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Fuel quality processing study, volume 1

A fuel quality processing study to provide a data base for an intelligent tradeoff between advanced turbine technology and liquid fuel quality, and also, to guide the development of specifications of future synthetic fuels anticipated for use in the time period 1985 to 2000 is given. Four technical performance tests are discussed: on-site pretreating, existing refineries to upgrade fuels, new refineries to upgrade fuels, and data evaluation. The base case refinery is a modern Midwest refinery processing 200,000 BPD of a 60/40 domestic/import petroleum crude mix. The synthetic crudes used for upgrading to marketable products and turbine fuel are shale oil and coal liquids. Of these syncrudes, 50,000 BPD are processed in the existing petroleum refinery, requiring additional process units and reducing petroleum feed, and in a new refinery designed for processing each syncrude to produce gasoline, distillate fuels, resid fuels, and turbine fuel, JPGs and coke. An extensive collection of synfuel properties and upgrading data was prepared for the application of a linear program model to investigate the most economical production slate meeting petroleum product specifications and turbine fuels of various quality grades. Technical and economic projections were developed for 36 scenarios, based on 4 different crude feeds to either modified existing or new refineries operated in 2 different modes to produce 7 differing grades of turbine fuels. A required product selling price of turbine fuel for each processing route was calculated. Procedures and projected economics were developed for on-site treatment of turbine fuel to meet limitations of impurities and emission of pollutants.

Ohara, J. B.↗

Analytical evaluation of effect of equivalence ratio inlet-air temperature and combustion pressure on performance of several possible ram-jet fuels

The results of an analytical investigation of the theoretical air specific impulse performance and adiabatic combustion temperatures of several possible ram-jet fuels over a range of equivalence ratios, inlet-air temperatures, and combustion pressures, is presented herein. The fuels include octane-1, 50-percent-magnesium slurry, boron, pentaborane, diborane, hydrogen, carbon, and aluminum. Thermal effects from high combustion temperatures were found to effect considerably the combustion performance of all the fuels. An increase in combustion pressure was beneficial to air specific impulse at high combustion temperatures. The use of these theoretical data in engine operation and in the evaluation of experimental data is described.

COMBUSTION - TURBINE ENGINES↗

Techno-Economic Assessment of CHP Systems in Wastewater Treatment Plants

Wastewater treatment plant (WWTP) utilization of combined heat and power (CHP) systems allows for the efficient use of on-site biogas production, as well as increased annual savings in utility costs. In this paper, a review of biogas energy recovery options, CHP prime mover technologies, and the costs associated with biogas cleaning give a broad summary of the current state of CHP technology in WWTPs. Even though there are six different prime mover technologies, the main ones currently being implemented in WWTPs are micro turbines, fuel cells and reciprocating engines. Different prime movers offer varying efficiencies, installation costs, and biogas impurity (H2S, siloxanes, HCl) tolerances. To evaluate the long-term savings capabilities, a techno-economic assessment of a CHP installation at a case study WWTP shows the payback, annual savings, and initial costs associated with the installation of a CHP system. In this case, a study a payback of 5.7 years and a net present value of USD 709,000 can be achieved when the WWTP generates over 2,000,000 m3 of biogas per year and utilizes over 36,000 GJ of natural gas per year.

54 ENVIRONMENTAL SCIENCES↗

Evaluation of advanced regenerator systems

The major considerations are discussed which will affect the selection of a ceramic regenerative heat exchanger for an improved 100 HP automotive gas turbine engine. The regenerator considered for this application is about 36cm in diameter. Regenerator comparisons are made on the basis of material, method of fabrication, cost, and performance. A regenerator inlet temperature of 1000 C is assumed for performance comparisons, and laboratory test results are discussed for material comparisons at 1100 and 1200 C. Engine test results using the Ford 707 industrial gas turbine engine are also discussed.

Cook, J. A.↗

Evaluation of turbo-propulsion simulators as a testing technique for fighter aircraft

Ames Research Center has under way a program to develop the technology for using turbine-powered jet engine simulators as a test technique for simulating installed jet engine characteristics in small-scale wind-tunnel models of complete VSTOL fighter configurations. The program consists of three key elements: (1) static testing SN003 prototype turbine engine simulator (MAPS), (2) the development of the Propulsion Simulator Calibration Laboratory at Ames, and (3) the design, fabrication, and testing of a twin-engine 'closely coupled' V/STOL fighter wind-tunnel model. The model will use the Compact Multi-mission Propulsion Simulator (CMAPS) and will also be tested in flow-through and jet-effects modes to assess the effect of simultaneous inlet and nozzle flow simulation. This paper includes a description of the planned effort and anticipated future tasks.

Bailey, R. O.↗

Investigation of Semivaneless Turbine Stator Designed to Produce Axially Symmetrical Free-vortex Flow

A semivaneless turbine stator designed to eliminate blade wakes and secondary-flow accumulations of boundary-layer air was built and tested. Performance of this stator was evaluated with static pressures measured in the vaneless section and surveys of total pressure and flow angle made at the stator exit. Results are presented in terms of theoretical and experimental velocities and flow angles, boundary-layer parameters, and contours of total-pressure loss across the stator.

TURBINES - MIXED-FLOW↗

Advanced controls for airbreathing engines, volume 3: Allison gas turbine

The application of advanced control concepts to airbreathing engines may yield significant improvements in aircraft/engine performance and operability. Screening studies of advanced control concepts for airbreathing engines were conducted by three major domestic aircraft engine manufacturers to determine the potential impact of concepts on turbine engine performance and operability. The purpose of the studies was to identify concepts which offered high potential yet may incur high research and development risk. A target suite of proposed advanced control concepts was formulated and evaluated in a two-phase study to quantify each concept's impact on desired engine characteristics. To aid in the evaluation specific aircraft/engine combinations were considered: a Military High Performance Fighter mission, a High Speed Civil Transport mission, and a Civil Tiltrotor mission. Each of the advanced control concepts considered in the study are defined and described. The concept potential impact on engine performance was determined. Relevant figures of merit on which to evaluate the concepts are determined. Finally, the concepts are ranked with respect to the target aircraft/engine missions. A final report describing the screening studies was prepared by each engine manufacturer. Volume 3 of these reports describes the studies performed by the Allison Gas Turbine Division.

Bough, R. M.↗

Development of improved-durability plasma sprayed ceramic coatings for gas turbine engines

An investigation is reported of improving the durability of plasma sprayed ceramic coatings for the vane platforms in the JT9d turbofan engine. The program aims for reduced fuel consumption of commercial aircraft engines; the use of improved strain tolerant microstructures and control of the substrate temperature during coating application are being evaluated. The initial burner rig tests at temperatures up to 1010 C indicated that improvements in cyclic life greater than 20:1 over previous ceramic coatings were achieved. Three plasma sprayed coating systems applied to first stage vane platforms in the high pressure turbine were subjected to a 1000-cycle JT9D engine endurance test with only minor damage occurring to the coatings.

Sumner, I. E.↗

Case Study: Applying the Idaho National Laboratory Resilience Framework to St. Mary’s, Alaska

The Idaho National Laboratory (INL) resilience framework has been developed to broadly apply to EEDS so that all elements of systems that contain distributed wind can be part of the resilience evaluation. The users or audience for this framework can include any stakeholders associated with the EEDS. Not all electrical energy systems have the same stakeholders; customers, owners, and operators are generally present but have different interests. Considering the broad electrical grid, customers, regulators, investors, utility planners, engineers, and operators each have an interest in system resilience driven from different motivating factors. This document focuses on the planning stage of the framework. In this document, each step is explained briefly before demonstrating its application to the St. Mary’s-Mt. Village system. The framework can be used for many types of resilience planning. It can be used to evaluate current overall resilience, or the resilience of certain subsystems. It can be used to explore existing resilience weak points and propose mitigations. It can also be used to evaluate the resilience benefits of a new investment. We use the latter application for this case study. Although the wind turbine in St. Mary’s has already been installed, the resilience benefits that the turbine provided were not well defined. It was installed with the main objective to generate electric power from a renewable resource in an effort to reduce the local dependency on fuel oil as the sole source of electric power generation, which is a resilience goal on its own, but there are other ways in which the turbine can add resilience to the system, as well as scenarios of interest to analyze how resilient the wind turbine itself is against different hazards. In this case study, we analyze the operation of the St. Mary’s power system both with the wind installed and without the wind installed during different resilience hazards of interest. This allows us to compare the performance with wind and without wind and to quantify the resilience benefits provided by wind. Our MIRACL partners at PNNL will then take the resilience benefits and assign value to the resilience provided by wind based on costs and costs avoided in the different scenarios.

17 WIND ENERGY↗

New opportunities for future, small, General-Aviation Turbine Engines (GATE)

The results of four independent contracted studies to explore the opportunities for future small turbine engines are summarized in a composite overview. Candidate advanced technologies are screened, various cycles and staging arrangements are parametrically evaluated, and optimum conceptual engines are identified for a range of 300 to 600 horsepower applications. Engine improvements of 20 percent in specific fuel consumption and 40 percent in engine cost were forecast using high risk technologies that could be technically demonstrated by 1988. The ensuing economic benefits are in the neighborhood of 20 to 30 percent for twin-engine aircraft currently powered by piston engines.

Strack, W. C.↗

Rocket engine injection element characterization

Characterization of liquid rocket engine injection elements is an important part of the development process for rocket engine combustion devices. Modern nonintrusive instrumentation for flow velocity and spray droplet size measurement and automated, computer-controlled test facilities allow rapid, low-cost evaluation of injection element performance and behavior. Application of these methods in rocket engine development, paralleling their use in gas turbine engine development, will reduce rocket engine development cost and risk. Two types of liquid rocket engine injection elements have been characterized using such methods.

Cox, George B., Jr.↗

Combustor diffuser interaction program

Advances in gas turbine engine performance are achieved by using compressor systems with high stage loading and low part count, which result in high exit Mach numbers. The diffuser and combustor systems in such engines should be optimized to reduce system pressure loss and to maximize the engine thrust-to-weight ratio and minimize length. The state-of-the-art combustor-diffuser systems do not meet these requirements. Detailed understanding of the combustor-diffuser flow field interaction is required for designing advanced gas turbine engines. An experimental study of the combustor-diffuser interaction (CDI) is being conducted to obtain data for the evaluation and improvement of analytical models applicable to a wide variety of diffuser designs. The CDI program consists of four technical phases: Literature Search; Baseline Configuration; Parametric Configurations; and Performance Configurations. Phase 2 of the program is in progress.

Srinivasan, Ram↗

Injector element characterization methodology

Characterization of liquid rocket engine injector elements is an important part of the development process for rocket engine combustion devices. Modern nonintrusive instrumentation for flow velocity and spray droplet size measurement, and automated, computer-controlled test facilities allow rapid, low-cost evaluation of injector element performance and behavior. Application of these methods in rocket engine development, paralleling their use in gas turbine engine development, will reduce rocket engine development cost and risk. The Alternate Turbopump (ATP) Hot Gas Systems (HGS) preburner injector elements were characterized using such methods, and the methodology and some of the results obtained will be shown.

Cox, George B., Jr.↗

Effect of thermal shock on fiber-reinforced superalloy composites

An evaluation is presented of the thermal shock behavior of tungsten fiber-reinforced superalloy (FRS) composites with respect to the turbine blade requirements of rocket engine turbopumps. Each composite was reinforced unidirectionally with 40-volume-pct continuous tungsten fibers. The start-up conditions of the first-stage turbine blades of the high-pressure fuel turbopump in the Space Shuttle Main Engine (SSME) were used to investigate the thermal shock behavior of these materials. The FRS composites showed excellent thermal shock resistance, two to nine times better than the turbine blade material used in the SSME. Thermal shock cycling produced microcracks on the surfaces of the irradiated area that were less than 0.13 mm long and 0.005 mm deep. Neither fiber/matrix debonding nor microvoiding was observed.

Yuen, J. L.↗

Brush seals for turbine engine fuel conservation

The program objective is to demonstrate brush seals for replacing labyrinth seals in turboprop engines. The approach taken was to design and procure brush seals with assistance from Sealol, modify and instrument an existing T407 low pressure turbine test rig, replace inner balance piston and outer balance piston labyrinth seals with brush seals, conduct cyclic tests to evaluate seal leakage at operating pressures and temperatures, and evaluate effect of seal pack width and rotor eccentricity. Results are presented in viewgraph format and show that brush seals offer performance advantages over labyrinth seals.

Sousa, Mike↗

Thermal Analysis and Testing of Fastrac Gas Generator Design

The Fastrac Engine is being developed by the Marshall Space Flight Center (MSFC) to help meet the goal of substantially reducing the cost of access to space. This engine relies on a simple gas-generator cycle, which burns a small amount of RP-1 and oxygen to provide gas to drive the turbine and then exhausts the spent fuel. The Fastrac program envisions a combination of analysis, design and hot-fire evaluation testing. This paper provides the supporting thermal analysis of the gas generator design. In order to ensure that the design objectives were met, the evaluation tests have started on a component level and a total of 15 tests of different durations were completed to date at MSFC. The correlated thermal model results will also be compared against hot-fire thermocouple data gathered.

Nguyen, H.↗