TESTING SYNTHETIC FUELS FOR USE IN U.S. ARMY GROUND VEHICLES Presented to Diesel Engine-Efficiency and Emissions Research (DEER) 2006 Conference August 21, 2006 PANEL: NEW FEEDSTOCKS AND REPLACEMENT FUELS Herb Dobbs Patsy A. Muzzell U.S. Army RDECOM-TARDEC Eric R. Sattler Team Leader, Alternative Fuels and Brian J. McKay Fuel Cell Technology U.S. Army REDCOM-TACOM 586 574 5157 [email protected] Leo L. Stavinoha, Stavinoha Enterprises 1 OSD Assured Fuels Initiative Vision: To catalyze commercial industry to produce clean fuels for the military from secure domestic resources using environmentally sensitive processes as a bridge to the future. 2 FischerFischer--TropschTropsch ProcessProcess Natural Gas Coal Pet Coke Biomass Wastes CO Tail H2 FT Gas Synthesis Gas Product Power Liquid Production Recovery Generation Synthesis O 2 Hydrogen Liquid Oxygen Wax Recovery Air An Fuels H Plant 2 Option Hydrogen Wax Separation Hydrocracking Liquid Fuels Transportation Hydrogen Fuels 3 EvaluatingEvaluating AllAll USUS EnergyEnergy ResourcesResources Coal Oil Shale Enhanced Oil Recovery (EOR) Domestic Resources • 1.4 trillion barrels (shale) • 900 billion barrels of FT (coal) • 0.15 billion barrels (pet coke) • 22.7 billion barrels oil reserves • 32+ billion barrels of oil (EOR) • 100 million pounds of pulp waste/year 4 Total 2.3+ trillion barrels equivalent OSDOSD AssuredAssured FuelsFuels InitiativeInitiative GoalsGoals • Total Energy Development (TED) – Catalyze the industry to produce fuels for the military from domestic energy resources – Develop a roadmap to provide fuel for the Joint Battlespace Use Fuel of the Future program and implementation • Joint Battlespace Use Fuel of the Future (J-BUFF) – Develop fuel specifications that include non-petroleum components, for use in military equipment, aircraft, ships and ground vehicles – Validate use of the fuels in all tactical vehicles, aircraft and ships – Provide a transition plan for DoD wide deployment 5 ResearchResearch ParticipantsParticipants • Air Force – Air Force Fuels Research Laboratory/NAFRC – University of Dayton Research Institute • Army – TARDEC Fuels & Lubricants Laboratory – Southwest Research Institute • Navy – NAVAIR Fuels and Lubricants Laboratory – Naval Fuels and Lubricants Integrated Product Team • DOE – National Energy Technology Laboratory • Syntroleum Corp. 6 Nitrile Elastomer Coupon & O-Ring Volume Changes With Switches Between Synthetic FT "JP-8" & JP-8 FT FT FT FT JP-8 JP-8 JP-8 "JP-8" "JP-8" "JP-8" "JP-8" ) 15 (% Coupon Data e g 10 an h C e m 5 u l o e V 0 O-Ring ag Data er v A -5 1 2 3 4 5 6 Switch # Fuel Aromatic Content FT "JP-8" = 0% vol. JP-8 = 18% vol. 7 Predicted Fuel Blend Properties Cumulative Quantity of JP-8 in Continental U.S. vs. Aromatic Content Level Additional S-8 Conc. Possible in S-8/JP-8 Blend to Meet Just 8.0 vol. % Aromatic Content Max. S-8 Conc. Possible in S-8/JP-8 Blend to Meet 8.0 vol. % Aromatic Content & 0.775 kg/L Density JP-8 Wt. Mean Density at JP-8 Aromatic Content Level Density of S-8/JP-8 Blend with a 8.0 vol. % Aromatic Content Min. Density Limit JP-8 Spec 100 0.83 90 ) 0.82 L / g d k ) 80 , . n e ] c e ) 0.81 l m -8 y al t u i P B c l 70 t 8 ot ) NUS o J - n l ot y ( L v a l t P / O P ty y 0.80 i u J g ti C s it / s 60 P t [ q t nd n 8 n k ne o . - , i e o a l e ns l -8 S n u e P a P 0.79 D Line l bl 50 d L a e r P J D i Q d U. a d l in S l l 8 t e e 8 - a o m v - Ba o en t ta h l Are 0.775 kg/L Minimum Density P S t. ti t n 40 s J S a 0.78 e a B l to of (JP-8 spec) (w n 8 of u D i - t . % m P % n 30 s J u s nc (a 0.77 a C 8/ o ( Co - C 20 S 0.76 10 0 0.75 2345 6 7891 01 11 21 31 41 51 61 71 81 92 02 12 22 32 425 JP-8 Aromatic Content Levels, vol. % 8 Lubricity of treated synthetic fuel FT Fuel Duration Change1 CI/LI Test Pump (hours) (mm) (mg/L) 1 95.6 0.096 1 Untreated 2 150.7 0.068 3 500 0.007 12 2 4 500 -0.006 (Min.2) 5 500 0.005 22.5 Data courtesy 3 SwRI – TARDEC 6 500 0.002 (Max.2) 1 Fuels & Lubricants Change in roller-to-roller dimension pre-& post- test. Research Facility 2 Min. and Max. treat rates per QPL-25107. Testing in rotary injection pump test rig established improvement in neat FT fuel treated with lubricity improver additive, CI/LI, indicative of acceptable field performance. [SAE 2004-01-2961] 9 Next Army Steps Next Army steps: Progressive engine, fuel system, equipment, vehicle and fleet tests thru 2009, leading to qualification for use in Army ground vehicles, aircraft and equipment. Air Force and Navy timetables are comparable. • Document engine performance of blend fuels versus petroleum JP-8 • Continue research in the effects on elastomer seals of switch- loading petroleum and synthetic fuels, and additives to promote seal swell in non-aromatic fuels. • Continue research in lubricity of blended fuels and potential lubricity additives. • Develop a knowledge-based qualification approach to minimize expense and time. 10 .