Fuel Certification Overview - FORUM-AE · PDF fileSPARE SLIDES TO SUPPORT FURTHER ... saccharification Thermal-catalytic or li gasification Catalytic lipids hydroprocessing pyrolysis

Fuel Certification

Overview

Chris Lewis – Engineering Specialist - Fuels

© 2014 Rolls Royce plc

FORUM-AE, Madrid. October 2014.

© 2014 Rolls-Royce plcThe information in this document is the property of Rolls-Royce plc and may not be copied or communicated to a third party, or used for any purpose other than that for which it is supplied without the express written consent of Rolls-Royce plc.This information is given in good faith based upon the latest information available to Rolls-Royce plc, no warranty or representation is given concerning such information, which must not be taken as establishing any contractual or other commitment binding upon Rolls-Royce plc or any of its subsidiary or associated companies.

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Fuel criteria

Safety and operability issues including Energy density Chemical characteristics and more….

Environmental and social issues Fuel lifecycle CO2 emissions Change in land and water usage Feedstock competition with food crops

Large-scale commercial production issues Fuel technology maturity level Production capability and readiness level Production capability and readiness level

© 2014 Rolls‐Royce plc

Advanced engine concepts Fuel Performance RequirementsWill increase!

Future and Novel Technology

Advanced High Temperature Materials Advanced High Temperature Materials

Complex Combustion, Aerothermal & Fluid Systems

Ad d T i i S t Advanced Transmission Systems

Potential Challenges and Opportunities ?g pp

Improved SFC and Reduced Emissions

Noise abatement challenge Noise abatement challenge

Advanced Fluid Systems and Heat Management


Jet fuel – A multi-functional fluid

Energy storage Airframe and engine Provides fuel for in aircraft coolant combustion

/High energy density for good range/payload




Wide operating temperature: ‐47°C Freeze Point, 38°C p g pFlash Point and good Thermal Stability (heat

management)




Specific combustion characteristics for OperabilitySpecific combustion characteristics for Operability, Emissions and Hot‐end Life


Impact of fuel propertiesS f t F t T h l D itiFl id P f

Certification

SafetyFlash Pt., Freezing Pt.

Microsep

Future TechnologySpecific Heat, Thermal Stab.

Aromatics, Sulfur/polar Materials

Deposition(coking)

Thermal stability, Gum,Distillation

Fluid PerformancePrediction

Freezing Pt., viscosityDistillation, Thermal stability

All Characteristics

Cost ofOwnership

Hot-End LifeThermal Stability, Acidity

Aromatics, Sulfur

E i i

DurabilityAs Above

OwnershipThermalStab.

Exist. GumSulfur

Cold Start &

EmissionsAromatics, Sulfur

distillation

M t i l

As AboveLubricityAcidity

PerformanceHeating Value

Density

Alt re-lightFlash Pt., Heating Value

Distillation, viscosity

MaterialCompatibilityAromatics, freezing pt.Acidity, Copper Strip

MaintenanceSame as Durability

DensityFlash/Freezing Pts.

Legacy HardwareAromatics, lubricity

System Design& MaterialsAll Characteristics

PhysicalProperties

ChemicalProperties


Designed for each other

Engine certification Fuel specificationEngine certification Fuel specification

Operate on Jet A/A-1 f l W ld id

Composition properties d ffuels - World-wide

standard

Ensure safety emissions

and performance

Allowable source materials and processesEnsure safety, emissions,

performance and durability

materials and processes

Quality Assurance

Fuel outside scope require testing and certification

Fuel has to be “drop‐in” to be technically viable


Industry qualification ASTM D4054 process

Specification Properties

Engine/APU Testing

Fit-For-Purpose Properties

Component/Rig TestingProperties TestingProperties Testing

A t

ASTM

Review

& BallotA t

ASTM

Review

& Ballot

ASTM Research

ReportASTM

Accept & Ballot

Re-EvalAs Required

Reject

ASTM

Accept & Ballot

Re-EvalAs Required

Reject

FAA & OEM Review & A l

ASTM Balloting Process

pSpecificationSpecification

Def-Stan ApprovalDef-StanJP8/5…

Courtesy of Mark Rumizen, FAA – Note Some items added by Rolls-Royce


Synthetic Paraffinic Kerosine - SPK

AromaticParaffinic(AKA: SPK, FT-SPK, Bio-SPK, HRJ, HEFA...)


Fuel clearance status

Def Stan 91‐91 approved SASOL semi‐synthetic Coal‐To‐Liquid late1990s

Def Stan 91-91 approved SASOL fully synthetic in Coal To Liquid 2008Coal-To-Liquid -2008.

ASTM approved the use of 50% Generic XtL blend via ppASTM D7566 – ASTM D1655 Jet A/A‐1 ‐ 2009.

l f ASTM approval of:

Hydrogenated veg oils/fats (HEFA)– incorporated into ASTM D7566 ‐ 2011into ASTM D7566 ‐ 2011.

Synthesized iso‐paraffins from hydroprocessed fermented sugars (SIPS) – 2104. g ( )


Syn GasCoalFischer-Tropsch (FT) Conventional Refinery

P

Potential alternative aviation fuels - 1Syn Gas (CO, H2)

Coal

Natural GToday

ProcessesHydroprocessing

HydrogenationGas

Biomass

y

Syn-Crude

Hydrogenation- Produces paraffins

Isomerisation- Improved Fz pt

FT ProcessGasify

5

HEFA from Plant OilHydrocracking-Molecules in jet

range

Oil E traction

Plants/Nuts

5 years

Hydroprocessing

Bio-Crude

Oil Extraction

HarvestedAlgae

HEFA from AlgaeHydroprocessing

All above used to produce/upgrade

conventional jet fuel

Bio Crude

Process Facilitators

Oil Extraction

Algae

10 years

Jet FuelOil Extraction



Potential alternatives in R&D phase - 2Synthetic Biology

Genetically Engineered Microbes

Fermentation

Jet Fuel

C ti l R fisugarcane Alcohol Oligomerization Conventional Refinery ProcessesSugar

switchgrassDehydrationFermentation

PolymerizationOlefins

corn stover

Pyrolysis

Jet FuelLignocellulose

forest waste

HydroprocessingBio-CrudePyrolysis

Hydroprocessing



Rolls-Royce alternative fuel programmesy p g

CurrentFAA CLEEN programme

Current

003782


Summary - Bio-fuel timelineTimeline Focus of Industry Activity

Early 1990’s to mid 2000’s Early Approval Process DevelopmentDefining fuel norms and experienceg pApproval of Sasol CtL

2004 ‐ Today R & D and Approval Process DefinitionDefinition & EvaluationDefinition & EvaluationSpecification Development

Today Fuel ApprovalsXtL d HRJ k SPK HEFA tXtL and HRJ – aka SPK, HEFA etcNovel raw materials/processes

2011 ‐ 2050 Options & DeploymentCapacity and CommercialisationQuality Assurance and RegulationImproved Production Flexibility and Efficiency

b l fSustainability Certification


Thank You

SPARE SLIDES TO SUPPORT FURTHER DISCUSSION IF REQUIRED

Tracking progress‐ Fuel Readiness Levels (FRL)‐ Fuel Readiness Levels (FRL)

FRL 1: Feedstock/Process Basic Principles

FRL 2: Feedstock/ Process Concept

FRL 3: Fuel Sample for Basic Fuel Properties R & D Phase Certification &

FRL 4.1: Performance StudiesFRL 4.2: Spec Properties

Phase Certification & Qualification Phase

FRL 5.1: Lab Production DevelopmentFRL 5.2: Subscale Production DevelopmentFRL 5.3: Production ScalabilityFRL 5.4: Pilot Plant Capability

FRL 6.1: Fit‐For‐Purpose Properties

FRL 6.2: Turbine Hot Section

FRL 6.3: Component/Rig Testing

Business Phase

FRL 6.4: Engine Testing

FRL 7: Fuel Class Listed in Int’l Fuel Specifications

FRL 8: Commercial ValidationFRL 8: Commercial Validation

FRL 9: Production Capability


Current Status of Synthetic Aviation Fuel Task Forces

Status Class Process Feedstock Companies TF LeaderCompletedAnnex A1 FT SPK Fischer Tropsch (FT) derived SPK

Coal, Natural Gas, Biomass

Annex A2 HEFA SPK Hydroprocessed Fats and Oils (HEFA) derived SPK Triglyceride OilsIn the Approval Process

FT SKA FT derived SKA, Further Materials Compatibility Testing RequiredCoal, Natural Gas, Biomass Sasol, Rentech, Cliff Moses

ATJ SPKFermentation alcohol, oligmerized and hydrotreated (ATJ) derived SPK ‐ Research Report ready for OEM review. Sugar, Alcohol GEVO, Philips 66,

Glenn Johnston (GEVO)

HDCJ SKAHydroporcessed Depolymerized Cellulose derived SKA – Research Report still in process. Lignocellulose Kior, UOP

Jeff Trewella (KiOR)

DSHC SPK Direct Fermentation to SPK – Research Report in initial Ballot . Sugar Amyris/TotalFernando Garcia (Amyris)

In DevelopmentGregg

ATJ SAK Catalysis to SAK, primarily aromatics Sugar, Alcohol Virent/Shell, SwiftHemighaus (Virent)

ATJ SKA ATJ derived SKA, partial aromatics Sugar, AlcoholByogy, Cobalt, Swedish Biofuels

Kevin Weiss (Byogy)

CH SKA Hydrothermal Cracking and Cyclization derived SKA Triglyceride OilsApplied Research Associates (ARA)

Ed Coppola (ARA)G

CRJ SPK Catalysis, oligermerized and hydrotreated derived SPK Sugar, Alcohol Virent

Gregg Hemighaus (Virent)

HEFA SPK In Situ Coprocessed Triglyceride Oils Conoco, Chevron

Enrico Lodrigqueza (Phillips 66)

HEFA SKA HEFA derived SKA Triglyceride Oils Dicussed no champion yetHEFA SKA HEFA derived SKA Triglyceride Oils Dicussed, no champion yet

SPK Synthetic Paraffinic KeroseneSKA Synthetic Kerosene with AromaticsSAK Synthetic Aromatics, Kerosene boiling range

Courtesy of Stan Seto - ASTM Chairman© 2014 Rolls‐Royce plc

ASTM D7566 TASK FORCES

Alternative Jet Fuel Pathways

Adapted from Brown, Iowa State, 2012 and Tim Edwards, USAF/AFRL

D ft ASTM R h R tCrude oil

Courtesy of Stan Seto - ASTM Chairman

y

lipid-based fuels carbohydrate-based fuels coal, natural gas

R Draft ASTM Research ReportCrude oil

camelina, algae, etc. sugar cane, etc. lignocellulosic biomass

bagasse

saccharification

Thermal-catalytic or

l i gasificationCatalytic

lipids

hydroprocessing

saccharification pyrolysis gasification

sugars syngas

Hydrothermolysis

bio-oil

catalytic upgradingalcohol

hydroprocessing

fermentationHEFA

Annex A2 ATJ SK SAK HDCJCH

Task FT SKAAnnex A2 DSHCTask Force

ATJTask Force

SK, SAKTask Force

HDCJTask Force

FT-SPK Annex A1

Task Force

FT-SKA Task Force

July 2011

ARAAmyris/Total SPK

SKA

VirentKiOR,

RRCo-Procss’d Annex A1

GEVO, Cobalt/USN, UOP, LanzaTech, Swed

Biofuels

Byogy, LanzaTech, Swed

Biofuels

KiOR, UOP

SASOL, Rentech

Sept 2009

RR

May 9, 2013

Task Force

Chevron, BP, Philppps66© 2014 Rolls‐Royce plc

Documents

Fuel Certification Overview - FORUM-AE · PDF fileSPARE SLIDES TO SUPPORT FURTHER ... saccharification Thermal-catalytic or li gasification Catalytic lipids hydroprocessing pyrolysis