investigating the production and use of …
TRANSCRIPT
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The Energy Center
INVESTIGATING THE PRODUCTION AND USE OF TRANSPORTATION FUELS FROM INDIANA COALS
A presentation to the Advisory Panel ofThe Indiana Center for Coal Technology Research
John Abraham, Mechanical Engineering Rakesh Agrawal, Chemical Engineering
William Anderson, Aeronautics and Astronautics Gary Blau, Discovery Park
James Caruthers, Chemical Engineering W. Nicholas Delgass, Chemical Engineering
Jay P. Gore, Mechanical Engineering Stephen Heister, Aeronautics and Astronautics
Hilkka Kenttämaa, Chemistry Robert D. Lucht, Mechanical Engineering Fabio H. Ribeiro, Chemical Engineering Yuan Zheng, Mechanical Engineering
Purdue Calumet, HammondDecember 6, 2006
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The Energy Center
Integrated Strategy• Fuel performance is governed by its molecular
make up• Discover molecule/performance relation
(MPR) by engine testing• Use MPR and economic trade offs to define
goals for FT fuel production• Develop high resolution fuel analysis to
understand and control fuel composition, including low concentration problem species
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The Energy Center
Production Issues and Fischer-Tropsch
Rakesh Agrawal, Gary Blau, W. Nick Delgass, Fabio Ribeiro School of Chemical Engineering
College of Engineering
Hilkka KenttämaaDepartment of Chemistry
College of Science
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The Energy Center
Molecular level characterization of F-T fuels needed to establish relationships between fuel composition and • Fischer Tropsch reaction conditions• Fuel refining methods• Fuel performance in engines
Coal To Liquids, CTL
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The Energy Center
• No commercial methodology exists for detailedcharacterization of very complex hydrocarbon mixtures
• Hence, new analytical methods must be developed for F-T-fuel analysis
• These special methodologies are best implemented on ultra-high resolution mass spectrometry because of the molecular complexity of the fuels
F-T Fuel Characterization
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The Energy Center
• Most promising analytical approach: - Laser-induced acoustic desorption (developed at Purdue)- Ionization with chemical reactions specifically developed
to ionize hydrocarbons without fragmentation- Ultra-high resolution FT-ICR mass spectrometry
• First steps:- Test the existing methodology (medium-resolution)- Use existing F-T fuels and pure compound blends
• Goals:- Determine the critical areas (in addition to resolution) that
need improvement for complete F-T fuel characterization
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The Energy Center
• Goals:- Make initial correlations between fuel’s molecular
composition and performance information obtained by the engine testing group
- This information will aid the F-T production group in optimization of the selectivity of the F-T process
- Preliminary characterization of F-T fuels generated by the production group will lead to initial correlations between the fuel composition and F-T catalyst composition and reaction conditions
All the above correlations must be re-evaluated when analytical procedures have been developed for complete F-T fuel characterization
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The Energy Center
Production of F-T Fuels:Four major focus areas identified
Optimizing SelectivityFischer-Tropsch MechanismIntegration of F-T Mechanism with reactant consumption and product distributionCO2 recycle
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The Energy Center
Implications of CTL IntegrationOur idea is to develop the facility to quickly add new chemistries to a full plant model so we can immediately understand their implications to the final product cost
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The Energy Center
Integration of F-T Mechanism with Reactant Consumption and Product Distribution
• None of the available models are accurate enough
• Lack of reliable kinetic equations for all products
• Models combining overall consumption of reactants and product distribution are scarce in the literature
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The Energy Center
Performance of FT Fuels in Diesel Engines
John Abraham, MEJim Caruthers, CHE
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The Energy Center
• Integrated program focusing on fuel modification and engine and aftertreatment designs will maximize benefits of utilizing FT fuels.
• Diesel engine designers are faced with challenge of reducing particulate and NOx emissions. Need for aftertreatment devices and high levels of exhaust gas recirculation in current engines. Results in increased cost.
• Process modification can change FT fuels to meet specific requirements, e.g. cetane number, lubricity, volatility.
• Fuel structure modification will enable the combustion process to be altered to meet the limits on pollutants at lower cost.
• Economic cost of modifying FT fuel has to be weighed against economic benefits. Engine tests and aftertreatment catalyst evaluation will determine economic benefits.
FT Diesel Fuels Research
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The Energy Center
• Evaluate FT fuels and fuel blends of known properties– Measure engine performance parameters, including
emissions– Create link between molecular species in fuel and
engine performance to establish targets for fuel production
• Extend NOx after-treatment model to inlet compositions that are relevant for diesel engine running on FT fuels
FT Diesel Fuels Research – Immediate Tasks
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The Energy Center
• Ray W. Herrick Laboratories• Maurice J. Zucrow Laboratories• Mechanical Engineering Building
Diesel Engine Test Facilities
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The Energy Center
• October 2002 Certified ISB 5.9 L Cummins Diesel – EGR & VGT (with Cummins Calterm II 7.63)
• 800 hp Eddy Current Dynamometer w/ Dyn-Loc IV Controller
Diesel Engine Test Facility
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The Energy Center
Diesel Engine Test Facility
• 1998 ISB 5.9 L Cummins Diesel• 500 hp Go-Power DT-1000 Water Brake Dynamometer
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The Energy Center
Additional facilities include:• Cummins B-series engine with in-cylinder pressure transducer,
and optical shaft-encoder, on an eddy-current dynamometer/controller.
• Single-cylinder version of the Cummins N-series engine with in-cylinder pressure transducer, optical shaft-encoder, external regulation of oil and coolant temperatures, external regulation of intake air pressure and temperature, capability to measure fuel and air flow rates, on an electric dynamometer/controller. This engine has been used for evaluation of piston bowl shapes, swirlnumbers, injectors, and alternative fuels.
• Computerized data-acquisition/analysis systems for measurements and analysis of in-cylinder pressure, heat release rates, and exhaust gases.
Diesel Engine Test Facility
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The Energy Center
Single-Cylinder Engine
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The Energy Center
Spark-Ignition Engine Test Facility
• 4.6 L Ford Spark-Ignition V-8• 175 hp Eddy-Current Dynamometer w/ Dyn-Loc IV Controller
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The Energy Center
• Cambustion Emissions Analyzer Heads
HC Fast FID
NOX Fast CLD
CO-CO2Fast NDIR
Emissions Measurement Capabilities
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The Energy Center
Emissions Measurement Capabilities
• Cambustion Emissions Analyzers:
– HC: HFR 500 Fast FID (Flame Ionization Detector)(0.9 ms Response Time)
– NO & NO2: f NOx 400 Fast CLD (Chemiluminescent Detector)(<2 ms Response Time)
– PM: AVL Smokemeter
– CO & CO2: NDIR (Non-Dispersive Infra-Red Detector) 500 Fast CO & CO2(5 ms Response Time)
• Each Analyzer has Two Measurement Channels
• dSPACE Open-Architecture Control Platform with Data Acquisition and Anti-Aliasing Filter Banks
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The Energy Center
Reaction Unit for Kinetic Measurements of After-Treatment Systems
MFC Controllers
NOx Analyzer
Mass Flow Meters
Reactor Oven
Mass Spectrometer
Turbo Pump
Temperature Display
Data Collection Module
Automatic Valves
Water Feeding Pump
Catalyst
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The Energy Center
Aftertreatment Model DevelopmentImportant Assumptions
Laminar Flow Plug Flow
Complex porous catalyst washcoat
Flat support with deposited particles
Flat uniform surfaceBoudary Layer
Catalyst
NOx breakthrough curves
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Oxidation predictions
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The Energy Center
Gas Turbine Usage Issues and F-T Commercialization
Gas Turbine Research – Steve Heister (AAE), Bill Anderson (AAE), Jay Gore (ME), Yuan Zheng
(ME), Bob Lucht (ME)
Presentation at the CCTR Advisory Panel MeetingPurdue Calumet, December 6, 2006
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The Energy Center
FT Fuels Utilization in Gas Turbines• Focus of the proposed effort is on aircraft gas turbines
• Use of FT fuel as an endothermic coolant for aircraft systems – endotherms and coking behavior must be investigated
• Particulate and pollutant generation – investigation of sooting behavior of FT fuels and blends with JP8 – low aromatic content may lead to lower soot emissions
• In general, atomization, mixing, ignition properties of FT fuels and fuel blends must be studied systematically
• Purdue’s Zucrow Laboratory complex has unique facilities and expertise to address these issues
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The Energy Center
FT Fuels Utilization in Gas Turbines
Rolls Royce Combustor Can
GT Combustor Facility in the High Pressure Laboratory
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The Energy Center
FT Fuels Utilization in Gas TurbinesPurdue-Rolls Royce team was recently notified that a proposal to modify the combustor for optical access and perform advanced laser diagnostics was selected for funding under the NASA Fundamental Aeronautics program.
Proposed Window Assembly
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The Energy Center
Zucrow Lab Facilities for Gas Turbine Testing2000 actual cubic feet of 2,000 psi air storageRecently modernized air compressor plant
produces nearly 1 lbm/sec of dry air at 2,000 psiLarge natural gas fired heat exchanger capable of
950 deg F air discharge temperature at 9 lbm/sec and 700 psi
Precise flow rate and pressure control with large dome-loaded pressure regulator and sonic orifices, system blow-down performance well characterized
Recently upgraded emissions monitoring system, state-of-the-art FTIR and flame ionization detector installed
Laser diagnostic capabilities for probing harsh GT environment are being developed
HP Air Tanks
Laser Imaging of Fuel Spray
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The Energy Center
Fuel Tank
N2
Flow MeterOil Bath
Preheater
Rope HeatersN2
T T
PT
WaterBath
T
PurgeValve
Run Valve
Preheater Valve
T
T
T
Filter
Dump Valve
WasteDrum Filter
T
Sample Collection
3-Way Valve
ControlValve
PT
PT
PT
Furnace
Cu
TT
FT Fuels Coking Test Facility
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The Energy Center
Rolls-Royce High Mach UTC
Advanced heat exchanger (HEX) configurations
Coking studies and development of non-coking catalytic reactors for endothermic fuels
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The Energy Center
Coking Deposition Mechanism is Dependent on Fuel Chemistry
JP-10
JP-8
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The Energy Center
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Increased heat sink due to thermal cracking (good)is accompanied by coking and subsequent HEX fouling (bad)
No catalyst
With zeolite catalyst
Increase in apparent Cp at lower-than-coking T
UTC endothermic fuels research is aimed at developing non-fouling catalyst combinations
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The Energy Center
FT Fuels in Gas Turbine Engines: Proposed Work
Initiate studies on specifications of fuel for aircraft gas turbine engine use.
Identify desirable chemical structures for non-coking endothermic fuels.
Test coking properties of FT fuels and fuel blends.
Test ignition, performance, and emissions for FT fuels and fuel blends in Zucrow Laboratories gas turbine combustion facility.