General Designer of ODK-Kuznetsov Pavel Chupin — about domestic power units for space, aviation and ground applications
Reusable rocket engines are being designed in Russia, which will allow the spent stages of ultralight rockets to be safely returned to Earth. Pavel Chupin, General Designer of ODK-Kuznetsov, told Izvestia about this in an interview. He also reported on the creation of units for pumping and liquefying gas, green technologies in the engine industry and the world's most powerful gas turbine locomotive. Read more about the new domestic power plants in an interview with Izvestia.
"These engine systems provide ample opportunities for reusable use"
— Pavel Vladimirovich, your company is the flagship in the creation of rocket engines. What developments are underway in this area?
NK-33 engine
Image source: Photo: RIA Novosti/Anton Denisov
— Our company performs a full cycle of development and production of rocket engines. In this sense, it is unique in the Rostec circuit. All domestic manned astronautics fly on engines that are manufactured by our company. If we talk about the NK-33 engine, it is not only manufactured, but also developed at PJSC ODK-Kuznetsov.
Of the new projects, preliminary design of the first and second stage engines, which run on oxygen–kerosene steam, for the newest ultralight launch vehicle is currently being carried out. Their thrust in various conditions will be 3-4 tons-force (tc). It is assumed that reusable Russian engines will safely return the rocket stages to Earth. These works are carried out in the interests of the commercial customer.
— What features make engines reusable?
— During each flight, the engines will be able to perform several inclusions, which is achieved due to the technology when the ignition of the fuel mixture is carried out using either reusable pyrotechnics or an electric ignition system. This distinguishes our development from traditional solutions where single-use pyrotechnics are used.
Photo: IZVESTIA/Dmitry Korotaev
Image source: iz.ru
In this case, the thrust vector will be controlled using electric drives. They allow you to change the position of the engine nozzle relative to the axis of the rocket and thereby adjust the trajectory of its movement. At the same time, the engine control system allows you to change thrust in a wide range based on signals from the launch vehicle control system. Together, all these rocket engine systems provide extensive maneuvering and reusable capabilities.
"The main competitive advantages are the fusion of rocket and aviation technologies"
— In what other areas are your developments in demand?
— Our company is involved in a large number of projects. These are helicopter and aircraft construction, and energy. For example, now the specialists of ODK-Kuznetsov are designing a new engine for a heavy-duty helicopter. Another important area is the development of onshore gas turbine engines for gas transportation and power generation in the oil and gas industry and the electric power industry.
Photo: RIA Novosti/Vitaly Nevar
Image source: iz.ru
In particular, we have developed and started manufacturing a prototype industrial installation with a capacity of 32 MW. It is intended for use as a drive for operation as part of gas transportation equipment in main pipelines and gas liquefaction.
Previously, the production of such engines in our country was limited to a capacity of 25 MW. In the future, we are considering the possibility of increasing the unit capacity of manufactured engines to 40-50 MW for import substitution of foreign equipment, if there is interest from our customers. Imported units of this class, which are currently being operated in our country, are gradually developing their resource and will soon require major repairs or complete replacement.
— Can you tell us about the non-standard areas where your engines are used?
— The special pride of the Kuznetsovsky team is the ability to solve non—standard tasks. Some time ago, our specialists created a power unit for a gas turbine locomotive with a gas turbine power plant. The project implements the main competitive advantages of the enterprise — a fusion of rocket and aviation technologies.
The manufactured engine is designed to run on cryogenic fuel (liquefied methane). In terms of power, it significantly exceeds known analogues. A gas turbine locomotive equipped with this installation holds the world record for the mass of a railway train. An additional advantage of a gas turbine locomotive is the ability to transport goods on non-electrified sections of railways.
Layout of a gas turbine locomotive
Image source: Photo: RIA Novosti/Pavel Lisitsyn
If we talk about exotic destinations, we can recall a request from a potential customer to create an installation based on a rocket engine for spraying a special reagent in order to organize rainfall in arid areas of the country.
In 2013, ODK-Kuznetsov received an order to create a burner device for the Olympic flame bowl of the XXII Winter Olympics in Sochi. The six-meter flame of the torch was supposed to work at a height of 50 m, taking into account possible natural changes. Therefore, the torch was tested in conditions of a hurricane and heavy rain. The NK-12MA serial aircraft engine was used to simulate extreme weather.
When performing work inside the gas pipeline, the main, backup and backup branches of the basin supply are mounted. In general, the developers needed to go significantly beyond the usual and explore many related areas.
"Specialists are developing promising combustion chambers for green gas turbine engines"
— Eco-friendly technologies are being actively introduced in the world. How do these trends affect the work of the enterprise?
Photo: IZVESTIA/Dmitry Korotaev
Image source: iz.ru
— Back in the late 1980s, the company developed aircraft engines that used liquefied natural gas and hydrogen as fuel. These components make it possible to minimize (in the case of LNG) or reset (for hydrogen) the so-called carbon footprint. These projects were ahead of their time, but today we return to this topic again.
For example, as part of one of the research works, the design of the combustion chamber of a gas turbine engine was designed, in which the combustion of a mixture of natural gas and hydrogen made it possible to reduce harmful emissions of carbon oxides several times compared with using only natural gas as fuel.
Currently, specialists are developing promising combustion chambers for green gas turbine engines, primarily for ground applications. It is assumed that at the first stage they will be adapted to work on a mixture of natural gas and hydrogen, and in the future — on pure hydrogen.
Photo: RIA Novosti/Sergey Mamontov
Image source: iz.ru
— How does the creation of a new engine usually begin?
— The creation of a new generation engine begins with the development of promising, "critical" technologies that will later be used in the design. This is the creation of new materials with improved physical and mechanical characteristics, design, manufacturing and testing technologies. The work involves close interaction with industry and university science, and the performance of research work.
If the technologies being created have confirmed a high level of readiness, they are used in the design of a new product. The result of the development work is an engine sample that has passed a full range of tests and confirmed all the requirements for it.
— Does the shortage of personnel affect the work of the industry?
— Today, all industrial enterprises are faced with a shortage of personnel. It is difficult to find highly qualified designers, technologists and workers. Rostec provides great support. The state Corporation opens engineering classes in schools, develops targeted training in universities and colleges, and trains multi-specialists in production and training centers.
Photo: IZVESTIA/Dmitry Korotaev
Image source: iz.ru
Our company implements internal training and retraining programs for specialists. Future designers and technologists, starting from the first year of study, are employed at ODK-Kuznetsov and, getting a second profession, spend one day a week at the enterprise and are involved in the workflow.
As an industrial partner, we support supporting universities. For example, Samara State University.
Andrey Korshunov
