Parametric Sizing Model for Cryogenic Heat Exchangers for Early Aircraft Design

The aviation industry aims to reduce environmental impact by adopting alternative propulsion systems, including hydrogen-based, hybrid-electric, and all-electric architectures, requiring a new Thermal Management System (TMS). In addition, new design methods are needed for the TMS, at the system and component levels, to handle various fluids and varying fluid properties. Within the TMS, heat exchangers are critical components that may require significant space and must be considered early in the design process. This paper presents a parametric sizing methodology for heat exchangers suitable for early design phases within a Multidisciplinary Design Analysis and Optimization (MDAO) framework, specifically for cryogenic heat transfer. The method combines physical equations with validated empirical relationships, using iterative solver algorithms for sizing. To address multi-variable design challenges, the methodology integrates discretization schemes for fluid properties, temperature, and energy calculations, and constraint-based optimization with a weighted-sum approach for solution selection. The methodology is validated with a commercial heat exchanger, and cross-validated with a cryogenic Heat Exchanger (HX). A case study for an all-electric hydrogen fuel cell aircraft architecture with a 7.6 MW propulsion system is presented to demonstrate the effectiveness of the methodology. The presented heat exchanger performance can be predicted across multiple conditions quickly enough to enable large design space exploration. Overall, the presented model is a crucial element for the design of a TMS for future aircraft with hydrogen-based propulsion systems.