Alternative Aviation Fuels

Tim Edwards

Propulsion Directorate

88ABW-2009-4026

2

DoD Fuel Costs

DoD Fuel Costs Are

Volatile AndHave Risen

Dramatically

APPROVED FOR PUBLIC RELEASE, AFRL-WS 07-1431 4

Fuel – Gallons (1) 2.5B 0.3B 1.8B 4.6B

Fuel – Cost $10.2B $1.2B $7.3B $18.7B

Air Force Army Navy Total

(1) Compiled from the Air Force Cost Analysis Agency

DESC – Defense Energy Support Center Data

DESC (Jul 2008) adjustment to $4.07/ Gallon

1997

1998

1998

2000

2001

2002

2003

2004

Oct

200

5Ju

n 20

06

Oct

200

6

Feb

200

7Ju

n 20

07Dec

200

7Ju

l 200

8$0.0

$0.5

$1.0

$1.5

$2.0

$2.5

$3.0

$3.5

$4.0

+354%

J P- 8

Pri

ce p

er

Gal

l on

Aim for Balanced Solutions

Energy Strategy

Need to Consider Inter-related

Consequences of Energy Strategies

Tim Skone DOE/NETL 2008RZ-08-0530

4

U.S. Air Force Energy Approach

Strategy:

Reduce Demand

Increase Supply

Change the Culture

Vision:Make Energy A Consideration In All We Do

5

5

AVIATION Fuel Used: 2.5B gallons Fuel Cost: $5.6B

FACILITIES Energy Used: 71.2M MMBTU Energy Costs: $1.1B

GROUND EQUIPMENT AND VEHICLES Fuel Used: 138.4 M gallons Fuel Costs: $302.3M

U.S. Air Force 2007 Energy Use

$7 billion spent for energy in 2007

Facilities 15%

Ground Equipment 4%

Aviation 81%

6

Sponsors

FAA

ATA

AIA ACI

Aerospace Industries Association

Aircraft Engine OEMs

Aircraft OEMs

Aircraft Equip Cos

DOCDOEUSDA

USAF

USNDARPA

US Army

DESC

NISTNASA Oil

Companies

Energy Companies

ASTM

CRC

Bio-Fuels Companies

Airports Council International

Federal Aviation Administration

Air Transport Association

UK MoD

Bauhaus

NRC Canada

ANP Brazil

UniversitiesThink Tanks

Consultants

Airlines

ALPA

Air Cargo

Airport Operators

NetJets

CAAFI’s Member / Contributors

….150 Contributors from

4 Continents

The CAAFI Coalition seeks energy security and environmental sustainability for aviation, … to promote the development of alternative fuel options that offer equivalent levels of safety and compare

favorably with petroleum based jet fuel on cost and environmental bases, with the specific goal of enhancing security of energy supply

77

CO2 Sequestration)

CoalOil Shale

Alternatives to Oil:US Energy Resources

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 • 240 billion barrels of oil (EOR)• 100 million pounds of pulp waste/year Total 2.3+ trillion barrels equivalent

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 • 240 billion barrels of oil (EOR)• 100 million pounds of pulp waste/year Total 2.3+ trillion barrels equivalent

8

Mature Process:Fischer Tropsch is a proven

process with benefits including:

• Maturity: South African aviation use 1999• CTL – South Africa,

China• GTL – Malaysia, Middle

East • BTL -- Germany

• Chemical similarities to conventional fuels

• Manufactured fuel– No sulfur– Reduced particulates– High/Low temperature

stability

Fischer-Tropsch Technology

Natural GasCoal

Pet CokeBiomassWastes

Synthesis GasProduction

OxygenPlant

Air

O 2

F-TLiquid

Synthesis

ProductRecovery

LiquidFuels

TransportationFuels

TailGas

PowerGeneration

H 2

HydrogenRecovery

WaxHydrocracking

Wax

HydrogenSeparation

Hydrogen

LiquidFuels

AnOption

COH2

Co Capture and Reuse

2

First Generation Alternative Fuels

Fuels From Alternate SourcesWe Could Be the New Middle East

2.3+ Trillion Barrels

Old Middle EastSaudi Arabia:

261.8 Billion BarrelsIraq:

112.5 Billion BarrelsUAE:

97.8 Billion BarrelsKuwait:

96.5 Billion BarrelsIran:

89.7 Billion Barrels Qatar:

15.2 Billion BarrelsOman:

5.5 Billion BarrelsYemen:

4.0 Billion BarrelsSyria:

2.5 Billion Barrels

TOTAL 685.5 Billion Barrels

Appalachian States 0.9+ T Bbls

Western States 1.4+ T Bbls

TOTAL: 2.3+ T Bbls

Domestic SourcesDomestic SourcesCoal and ShaleCoal and Shale

TOTAL 2.3+ T Bbls Equivalent

Indiana Coal: 20B Bbls

Value Added Choices For Coal

1 ton ofIl. Coal$32/ton

Combustion

Gasificatio

n

Gasification

Electric Power ProductionProducts Value

2 MWh electricity $70.00Total $70.00

FT Fuels and Power Products Value

0.41MWh electricity $14.000.34 bbls naphtha $15.001.36 bbls jet fuel $81.00Total $110.00

A choice to make:

Fertilizer, FT Fuels and Electric Power Products Value 0.07 MWh electricity $ 0.230.17 bbls naphtha $ 8.000.78 bbls jet fuel $46.500.25 tons of ammonia $87.00Total $141.73

Gasification

Projected Numbers RenTech 2006

11

Franz Fischer and Hans Tropsch

Franz Fisher

Hans Tropsch

12

Converting Coal to Liquid Fuel

13

Sasol Secunda South Africa

14

14

B-52 Certified for 50/50 Blend!B-52 Certified for 50/50 Blend!8 Aug 20078 Aug 2007

15

Alternative Fuels Certification Office Certification Process Execution

15

Process owner: ASC• Coordinates gap analysis• Coordinates sustaining engineering• Ensures data flow between SMs• Updates MIL-Handbook with lessons learned• Revise Specification (if req’d)

Tech DataHandbook

Identify Gaps (System/Class)

Sustaining Engineering

Fills Gaps

Evaluation/Risk

Analysis

Fuel RejectedFuel Rejected

Fuel Approved“Restricted”

Fuel Approved“Restricted”

No Gaps –Performs “Like” JP-8

Knowledge Gaps

SingleManagers

Process Owner CoordinatesSingle Managers Execute

• MIL-HDBK-510 – used for fuel approval• Specification – used for fuel procurement

B-52/C-17 approach consistent with this processB-52/C-17 approach consistent with this processB-52/C-17 approach consistent with this processB-52/C-17 approach consistent with this process

Fuel Approved“Unrestricted”

Fuel Approved“Unrestricted”

Fuel Approved“Unrestricted”

Fuel Approved“Unrestricted”

16

Early 2011 Certification Goal

Certify entire AF Fleet to use a 50/50 SynFuel blend

2016 Acquisition Goal

Acquire 50% of CONUS aviation fuels from domestically produced synthetic fuel-blends from sources using

CO2 capture and reuse

AF Developing Biofuel Strategy

Current USAF Perspective

Maximizing War-winning Capabilities For… Every Airman…Every Aircraft

Alternative Fuels Certification OfficeFT-Blend Summary Certification Schedule/Status

FY08 FY09 FY10 FY11

C-17

B-1

GSE / ESOH / Infrastructure

KC-135

B-2

All Transports

All Fighter/Attack

Heli/Special

Trainers

All USAF Systems

B-52

F-15

F-16

F-22

Gap Analysis Cert. Completion FSE

Today

Engine Test

Cert Complete

Flight Complete

25 Nov 09NOTIONAL

Excludes F-35

Excludes CV-22

AFRL Major Thrusts

• High level goals:– 2011 – 50/50 F-T blend certification for all systems (Alternative Fuel

Certification Office (AFCO))– 2016 – 50% of domestic consumption contains synthetics (F-T + ?)

(~400M gal), “greener” than petroleum, cost-competitive• AFRL major efforts (joint w/ AFPET) (coord w/ CAAFI)

– F-T certification support (properties, mat’l compatibility, toxicology)– Aviation biofuel certification– Key parameters

• Performance (“drop-in”)• Cost (“competitive”)• Production potential (“significant”)• Lifecycle greenhouse gas footprint (“less than petroleum”)• Sustainability (“?”)

18

19

Timeline Summary

July Aug

FT ASTM Research Rpt Issued

Draft FT ASTM Research Rpt

FT ASTM Research Rpt OEM App’l

FT ASTM Research Rpt ASTM Ballot

FT Fuel Spec ASTM Ballot

ASTM Approval of Spec and Research Rpt

Sept Oct Nov Dec

HRJ Task Force

2008 2009 2010 20122011 2013

DXXXX Spec Wrkg Grp HRJ ASTM Research Rpt Issued

DARPA Fuel Samples at WPAFB DXXXX Spec Ballot

HRJ xx% Blend ASTM App’l HRJ ASTM App’l

Longer-Term Strategy

Near-Term Strategy

2008

19

ASTM Synthetic Fuels Task Force19Federal Aviation

AdministrationDecember 8, 2008Mark Rumizen, CAAFI

Certification “Pipeline”

20

R&D

Potential alternative

fuels

HRJ 50/50

?

TRL 1 TRL 5-6

CertificationTRL 9

Sasol SSJF ‘99

Sasol

FSJF

‘08

Jet A/A-1

JP-8/5

100% F-T

100% bio

• Fuels may travel along conveyor at different rates!• AF energy security goals benefit by feedstock diversity

moving fast, “drafting” F-T SPKDARPA

Approved fuels (ASTM D7566, MIL-DTL-83133F)

incubator

non-HRJ

bio

F-T SPK

50/50

New! ASTM D7566

New! DESC SolicitationSP0600-09-R-0704 600K gal

Aviation

FAA Partner Studies

MIT Partner Study

Alternative fuels must have a life cycle greenhouse gas footprint equal or less than

petroleum (Sect 526 EISA 2007)

22

U.S. Air Force Greenhouse Gas Inventory Initiative

CO2 inventory paves way for change

• Voluntary carbon dioxide (CO2) inventory used to:

– Evaluate policy and operational impacts

– Support sustainability– Identify risk areas– Understand investment

and mitigation areas

23

0 50 100 150 200 250 300

Biomass to F-T Fuel

Crude to Conventional Jet Fuel

Crude to ULS Jet Fuel

Coal to F-T Fuel (with carbon capture)

Oil Sands to Jet Fuel (surface)

Natural Gas to F-T Fuel

Oil Sands to Jet Fuel (in-situ)

Oil Shale to Jet Fuel

Palm Oils to Biojet

Coal to F-T Fuel (without carbon capture)

Soy Oil to Biojet

Life-cycle GHG Emissions per unit Energy (g CO2e/MJ)

Recovery

Processing

Transportation

Land Use Change

Combustion

WTT N2O

WTT CH4

Life-Cycle GHG Emissions Results - H.M. Wong S.M. Thesis (2008)

Baseline EmissionsRepresentative Results

Air Force Leading a Multi-Agency/University LCA

Analysis Team

Potential for Renewable Fuels - H.M. Wong S.M. Thesis (2008)5

Carbon Neutral U.S. Aviation Growth

• Assessed potential for carbon neutral growth from 2006 to 2025.

• Analysis used biofuel life-cycle GHG emissions and yield per hectare.

• Circles show land area requirements for three existing and two hypothetical feedstocks.

• Soybean and palm requirements both exceed current production levels.

• Analysis looked at single feedstock solutions – practical approach is to consider multiple feedstock solutions.

• Need feedstocks with high yield and low life-cycle emissions that do not require arable land.

Notes:

1. Assumed no land use change emissions with all of the feedstocks.

2. Land areas are given relative to continental U.S. for illustrative purposes (e.g., palm trees do not grow in Colorado).

Jim Hileman MIT

Sustainability

• Need to develop an aviation consensus view– Environmental sustainability

• Water usage• Water pollution• Local air quality• Global air quality• Land use changes

– Business sustainability• Aviation sector performance is closely linked to fuel

costs

25

Uncertainties:

• Feedstock variation

• Process efficiency

• Carbon capture efficiency

Land use change scenarios:1. Use Marginal Land or Waste Product

2. Conversion of Brazilian Cerrado

3. Wide-Spread Agricultural Changes

4. Destruction of Peatland Rain Forest

Quantifying Well-to-Wake Benefits - Hileman et al. (2008)5

Assessing Uncertainties

Jim Hileman MIT

Supply Cost Curve for Low-Carbon-Footprint Diesel Fuels

75.0

100.0

125.0

150.0

175.0

200.0

225.0

250.0

275.0

0 50 100 150 200 250 300 350 400

% Reduction in Life-Cycle GHG Emissions Below the Petroleum Baseline

Cru

de

Oil

Eq

uiv

. Req

. Sel

ling

Pri

ce,

Ja

n-0

8 $/

bb

l

$0/metric ton CO2-equiv.

$30/metric ton CO2-equiv.

D/E=60/40; Int.=7.5%;

Term=25 yrs.;IRROE=20%

CTL w ith CCS+ATR, 50K bpd

CTL w ith CCS, 50K bpd

15 w t% CBTL w ith CCS+ATR, 50K bpd

30 w t% CBTL w ith CCS+ATR, 30K bpd

BTL w ith CCS+ATR, 5K bpd

15 w t% CBTL w ith CCS, 50K bpd

BTL w ithout CCS, 5K bpd

30 w t% CBTL w ith CCS, 30K bpd

Credit for Life-Cycle CO2 Emissions Below Petroleum

BTL w ith CCS, 5K bpd

How Does the Cost of Carbon Effect the Price of Fossil/Bio Fuels?

Tim SkoneDOE/NETL

EconomicReadiness

BusinessReadiness

AF Alternative Fuel Score Card

Med

Med

Med

$1.00

Summary

• Alternative fuels offer potential to reduce green house gases and particulate emissions

• Air Force will certify its entire fleet by 2011 to use a 50/50 blend of FT fuels

• FT fuels can be produced from coal, biomass, natural gas as well as coal and biomass

• Sect 526 EISA 2007 governs DoD purchases of alternative fuels• Coal derived FT fuels could be produced with a CO2 footprint

equal to or less than petroleum• Developing assessment “rules and tools” to compare

alternative fuels

30

Triglycerides (fats, oils)

Aviation Biofuel Production Options

jet fuel components

Cellulose

CO + H2

Fischer-Tropsch

“BTL”

“first generation” - ?“second generation” - ?

Lignin gasification

(or co-gasification with coal)

“HRJ”

“Bio SPK”

C18:0

C16:1

Sugars“direct fermentation”

alcohols

pyrolysis oil

hydroprocessing

catalysis

1

2

31

SpecificationPropertiesFail

Fit ForPurpose

Properties(FFP)

Comp/RigTesting

FurtherEvaluation?

EngineTesting

Fail

Fail

Fail Pass

Pass

Pass

Pass

No

Start

Yes

Yes

No

No

Fuel Evaluation(ASTM Guidance)

FurtherEvaluation?

FurtherEvaluation?

Report

Yes

Equipment Evaluation/Approval

FAAReview

OEMSpec/SB

Approved

OEMInternalReview

Reject

Report

Fail

Add’l DataAs Required

Pass

Fuel Specification Approval

(ASTM Process)

ASTMSpecification

Accept

ASTM

Review

& Ballot

Re-EvalAs Required

Reject

ASTMSpecification

Accept

ASTM

Review

& Ballot

Re-EvalAs Required

Reject

Certification Processes – MIL-HDBK-510, ASTM D4054

which rigs?

which engines?

32

Fit-for-Purpose Test Results(for Research Report)

FIT-FOR-PURPOSE PROPERTIES

CHEMISTRYHydrocarbon chemistry (carbon

number, type, distribution)Trace Materials/Metals

BULK PHYSICAL AND PERFORMANCE PROPERTIES

Boiling Pt DistributionVapor/Liquid RatioThermal Stability BreakpointLubricityResponse to Lube ImproverViscosity vs TempSpecific Heat vs TempDensity vs TempSurface Tension vs TempBulk Modulus vs TempThermal Conductivity vs TempWater Solubility vs TempSolubility of Air (oxygen/nitrogen)

FIT-FOR-PURPOSE PROPERTIES

ELECTRICAL PROPERTIESDielectric Constant vs DensityElectrical Conductivity and Response

to Static Dissapator

GROUND HANDLING/SAFETYEffect on Clay FiltrationFitration (Coalescers & monitors)Storage Stability

PeroxidesPotential Gum

ToxicityFlammability LimitsAutoignition TemperatureHot Surface Ignition Temp

COMPATIBILITYOther Additives/FuelsEngine/Airframe Seals, Coatings,

Metallics

Completed on multiple samples In progress Planned

Research Reports

33

• Used to support commercial specifications (data also used for military certification)

• Addresses whether “drop-in” fuels fall within experience base

Experience Base

34JP-8 Spec Limits(0.775-0.839)

Syn

tro

leu

m 5

0/5

0 B

len

d

(0.7

86

)

Sh

ell

50

/50

Ble

nd

(0.7

77

)

Syn

tro

leu

m 1

00

% F

T

(0.7

55

)

Sh

ell

10

0%

FT

(0.7

37

)

• World Fuel Survey

• PQIS database

• Newly developed data

NIST

35

Key Provisions

– Body of Spec Applies to Finished Semi-Synthetic Fuel

– Annex for Each Class of Synthetic Blending Component

– Allow Re-Certification to D1655No need for separate tracking

– Annex 1Hydroprocessed SPK

– Includes 50% FT Fuel

– Issued in August 2009– Hydroprocessed Renewable

Jet (HRJ) Added to Annex 1 in Next Revision

ASTM D7566 Fuel Specification

Blend Comp’s Criteria and Blend % Limits

Annex 3

Other Adv Fuels or Processes

Annex 2

Other Adv Fuels or Processes

Annex 1

50% Hydpross’d SPK Fuel Blends

Fuel Produced to D7566 Can Be Designated as D1655 Fuel

5.1 Materials and Manufacture

D1655

Table 1

D7566Av Turbine Fuel Containing

Syn HC’s

Table 1Blended Fuel Performance Properties

Baseline Fischer-Tropsch Fuels

n-paraffins

• Form basis of Research Report to support specification

B-52, T-38

C-5, C-130, A-10, F-16

C-17, B-1, F-15F-22, KC-135R

36

Cetane = 31

Cetane=60

Cetane=60

Alternative FuelsOn-Going Analysis

5 10 15 20 25 30Time-->

5 10 15 20 25 30

5 10 15 20 25 30

-->

F-T SPK (blend stock)

HRJ - hydrotreated fats/oils (blend stock)

4751 JP-8

C13 C14 C15C16

C12C9

C8C7

C11C10

C17 C18 C19

TRL 2-3

TRL 2

TRL 9 –current fuels JP-8, Jet A

TRL 8 – generic F-T 50/50

TRL 5 (?) – HRJ 50/50(flight demonstrated)

More Challenging

Biofuels

37

Combustion Evaluation

38

• Lean blow out• Altitude relight• Transient accel/decel• Instability• Emissions/efficiency• Liner/nozzle heating• Engine control response• …

• Density vs T• Viscosity vs T• Flash point• Heat of combustion• Boiling range• Vapor pressure• Surface tension• Cetane• …

Composition

Properties

CombustionPerformance

• Aromatics, cycloparaffins, n- and i-paraffins• Hydrocarbon chain length

Prototype Combustion Evaluation Process

H: FA8650-09-D-2925-0005P: FA8650-09-D-2923-0010G: FA8650-09-D-2922-0007W: FA8650-09-D-2924-0006R: FA8650-09-D-2921-0007

39

O2

Fuel+Inert

Non-Premixed Flame

Stagnation Plane

Fundamental expts

Flame tube rigs

Sector rigs

Full annular

Engines

fail

pass

“Biocarbon” Analysis

• ASTM D6866 assesses fraction of carbon that is “modern” using C14

• Initial assessment

40

FuelWPAFB JP-8

Sasol IPKShell SPK

Syntroleum R-8R-8X

JP-8/R-8 50/50UOP DARPA “biojet”

Feedstockpetroleum

coalnat. gas

fat/oilSalicornia

blendbio + pet. aromatics

% modern C000

961004973

Summary

41

• Interest in alternative fuels remains high

• Biomass-derived fuels are current S&T focus– “Drop-in” petroleum replacements/blendstocks are

focus in near term – fully synthetic in mid term

– Assessment criteria must be defined: performance, cost, manufacturing potential, GHG footprint, sustainability

– Biofuels may not always be “greener” than petroleum or CBTL (w/CCS)

– Scale-up/cost/land use issues

42

SECNAV Energy GoalsSECNAV Energy Goals

At the Naval Energy Forum, the Honorable Ray Mabus expressed support for President Obama’s goal to reduce consumption of fuel and water and reduce overall greenhouse gas emissions. He announced five DON Energy Goals:

New Requirements for Acquisition Processes • Mandatory evaluation factors used when awarding contracts for platforms, weapon

systems, and buildings will include:

– Lifecycle energy costs– Fully-burdened cost of fuel– Contractor energy footprint

Sail the “Great Green Fleet” • DON will demonstrate a Green Strike Group in local operations by 2012 and sail it by 2016

– Nuclear ships– Surface combatants using biofuels with hybrid electric power systems– Aircraft flying on biofuels

Reduce Petroleum Use in Non-Tactical Vehicles• By 2015, DON will reduce petroleum use in the commercial fleet by 50 percent

– Flex fuel vehicles– Hybrid electric vehicles– Neighborhood electric vehicles

Increase Alternative Energy Ashore• By 2020, DON will produce at least 50 percent of shore-based energy requirements from

alternative sources– Solar, Wind, Ocean, Geothermal

Increase Alternative Energy Use Navy-wide• By 2020, 50 percent of total DON energy consumption will come from alternative sources

What’s Next After HRJ?

• Fully synthetic fuels (cycloparaffins, aromatics for density, seal swell)

• Need to access non-fat/oil feedstocks• Fermentation (w/ microorganisms) to alcohols, conversion to

hydrocarbons (or direct)– Initially using sugar, ultimate goal is cellulosic

• Pyrolysis of ligno-cellulosics

43

sugars alcohols jet fuels, components

fermentation

dehydration, oligomerization, hydroprocessing

“direct fermentation”

biomass “pyrolysis oil” jet fuels, components

stabilization,

hydroprocessing

Gevo Public Data

44

• Fermentation to isobutanol, followed by dehydration/ oligomerization/hydroprocessing