© 2009 Rolls-Royce Corporation The information in this document is the property of Rolls-Royce Corporation 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 Corporation. This information is given in good faith based upon the latest information available to Rolls-Royce Corporation, 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 Corporation or any of its subsidiary or associated companies.

Page 1

Overview of the relationship between fuel properties and engine performance

Nader RizkRolls-RoyceIndianapolis, IN

ICAO Workshop, Aviation & Alternative FuelsMontreal, Canada10-12 February 2009

2

Outline of Presentation

• OEMs’ joint test program• Evaluation of fully synthetic aviation kerosene

Full annular combustor test

Material compatibility

Full system evaluation

• Summary• Concluding remarks

3

Alternative fuels requirements

Offering longer term potential for ‘drop-in’ fuels

4

Fuel approval process - Now in ASTM ballot

•Seal Swell•Lubricity•Bulk Modulus•Material Compatibility•Additive Compatibility etc

Fit-for-PurposeProperties

Fuel SpecProperties •ASTM D1655/•Def-Stan 91-91

Component Test• Fuel control• Fuel pump• Nozzle• Turbine• Combustor Rig

Yes

EngineTest

Required?

No Anomalies

NegativeImpact

NegativeImpact

No Anomalies

Yes

Engine Test

Incorporate into fuel spec

No

Approval

NoComponentTest

Required?

No Effect

Negative Impact

Negative Impact Reject & File Report

5

OEMs engine and combustor test program

To assess effects of SASOL fully synthetic jet fuel (FSJF) on

engine performance and operation, engine manufacturers (RR,

P&W, GE and Honeywell), in coordination with SwRI, conducted

engine and combustor tests:

• Engine performance and endurance (P&W)• Emissions (United Technologies - P&W)• Low temperature atomization (Honeywell)• Cold ignition, altitude relight and lean blowout (Rolls-Royce

and Honeywell)

To assess effects of SASOL fully synthetic jet fuel (FSJF) on

engine performance and operation, engine manufacturers (RR,

P&W, GE and Honeywell), in coordination with SwRI, conducted

engine and combustor tests:

• Engine performance and endurance (P&W)• Emissions (United Technologies - P&W)• Low temperature atomization (Honeywell)• Cold ignition, altitude relight and lean blowout (Rolls-Royce

and Honeywell)

6

Pratt & Whitney – United Technologies tests

• JT9D engine endurance test for 500 test cycles• Pre and post-test inspection involved:

Fuel delivery system including control scheduling, O-rings, filters, etc.

Fuel nozzles (position, flow, internal passages, etc.)Combustor liners (visual and video borescope)

• Emissions tests for an 80o, four-nozzle arc sector of commercial combustor involved:

ICAO LTO cycle and cruise:– NOx, CO, and UHC– CO2 and combustion efficiency– Smoke number

7

Honeywell cold atomization tests

• Cold fuel atomization bench test for spray measurements• Fuel atomizers tested included:

Two representative pressure atomizers used in APUs of commercial and military transport in addition to regional aircraftAirblast atomizer used in several propulsion engines and some APUs

• Malvern particle analyzer determined spray droplet size distribution and Sauter mean diameter (SMD)

• Spray visualization and angle• Fuel temperature down to level consistent with high altitude

temperatures

8

Rolls-Royce cold-day ignition and altitude relight test• Test conducted at high altitude test facility with an annular

combustion system fully representative of a modern gas turbine

• Testing involved:Ignition under high altitude condition across full altitude relight envelopeA ground ambient cold day condition – ignition and extinctionExtinction boundaries and blowout

9

Honeywell combustor lean stability test• An annular combustor rig for a small turboshaft (helicopter)

engine was used• Lean blowout testing completed at representative flight and

ground deceleration conditions• Testing used FSJF, Jet A fuel, and weathered JP-5 fuel for

comparisons• FSJF and weathered JP-5 had flat distillation curves• Lean blowout was detected by a rapid drop in combustor

exit temperature

10

• Objective: Assess impact of Syntroleum Fischer-Tropsch fully synthetic aviation kerosene on performance and material compatibility of aircraft gas turbine engines by evaluating:

Combustion characteristics in a production annular combustor and fuel nozzle assemblyEffect on oxidation of turbine blade and vane alloys in a cyclic oxidation rig

• Project sponsored by Wright Patterson AFRL • University of Dayton participated in material analysis

• Objective: Assess impact of Syntroleum Fischer-Tropsch fully synthetic aviation kerosene on performance and material compatibility of aircraft gas turbine engines by evaluating:

Combustion characteristics in a production annular combustor and fuel nozzle assemblyEffect on oxidation of turbine blade and vane alloys in a cyclic oxidation rig

• Project sponsored by Wright Patterson AFRL • University of Dayton participated in material analysis

Rolls-Royce experimental evaluation of FSJF

11

Distillation profiles of F-T and JP-8 fuels

• Syntroleum F-T fully synthetic fuel exhibits fairly similar distillation profile to that of JP-8 tested under present study and both meet the JP-8 specifications

• SASOL F-T fuel has been approved for use in commercial aircraft but has distillation limitations to ensure typical profile

• Syntroleum F-T fully synthetic fuel exhibits fairly similar distillation profile to that of JP-8 tested under present study and both meet the JP-8 specifications

• SASOL F-T fuel has been approved for use in commercial aircraft but has distillation limitations to ensure typical profile

Distillation Profiles

0

50

100

150

200

250

300

0 20 40 60 80 100% Recovered

Tem

pera

ture

, C

JP-8 Spec MaxSASOL F-T TestedSyntroeum F-T Tested

Distillation Profiles

0

50

100

150

200

250

300

0 20 40 60 80 100% Recovered

Tem

pera

ture

, C

JP-8 Spec MaxJP-8 TestedSyntroleum F-T Tested

12

Annular combustor rig

• Full annular combustor rig is used for testing AE 3007, AE 2100, and AE 1107 combustors, which have common parts with minor variations

• F-T and JP-8 tests used same combustor build• The 100% SPK was held in a specially cleaned trailer and passed

directly to the annular combustor

F-T fuel trailerF-T fuel trailer

13

Full annular combustor test• Stability boundaries

Ignition and LBO characteristics• Emissions at selected performance points

Combustion efficiency mapGaseous emissions (NOx, CO, and UHC)Smoke

• Exhaust gas temperature profilesRadial temperature profilesExit pattern factor

• Combustor liner temperaturesThermocouples measurementThermal paint

14

Impact of key properties on performance

15

Impact of fuel on gaseous emissions

16

NOx emissions

• NOx emissions for FSJF are in general higher than for JP-8• Higher combustion heating value of FSJF results in favorable

conditions for NOx formation

NOx Emissions for JP-8 and F-T Fuels

0

10

20

30

0 200 400 600 800 1000BIT, F

NO

x em

issi

ons,

g/k

g fu

el JP-8F-T

17

Liner thermocouple temperature

• Thermocouple data were compared at two conditions having similar BOT: Moderate FAR and high pressure representative of T/OHigh FAR, low pressure such as during cruise-climb

• FSJF had a higher heating value resulting in an increase in BOT relative to JP-8 under same operating conditions

• Liner temperatures are fairly similar at most locations with some advantage for FSJF under T/O conditions

• Thermal paint results did not reveal differences in localized hot or cold spots

• Thermocouple data were compared at two conditions having similar BOT: Moderate FAR and high pressure representative of T/OHigh FAR, low pressure such as during cruise-climb

• FSJF had a higher heating value resulting in an increase in BOT relative to JP-8 under same operating conditions

• Liner temperatures are fairly similar at most locations with some advantage for FSJF under T/O conditions

• Thermal paint results did not reveal differences in localized hot or cold spots

700

900

1100

1300

1500

0 2 4 6 8 10 12 14Thermocouple (order by position)

Line

r wal

l tem

pera

ture

. F

JP-8, Altitude Cruise100% F-T, Altitude Cruise

Front Rear700

900

1100

1300

1500

0 2 4 6 8 10 12 14Thermocouple (order by position)

Line

r wal

l tem

pera

ture

. F

JP-8, Takeoff100% F-T, Takeoff

Front Rear

18

Impact on other key performance parameters• FSJF fuel exhibits similar stability and ignition characteristics at

low and higher operating conditions to those for JP-8 fuel within

experimental error

• CO and UHC emissions are similar for both fuels • Full annular AE3007 combustor behaves like engine in

producing extremely low smoke and remains nearly smoke free

for both FSJF and JP-8 fuels

• No measurable differences are observed in pattern factor and radial profiles between JP-8 and FSJF fuels suggesting no

adverse impact on turbine vane lives

19

Impact of F-T fuel on material

• A set of 12 alloy specimen rods and 2 thermocouple rods were mounted in a 600 RPM rotating carousel and cycled between hot and cold jets

Becon combustion rig

20

• In order to determine whether FSJF fuel had same or different effect on several alloys used in engines as normal JP-8 fuel, test pins from Becon combustion rig test were analyzed by University of Dayton

Analysis of test specimens

• Samples were examined by two main methods:Visual analysis and optical metallographyX-ray-fluorescence (XRF) and scanning electron microscopy (SEM)

• Photomicrographs of sections of 12 samples at both 100x and 400x magnifications showed that no significant difference wasevident for any material in the two fuel environments

• Also, based on elemental intensity values, it would appear thatthe use of FSJF does not result in any significant compositional differences in material relative to compositions found for materials that were tested using JP-8 fuel

21

Airbus / Shell / Rolls-Royce A380 demo• Flight evaluation of a 40% GTL kerosene fuel blended with conventional fuel• Part of research program to understand renewable fuels and potential future

applications:Aircraft - Airbus A380 MSN4Engine - Trent 900 – only one engine used the derived fuelTiming – 1 Feb 2008

• Data gathered throughout the test process reported and contributing to the capabilities and limitations of FT and also more recently renewable synthetic fuels

22

Rolls-Royce joins Air New Zealand, UOP and Boeing in renewable fuels study program• Flight evaluation of a renewable bio fuel blended with kerosene fuel source

Aircraft ANZ 747-400, Engine RB211-524GT, only one engine uses the fuelTiming –30th Dec 2008

• Fuel analysis shows fuel meets/exceeds current specification requirements50:50 Blend - Jatropha derived SPK (Hydrogenated Vegetable Oil) and standard Jet A-1, therefore is drop-in

• Data gathered throughout the test process has contributed to understanding of the capabilities and limitations of renewable fuels

• Pre and Post engine hardware inspection is taking place

23

• OEMs joint test program, in coordination with SASOL and SwRI, provided significant engine and component performance data insupport of FSJF assessment and approval

Summary

• Rolls-Royce assessed impact of Syntroleum fully synthetic aviation kerosene on performance and material compatibility of aircraft gas turbine though combustion testing in production annular combustor and Becon combustion rig

• Fuel properties impact almost all engine performance parameters and hot section material durability through their effects on fuelinjection/spray evaporation processes and combustion characteristics

• ICAO can play a significant role in promoting development of alternative fuels and incorporation in future regulation activities

• Engine operability has been demonstrated for 2 different alternative fuels

24

Concluding remarks - The future• Existing Rolls-Royce programs goals• Meeting the challenge

Supporting development of truly sustainable and viable alternative fuels for aviation:−Whole life cycle evaluation−Performance measurement and prediction−Integration with engine development programs

• Creating the opportunitiesCreating new collaborative partners to evaluate and demonstrate alternative fuels e.g Qatar ConsortiumContribution to European Union funded sustainable fuel programs- e.g, ALFA-BIRD, SWAFEAEngagement with key industry bodies – e.g. CAAFI, Specification Owners (ASTM, Defence Standards), US Coordinating Research CouncilImproving test and evaluation capability, e.g, university collaborationsSupporting the approval and rapid adoption of suitable alternative fuels

25

Thank you.Thank you.

/ColorImageDict > /JPEG2000ColorACSImageDict > /JPEG2000ColorImageDict > /AntiAliasGrayImages false /CropGrayImages true /GrayImageMinResolution 300 /GrayImageMinResolutionPolicy /OK /DownsampleGrayImages true /GrayImageDownsampleType /Bicubic /GrayImageResolution 300 /GrayImageDepth -1 /GrayImageMinDownsampleDepth 2 /GrayImageDownsampleThreshold 1.50000 /EncodeGrayImages true /GrayImageFilter /DCTEncode /AutoFilterGrayImages true /GrayImageAutoFilterStrategy /JPEG /GrayACSImageDict > /GrayImageDict > /JPEG2000GrayACSImageDict > /JPEG2000GrayImageDict > /AntiAliasMonoImages false /CropMonoImages true /MonoImageMinResolution 1200 /MonoImageMinResolutionPolicy /OK /DownsampleMonoImages true /MonoImageDownsampleType /Bicubic /MonoImageResolution 1200 /MonoImageDepth -1 /MonoImageDownsampleThreshold 1.50000 /EncodeMonoImages true /MonoImageFilter /CCITTFaxEncode /MonoImageDict > /AllowPSXObjects false /CheckCompliance [ /None ] /PDFX1aCheck false /PDFX3Check false /PDFXCompliantPDFOnly false /PDFXNoTrimBoxError true /PDFXTrimBoxToMediaBoxOffset [ 0.00000 0.00000 0.00000 0.00000 ] /PDFXSetBleedBoxToMediaBox true /PDFXBleedBoxToTrimBoxOffset [ 0.00000 0.00000 0.00000 0.00000 ] /PDFXOutputIntentProfile () /PDFXOutputConditionIdentifier () /PDFXOutputCondition () /PDFXRegistryName () /PDFXTrapped /False

/Description > /Namespace [ (Adobe) (Common) (1.0) ] /OtherNamespaces [ > /FormElements false /GenerateStructure true /IncludeBookmarks false /IncludeHyperlinks false /IncludeInteractive false /IncludeLayers false /IncludeProfiles true /MultimediaHandling /UseObjectSettings /Namespace [ (Adobe) (CreativeSuite) (2.0) ] /PDFXOutputIntentProfileSelector /NA /PreserveEditing true /UntaggedCMYKHandling /LeaveUntagged /UntaggedRGBHandling /LeaveUntagged /UseDocumentBleed false >> ]>> setdistillerparams> setpagedevice