Next Generation OBIGGS: Developments at Phyre

Technologies

Santosh Y. LimayePhyre Technologies, Inc.

November 2, 2005

Atlantic City, NJ

Presented at International Aircraft Systems Fire Protection Working Group Meeting

The Concept

Treat the ullage from the fuel tank to create inert gas

Inexpensive catalytic system Avoid the use of bleed air

This concept resulted from liquid fuel de-oxygenation system development

0

2

4

6

8

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12

14

JP-8 JP-8+100 JP-8+225 JP-900 Endo JP

Hea

t si

nk r

elat

ive

to J

P-8

325 F425 F

550 F

900 F

>1300 F

Near term Mid - Term

Fuel Temperature, F

Fuel Temperature, C

Combustor

Endothermic fuels

pyrolytic deposits

Fuel FlowJP-8 JP-8+225 JP-900

thermal-oxidativedeposits

JP-8+100

600400200 300 500

400 500 800 1000 1100900600 700300

Filamentous CondensationAmorphous

• Increase Thrust-to-weight– enables higher T41

• Reduce take-off gross weight– reduce fuel recirculation & ram air HX wt

• Improve SFC– enables higher T3 and P3

• Reduce component operating temp.– higher heat sink capability

High Heat Sink Fuels Benefits

High Heat Sink Fuels:Enable Advanced Propulsion

Deposition is The Significant Challenge for High Heat Sink FuelsDeposition is The Significant Challenge for High Heat Sink Fuels

Quick Review of De-Oxygenation System

Fuel GasContactor

ContaminatedFuel

Inert Gas

De-OxygenatedFuel

Inert Gas + O2

+ Fuel Vapor

Gas Treatment System

Oxygen free gas

For RecyclingPump

Fuel GasSeparator

Removing dissolved oxygen in fuel prevents premature oxidation; a primary cause of coking. Dissolved oxygen = cholesterol

Mass Transfer Issue

Mass Transfer Region

O2 Concentration Gradient

Diesel Droplet in N2 Gas

N2 Bubble in Diesel

Does it work? - - YES!

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60

0 0.5 1 1.5 2 2.5 3 3.5 4

Fuel Flow (lpm)

O2 C

on

ce

ntr

ati

on

(p

pm

)

O2 = 5 ppm

Fuel O2 = 57.9 ± 5.4 ppm

N2 flow: 2.5 Liter/Min; lpm

FDV Hysteresis - Pre-Post Test Comparison - Check #2

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140.00

120.00 130.00 140.00 150.00 160.00 170.00 180.00 190.00 200.00

Actuation Delta-P (PSID)

Flo

w R

ate

, P

PH

PreTest

PostTest

Run Number 79 Fuel Used: JP-8

FDV Hysteresis - Pre-Post Test Comparison - Check #2

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20.00

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80.00

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120.00

140.00

120.00 130.00 140.00 150.00 160.00 170.00 180.00 190.00 200.00

Actuation Delta-P (PSID)

Flo

w R

ate

, P

PH

PreTest

PostTest

Run Number 76 Fuel Used:

FDV Hysteresis - Pre-Post Test Comparison - Check #2

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20.00

40.00

60.00

80.00

100.00

120.00

140.00

120.00 130.00 140.00 150.00 160.00 170.00 180.00 190.00 200.00

Actuation Delta-P (PSID)

Flo

w R

ate

, P

PH

PreTest

PostTest

Run Number 79 Fuel Used: JP-8

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40

60

80

100

120

100 125 150 175 200

Pre-Test Increasing Post-Test IncreasingPre-Test Decreasing Post-Test Decreasing

Baseline JP-8 PADS Deox JP-8 (Catalyst)

PADS DeOx JP-8 (LN2)

JP-8+100

FDV Hysteresis - Pre-Post Test Comparison - Check #2

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20.00

40.00

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100.00

120.00

140.00

160.00

120.00 130.00 140.00 150.00 160.00 170.00 180.00 190.00 200.00

Actuation Delta-P (PSID)

Flo

w R

ate

, P

PH

PreTest

PostTest

Run Number 80 Fuel Used:

Run75

Run80

Run79/81

Run76

PADS Deox JP-8 (Nitrogen)

Results from Testing at AFRL

OBIGGS

OBIGGS Considerations

FlammabilityRegion

5 10 15 20

5

10

15

OxygenVolume Fraction (%)

Hyd

roca

rbo

n V

apo

rV

olu

me

Fra

ctio

n (

%)

Dilution with Air

Critical Dilution with Air

Iner

t A

ir P

urge

Catalytic Inerting System (CIS): Next Generation OBIGGS Concept

Fuel

Air + Fuel Vapor

Catalytic Gas Treatment System

21%

oxy

gen

+

Fue

l va

por

+ N

2

<10

% o

xyge

n +

Fue

l va

por

+ C

O2 H

2O +

N

2

Make up air to consume hydrocarbon vapor and pressure equalization

safety device

Pump Watertrap

PATENT PENDINGPATENT PENDING

Reverse Flow Valve

Reverse Flow Valve

Low Temp. air to air Heat Exchangers

Size: 12”x12”x 40”

Capacity: 150 CFM

# of passes to 10% O2 : 3

Support Systems

Automatic MoistureDrain Valves

Water Drain

Oxygen Sensors

Power

Control Unit

Optional, High Removal Rate, Vapor Fuel Control

Inlet OxygenSample Port

Heat Exchanger & Heaters

Catalyst Bed,5” Dia x 4.5”length

Blower

Inlet

Outlet

CIS System Description

CIS Catalytic Chemistry

Saturated vapor phase of fuel vapor : C9H20 (Nonane) As per DOT/FAA/AR-04/8 report (page

12), the precise composition is C9.05H18.01

Vapor pressure of Nonane is estimated to be 8000 ppmv at 70F

Stoichiometric Reaction of 8000 ppmv Nonane will consume 112,000 ppmv (or 11.2%) oxygen to provide 70,000 (7%) and 40,000 (4%) ppmv of CO2 and H2O

Vapor Pressure of NonaneVapor Pressure of Nonane (Jet Fuel) (Jet Fuel)

T C T K VP Pa Atmospheres

-46.8 226.35 1 0.00001

-26 247.15 10 0.00010

0 273.15 100 0.00097

34 307.15 1,000 0.00971

80.8 353.95 10,000 0.09709

150.3 423.45 100,000 0.97087

Stoichiometric ReactionC9H20 + 14O2 + 52.67 N2 9 CO2 + 10 H2O + 52.67 N2

.008 @ 70F.008 @ 70F

Oxygen Removal Rate

Pass # O2 % Corrected O2Ratio

Corrected/Uncorrected

0 21.00

1 13.82 14.02 1.01

2 9.09 9.45 1.04

3 5.98 6.44 1.08

4 3.94 4.46 1.13

1. If H2O is removed from the product, additional fresh air is needed to compensate the gas pressure in the reactant.

2. The corrected O2 column shows new concentration based on fresh addition of air to replace water molecules.

3. Three passes will ensure reduction of O2 below 10%.

0.0%

5.0%

10.0%

15.0%

20.0%

25.0%

0 10 20 30 40 50 60 70 80 90

Time, Minutes

Oxy

gen

Co

nte

nt

20 scfm

40 scfm

60 scfm

80 scfm

Plug Flow Reactor Model Numbers(for comparison purposes)

CSR Model: Oxygen Depletion RateFor 450 Cu. Ft. Ullage

Experimental Schematic

Ullage VolumeVU

Fuel VolumeVF

Pump

Flow RateFR

Flow Meter

Pressure gage

Moisture trap

Controller for heater

Catalyst Temp.CT

Catalyst Downstream Temp.CDT

Oxygen Sensor*

Fuel Tank

Catalyst

Heater

Ullage O2 Conc.Post Catalyst O2 Conc.

Experimental limitations: Very small ullage volume Limited flow rate control

Objective was proof of concept to validate theoretical calculationsObjective was proof of concept to validate theoretical calculations

Limitations on catalyst volume (smallest 1.2 cc) Delayed response due to long oxygen sensor lines

Initial Results – Experiment #1OBIGGS CATALYTIC CONVERTER TESTING

JP-8 Fuel @ Amb. Temp., Input/Output Vents 0.5" Above Fuel Level, no Sparging, 100,000/hr GHSV

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Time (minutes)

Ox

ygen

(%

)

200

202

204

206

208

210

212

Lo

we

r C

at.

C.

Te

mp

. °F

Ullage % oxy

Post Cat. % oxy

Lower Cat. Temp °F

Poly. (Ullage % oxy)

Poly. (Post Cat. % oxy)

Poly. (Lower Cat. Temp°F)

CT = 460°FCV = 1.2cc (29 balls)VU = 1.5 litersVF = 2.5 literFR = 2 l/mVTE = 5.3 (for 10% O2)

ConclusionBenefits No need for bleed air, eliminate ozone destruction device Low temperature process Only power necessary: blower operation Smaller foot-print, lighter weight, lower cost Closed loop system Ability to reduce oxygen level as well as fuel vapor level

Other Concerns Addressed Use of fuel vapor phase means no sulfur contamination, no corrosion Instead of purging the fuel vapor, it is consumed in the process, hence no VOC

emissions from the tank Ability to precisely control gas partial pressures

Next Steps Prototype Development Testing Phase Strategic Partnership Development