wh/km/PAX (range - endurance specific energy dE*/dfe = -29.4 Wh/kg/10% STO-MP-AVT-209 9 - 29 UNCLASSIFIED Battery: Energy E = 793.80 kWh Mass mb = 4500.0 kg Volume V = 793.8 liters Voltage U = 1800.0 V Capacity C = 441.0 Ah C spec. E* = 180.0 Wh/kg Limit I I max = 2205.0 A (5*C/h) Limit P P max = 3969.0 kW (5*C/h) Climb Segment: prescribed climb angle theta = 7.5 degrees. Altitude H = 0.0 ... 3000.0 m Time t = 0.1 h Distance R = 22.8 km Speed avg v = 333.7 km/h (mean) Climb rate vz = 12.1 m/s (mean) Energy E = 296.26 kWh (from battery) Power, a/c P = 2798.55 kW (mean, for aircraft) Thrust, a/c T = 30189.1 N (mean, for aircraft) CL avg CL = 0.8 (mean) CD avg CD = 0.054 (mean) L/D avg L/D = 15.655 (mean) eta, prop avg eta = 74.88 % (mean) eta total avg eta t = 65.44 % (mean) Power, batt P = 4296.77 kW (mean, from battery) Voltage, batt U = 1812.3 V (mean) Current, batt I = 2389.9 A (mean)
  • 31. UNCLASSIFIED Electric Flight – Potential and Limitations 9 - 30 STO-MP-AVT-209 UNCLASSIFIED Cruise Segment: Altitude H = 3000.0 ... 3000.0 m Time t = 0.4 h Distance R = 125.0 km Speed avg v = 290.3 km/h (mean) Speed avg M = 0.2 (mean) Energy E = 493.87 kWh (from battery) Power, a/c P = 775.53 kW (mean, for aircraft) Thrust, a/c T = 9638.7 N (mean, for aircraft) CL avg CL = 1.0 (mean) CD avg CD = 0.061 (mean) L/D avg L/D = 16.2 (mean) eta prop avg eta p = 79.26 % (mean) eta total avg eta t = 69.26 % (mean) Power, batt P = 1143.94 kW (mean, from battery) Voltage, batt U = 1796.7 V (mean) Current, batt I = 654.9 A (mean) Descent Segment: Altitude H = 3000.0 ... 0.0 m Time t = 0.1 h Speed avg v = 332.0 km/h (mean) Descent rate vz = -5.7 m/s (mean) Distance R = 48.5 km Energy E = 3.66 kWh CL avg CL = 0.9 (mean) CD avg CD = 0.054 (mean) L/D avg L/D = 16.2 (mean) Power, batt P = 25.00 kW (mean, from battery) Voltage, batt U = 1800.1 V (mean) Current, batt I = 13.9 A (mean) Complete Mission: Time t = 0.65 h Distance R = 196.3 km Energy a/c Eac = 532.78 kWh Energy battery Eb = 793.80 kWh spec. Energy Eb* = 126.4 Wh/PAX/km = 12.64 kWh/PAX/100 km - Equivalent turbofan propulsion: Fuel mass mf = 173.81 kg Kerosene Fuel volume Vf = 231.75 liters Kerosene Fuel volume V* = 3.69 l/PAX/100 km efficiency eta total = 0.269 - Equivalent turbopop propulsion: Fuel mass mf = 129.95 kg Kerosene Fuel volume Vf = 173.26 liters Kerosene Fuel volume V* = 2.76 l/PAX/100 km efficiency eta total = 0.360 - Equivalent piston-prop propulsion (BMW radial engines): Fuel mass mf = 133.19 kg Kerosene Fuel volume Vf = 177.59 liters Kerosene Fuel volume V* = 2.83 l/PAX/100 km efficiency eta total = 0.351 Powered segments (climb and cruise): Time t = 0.50 h Distance R = 147.8 km Energy battery E = 790.14 kWh Energy a/c E = 532.78 kWh spec. Energy E* = 125.8 Wh/PAX/km