Chemical, Thermal Stability, Seal Swell, and Emissions Studies of Alternative Jet Fuels

This effort describes laboratory evaluations of six alternative (nonpetroleum) jet fuel candidates derived from coal, natural gas, camelina, and animal fat. Three of the fuels were produced via Fischer-Tropsch (FT) synthesis, while the other three were produced via extensive hydroprocessing. The thermal stability, elastomer swell capability, and combustion emissions of the alternative jet fuels were assessed. In addition, detailed chemical analysis was performed to provide insight into their performance and to infer potential behavior of these fuels if implemented. The fuels were supplied by Sasol, Shell, Rentech, UOP, and Syntroleum Corporation. Chemical analyses show that the alternative fuels were comprised of mostly paraffinic compounds at varying relative concentrations, contained negligible heteroatom species, and were mostly aromatic-free. The six paraffinic fuels demonstrated superior thermal oxidative stability compared to JP-8, and therefore, have increased resistance to carbon formation when heated and can be exposed to higher temperatures when used to cool aircraft systems. Material compatibility tests show that the alternative fuels possess significant seal swelling capability in conditioned nitrile O-rings; however, elastomer swelling was significantly lower than for JP-8, which may likely result in fuel leaks in aircraft systems. Engine tests with the alternative fuels demonstrated no anomalies in engine operation, production of significantly lower nonvolatile particulate matter (soot), and moderately lower unburned hydrocarbons and carbon monoxide emissions compared to baseline JP-8 fuel. Also, no penalty (i.e., increase) in fuel flow requirement for equal engine power output was observed. In general, this study demonstrates that paraffinic fuels derived from different feedstocks and produced via FT synthesis or hydroprocessing can provide fuels with very similar properties to conventional fuels consisting of excellent physical, chemical, and combustion characteristics for use in turbine engines. These types of fuels may be considered as viable drop-in replacement jet fuels if deficiencies such as seal swell, lubricity, and low density can be properly addressed.