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THE AMERICAN SOCIETY OF MECHANICAL ENGINEERS

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Copyright 0 1999 by ASME All Rights Reserved Printed in U.S.A.

THE USE OF BIO-FUELS AS ADDITIVES AND EXTENDERS' 1111111111111111111111111


FOR AVIATION TURBINE FUELS

Melanie A. Kimble-Thom David L. Stanley


Baere Aerospace Consulting Purdue University
80 N. Sharon Chapel Road Department of Aviation Technology
West Lafayette, Indiana 47906 1 Purdue Airport Road
United States West Lafayette, Indiana 47906
765-494-9757 United States
765-494-2305 765-494-6266
102741.424@compuseive.com 765-494-2305
dIstanley@rtech.purdue.edu
John T. Cholis
Purdue University
Aviation Technology Denver W. Lopp
1 Purdue Airport Road Purdue University
West Lafayette, Indiana 47906 Department of Aviation Technology
United States 1 Purdue Airport Road
765-494-6266 West Lafayette, Indiana 47906
765-494-2305 United States
765-494-6387
765-494-2305
dwlopp©tech.purdue.edu

ABSTRACT WHY USE BID-FUELS IN ASTM 0-1655 TURBINE FUEL?


The use of biologically derived oils and fuels has received In recent months the use of bio-fuels as replacements for
increasing visibility in recent years. A combination of filel traditional petroleum based materials has received a lot of press. One
availability, refinery capacity and environmental icspunsibility has of the major activities of the National Soybean Growers Association
resulted in interest in their use in turbine engine fuels. is to find new markets for soy based products. To this end, the
Such a soy methyl ester (SME) is being evaluated as a possible Indiana Soybean Development Council has funded research on the
extender and/or additive for aviation turbine fuel per ASTM D-1655. viability and challenges of using soy methyl esters (SME) as an
Laboratory testing indicates additive levels of up to 2% by volume extender for commercial aviation turbine fuel.
can be used while still meeting ASTM D-1655. Engine testing Indeed, there are several potential benefits to be obtained aside
performed at 20% blending levels have demonstrated potential fuel from the extension of current petroleum resources. The use of soy
consumption improvements as well as reduction in NO emissions. diesel in ground based applications like city buses has resulted in an
The final blend levels have not yet been determined. observed reduction in emissions, possible power benefits and
The use of SME even at low levels could provided performance improved environmental friendliness with odor abatement and
benefits. Because of the oil nature of SME, a small addition could biodegradability.
result in significant increases in lubricity. The use of the higher It was hoped the use of SME as an extender to current aviation
flashpoint SME could result in an upward shift in flashpoint with turbine fuels would allow for more end gallons of fuel from current
little or no effect to other physical properties. With increased petroleum reserves while reaping some of the benefits observed in
visibility to work place considerations, the potential for "odor" other applications using SME and possibly benefits unique to the
abatement is also of interest application.

Presented at the International Gas Turbine & Aeroengine Congress & Exhbdion
Indianapds, Indiana — June 7-June 10, 1999
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Aviation Turbine Fuel Availability otherwise secured, the sampling probe for emissions was located at
In 1997, the US commercial airline industry used 1.4 million the approximate center of the exhaust plume just at the tailpipe exit
barrels of fuel per day or 77 million gallons of jet fuel per day A heated Teflon sample line carried the sample gases to the
(Salisbury, 1997). To make those 77 million gallons, it took Continuous Emissions Monitoring system while maintaining
approximately 750 million gallons of crude oil or 14 million barrels temperatures above 121°C (250°F) to prevent condensation of
per day. An average jet fuel yield on the refmery runs in May 1997 moisture within the line.
was 10.3% (Petroleum Intelligence, 1997). 02, CO2, SO2, NOx, and CO concentrations were measured
With increasing pressure to tind alternate sources for petroleum, following the removal of moisture through a standard condensation
pressure to reduce dependence on foreign sources and environmental process. These gas concentrations were measured on a dry volumetric
pressures to improve the cleanliness of combustion engines, the use basis (ppmdv). Total hydrocarbons (THC) were measured on a wet
of SME in aviation turbine fuel warrants investigation. If Jet A were volumetric basis (ppmwv). Analyzers were calibrated with EPA
extended 5% with SME, this would equate to 3.9 million gallons of certified gases prior to testing, and sampling system bias and
fuel or 37.5 million gallons of base crude oil per day. calibration drift were checked prior to and after each of the test
Because of poor refining margins and sharper focus on gasoline, operations.
there could be a cut into the jet net inventories. Slim gasoline Engine operations were performed on three different fuel
inventories and weak jet fuel prices relative to gasoline could push samples: 100% Jet-A, 98% Jet-A and 2% SME, and 80% Jet-A and
refuters to adjust yields in favor of gasoline and overall throughput 20% SME. Given the large amount of time the aircraft spends on the
reductions may be in store to improve refining margins. ground holding or taxing, one goal of the project was to examine idle
power exhaust emissions, which presented no operational problem.
Lubricity Improvements However, studies at high power - the opposite end of the spectrum -
While the effects of poor lubricity are generally not observed in did present operational considerations, with respect to both engine
the US market, "dry" fuel is becoming more and more of a problem temperatures, and safety. In view of these considerations, it was
for non-US fuel users. New environmental requirements have decided to conduct tests at idle and at medium power, approximately
resulted in refiners more severely hydrotreating their fuels. The fuel 500 horsepower.
made by this method is more "dry", meaning it has less ability to For idle operations, little if any change was observed across the
lubricate fuel wetted components in the engine system. This loss of three test fuels for oxygen, carbon dioxide, nitrogen oxide, and total
• lubricity means the potential for a reduction in the useful life of hydrocarbons. On the other hand, both sulfur dioxide and carbon
critical components which are dependant on this lubrication. monoxide trended upwards as the percent of SME increased For
Problems involving these more severely hydrotreated fuels have been operations at the higher power settings, little change was observed for
seen in isolated markets since 1996. oxygen, carbon dioxide, and nitrogen oxides. Sulfur dioxide,
One of the potential benefits obtained from the use of SME, however, was measured at 7.63 ppmdv for Jet-A, decreased to 7.38
even at low levels, is an improvement in lubricity. Laboratory testing ppmdv for the 98% Jet-A blend, and continued dropping to 4.85
was done using the Ball on Cylinder Lubricity Evaluator (BOCLE) ppmdv for the 80% Jet-A / 20% soybean methyl ester blend Carbon
per ASTM D-5001. Lubricity is a measurement of the size of a wear monoxide measured 24.1 ppmdv for Jet-A operations, dropped to
scar formed on the surface of the test ball. The measurement is the 16.4 ppmdv on the 9804 Jet-A /2% SME blend, and then reverse-
average of the maximum and minimum axes of the wear scar, trended upwards to 21.6 ppmdv on 80% Jet-A / 20% SME. The
measured in millimeters and reported as a wear scar diameter (WSD). reason for the trend was unclear and further research on this result is
A smaller value is preferable. recommended.
The laboratory testing was performed with 2% soy methyl esters To summarize the emissions fmdings, test results for the high
in iso-octane. The resulting lubricity value was 0.56nun avenge power settings, two values changed significantly as a percentage:
WSD. The base iso-octane was so dry, it could not be accurately sulfur dioxide and carbon monoxide. Both of these showed lower
measured due to changes in the wear mechanism during the test concentrations in the SME-blended fuels. It is interesting to note,
(adhesive and scuffing wear). For comparison, the average WSD of a however, that for idle power operations, the trend for sulfur dioxide
typical aviation fuel Was 0.50 to 0.60mm avg. WSD. The lubricity of was upwards, that is, concentrations increased with higher blending
some of the "dry" fuels has been observed to be greater than 0.70nun ratios of SME. None of the changes observed appear to be
remarkable or particularly anomalous, and neither do these results
Improved Emissions appear to contraindicate further testing. (Table 1).
Aircraft engines are one of the fastest growing sources of NO
and CO especially around airport areas. In terms of public
perception, this growth seems even worse due to the fact that other More Pleasant Combustion Odor
sources of NO and CO are being reduced The Environmental Anyone who has had to follow behind a city bus is familiar with
Protection Agency (EPA) has established National Ambient Air the foul smelling belch of black smoke corning from the exhaust.
Quality Standards (NAAQS) for air pollutants. Because aircraft Testing has been done in many US markets using soy diesel instead
exhaust is a significant contributor to these pollutants, the of traditional diesel in the buses. As a result, not only was the belch
International Civil Aviation Organization (ICAO) aircraft standards of smoke reduced, the odor was more like french fries or baking
have been included into NAAQS. For the first time EPA regulations bread.
will be consistent across aircraft and engine type and testing will be During the 1998 meeting of the Coordinating Research Council
included into the base fuel specifications (Bokulich, 1998). This (CRC), a professional organization which provides technical data for
means anything which can help improve these emissions will have a ASTM under the auspices of the American Petroleum Institute (API),
positive impact on aviation fuel. a new concern was presented. It was announced there was an
Exhaust emissions testing was performed on-site at the Purdue indication that a group might be formed to address the odor of burnt
University Airport by Clean Air Engineering of Palatine, IL. A kerosene. Ramp workers, baggage handlers and other personnel who
Garrett TPE-331-3U turboprop engine on the wing of a Hadley-Paige must work around jet aircraft had voiced a concern regarding the
HP 137 was used for this project. With the aircraft chocked and odor and it was thought this concern should be addressed

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If the odor benefits observed with the use of SME on city buses Actual freeze point testing on a 2% blend showed no change in the
could be obtained through the use of SME in Jet A, ramp workers base freeze point of the Jet A.
could find the work environment much less unpleasant Initial engine
testing with 20% blends did show some changes in the exhaust odor Density (Specific Gravity). The density of the SME, 0.883
to more of an "food oil" type odor. The extent to which such g/cc, is much higher than the specified density rangeof 0.775 to
improvements might be made still needs to be studied. 0.840 glee. There were concerns for both the ability to meet the
specified density range as well as the potential for separation due to
Increased FlashpoiM different densities.
Following the explosion and crash of a Boeing 747 out of Testing was done on various blend ratios, and the mixture was
Kennedy Airport, a lot of attention was placed on the safety of the jet found to be stable with no separation observed over time. Using a
fuel. Concerns were raised regarding the flanunability of kerosene, density meter, testing showed the 2% by volume blend was well
especially as a vapor in an empty or nearly empty fuel tank. One of within specification limitations. Further testing showed additive
the potential solutions was an evaluation of the flashpoint of fuel. levels to nearly 50% by volume would not drive an average density
Flashpoint is directly related to the lighter distillates being able fuel out of specification.
to evaporate and form a flammable mixture. Most methods of raising
the flashpoint involve changing the distillation range of the entire Viscosity. The viscosity of SME is nearly four times the
fuel. One of the impacts of this shift is reduced flammability, which typical value of Jet A. In addition, because of the higher freeze point,
is the goal. Unfortunately, such a change also causes changes in the fuel may not be able to meet the 8 cSt maximum requirement at
other properties, including viscosity and combustibility. These —20°C (-4°F).
changes negatively effect engine performance such as cold starting Viscosity testing per ASTM 0-445 was performed using the 2%
capabilities and air starts at altitude. by volume blend The resulting values did show an observable shift
If SME, which has a much higher flashpoint (112°C (234°F) by from the values of the base jet fuel, but still met the 8.0 cSt maximum
ASTM 0-93, Penslcy-Martens) is added to Jet A (minimum requirement at —20°C (-4°F).
flashpoint of 38°C(101°F)), then the overall percentage of light ends
to the total fuel volume will be reduced. This is done without Total Acid Number. The total acid number (TAN) of SME is
actually shifting the base distillation curve of the kerosene. about four times that allowed by ASTM 0-1655. Concerns would be
Laboratory testing will be required to determine if this produces a the high acid number of the soy diesel could cause the entire fuel
reliable shift in flashpoint. blend to fail TAN, could cause premature degradation of the fuel,
and/or elastomeric attack. The loss of fuel stability means either the
CHEMICAL EVALUATION OF SOY METHYL ESTER *fuel can not be stored or there will be coking and deposits within the
BLENDS engine. In addition, the long term stability of the diesel may not be as
In order to evaluate the viability of using SME as a fuel good as that of the Jet A.
extender, it was necessary to evaluate base chemical properties and Testing done with a 2% blend did indeed show a ten-fold
determine whether any would pose an insurmountable obstacle. Also, increase in the TAN of the base Jet A. While it was still well within
it was necessary to determine what, if any, changes would need to be the specified limit (0.028 mg KOH versus 0.10 max), this increase
made to the base SME. In addition, an evaluation of these properties could cause storage stability and fuel life issues. In addition, this
would provide likely blending levels of SME which would not same testing showed the existent gum content of the fuel using a 2%
adversely affect the end jet fuel meeting current specifications. This blend would not meet the specification (42 mg/L versus 7 mg/L
additive level would need to be such that a marginal fuel would not max.)
fail to meet specification after the addition of SME.
In 1995, under a grant from the Indiana Soybean Development ENGINE PERFORMANCE
Council, an Impact Evaluation Study was performed to determine Dynamic testing phases were performed during the summers of
which properties were likely to prevent the use of SME in Jet A, and 1996, '97, and '98. The test vehicle was a Garrett WE 331-3U
which might necessitate an adjustment to current fuel specifications. Turbo Prop engine as standard equipment on a Hadley Page Jet
Once these properties were identified, testing to determine how Stream Mark 1 aircraft. Normal operating parameters for this engine
severe the effects would be and to determine what was the maximum were established using Garrett's performance figures as a data base
amount of SME which could be added. for comparison (Figure 2.) The data was collected through operator
observation at predetermined time intervals. The aircraft
Show Stoppinq Properties of SME as a Jet Fuel Extender instrumentation was used for data monitoring. .
After reviewing the physical properties of SME, four properties The aircraft fuel system was modified to accommodate three
were identified as potential obstacles. Those properties were external tanks as the fuel source for SME / JET-A blended fuels.
freeze/cloud point, viscosity, density, and total acid number (TAN). Each tank had a designation of either straight JET-A, a blend of 98%
Freeze Point. Of the four properties, the one of greatest JET-A / 2% SME, or 80% JET-A / 20% SME. Positive and
concern is cloud point. Because SME products do not actually immediate control of the three fuel sources was obtained through a
freeze, the concern is the formation of waxy particles which can system of external valves and manifolds.
block filters and valves. The cloud point for SME is reported as For the test session in 1996, a target horsepower of 550 was
—3°C (26°F), significantly above the maximum freeze point of —40°C established as a safe ground operating range. However, that was
(-40°F) for Jet A. reduced to 500 for subsequent testing in 1998. The time window for
This property was assumed to be the greatest hurdle, so testing supplying the three different fuels to the engine was 6 minutes each
was done to determine the greatest amount of SME which could be in 1996 and 10 minutes each in 1998, at the target horsepower. The
added to Jet A without the obvious formation of waxy particles. run times were constrained by the fuel handling system and the
Based on testing done at —28°C (-20°F), it was determined additive supply fuel tank capacities.
levels greater than 3% were definitely unacceptable. At 3% by Critical to the results of the research, it is important to note once
volume, the formation of crystals was observed in the bulk sample. the target horsepower was obtained no manual throttle changes were

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attempted, as any change would invalidate the data. Failure of an separated from the bulk SME. It has been hypothesized the
engine fuel control unit iti 1997 precluded further testing that summer differences in observed combustion properties may have been due to
and no data was obtained for that period. The failure was identified as contamination of the original SME with cleaning solution as well.
a mechanical problem not related to the use of SME. During the course of the investigation, it was concluded such
Critical engine operating parameters of turbine temperature, contamination of the barrels is not a completely uncommon
fuel pressure, and fuel flow were all nominal values and within the occurrence. While such contamination may have less of an impact on
engine manufacturer's specifications. Engine start and transient current uses of SME, it is of significant concern for a safety critical
conditions showed no abnormalities. application such as aviation fuel. Such quality issues would have to
Horsepower readings were observed closely and recorded be addressed and contamination prevention methods demonstrated
constantly. The test results for 1996 are presented in Table 2, and for before SME would ever be approved for use in commercial or private
1998 in Table 3. aircraft applications.

FUEL CONSUMPTION Materials Compatibility


Fuel consumption tests were made for three different fuel Another issue with SME was its compatibility with the rubber
mixtures; I) 100% Jet A, 2) 98% Jet A, 2% SME and 3) 80% Jet A, used in typical aviation environment, particularly supply hoses. The
20% SME. With the engine settings fixed, consumption rates and neat SME was found to be very aggressive to the fuel hoses used
related horsepower readings were recorded for each mixture. The during the testing. It dissolved the rubber almost instantly. These
results for 1996 are presented in Table 4 and for 1998 in Table 5. hoses were manufactured using Buna-N, a nitrite rubber which was
Using an 80% Jet A, 20% SME mixture, an additional analysis common in older aircraft systems.
was conducted in the 1998 test by advancing the power from 480 The presence of SME in an aviation environment will need to be
horsepower to the initial Jet A 500 horsepower setting. The result is carefully controlled to prevent the contamination of fuel supply hoses
recorded in Table 6. Instead of increasing fuel consumption, fuel with neat SME. In addition, full rubber compatibility testing will
flow actually decreased with the elevated power reinstated to 500 need to be performed.
horsepower. Although this could not be rationalized, one suggestion
may be that with the adjustment of the engine settings to 500 CONCLUSIONS
horsepower, fuel control parameters were reprogrammed and the The testing performed to date was limited by available funding,
results were not measurable with the instnunentation used in the test • available hardware and the requirements of the involved grant. This
In summary, the tests suggest that fuel consumption will research was designed to be exploratory in nature. The goal was to
decrease with a higher ratio mixture of Jet A and SME, along with a prove or negate the value of further testing SME as an extender for
decrease in engine horsepower. Because of the irregular result of a commercial aviation filets. Based on the completed activities several
decreased fuel consumption rate in an 80120 mixture during an general conclusions could be made. These conclusions were
increased power setting, additional research in this area would be grouped as chemicaU physical, and operational. At the completion of
recommended using improved instrumentation and controlled the funded testing, it was concluded that further testing would be
environmental conditions. warranted

ISSUES WITH THE USE OF SOY METHYL ESTERS Chemical/Physical Conclusions


The use of soy methyl esters as an extender for such a critical The chemical testing done with respect to chemical and physical
application as aviation fuel, raises several concerns. These concerns properties indicated:
range from the available supply of soybeans, to the quality of the end
product, to materials compatibility. I. The maximum blend level likely without a change to current
aviation fuel specifications was 2% SME by volume. This was
Soybean Supply and Soy Methyl Ester Consistency dictated by the freeze point
As noted at the beginning of this article, a 5% extension of just 2. The 2% SME by volume did not force any of the required
the fuels used in the US would require 3.9 million gallons of SME properties of Jet A per ASTM D-1655 out of specification.
per day. With all of the other applications for soybean oil, there are 3. Total acid number was significantly affected by the presence of
concerns regarding the ability of the soybean growers to be able to 2% SME. The long term consequences of this effect would
supply sufficient quantities of SME. Due to the nature of jet fuel need to be detamined
specifications, it would be difficult to change back and forth from 4. Significant lubricity improvements were observed with the
using or not using SME. addition of 2% SME.
Experiments performed at Purdue University during 1997 and 5. The use of SME with Buna-N o'rings and other packings is not
1998 demonstrated fluctuations in the consistency of the soy product. recommended due to excessive swell.
During engine testing, differences in performance properties were
observed between the first product received and subsequent Operational Conclusions
deliveries. The reason for these differences could not be determined I. The available test hardware had several variables which could
as a physical property difference. One hypothesis was the difference have had a affect on the resultant data. Further testing should be
was actually a difference in product quality. performed using hardware without these multiple variables.
2. Testing to date did not confirm or disprove the hypothesis of
Soy Methyl Ester Quality improved emissions. Data taken to date showed indications of
During the course of testing at Purdue University, the second positive trending. This indicated there was a potential for
shipment of SME was determined to have been contaminated with a operational improvements.
highly volatile cleaning solution which was used to clean the barrels 3. Within the limited rim time, there were indications of fuel
in which the SME was provided. This caused significant problems consumption improvements.
with the engine perfomuince and with compatibility with the rubber
components. The material was a low flashpoint fluid which

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FUTURE WORK Table 1
The testing performed to date was very limited in nature and Summary of Exhaust Emissions Test Results
was designed as a screening test. The testing did indicated there was
a potential application and did not counter indicate further testing Medium Horsepower (Approximately 500 Horsepower
being performed Subsequent grant activities are recommended with Source Constituent 0% SME 2% SME 20% SME
the following tests suggested. Oxygen (%) 17.2 17.3 17.3
Carbon dioxide (%) 2.73 2.65 2.65
I. Design and perform a full rubber compatibility matrix to Sulfur dioxide (ppmdv) 7.63 7.38 4.85
determine the potential for o'ring and other rubber damage. Nitrogen dioxide (ppmdv) 67.3 66.6 66.1
2. Perform TAN and thermal stability testing on the reference Carbon monoxide (ppmdv) 24.1 16.4 21.6
blend sample from original test fluid to determine thermal Total hydrocarbons (ppmwv) 1.79 1.42
3.58
stability over time.
3. Obtain multiple Jet A samples, containing marginal fuels at both
ends of the specification. Use these base fuels for further
blending studies to evaluate the impact of adding SME to Ensine Idle
Source Constituent 0% SME 2% SME 20% SME
physical properties.
4. Repeat actual engine testing under controlled test cell Oxygen (%) 19.0 19.0 19.0
conditions. Testing should be nut on a single test fluid for a Carbon dioxide (%) 1.41 1.42 1.45
longer duration, and emission and horsepower data obtained Sulfur dioxide (ppmdv) 10.1 13.8 16.7
over time. Nitrogen dioxide (ppmdv) 11.3 11.6 11.8
5. While actual aircraft testing is beyond the scope of this research Carbon monoxide (ppmdv) 460 463 510
facility, should continued ground testing support it, testing Total hydrocarbons (ppmwv) 280 291 291
across the full aircraft operations envelope is recommended.
Table 2
Resultant Horsepower with Fuel Blends
1996 Tests

1996 JET-A .98 /.02 .80 / .20


TEST 1 Horsepower 550 550 540
TEST 2 Horsepower 550 550 540
TEST 3 Horsepower 550 NO DATA 540
TEST 4 Horsepower 550 550 510

Table 3
Resultant Horsepower with Fuel Blends
1998 Tests

1998 JET-A .98 / .02 .80 / .20


Figure 1 TEST 1 Horsepower 498 460 440
Soy Methyl Ester Attack on Buna-N Hose TEST 2 Horsepower 500 498 480

Table 4
Fuel Consumption 1996

Parameter ° JET A 98/2 80/20


Consumption 1.092 gal/min 1.35 gal/min 1.007 gal/min
Horsepower 550 550 540

Table 5
Fuel Consumption

Parameter JET A 98/2 80/20


Consumption 1.47 gal/min 1.46 gal/min 1.38 gal/min
Horsepower 500 498 480

Figure 2
Diagram of the Engine Run Test Setup

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Table 6
Fuel Consumption at Equivalent Horsepower

80/20 I 1.15 gal/min 500 horsepower

Table 7
Jet A : Soy Methyl Ester Test Fluids

Jet A Fuel purchased from local FB0


Soy Methyl Esters Three different batches available
commercially
Test Blend #1 by volume 98% Jet A 2% SME
Test Blend #2 by volume 80% Jet A 20% SME

REFERENCES

Bolculich, F., July 1998, "Aircraft Emissions Standards", Aerospace


Engineering,p. 12.

Petroleum Intelligence Weekly News release, June 16, 1997, "US Jet
Fuel Prices Set Course for Smoother Summer",
hmil/www.enerayinte1.com/pr061397.htrn.

Salisbury, L., Feb 13, 1997, "AMR strike —jet fuel prices", Reuters
Ltd.

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