Rolls-Royce Develops Durable Jet Engine Project for Middle East Market

Nov 22, 2025
Technology

Photo: Rolls-Royce Trent XWB-97 engine powering an Airbus A350 on a long-haul flight. (Courtesy)

Staff Report | PNN

British aircraft manufacturer Rolls-Royce is testing a new technology in Derby designed to protect jet engines from damage caused by desert sand and dust—issues that heavily affect airlines operating in the Middle East, one of the company’s key markets.

Fine sand and dust entering the hottest parts of an engine can cause erosion. Blocked coolant holes increase engine heat. While this does not directly affect flight safety, it reduces engine efficiency and increases maintenance requirements.

Pat Hilton, head of Rolls-Royce’s test facilities, said, “Dust entering the hottest parts of the engine increases wear on components. This is very important for us, especially for the Middle East market.”

Under the testing program, the company has modified certain engine metals to withstand high heat and sand erosion. Coolant hole positions were also adjusted to reduce blockage risk.

The project is part of Rolls-Royce’s £1 billion durability program, aiming to enhance engine longevity, including the Trent XWB-97. The Trent XWB-97 is the company’s most powerful engine, running hotter than other models.

Testing is conducted in three phases at Testbed 80 in Derby. Engines from the first two phases have returned to service, capable of flying 60% longer before overhaul. Manchester University has created artificial fine sand similar to that found in the Middle East for testing purposes.

Hilton said, “We want these engines to fly twice as long. It’s a matter of pride that today’s work will serve for years to come.” Currently, a Trent engine can fly the equivalent of 500 times around the Earth before major component replacement. After final tests in 2028, flight duration is expected to double.

Last year, Emirates Airlines President Sir Tim Clark questioned the engine’s durability. The Trent XWB-97 powers the Airbus A350, used on long-haul flights by airlines such as Emirates and Etihad. Rolls-Royce confirmed the program aims to resolve this issue fleet-wide.