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Rolls-Royce develops UltraFan engine aiming for higher efficiency than GE9X

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Rolls-Royce develops UltraFan engine aiming for higher efficiency than GE9X
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Tufan Erginbilgic, Chief Executive | Rolls-Royce Airline

Rolls-Royce is advancing its position in the aviation engine market with the development of the UltraFan, a large and efficient turbofan engine that could impact competitors such as General Electric (GE). The UltraFan, known as UF001, features a 140-inch fan diameter, making it larger than GE Aviation’s GE9X, which has a 134-inch fan. According to Rolls-Royce, “UltraFan also features a new geared architecture (introduced between the fan and intermediate pressure compressor), ensuring the fan runs at optimum speed, as does the engine compressor and turbine thanks to the core architecture. The carbon titanium fan system is further developed to allow the removal of the thrust reverser, enabling a truly slim-line nacelle system.”

The size of a turbofan engine plays a key role in its efficiency. Larger engines can move more air at lower acceleration rates, which leads to improved fuel efficiency. The UltraFan is designed for a 15:1 bypass ratio and 70:1 overall pressure ratio. In comparison, GE’s GE9X offers a 10:1 bypass ratio and 60:1 overall pressure ratio.

The UltraFan project includes two planned variants—the UltraFan 30 for narrowbody aircraft and the UltraFan 80 for widebodies. Alan Newby, director of research and technology at Rolls-Royce, said regarding the smaller variant’s fan size: “will be bigger than current narrowbody engines [...] pushing towards 90 inches.” He added, “What we are trying to do now is to develop an integrated development programme that features both small and large assets.”

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A significant feature of the UltraFan is its compatibility with sustainable aviation fuels (SAF). With no modifications required, it can run on 100% SAF. Rolls-Royce states: “There is also potential to transfer technologies from UltraFan to current inservice engines to provide even greater fuel efficiency and reductions in emissions.” Another statement reads: “The engine will then go on test at the new engine test facility, Testbed 80, in Derby UK later this year. [...] The first run will be on 100 per cent Sustainable Aviation Fuel.”

Rolls-Royce claims up to an 80% reduction in lifecycle carbon footprint when using SAF compared to traditional jet fuel engines. There are also improvements in nitrogen oxide emissions—up to 40% better than previous models—and noise levels are reduced by approximately 35%.

Development milestones include initial plans unveiled in January 2014 with composite fan blades and geared turbofan technology introduced for this class of engine. By May 2023, ground tests were performed using an UltraFan demonstrator configured for an output of around 80,000 pounds of thrust.

While there are some concerns about whether such large engines can fit existing airframes—potentially requiring changes like gull-wing designs—the company aims for modularity and maintainability with these new products.

Rolls-Royce continues research into hybrid-electric and hydrogen solutions alongside SAF compatibility as part of broader efforts toward sustainability within commercial aviation.

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