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At least 19 records

Deposit formation in hydrocarbon fuels

The hydrocarbon fuels RP-1, commercial-grade propane, JP-7 and chemically pure propane were subjected to tests in a high pressure fuel coking apparatus in order to evaluate their thermal decomposition limits and carbon deposition rates in heated copper tubes. A fuel thermal stability parametric evaluation was conducted at 136-340 atmospheres, bulk fuel velocities of 6-30 m/sec, and tube wall temperatures of 422-811 K, and the effect of inside wall material on deposit formation was evaluated in tests using nickel-plated tubes. Results show RP-1 deposit formation at wall temperatures between 600 and 800 K, with peak deposit formation near 700 K. Substitution of deoxygenated JP-7 for RP-1 showed no improvement, and the carbon deposition rates for propane fuels were found to be higher than those of either of the kerosene fuels. Nickel plating of the tube walls significantly reduced RP-1 carbon deposition rates.

Roback, R.↗

Supply Chain Sustainability Analysis of Renewable Hydrocarbon Fuels via Hydrothermal Liquefaction, Combined Algal Processing, and Biochemical Conversion: Update of the 2022 State-of-Technology Cases

The Department of Energy's (DOE) Bioenergy Technologies Office (BETO) aims to develop and deploy technologies to transform renewable biomass resources into commercially viable, high-performance biofuels, bioproducts, and biopower through public and private partnerships. BETO and its national laboratory teams conduct in-depth techno-economic assessments (TEA) of biomass feedstock supply and logistics and conversion technologies to produce biofuels. There are two general types of TEAs: A design case outlines a target case (future projection) for a particular biofuel pathway. It informs R&D priorities by identifying areas in need of improvement, tracks sustainability impact of R&D, and provides goals and benchmarks against which technology progress is assessed. A state of technology (SOT) analysis assesses progress within and across relevant technology areas based on actual results at current experimental scales relative to technical targets and cost goals from design cases, and includes technical, economic, and environmental criteria as available. In addition to developing a TEA for a pathway of interest, BETO also performs a supply chain sustainability analysis (SCSA). The SCSA takes the life-cycle analysis approach that BETO has been supporting for over 20 years. It enables BETO to identify energy consumption, environmental, and sustainability issues that may be associated with biofuel production. Approaches to mitigating these issues can then be developed. Additionally, the SCSA allows for comparison of energy and environmental impacts across biofuel pathways in BETO's research and development portfolio. This technical report describes the SCSAs for the production of renewable hydrocarbon transportation fuels via a range of conversion technologies in the 2022 SOTs: (1) renewable hydrocarbon fuels via hydrothermal liquefaction (HTL) of wet sludge from a wastewater treatment plant; (2) renewable hydrocarbon fuels via biochemical conversion of herbaceous lignocellulosic biomass; (3) renewable hydrocarbon fuels via HTL of an algae/woody biomass blend; and (4) renewable hydrocarbon fuels via combined algae processing (CAP).

09 BIOMASS FUELS↗

Processes for the conversion of mixed oxygenates feedstocks to hydrocarbon fuels

A method for forming a desired hydrocarbon fuel product from a mixed oxygenate feedstock by utilizing chemical processes to form ketones from the oxygenate feed, upgrade the ketones, recycle selected upgraded ketones through the upgrading process to obtain a desired intermediate and hydrogenating the desired intermediate to obtain the desired hydrocarbon fuel product. In various alternative configurations and embodiments this can be accomplished in a number of ways, and originate in a number of different positions and occasions.

Kallupalayam Ramasamy, Karthikeyan↗

Determination of Combustion Product Radicals in a Hydrocarbon Fueled Rocket Exhaust Plume

The identification of metallic effluent materials in a rocket engine exhaust plume indicates the health of the engine. Since 1989, emission spectroscopy of the plume of the Space Shuttle Main Engine (SSME) has been used for ground testing at NASA's Stennis Space Center (SSC). This technique allows the identification and quantification of alloys from the metallic elements observed in the plume. With the prospect of hydrocarbon-fueled rocket engines, such as Rocket Propellant 1 (RP-1) or methane (CH4) fueled engines being considered for use in future space flight systems, the contributions of intermediate or final combustion products resulting from the hydrocarbon fuels are of great interest. The effect of several diatomic molecular radicals, such as Carbon Dioxide , Carbon Monoxide, Molecular Carbon, Methylene Radical, Cyanide or Cyano Radical, and Nitric Oxide, needs to be identified and the effects of their band systems on the spectral region from 300 nm to 850 nm determined. Hydrocarbon-fueled rocket engines will play a prominent role in future space exploration programs. Although hydrogen fuel provides for higher engine performance, hydrocarbon fuels are denser, safer to handle, and less costly. For hydrocarbon-fueled engines using RP-1 or CH4 , the plume is different from a hydrogen fueled engine due to the presence of several other species, such as CO2, C2, CO, CH, CN, and NO, in the exhaust plume, in addition to the standard H2O and OH. These species occur as intermediate or final combustion products or as a result of mixing of the hot plume with the atmosphere. Exhaust plume emission spectroscopy has emerged as a comprehensive non-intrusive sensing technology which can be applied to a wide variety of engine performance conditions with a high degree of sensitivity and specificity. Stennis Space Center researchers have been in the forefront of advancing experimental techniques and developing theoretical approaches in order to bring this technology to a more mature stage.

Langford, Lester A.↗

Hydrocarbon-fuel/combustion-chamber-liner materials compatibility

Results of material compatibility experiments using hydrocarbon fuels in contact with copper-based combustion chamber liner materials are presented. Mil-Spec RP-1, n- dodecane, propane, and methane fuels were tested in contact with OFHC, NASA-Z, and ZrCu coppers. Two distinct test methods were employed. Static tests, in which copper coupons were exposed to fuel for long durations at constant temperature and pressure, provided compatibility data in a precisely controlled environment. Dynamic tests, using the Aerojet Carbothermal Test Facility, provided fuel and copper compatibility data under realistic booster engine service conditions. Tests were conducted using very pure grades of each fuel and fuels to which a contaminant, e.g., ethylene or methyl mercaptan, was added to define the role played by fuel impurities. Conclusions are reached as to degradation mechanisms and effects, methods for the elimination of these mechanisms, selection of copper alloy combustion chamber liners, and hydrocarbon fuel purchase specifications.

Gage, Mark L.↗

Combustion efficiency and altitude operational limits of three liquid hydrocarbon fuels having high volumetric energy content in a J33 single combustor

Combustion efficiency and altitude operational limits were determined in a J33 single combustor for AN-F-58 fuel and three liquid hydrocarbon fuels having high volumetric energy content (decalin, tetralin, and monomethylnaphthalene) at simulated altitude and combustor inlet-air conditions. At the conditions investigated, the combustion efficiency for the four fuels generally decreased with an increase in volumetric energy content. The altitude operational limits for decalin and tetralin fuels were higher than for AN-F-58 fuel; monomethylnaphthalene fuel gave the lowest altitude operational limit.

Stricker, Edward G↗

Experimental study of the thermal stability of hydrocarbon fuels

The thermal stability of two hydrocarbon fuels (premium diesel and regular diesel) was determined in a flow reactor under conditions representing operation of an aircraft gas turbine engine. Temperature was varied from 300 to 750 F (422 to 672 K) for fuel flows of 2.84 to 56.8 liters/hr (corresponding to 6.84 x 0.00010 to 1.63 x 0.010 kg/sec for regular diesel fuel and 6.55 x 0.00010 to 1.37 x 0.010 kg/sec for premium diesel fuel); test times varied between 1 and 8 hr. The rate of deposition was obtained through measurement of weight gained by metal discs fixed along the channel wall. The rate of deposit formation is best correlated by an Arrhenius expression. The sample discs in the flow reactor were varied among stainless steel, aluminum and brass; fuels were doped with quinoline, indole, and benzoyl perioxide to yield nitrogen or oxygen concentrations of approximately 1000 ppm. The most substantial change in rate was an increase in deposits for brass discs; other disc materials or the additives caused only small perturbations. Tests were also conducted in a static reactor at temperatures of 300 to 800 F for times of 30 min to 2 1/2 hr. Much smaller deposition was found, indicating the importance of fluid transport in the mechanism.

Marteney, P. J.↗

Heat Transfer and Thermal Stability Research for Advanced Hydrocarbon Fuel Technologies

In recent years there has been increased interest in the development of a new generation of high performance boost rocket engines. These efforts, which will represent a substantial advancement in boost engine technology over that developed for the Space Shuttle Main Engines in the early 1970s, are being pursued both at NASA and the United States Air Force. NASA, under its Space Launch Initiative s Next Generation Launch Technology Program, is investigating the feasibility of developing a highly reliable, long-life, liquid oxygen/kerosene (RP-1) rocket engine for launch vehicles. One of the top technical risks to any engine program employing hydrocarbon fuels is the potential for fuel thermal stability and material compatibility problems to occur under the high-pressure, high-temperature conditions required for regenerative fuel cooling of the engine combustion chamber and nozzle. Decreased heat transfer due to carbon deposits forming on wetted fuel components, corrosion of materials common in engine construction (copper based alloys), and corrosion induced pressure drop increases have all been observed in laboratory tests simulating rocket engine cooling channels. To mitigate these risks, the knowledge of how these fuels behave in high temperature environments must be obtained. Currently, due to the complexity of the physical and chemical process occurring, the only way to accomplish this is empirically. Heated tube testing is a well-established method of experimentally determining the thermal stability and heat transfer characteristics of hydrocarbon fuels. The popularity of this method stems from the low cost incurred in testing when compared to hot fire engine tests, the ability to have greater control over experimental conditions, and the accessibility of the test section, facilitating easy instrumentation. These benefits make heated tube testing the best alternative to hot fire engine testing for thermal stability and heat transfer research. This investigation used the Heated Tube Facility at the NASA Glenn Research Center to perform a thermal stability and heat transfer characterization of RP-1 in an environment simulating that of a high chamber pressure, regenerative cooled rocket engine. The first step in the research was to investigate the carbon deposition process of previous heated tube experiments by performing scanning electron microscopic analysis in conjunction with energy dispersive spectroscopy on the tube sections. This analysis gave insight into the carbon deposition process and the effect that test conditions played in the formation of deleterious coke. Furthermore, several different formations were observed and noted. One other crucial finding of this investigation was that in sulfur containing hydrocarbon fuels, the interaction of the sulfur components with copper based wall materials presented a significant corrosion problem. This problem in many cases was more life limiting than those posed by the carbon deposition process. The results of this microscopic analysis was detailed and presented at the December 2003 JANNAF Air-Breathing Propulsion Meeting as a Materials Compatibility and Thermal Stability Analysis of common Hydrocarbon Fuels (reference 1).

DeWitt, Kenneth↗

Design and evaluation of high performance rocket engine injectors for use with hydrocarbon fuels

The feasibility of using a heavy hydrocarbon fuel as a rocket propellant is examined. A method of predicting performance of a heavy hydrocarbon in terms of vaporization effectiveness is described and compared to other fuels and to experimental test results. Experiments were done at a chamber pressure of 4137 KN/sq M (600 psia) with RP-1, JP-10, and liquefied natural gas as fuels, and liquid oxygen as the oxidizer. Combustion length effects were explored over a range of 21.6 cm (8 1/2 in) to 55.9 cm (22 in). Four injector types were tested, each over a range of mixture ratios. Further configuration modifications were obtained by reaming each injector several times to provide test data over a range of injector pressure drop.

Pavli, A. J.↗

Processes and systems for reforming of methane and light hydrocarbons to liquid hydrocarbon fuels

Processes for converting methane and/or other hydrocarbons to synthesis gas (i.e., a gaseous mixture comprising H 2 and CO) are disclosed, in which at least a portion of the hydrocarbon(s) is reacted with CO 2 . At least a second portion of the methane may be reacted with H 2 O (steam), thereby improving overall thermodynamics of the process, in terms of reducing endothermicity (ΔH) and the required energy input, compared to “pure” dry reforming in which no H 2 O is present. Such dry reforming (reaction with CO 2 only) or CO 2 -steam reforming (reaction with both CO 2 and steam) processes are advantageously integrated with Fischer-Tropsch synthesis to yield liquid hydrocarbon fuels. Further integration may involve the use of a downstream finishing stage involving hydroisomerization to remove FT wax. Yet other integration options involve the use of combined CO 2 -steam reforming and FT synthesis stages (optionally with finishing) for producing liquid fuels from gas streams generated in a number of possible processes, including the hydropyrolysis of biomass.

Marker, Terry↗

Techno-Economic Assessment for the Production of Hydrocarbon Fuels via Catalytic Upgrading of Furans

This technical report documents the techno-economic analysis (TEA) implications of a biochemical/catalytic pathway for the production of long-chain hydrocarbon fuels in support to the multi-lab Catalytic Upgrading of Biochemical Intermediates (CUBI) project within the Chemical Catalysis for Bioenergy Consortium (ChemCatBio). Two distinct conceptual biorefineries centered around the process encompassing sugar dehydration to furans, aldol condensation between furans and a ketone (methyl ethyl ketone [MEK]), and a final step of hydrotreating to obtain hydrocarbons in the C 14 -C 16 range are considered: an integrated plant that simultaneously produces both furans (furfural and HMF) and ketone (MEK via 2,3-butanediol [BDO]) from sugars and a dedicated facility focused on producing furans from corn stover hydrolysate and procuring the ketone externally. In either plant, the main coproducts are adipic acid (derived from lignin) and sodium sulfate. The results from the assessment are quite comparable to those reported in previous design case focused on biological conversion of sugars to fermentation intermediates with subsequent catalytic upgrading of those intermediates to hydrocarbon fuels, thus presenting another viable alternative pathway to achieve similar fuel cost targets through purely catalytic upgrading of sugars. Since this study considers long-term performance targets for the full pathway dedicated to sugar upgrading to fuels, the critical remaining research points needed to achieve future cost goals are also discussed. Finally, this report presents a single-point sensitivity analysis around selected parameters to identify the major cost drivers of the biorefineries and provides a qualitative discussion on additional opportunities for cost reduction within the proposed concepts, namely through adding value to furans, to coproducts that may be obtained following BDO dehydration, and to lignin through alternative pathways.

09 BIOMASS FUELS↗

Effect of hydrocarbon fuel type on fuel

A modified jet fuel thermal oxidation tester (JFTOT) procedure was used to evaluate deposit and sediment formation for four pure hydrocarbon fuels over the temperature range 150 to 450 C in 316-stainless-steel heater tubes. Fuel types were a normal alkane, an alkene, a naphthene, and an aromatic. Each fuel exhibited certain distinctive deposit and sediment formation characteristics. The effect of aluminum and 316-stainless-steel heater tube surfaces on deposit formation for the fuel n-decane over the same temperature range was investigated. Results showed that an aluminum surface had lower deposit formation rates at all temperatures investigated. By using a modified JFTOT procedure the thermal stability of four pure hydrocarbon fuels and two practical fuels (Jet A and home heating oil no. 2) was rated on the basis of their breakpoint temperatures. Results indicate that this method could be used to rate thermal stability for a series of fuels.

Wong, E. L.↗

Hydrocarbon-Fueled Rocket Engine Plume Diagnostics: Analytical Developments and Experimental Results

A viewgraph presentation describing experimental results and analytical developments about plume diagnostics for hydrocarbon-fueled rocket engines is shown. The topics include: 1) SSC Plume Diagnostics Background; 2) Engine Health Monitoring Approach; 3) Rocket Plume Spectroscopy Simulation Code; 4) Spectral Simulation for 10 Atomic Species and for 11 Diatomic Molecular Electronic Bands; 5) "Best" Lines for Plume Diagnostics for Hydrocarbon-Fueled Rocket Engines; 6) Experimental Set Up for the Methane Thruster Test Program and Experimental Results; and 7) Summary and Recommendations.

Tejwani, Gopal D.↗

State Relationships of Laminar Permanently-Blue Opposed-Jet Hydrocarbon-Fueled Diffusion Flames

The structure and state relationships of laminar soot-free (permanently-blue) diffusion flames at various strain rates were studied experimentally using an opposed-jet configuration, motivated by the importance of soot-free hydrocarbon-fueled diffusion flames for many practical applications. Measurements of gas velocities, temperatures and compositions were carried out along the stagnation stream line. Flame conditions studied included propylene- and 1,3-butadiene-fueled opposed-jet diffusion flames having a stoichiometric mixture fractions of 0.7 and strain rates of 60-240/s at normal temperature and pressure. It was found that oxygen leakage to fuel-rich conditions and carbon monoxide leakage to fuel-lean conditions both increased as strain rates increased. Furthermore, increased strain rates caused increased fuel concentrations near the flame sheet decreased peak gas temperatures, and decreased concentrations of carbon dioxide and water vapor throughout the flames. State relationships for major gas species and gas temperatures for these flames were found to exist over broad ranges of strain rates. In addition, current measurements, as well as previous measurements and predictions of ethylene-fueled permanently-blue diffusion flames, all having a stoichiometric mixture fraction of 0.7, were combined to establish generalized state relationships for permanently-blue diffusion flames for this stoichiometric mixture fraction. The combined measurements and predictions support relatively universal generalized state relationships for N2, CO2, H2O and fuel over a broad range of strain rates and fuel types. State relationships for O2 in the fuel-rich region, and for CO in the fuel-lean region, however, are functions of strain rate and fuel type. State relationships for H2 and temperature exhibit less universality, mainly due to the increased experimental uncertainties for these variables. The existence of state relationships for soot-free hydrocarbon-fueled diffusion flames provides potential for significant computational simplifications for modeling purposes in many instances, allowing for effects of finite-rate chemistry while avoiding time-consuming computations of Arrhenius expressions.

Lin, K.-C.↗

State Relationships of Laminar Permanently-Blue Opposed-Jet Hydrocarbon-Fueled Diffusion Flames

The structure and state relationships of laminar soot-free (permanently-blue) diffusion flames at various strain rates were studied experimentally using an opposed-jet configuration, motivated by the importance of soot-free hydrocarbon-fueled diffusion flames for many practical applications. Measurements of gas velocities, temperatures and compositions were carried out along the stagnation stream line. Flame conditions studied included propylene- and 1,3-butadiene-fueled opposed-jet diffusion flames having a stoichiometric mixture fractions of 0.7 and strain rates of 60-240 s (exp -1) at normal temperature and pressure. It was found that oxygen leakage to fuel-rich conditions and carbon monoxide leakage to fuel-lean conditions both increased as strain rates increased. Furthermore, increased strain rates caused increased fuel concentrations near the flame sheet, decreased peak gas temperatures, and decreased concentrations of carbon dioxide and water vapor throughout the flames. State relationships for major gas species and gas temperatures for these flames were found to exist over broad ranges of strain rates. In addition, current measurements, as well as previous measurements and predictions of ethylene-fueled permanently-blue diffusion flames, all having a stoichiometric mixture fraction of 0.7, were combined to establish generalized state relationships for permanently-blue diffusion flames for this stoichiometric mixture fraction. The combined measurements and predictions support relatively universal generalized state relationships for N2, CO2, H2O and fuel over a broad range of strain rates and fuel types. State relationships for O2 in the fuel-rich region, and for CO in the fuel-lean region, however, are functions of strain rate and fuel type. State relationships for H2 and temperature exhibit less universality, mainly due to the increased experimental uncertainties for these variables. The existence of state relationships for soot-free hydrocarbon-fueled diffusion flames provides potential for significant computational simplifications for modeling purposes in many instances, allowing for effects of finite-rate chemistry while avoiding time-consuming computations of Arrhenius expressions.

Lin, K.-C.↗

Liquid Oxygen Cooling of Hydrocarbon Fueled Rocket Thrust Chambers

Rocket engines using liquid oxygen (LOX) and hydrocarbon fuel as the propellants are being given serious consideration for future launch vehicle propulsion. Normally, the fuel is used to regeneratively cool the combustion chamber. However, hydrocarbons such as RP-1 are limited in their cooling capability. Another possibility for the coolant is the liquid oxygen. Combustion chambers previously tested with LOX and RP-1 as propellants and LOX as the collant demonstrated the feasibility of using liquid oxygen as a coolant up to a chamber pressure of 13.8 MPa (2000 psia). However, there was concern as to the effect on the integrity of the chamber liner if oxygen leaks into the combustion zone through fatigue cracks that may develop between the cooling passages and the hot gas side wall. In order to study this effect, chambers were fabricated with slots machined upstream of the throat between the cooling passage wall and the hot gas side wall to simulate cracks. The chambers were tested at a nominal chamber pressure of 8.6 MPa (1247 psia) over a range of mixture ratios from 1.9 to 3.1 using liquid oxygen as the coolant. The results of the testing showed that the leaking LOX did not have a deleterious effect on the chambers in the region of the slots. However, there was unexplained melting in the throat region of both chambers, but not in line with the slots.

Armstrong, Elizabeth S.↗

Liquid oxygen cooling of hydrocarbon fueled rocket thrust chambers

Rocket engines using liquid oxygen (LOX) and hydrocarbon fuel as the propellants are being given serious consideration for future launch vehicle propulsion. Normally, the fuel is used to regeneratively cool the combustion chamber. However, hydrocarbons such as RP-1 are limited in their cooling capability. Another possibility for the coolant is the liquid oxygen. Combustion chambers previously tested with LOX and RP-1 as propellants and LOX as the coolant demonstrated the feasibility of using liquid oxygen as a coolant up to a chamber pressure of 13.8 MPa (2000 psia). However, there was concern as to the effect on the integrity of the chamber liner if oxygen leaks into the combustion zone through fatigue cracks that may develop between the cooling passages and the hot gas side wall. In order to study this effect, chambers were fabricated with slots machined upstream of the throat between the cooling passage wall and the hot gas side wall to simulate cracks. The chambers were tested at a nominal chamber pressure of 8.6 MPa (1247 psia) over a range of mixture ratios from 1.9 to 3.1 using liquid oxygen as the coolant. The results of the testing showed that the leaking LOX did not have a deleterious effect on the chambers in the region of the slots. However, there was unexplained melting in the throat region of both chambers, but not in line with the slots.

Armstrong, Elizabeth S.↗