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NASA NTRS2007

A Rapid Survey of the Compatibility of Selected Seal Materials with Conventional and Semi-Synthetic JP-8

Since the synthesis of a liquid hydrocarbon fuel from coal by Franz Fischer and Hans Tropsch in 1923, there has been cyclic interest in developing this fuel for military and commercial applications. In recent years the U.S. Department of Defense has taken interest in producing a unified battlespace fuel using the Fischer Tropsch (FT) process for a variety of reasons including cost, quality, and logistics. In the past year there has been a particular emphasis on moving quickly to demonstrate that an FT fuel can be used in the form of a blend with conventional petroleum-derived jet fuel. The initial objective is to employ this semi-synthetic fuel with blend ratios as high as 50 percent FT with longer range goals to use even high blend ratios and ultimately a fully synthetic jet fuel. A significant concern associated with the use of a semi-synthetic jet fuel with high FT blend ratios is the effect these low aromatic fuels will have on fuel-wetted polymeric materials, most notably seals and sealants. These materials typically swell and soften to some degree when exposed to jet fuel and the aromatic content of these fuels contribute to this effect. Semi-synthetic jet fuels with very low aromatic contents may cause seals and sealants to shrink and harden leading to acute or chronic failure. Unfortunately, most of the material qualification tests are more concerned with excessive swelling than shrinkage and there is little guidance offered as to an acceptable level of shrinkage or other changes in physical properties related to low aromatic content. Given the pressing need for guidance data, a program was developed to rapidly survey the volume swell of selected fuel-wetted materials in a range of conventional and semi-synthetic jet fuels and through a statistical analysis to make a determination as to whether there was a basis to be concerned about using fuels with FT blend ratios as high as 50 percent. Concurrent with this analysis data was obtained as to the composition of the fuel absorbed in fuel-wetted materials through the use of GC-MS analysis of swollen samples as well as other supporting data. In this presentation the authors will present a summary of the results of the volume swell and fuel absorbed by selected O-rings and sealants as well as a description of the measurement protocols developed for this program.

Graham, John L.↗

NASA NTRS1979

Compatibility of elastomers in alternate jet fuels

The compatibility of elastomeric compositions of known resistance to aircraft fuels was tested for potential use in Jet A type fuels obtainable from alternate sources, such as coal. Since such fuels were not available at the time, synthetic alternate fuels were prepared by adding tetralin to a petroleum based Jet A type fuel to simulate coal derived fuels which are expected to contain higher amounts of aromatic and hydroaromatic hydrocarbons. The elastomeric compounds tested were based on butadiene-acrylonitrile rubber, a castable Thiokol polysulfide rubber, and a castable fluorosilicone rubber. Batches of various cross-link densities of these rubbers were made and their chemical stress relaxation behavior in fuel, air, and nitrogen, their swelling properties, and response to mechanical testing were determined.

Kalfayan, S. H.↗

NASA NTRS2009

Synthetic and Biomass Alternate Fueling in Aviation

While transportation fueling can accommodate a broad range of alternate fuels, aviation fueling needs are specific, such as the fuel not freezing at altitude or become too viscous to flow properly or of low bulk energy density that shortens range. The fuel must also be compatible with legacy aircraft, some of which are more than 50 years old. Worldwide, the aviation industry alone uses some 85-95 billion gallons of hydrocarbon-based fossil fuel each year, which is about 10% of the transportation industry. US civil aviation alone consumes nearly 14 billion gallons. The enormity of the problem becomes overwhelming, and the aviation industry is taking alternate fueling issues very seriously. Biofuels (algae, cyanobacteria, halophytes, weeds that use wastelands, wastewater and seatwater), when properly sourced, have the capacity to be drop-in fuel replacements for petroleum fuels. As such, biojet from such sources solves the aviation CO2 emissions issue without the downsides of 'conventional' biofuels, such as competing with food and fresh water resources. Of the many current fundamental problems, the major biofuel problem is cost. Both research and development and creative engineering are required to reduce these biofuels costs. Research is also ongoing in several 'improvement' areas including refining/processing and biologics with greater disease resistance, greater bio-oil productivity, reduced water/nutrient requirements, etc. The authors' current research is aimed at aiding industry efforts in several areas. They are considering different modeling approaches, growth media and refining approaches, different biologic feedstocks, methods of sequestering carbon in the processes, fuel certification for aviation use and, overall, ensuring that biofuels are feasible from all aspects - operability, capacity, carbon cycle and financial. The authors are also providing common discussion grounds/opportunities for the various parties, disciplines and concerned organization to share both issues and potential ways for moving forward, and overall, trying to educate those concerned about the innate limitations of 'conventional' biofuels and the solutions provided by non-traditional feedstocks that used waste lands/water or saline/salt water have an immense capacity potential.

Hendricks, R. C.↗

NASA NTRS2009

Synthetic and Biomass Alternate Fueling in Aviation

Worldwide, aviation alone uses 85 to 95 billion gallons of nonrenewable fossil fuel per year (2008). General transportation fueling can accommodate several different fuels; however, aviation fuels have very specific requirements. Biofuels have been flight demonstrated, are considered renewable, have the capacity to become "drop-in" replacements for Jet-A fuel, and solve the CO2 climate change problem. The major issue is cost; current biomass biofuels are not economically competitive. Biofuel feedstock sources being researched are halophytes, algae, cyanobacteria, weeds-to-crops, wastes with contingent restraints on use of crop land, freshwater, and climate change. There are five major renewable energy sources: solar thermal, solar photovoltaic, wind, drilled geothermal and biomass, each of which have an order of magnitude greater capacity to meet all energy needs. All five address aspects of climate change; biomass has massive potential as an energy fuel feedstock.

Hendricks, R.C.↗

NASA NTRS2009

Synthetic and Biomass Alternate Fueling in Aviation

Must use earth's most abundant natural resources - Biomass, Solar, Arid land (43%), Seawater (97%) with nutrients (80%) plus brackish waters and nutrients resolve environmental triangle of conflicts energy-food-freshwater and ultrafine particulate hazards. Requires Paradigm Shift - Develop and Use Solar* for energy; Biomass for aviation and hybrid-electric-compressed air mobility fueling with transition to hydrogen long term.

Hendricks, Robert C.↗

NASA NTRS1977

Alternate aircraft fuels prospects and operational implications

The paper discusses NASA studies of the potentials of coal-derived aviation fuels, specifically synthetic aviation kerosene, liquid methane, and liquid hydrogen. Topics include areas of fuel production, air terminal requirements for aircraft fueling (for liquid hydrogen only), and the performance characteristics of aircraft designed to utilize alternate fuels. Energy requirements associated with the production of each of the three selected fuels are determined, and fuel prices are estimated. Subsonic commercial air transports using liquid hydrogen fuel have been analyzed, and their performance and the performance of aircraft which use commercial aviation kerosene are compared. Environmental and safety issues are considered.

Witcofski, R. D.↗

NASA NTRS1981

Low NOx Heavy Fuel Combustor Concept Program

The development of the technology required to operate an industrial gas turbine combustion system on minimally processed, heavy petroleum or residual fuels having high levels of fuel-bound nitrogen (FBN) while producing acceptable levels of exhaust emissions is discussed. Three combustor concepts were designed and fabricated. Three fuels were supplied for the combustor test demonstrations: a typical middle distillate fuel, a heavy residual fuel, and a synthetic coal-derived fuel. The primary concept was an air staged, variable-geometry combustor designed to produce low emissions from fuels having high levels of FBN. This combustor used a long residence time, fuel-rich primary combustion zone followed by a quick-quench air mixer to rapidly dilute the fuel rich products for the fuel-lean final burnout of the fuel. This combustor, called the rich quench lean (RQL) combustor, was extensively tested using each fuel over the entire power range of the model 570 K engine. Also, a series of parameteric tests was conducted to determine the combustor's sensitivity to rich-zone equivalence ratio, lean-zone equivalence ratio, rich-zone residence time, and overall system pressure drop. Minimum nitrogen oxide emissions were measured at 50 to 55 ppmv at maximum continuous power for all three fuels. Smoke was less than a 10 SAE smoke number.

Novick, A. S.↗

NASA NTRS1975

Hydrogen for the subsonic transport

Relations between air travel and fuel requirements are examined. Alternate fuels considered in connection with problems related to a diminishing supply of petroleum include synthetic jet fuel, methane, and hydrogen. A cruise flight of a subsonic aircraft on a hydrogen-fueled jet engine was demonstrated in 1957. However, more development work is required to provide a sound engineering base for a complete air transportation system using hydrogen as fuel. Aircraft designs for alternate fuels are discussed, giving attention to hydrogen-related technology already available and new developments which are needed.

Korycinski, P. F.↗

NASA NTRS1981

Future fuels and engines for railroad locomotives. Volume 2: Technical document

The potential for reducing the dependence of railroads on petroleum fuel, particularly Diesel No. 2 was studied. The study takes two approaches: to determine the use of Diesel No. 2 can be reduced through increased efficiency and conservation, and to use fuels other than Diesel No. 2 both in Diesel and other types of engines. Synthetic hydrocarbon fuels, probably derived from oil shale, will be needed if present diesel-electric locomotives continue to be used.

Liddle, S. G.↗

NASA NTRS1981

Future fuels and engines for railroad locomotives. Volume 1: Summary

The potential for reducing the dependence of railroads on petroleum fuel, particularly Diesel No. 2 was investigated. Two approaches are studied: (1) to determine how the use of Diesel No. 2 can be reduced through increased efficiency and conservation, and (2) to use fuels other than Diesel No. 2 both in Diesel and other types of engines. Because synthetic hydrocarbon fuels are particularly suited to medium speed diesel engines, the first commercial application of these fuels may be by the railroad industry.

Liddle, S. G.↗

NASA NTRS1979

Advanced air transport concepts

The concepts of laminar flow control, very large all-wing aircraft, an aerial relay transportation system and alternative fuels, which would enable large improvements in fuel conservation in air transportation in the 1990's are discussed. Laminar boundary layer control through suction would greatly reduce skin friction and has been reported to reduce fuel consumption by up to 29%. Distributed load aircraft, in which all fuel and payload are carried in the wing and the fuselage is absent, permit the use of lighter construction materials and the elimination of fuselage and tail drag. Spanloader aircraft with laminar flow control could be used in an aerial relay transportation system which would employ a network of continuously flying liners supplied with fuel, cargo and crews by smaller feeder aircraft. Liquid hydrogen and methane fuels derived from coal are shown to be more weight efficient and less costly than coal-derived synthetic jet fuels.

Molloy, J. K.↗

NASA NTRS1976

Hydrogen-fueled subsonic aircraft: A perspective

The performance characteristics of hydrogen-fueled subsonic transport aircraft are compared to those using conventional aviation kerosene. Additional aspects discussed include potential improvements in the exhaust emissions characteristics of aircraft jet engines, problems associated with onboard fuel containment, results of recent studies of the impact of hydrogen-fueled aircraft on the airport and associated ground support equipment, and estimates of the cost and thermal efficiency of producing synthetic aviation fuels from coal.

Witcofski, R. D.↗

NASA NTRS2017

Jet Fuel Thermal Stability Investigations Using Ellipsometry

Jet fuels are typically used for endothermic cooling in practical engines where their thermal stability is very important. In this work the thermal stability of Sasol IPK (a synthetic jet fuel) with varying levels of naphthalene has been studied on stainless steel substrates using spectroscopic ellipsometry in the temperature range 385-400 K. Ellipsometry is an optical technique that measures the changes in a light beam’s polarization and intensity after it reflects off of a thin film to determine the film’s thickness and optical properties. All of the tubes used were rated as thermally unstable by the color standard portion of the Jet Fuel Thermal Oxidation Test, and this was confirmed by the deposit thicknesses observed using ellipsometry. A new amorphous model on a stainless steel substrate was used to model the data and obtain the results. It was observed that, as would be expected, increasing the temperature of the tube increased the overall deposit amount for a constant concentration of naphthalene. The repeatability of these measurements was assessed using multiple trials of the same fuel at 385 K. Lastly, the effect of increasing the naphthalene concentration in the fuel at a constant temperature was found to increase the deposit thickness.In conclusion, ellipsometry was used to investigate the thermal stability of jet fuels on stainless steel substrate. The effects of increasing temperature and addition of naphthalene on stainless steel tubes with Sasol IPK fuel were investigated. It was found, as expected, that increasing temperature lead to an increase in deposit thickness. It wasAmerican Institute of Aeronautics and Astronautics6also found that increasing amounts of naphthalene increased the maximum deposit thickness. The repeatability of these measurements was investigated using multiple tests at the same conditions. The present work provides as a better quantitative tool compared to the widely used JFTOT technique. Future work will expand on the fuel types, temperature, and substrate materials.

thermal stability↗

NASA NTRS1973

Energy storage using high pressure electrolysis and methods for reconversion

Theoretical and experimental studies on high pressure electrolysis producing hydrogen and oxygen for energy storage and reconversion are reported. Moderate temperature, high pressure hydrogen/oxygen fuel cells with nickel electrodes are investigated for effects of pressure, temperature, and membrane porosity. Test results from an aphodid burner turbine generator combination obtained 40 percent kilowatt hours out of the fuel cell divided by kilowatt hours into the electrolyzer. It is concluded that high pressure hydrogenation of organic materials can be used to synthesize hydrozenes and methanes for making synthetic vehicular fuels.

Hughes, W. L.↗

NASA NTRS2009

Chemical Processing of Non-Crop Plants for Jet Fuel Blends Production

The use of Biofuels has been gaining in popularity over the past few years due to their ability to reduce the dependence on fossil fuels. Biofuels as a renewable energy source can be a viable option for sustaining long-term energy needs if they are managed efficiently. We describe our initial efforts to exploit algae, halophytes and other non-crop plants to produce synthetics for fuel blends that can potentially be used as fuels for aviation and non-aerospace applications. Our efforts have been dedicated to crafting efficient extraction and refining processes in order to extract constituents from the plant materials with the ultimate goal of determining the feasibility of producing biomass-based jet fuel from the refined extract. Two extraction methods have been developed based on communition processes, and liquid-solid extraction techniques. Refining procedures such as chlorophyll removal and transesterification of triglycerides have been performed. Gas chromatography in tandem with mass spectroscopy is currently being utilized in order to qualitatively determine the individual components of the refined extract. We also briefly discuss and compare alternative methods to extract fuel-blending agents from alternative biofuels sources.

Kulis, M. J.↗

NASA NTRS2010

Computational Analysis of Dynamic SPK(S8)-JP8 Fueled Combustor-Sector Performance

Civil and military flight tests using blends of synthetic and biomass fueling with jet fuel up to 50:50 are currently considered as "drop-in" fuels. They are fully compatible with aircraft performance, emissions and fueling systems, yet the design and operations of such fueling systems and combustors must be capable of running fuels from a range of feedstock sources. This paper provides Smart Combustor or Fuel Flexible Combustor designers with computational tools, preliminary performance, emissions and particulates combustor sector data. The baseline fuel is kerosene-JP-8+100 (military) or Jet A (civil). Results for synthetic paraffinic kerosene (SPK) fuel blends show little change with respect to baseline performance, yet do show lower emissions. The evolution of a validated combustor design procedure is fundamental to the development of dynamic fueling of combustor systems for gas turbine engines that comply with multiple feedstock sources satisfying both new and legacy systems.

Ryder, R.↗

NASA NTRS1981

Molten salt pyrolysis of latex

Latex-rich plants such as Guayule or extracts thereof are pyrolyzed in an inert nitrogen atmosphere inorganic salt melts such as a LiCl/KCl eutectic at a temperature of about 500 C. The yield is over 60% of a highly aromatic, combustible hydrocarbon oil suitable for use as a synthetic liquid fuel.

Bauman, A. J.↗

NASA NTRS2008

Intelligent Engine Systems: Alternate Fuels Evaluation

The performance and gaseous emissions were measured for a well-stirred reactor operating under lean conditions for two fuels: JP8 and a synthetic Fisher-Tropsch fuel over a range of equivalence ratios from 0.6 down to the lean blowout. The lean blowout characteristics were determined in LBO experiments at loading parameter values from 0.7 to 1.4. The lean blowout characteristics were then explored under higher loading conditions by simulating higher altitude operation with the use of nitrogen as a dilution gas for the air stream. The experiments showed that: (1) The lean blowout characteristics for the two fuels were close under both low loading and high loading conditions. (2) The combustion temperatures and observed combustion efficiencies were similar for the two fuels. (3) The gaseous emissions were similar for the two fuels and the differences in the H2O and CO2 emissions appear to be directly relatable to the C/H ratio for the fuels.

Ballal, Dilip↗