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Steven Zabarnick
300 College Park, KL463, University of Dayton Research Institute, Dayton, Ohio 45469-0140
Jet fuel is the primary coolant used in high-speed aircraft. A decrease in surface deposition (fouling)
is often seen as jet fuels and pure hydrocarbons are heated above approximately 370 °C, as measured
by the wetted wall or film temperature. This temperature is near the critical temperature of most
jet fuels. Two explanations have been offered for this decrease in deposition under supercritical
conditions. One explanation is that the decrease reflects the temperature where hydroperoxide
precursors to solids formation are depleted by thermal decomposition, interrupting the radical
chain reactions forming solids. Another explanation is that the solvent properties of the fuel become
enhanced under supercritical conditions, with the surface deposition reduced essentially by keeping
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the solids in solution. In single-tube heat exchanger tests with pure hydrocarbons and jet fuels of
widely varying critical temperature, it was found that the deposition decrease is insensitive to fuel
critical temperature but very sensitive to residence time/heating rate, indicating that the deposition
decrease is a fuel chemistry effect rather than an effect of the supercritical nature of the fuel.
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In the long term, the heat management requirements of composition data from (Martel, 1988).
future Air Force aircraft are expected to be sufficiently
demanding that the aircraft fuel system will need to operate exposed to heat and fuel flow) is on the order of hours.
at much higher temperatures. The goal for this long term Most researchers have seen a peak in surface deposition
near 370 °C (700 °F) when the deposition is plotted as a
fuel is to increase the thermal stability temperature limit
to480°C (900°F) (Edwards, 1993). This high temperature function of wetted wall or film temperature. This is
is above the fuel thermodynamic critical temperature, illustrated in Figure 1 for two sets of data from different
which typically ranges from 370 to 415 °C (700-780 °F) test devices (Taylor, 1974; TeVelde and Glickstein, 1983).
for current jet fuels (Martel, 1978). Typical fuel system The peak disappears if the dissolved oxygen in the fuel,
pressures are approximately 34-68 atm (500-1000 psia), typically about 65-75 ppm (w/w) in air-saturated fuel, is
well above the fuel critical pressure. Calculated critical removed (Bradley et al., 1974; Taylor, 1974). One goal of
data for typical fuels are shown in Table I. The physical our work is to investigate the source of this deposition and
and chemical properties of supercritical fuels are expected determine ways to reduce, avoid, or eliminate it without
to be dramatically different from gases and liquids. There resorting to removing the dissolved oxygen from the fuel.
is little information available on the properties of fuels The decrease in deposition above approximately 370
when operated at supercritical conditions (Edwards, 1993). °C has been given both physical and chemical explanations.
One area of concern for fuels operating at high tem- According to Taylor (1974), “the sharp drop in autoxidative
peratures is their thermal decomposition and the formation deposit formation rates... would appear to reflect an effect
of insoluble products that deposit onto metal surfaces of the transition between the liquid phase and the
(fouling). This area has been studied in heated metal tubes supercritical vapor phase.” Hazlett (1977) prefers a
(simulating aircraft nozzles and heat exchangers) by chemical explanation: “The deposit rating decreases above
various investigators (Hazlett, 1991; Hazlett et al., 1977; 385 °C. Since hydroperoxide is depleted at this temper-
Bradley et al., 1974; TeVelde and Glickstein, 1983; ature, the tie-in between hydroperoxide decomposition
Marteney and Spadaccini, 1986; Taylor, 1974; Faith et al., and deposit formation is reinforced.” Similarly, Marteney
1971; Chin and Lefebvre, 1992). These high-temperature and Spadaccini (1986) state “the sudden decrease in
tests cover a wide range of flow rates and residence times. deposit formation at temperatures above 645 K [372 °C]
The residence time of a given fuel molecule inside the may be indicative of a depletion of oxygen in the fuel,
heated tube is typically on the order of seconds, while the related to the known decomposition of hydroperoxides at
test time (or the amount of time the metal surface is elevated temperatures.”
0888-5885/93/2632-3117$04.00/0 © 1993 American Chemical Society
3118 Ind. Eng. Chem. Res., Vol. 32, No. 12, 1993
The research described in this paper was motivated by assessment of particulates formed in the heated section.
a desire to discover if the decrease in surface deposition A three-way valve downstream of the back pressure valve
above about 370 °C, which creates the deposition peak, is allows the product flow to be diverted to a sampling system
indeed due to supercritical fuel properties. Although other where the liquid products are analyzed (off-line) at ambient
conditions. The stainless steel test section is cut into 5-cm
investigators have studied a wide variety of conditions,
most ofthefuelsand hydrocarbons tested had very similar (2-in.) sections and analyzed by carbon burnoff (Leco
critical temperatures. One of the approaches of this work surface carbon analyzer) to measure carbon deposition.
was to investigate several similar hydrocarbons (e.g., the
The tube wall temperature distribution is measured by
normal paraffins) with widely varying critical tempera- K-type thermocouples spot-welded to the outside of the
tures, but presumably similar deposition chemistry, to tube. The fuel temperature at the furnace outlet is
determine the effect of fuel critical temperature on the measured by a thermocouple inserted into the flow.
Pressure was measured between the filter and the back
deposition behavior. A second approach was to test the
effect of fuel flow rate on the deposition-temperature pressure valve and also at the pump. The fuel temperature
behavior above 370 °C. The flow rate affects the wall/fuel distribution is estimated with a heat transfer program
temperature d ifference, the residence time, and the heating (Edwards, 1992; Edwards and Anderson, 1993) from the
rate. Pure hydrocarbon fuels are fairly expensive, so JP-7 measured wall temperature distribution, fuel flow rate,
was used in most of the tests as the baseline hydrocarbon
and the initial temperature of the fuel entering the furnace
fuel. JP-7 (MIL-T-38219) is the Air Force’s highest (20 °C). The fuel properties (density, thermal conduc-
thermal stability fuel and consists mainly of paraffins and tivity, viscosity, heat capacity) vary significantly through-
out the tube in a given test where the fuel temperature
cycloparaffins. Finally, a representative Jet A-l fuel was
studied for comparison to the JP-7 and pure hydrocarbon might vary from 20 to 620 °C (70-1150 °F) (Edwards,
results. These results will be used to develop computa- 1993), so the calculation uses temperature-dependent fuel
tional fluid dynamic and chemistry (CFDC) models of properties. It is found that test times on the order of
fuel system components (Katta and Roquemore, 1993). 10-20 h are required for JP-7 and pure hydrocarbons to
give reproducible deposition results above the measure-
ment background. For more typical (lower thermal
Experimental Section
stability) fuels, deposition amounts are much larger and
The apparatus used in this study is shown in Figure 2. test times can be shorter.
The fuel is air-sparged to assure air saturation of the fuel.
The flow system is initially purged with nitrogen prior to Results and Discussion
fuel introduction to remove any air present. The fuel is
pumped through the system with a high pressure liquid A typical result of a JP-7 experiment is shown in Figure
chromatography pump. An initial 0.45-/im filter is used 3. As described in the Introduction, the data is reduced
to remove any particulates present from fuel handling and by plotting the deposition (scaled by the tube surface area
to maintain a consistent filtration level between fuels. The and the total fuel flow) as a function of wall temperature,
test section consists of an 89-cm-long, 3.2 mm (0.125-in.) excluding points of decreasing wall temperature after the
o.d., 1.4-mm (0.055-in.) i.d. 304 stainless steel tube passing tube exits from the furnace. Thus, the deposition is
through a Lindbergh laboratory furnace. The tube makes reported as ng of deposit carbon/(g of fuel fed-cm2), or
a 180° bend inside the furnace, thus passing through the ppm/cm2. The deposition-wall temperature results for
30-cm (12-in.) actively heated portion of the furnace twice. several 12 mL/min flow rate experiments are shown in
After exiting from the furnace, the products are cooled to Figure 4. Various tests are shown spanning different
room temperature and filtered before passing through a ranges of wall temperature. The decrease in deposition
back pressure valve which regulates the system pressure. near 440 °C (825 °F) is very similar to the behavior shown
A 5-Mm filter is used to prevent particulates from fouling in Figure 1, although the deposition decrease begins at a
the back pressure valve; the filter also gives a visual temperature significantly higher than the fuel critical
Ind. Eng. Chem. Res., Vol. 32, No. 12,1993 3119
©— WalJT.C
S— Fuel T, C (calc) 0 C deposition, pg
-X— Fuel T, C (meas)
The chemical processes that result in deposit formation Edwards, T. “USAF Supercritical Hydrocarbon Fuels Interests”;
AIAA Paper 93-0807; AIAA: Washington, DC, January 1993.
are poorly understood. The absence of oxygen greatly
reduces deposit formation (Taylor, 1974; Bradley et al., Edwards, T.; Anderson, S. D. “Results of High Temperature JP-7
Cracking Assessment”; AIAA Paper 93-0806, AIAA: Washington,
1974; Hazlett, 1991). Hazlett (1977,1980) proposed alkyl DC, January 1993.
hydroperoxides as precursors to deposits due to the Edwards, T.; Liberio, P. D. The Thermal-Oxidative Stability of Fuels
observation that hydroperoxide depletion appeared to at 480 °C (900 °F). Paper be presented at Symposium on Distillate
correlate with tube deposit rating in a JFTOT. More Fuel Auto-Oxidation Chemistry, ACS National Meeting, San
recently, evidence has appeared demonstrating an inverse Diego, CA, March 1994.
correlation between the ability of a fuel to form peroxides Faith, L. E.; Ackerman, G. H.; Henderson, H. T. “Heat Sink
Capabilities of Jet A Fuel: Heat Transfer and Coking Studies”;
with its deposit-forming tendency (Heneghan and Zabar- NASA CR-72951; NASA Lewis Research Center: Cleveland, OH,
nick, 1992). Efforts are underway to incorporate oxygen July 1971.
consumption and solid deposition reactions into compu- Fish, A. Rearrangement and Cyclization Reactions of Organic Peroxy
tational fluid dynamic models of fuel system components Radicals. In Organic Peroxides; Swern, D., Ed.; Wiley-Inter-
(Katta and Roquemore, 1993). science: New York, 1970; Vol. I, pp 141-198.
Frankenfeld, J. W.; Taylor, W. F. Deposit Formation from Deoxy-
genated Hydrocarbons. 4. Studies in Pure Compound Systems.
Summary Ind. Eng. Chem. Prod. Res. Dev. 1980,19, 65-70.
Hazlett, R. N. Fuel Radical Reactions Related to Fuel Research. In
The results presented in this paper indicate that surface Frontiers of Free Radical Chemistry; Pryor, W. A., Ed.; Academic
deposition from supercritical hydrocarbon fuels is con- Press: New York, 1980; pp 195-223.
trolled by chemical processes in the fuel, rather than by Hazlett, R. N. Thermal Oxidation Stability of Aviation Turbine
supercritical solvent properties of the fuel. The primary Fuels; ASTM Monograph 1; American Society for Testing and
Materials: Philadelphia, 1991.
deposition property of interest was the decrease in
Hazlett, R. N.; Hall, J. M.; Matson, M. Reactions of Aerated
deposition usually seen at temperatures above approxi- n-Dodecane Liquid Flowing Over Heated Metal Tubes. Ind. Eng.
mately 370 °C (700 °F). The deposition decrease was Chem. Prod. Res. Dev. 1977,16, 171-177.
shown to be independent of fuel critical properties in two Heneghan, S. P.; Zabamick, S. Oxidation of Jet Fuels and the
ways. First, it was demonstrated that the deposition Formation of Deposits. Fuel 1993, in press.
decrease seen at high temperatures at a given flow rate Katta, V. R.; Roquemore, W. M. A Numerical Method for Simulating
could be shifted significantly in temperature by varying the Fluid-Dynamic and Heat Transfer Changes in a Jet Engine
the fuel flow rate. Thus, the deposition decrease is not Injector Feed Arm Due to Fouling. J. Thermophys. Heat Transfer
1993, in press.
solely a temperature effect, as it would be if supercritical Martel, C. R. Air Force Aviation Fuel Thermal Oxidation Stability
fuel properties were controlling the deposition. Second, R&D. In Jet Fuel Thermal Stability; NASA TM 79231; Taylor,
tests with fuels and pure hydrocarbons of widely varying W. F., Ed.; NASA Lewis Research Center: Cleveland, OH,
critical temperatures yielded very similar deposition- November 1978; pp 41-52.
temperature behavior, again demonstrating the high- Martel, C. R. Molecular Weight and Average Composition of JP-4,
JP-5, JP-8, and Jet A. Unpublished Results from Air Force Fuel
temperature deposition decrease is not primarily related Surveys. Unpublished memo, Air Force Aero Propulsion Labo-
to fuel supercritical properties. ratory, July 15,1988.
Marteney, P. J.; Spadaccini, L. J. Thermal Decomposition of Aircraft
Acknowledgment Fuel. J. Eng. Gas Turbines Power (ASME Trans.) 1986,108,648.
Moses, C. Southwest Research Institute. Unpublished work on NASA
This work was supported by the Air Force Office of Grant NAG 3-1342, 1992.
Scientific Research (AFOSR). Julian Tishkoff was the Reddy, K. T.; Cemansky, N. P.; Cohen, R. S. Modified Reaction
AFOSR Program Manager. The authors wish to thank Mechanism of Aerated n-Dodecane Liquid Flowing over Heated
Metal Tubes. Energy Fuels 1988, 2, 205-213.
Bill Schulz for his separation and analysis of the hexa-
Schulz, W. D. Oxidation Products of a Surrogate JP-8 Fuel.
decane oxidation products.
Prepr.—Am. Chem. Soc., Div. Pet. Chem. 1992, 37 (2), 383-392.
Taylor, W. F. Deposit Formation from Deoxygenated Hydrocarbons.
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1152-1156. Accepted September 20,1993*
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Tube”; AIAA Paper 92-0687; AIAA: Washington, DC, January
• Abstract published in Advance ACS Abstracts, November
1992. 1, 1993.