114RK-0014 Reaction Kinetics 9th U. S. National Combustion Meeting Organized by the Central States Section of the Combustion Institute May 17-20, 2015 Cincinnati, Ohio Capturing Soot Formation with the Use of Iso-Octane as a Surrogate for Fischer-Tropsch Fuel A. Makwana, Y. Wang, M. Linevsky, S. Iyer, R. Santoro, T. Litzinger, J. O’Connor* Mechanical and Nuclear Engineering, Pennsylvania State University, University Park, PA * Corresponding Author Email: [email protected] The goal of this work is to support the development of surrogate fuel mixtures that replicate the chemistry and flame characteristics of renewable Fischer-Tropsch (FT) fuels. In particular, we focus on capturing soot formation and growth with the use of iso-octane as a surrogate for FT jet fuel. An axisymmetric, co-flow, laminar flame configuration is used to study soot formation for non-premixed and rich-premixed mixtures at atmospheric pressure. A laser extinction technique is used to obtain spatially resolved soot volume fraction results, and thermocouple measurements provide profiles of gas temperatures in both the radial and axial directions. Comparisons of flame temperature measurements from both FT and iso-octane flames indicate that the temperatures are the same in both the axial and radial profiles within the uncertainty of the measurement. The flame temperatures for the non-premixed flame are 50100 degrees Celsius higher throughout the flame than those for the rich-premixed flame. Laser extinction measurements with both fuels show that the soot volume fraction profiles are very similar for FT fuel and iso-octane. Additional analysis shows the impact of premixing air on soot formation and the differences in time-scales of soot formation with and without the presence of oxygen. Keywords: Surrogate fuel, Fischer-Tropsch, iso-octane, soot 1. Introduction The Department of Defense (DOD) is pursing numerous initiatives for reducing its fuel needs and changing the mix of energy sources that it uses. In 2011, the DOD consumed approximately 117 million barrels of oil [1]. Specifically, gas turbine engines (GTEs) consume about 73% of the DOD’s total fuel and are the major source of carbon monoxide (CO), unburned hydrocarbons (UHC), oxides of nitrogen (NOx), and soot produced at military airbases [2]. The soot emitted has harmful effects on human health and the environment [3-6]. Scarce energy resources, stricter environmental requirements, worldwide air traffic growth, and rising fuel prices all lead to an increasing interest for understanding alternative jet fuels. Previous programs’ field studies of actual engines, e.g. Bulzan et al. [7] and Miake-Lye et al. [8] compared the emissions from engines fueled with petroleum-based fuels to several proposed alternative fuels and blends. The results indicate that the most significant effect of transitioning from JP-8 to alternative jet fuel is a change in soot emissions. It has also been observed that changes occur in emissions of specific hydrocarbon species, some of which are classified as Hazardous Air Pollutants (HAP). Generally, there is little or no change observed in NOx emissions. Experimental investigations found that a significant reduction in soot emissions (both mass and particle number) could be achieved through the use of synthetic paraffinic alternative fuels, both neat and in blends with petroleum-derived fuels [9]. 1 114RK-0014 Reaction Kinetics Future advances in the design of combustion-based aero-propulsion engines will rely, in part, on computational modeling predictions of fuel combustion kinetics. Normal jet fuels such as JetA and JP-8 are complex mixtures of hundreds of chemical components. Even Fischer-Tropsch (FT) fuels, which are less complicated in composition, are still not thoroughly understood with respect to combustion and emission characteristics. Consequently, a number of researchers use surrogate fuels, which typically consists of one or several pure hydrocarbon components from the representative classes of real jet fuels to reproduce the combustions characteristics or, in some cases, the physical properties of fuels [10-14]. This method reduces the complexity of creating a detailed model for predicting combustion processes. The goal of this work is to aid in the development of surrogate fuels by understanding soot formation processes, which contain some of the most complex hydrocarbon (HC) reactions. In particular, we are interested in understanding sooting processes of alternate jet fuels manufactured using a Fisher-Tropsch process from coal, natural gas, or other hydrocarbon feedstocks. FT technology is a catalytic process that converts synthesis gas (CO+H2) into a mixture of hydrocarbons (synthetic fuel) [15]. The FT fuels don’t contain sulfur and have higher thermal stability than petroleum-derived jet fuels [16, 17]. FT fuels are typically composed of normal- and iso-parrafins (>99% by volume) and less than 0.2% aromatics [18]. This work investigates the possibility of using iso-octane (2,2,4-trimethylpentane) as a surrogate for FT fuel. This one-component surrogate was selected to match the molecular structure, hydrogen to carbon ratio, and molecular weight of the FT fuel. Table 1 shows a comparison of properties of the two fuels. Table 1. Fuel properties. Fuel property FT Iso-octane Hydrogen to carbon ratio 2.14* 2.25 Molecular weight (g/mol) 151.38* 114.23 Threshold soot index (TSI) n/a 6.8** Density (g/mL) 0.759* 0.690 Heat of combustion (MJ/Kg) 43.9* 47.81*** 42* -12 Flash point (℃) *FT fuel quantified by GC×GC analysis and Ref. [18], **Ref. [19], ***Ref. [20] The data presented in this paper are relevant to fuel/air mixtures in GTE combustors. Typical gas turbine combustors burn a rich fuel/air mixture in the primary zone to ensure flame stability and aid in high-altitude relight if necessary. Soot is mostly produced in rich regions, like the primary zone of GTE combustor, and then is consumed downstream. Thus, the primary zone governs the soot formation rate, whereas the intermediate and dilution zones determine the soot oxidation. Consequently, the engine-out soot depends on the balance of these two processes. The current work is focused on non-premixed and rich-premixed flame conditions in order to simulate conditions in the primary zone. 2. Methods / Experimental 2.1 Burner and Burner system A co-annular laminar flame burner has been used in the present work to study the soot formation under the experimental conditions presented in Table. This burner is similar to the coannular laminar flame burner used by Santoro et al. [21]. The burner consists of two concentric brass tubes as shown in Figure 1. The inner fuel tube diameter is 11.1 mm. This tube protrudes 4 2 114RK-0014 Reaction Kinetics mm above the plane of the co-flow. The inner tube contains glass beads and screen to condition the flow. The outer air tube has a 101.6 mm diameter. The annular co-flow region consists of series of screens, glass beads, and honeycomb to provide a uniform exit velocity profile. Figure 1: Burner dimensions. The burner system used is shown in Figure 2. The fuel is stored in a Syringe D500 fuel pump and delivered through 1/16” tube to the vaporization unit. The vaporization unit consists of a ¼” brass Swagelok tee filled with fiber glass [22]. The energy for fuel vaporization is provided by heating tapes that are wrapped around the tubing system and Swagelok assembly. The heating tapes are wrapped from 30 cm below the mixing chamber to the end of the burner inner tube. A nitrogen stream is used to carry the vaporized fuel from the mixing chamber to the burner. A 100 micron orifice is installed after the mixing chamber to provide sufficient pressure and residence time to heat the fuel-nitrogen mixture. For premixed cases, the premixed air inlet is located after the orifice in the main tubing system. Five K-type thermocouples are placed on the tubing system to monitor the temperature at critical locations, as shown in Figure 2. Four filters are installed for nitrogen, fuel, fuel/nitrogen mixture, and air. The flow rate of premixed air and nitrogen is controlled by mass flow controllers (Brooks Instruments 5850 series). The mass flow controllers are calibrated using a bubble meter. The co-flow air is set at a constant flow rate of 4 scfm. The temperature of the heating tapes is maintained at 200ᵒ C in order to vaporize the fuel. The temperature is also properly maintained to prevent fuel pyrolysis in the tubing system. Gas chromatography has been used on the fuel-air-nitrogen mixture at the exit of burner tube to ensure that no fuel pyrolysis has occurred in the tubing system. The iso-octane fuel used in this experiment is 99.9% pure; the Fisher-Tropsch fuel used is a coal-based Sasol fuel. The nitrogen used was 99.9% pure industry grade and filtered air was supplied from an air compressor. A brass chimney (400 mm long) with screens on the top is placed around the flame. This chimney helps to protect the flame from surrounding air-currents and obtain a stable flame. Four slots are machined at symmetrical locations on the chimney to provide access for the laser beam and the thermocouple. The burner assembly can be moved in both the horizontal and vertical direction using stepper motor. 3 114RK-0014 Reaction Kinetics Figure 2: Burner system. 2.2 Diagnostics Method Soot volume fractions were measured using a laser extinction technique, as shown in Figure 3. The laser extinction measurements were obtained using a Coherent Innova 70 (2W) argon ion laser at a 514.5 nm wavelength. The laser input was 0.5 W and the beam was modulated at 1000 Hz using a mechanical chopper. A beam splitter (30%:70%) was used to deflect and monitor the incident laser beam (𝐼𝑜 ) by a PIN-10D silicon photodiode. A neutral density filter (NDF) was used before this photodiode to reduce the beam intensity to levels so that the photodiode operated in its linear region. A set of convex and concave lens were used to expand the laser beam before the photodiode measuring, 𝐼𝑜 . The laser beam was focussed on the flame using a 350 mm focal length lens. The transmitted power, 𝐼, was measured using a similar photodiode fitted on an integrating sphere. The integrating sphere was used to reduce the beam steering effect as laser beam passed through the flame. Figure 3: Optical setup for Laser extinction measurements. The output signals from both photodiodes were converted to voltages using a trans-impedance amplifier and then fed into a lock-in amplifier to reduce the noise from surrounding environment. The line-of-sight measurements were obtained every 0.25 mm and 1 mm in the radial direction 4 114RK-0014 Reaction Kinetics and axially along centerline, respectively. The extinction profiles are deconvoluted using a Fourier inversion technique [23]. The refractive index of soot was taken as 𝑚 ̃ = 1.57 − 0.56𝑖 to be consistent with the previous published work [24]. Temperature measurements were obtained using 125 micron Pt/Pt-13% Rh fine-wire, uncoated R-type thermocouples. The thermocouple configuration used is shown in Figure 4. The thermocouple apparatus consists of a single ceramic tube that was fixed on a horizontal translation stage. The thermocouple wires pass through the two holes inside the ceramic tube. One side of the thermocouple wires are affixed to the connector, and at the other end, the wires are bent at 90 degrees to point vertically down approximately 3 mm. Temperature gradients being small in the axial direction compared to the radial direction helped to reduce the conduction along the wires. Temperature measurements were obtained every 1 mm in both the radial direction and axially along centerline from the burner exit by moving the burner in a horizontal or vertical direction. In regions containing soot, soot particles deposited on the thermocouple junction; the junction was cleaned by moving it to an oxidizing region of the flame. Thermocouple measurements have been corrected for radiation losses and heat conduction along the thermocouple wires has been neglected. The emissivity for Pt/Pt-13% Rh was taken from Bradley and Entwistle [25]. The conductivity and viscosity of the gas were taken as that of nitrogen. The bead was considered spherical and the Nusselt number was estimated by a correlation from Eckert and Drank [26]. The velocities typically ranged from 30-250 cm/sec inside the flame [27] and a value of 60 cm/sec was considered for the radiation correction. The data for both laser extinction and temperature measurement were collected by a National Instruments data acquisition system at a sampling rate of 10 samples/sec for 4 sec. Figure 4: Thermocouple configuration. 2.3 Experimental Conditions The flames investigated are non-premixed (equivalence ratio of “infinity”) and rich premixed (equivalence ratio of 6) in order to have fuel rich conditions similar to those in the primary zone of an aircraft engine combustor. The flow rate of nitrogen was selected such that it is sufficient to carry the vaporized fuel to obtain a stable flame. The total carbon flow rate was held constant for all flames at 0.0111 mole/min. The carbon flow rate was fixed to match carbon flow from the base flame, a 75% dodecane and 25% m-xylene mixture. The experimental conditions are provided in Table 2. 5 114RK-0014 Reaction Kinetics Fuel FischerTropsch IsoOctane Table 2. Experimental conditions. Carbon Flow N2 Flow Equivalence Fuel flow Rate Rate ratio (phi) rate (sccm) (mole/min) (slpm) Inf 0.208 0.0111 0.2 6 0.208 0.0111 0.2 Inf 0.230 0.0111 0.2 6 0.230 0.0111 0.2 Mean exit velocity (cm/s) 4.33 9.93 4.63 10.22 Co-flow flow rate (slpm) 4.0 4.0 4.0 4.0 3. Results and Discussion 3.1 Flame Heights Figure 5 shows visible flame pictures taken using a commercial camera. The camera settings (aperture and shutter speed) were adjusted in order to take clear visible flame images at each condition. This means that the relative intensities of these images should not be compared. These images indicate that flame heights for both fuels are nearly equal at same equivalence ratio; these heights are also presented in Table 3. The flame height of the rich-premixed flame is smaller compared to the non-premixed flame for both fuels, consistent with previous work [28]. Table 3. Flame height comparison. Phi = Infinite Flame FT iso-octane FT Height above burner [mm] 62.2 62.7 47.8 Phi=6 iso-octane 50.0 Figure 5. Flame picture (a) FT- phi=Infinite flame (b) iso-octane - phi=Infinite flame (c) FT- phi=6 flame (d) iso-octane - phi=6 flame. 3.2 Temperature Distributions Temperature was measured in the lower part of the flames using a thermocouple. The primary reason to compare the temperature in lower part of the flame is because this temperature has a great impact on the soot production [29]. Figure 6 shows a comparison of radial profiles of temperature for FT fuel and iso-octane at two heights above the burner exit (HAB). The radial 6 114RK-0014 Reaction Kinetics temperature profiles are consistent with the typical shapes for laminar flames [21]. The peak temperature and radial temperature profiles for both FT flames and iso-octane flames are quite similar for both phi=infinite and phi=6 flame conditions. (a) (b) (c) (d) Figure 6. Comparison of radial profiles of temperature for FT flame and iso-octane flame: (a) phi=Infinite flame-5mm height above burner (HAB), (b) phi=Infinite flame-10mm HAB, (c) phi=6 flame-5mm HAB, (d) phi=6 flame, 10mm HAB. Figure 7 shows the comparison of the axial temperature profile for FT fuel and iso-octane under both phi=Infinite and phi=6 conditions. The measurements were taken until 20 mm height above the burner. Temperature measurements above this height were not possible as the flame shape was significantly altered by the presence of the thermocouple in this region. The temperature profiles along the centerline of the flame for both premixed and non-premixed conditions are 7 114RK-0014 Reaction Kinetics consistent with previous work [21, 30]. The temperature from the burner exit to approximately 14 mm above the burner for phi=6 is lower compared to non-premixed flames. Further downstream, the temperature profiles for the phi=6 and phi=Inf flames cross and the phi=6 flames are hotter; this is due to heat release at inner flame front in phi=6 flame [30]. The temperatures measured along the centerline at a given equivalence ratio are quite similar for both FT and iso-octane flames. Figure 7. Comparison of axial profiles of temperature for FT flame and iso-octane flame for phi=Infinite and phi=6. 3.3 Laser Extinction Figure 8 shows the comparison of line-of-sight integrated soot volume fraction for both FisherTropsch and iso-octane flames as a function of normalized distance above the burner; distance is normalized by the flame height in each case. The visible flame widths, obtained using a digital camera, were used as extinction path lengths for the calculation of soot volume fraction. In general, the soot profile for the iso-octane flame follows the soot volume fraction of the FT flame in both the premixed and non-premixed cases. The soot volume fraction increases first in the lower part of the flame due to soot production and then it decreases due to soot burnout. The figure shows that the soot volume fraction is higher for non-premixed flames than in premixed flames. The soot volume fraction peaks earlier at a normalized height of nominally 0.6 for non-premixed flames compared to a normalized height of 0.66-0.76 for premixed flames. 8 114RK-0014 Reaction Kinetics Figure 8. Line-of-sight soot volume fraction along axial direction for Fisher-Tropsch and iso-octane fuel under equivalence ratio of Inf and 6. (a) (b) Figure 9. (a) Maximum soot volume fraction and (b) centerline soot volume fraction along the axial direction for Fisher-Tropsch and iso-octane fuel. Figure 9(a) shows the variation of maximum soot volume fraction for both fuels as a function of downstream distance; the radial location of the maximum soot volume fraction at each downstream location may differ in each flame. The shape of the maximum soot volume fraction curves for both fuels is quite similar. In the lower part of the flame, the soot volume fraction is similar in the FT and iso-octane flames for both the phi=Inf and phi=6 conditions. Further downstream, the maximum soot volume fraction is higher for the iso-octane flame as compared to 9 114RK-0014 Reaction Kinetics the FT flame. The highest magnitude of the maximum soot volume fraction for the iso-octane flame is roughly 1.4 times that of the FT flame for both the pre-mixed and non-premixed condition. Figure 9(b) shows the variation of soot volume fraction along the centerline of the flame. The profiles for centerline soot volume fraction have similar shapes for both fuels and for the nonpremixed and premixed condition. The peak centerline soot volume fraction is higher by 28% and 48% for iso-octane fuel compared to FT fuel for the non-premixed and premixed conditions, respectively. This could be due to greater surface growth, particle agglomeration, and slower burnout in the surrogate fuel. However, further investigation of the distribution of large aromatics and species concentration would be necessary to establish a more detailed explanation. The profiles of the soot distribution in the radial direction are symmetric about the centerline. To compare radial profiles of the iso-octane and FT flames, only half-profiles have been plotted in Figure 10. The left half from r=-6 to 0 mm is the radial profile of soot volume fraction in the FT flame, while the right half from r=0 to 6 mm is for the iso-octane flame. The soot distribution pattern in the radial direction has a similar profile to previously reported data [21]. In the lower region of the flame, the maximum soot volume fraction occurs in the annular region close to the flame front where temperature is high. At locations farther downstream, the concentration of soot in the annular region decreases due to soot oxidation. The central region has less soot near the base, but the soot volume fraction increases with downstream distance to its peak near 30-35 mm and then decreases due to oxidation. Figure 10(a) shows a comparison of the radial distribution of the soot volume fraction in the lower part of the flame for the non-premixed condition. The radial profiles and maximum soot volume fraction for the iso-octane flame match very well to the FT flame at the base of the flame. At a height of 30mm to 35mm above the burner in Figure 10(b), the peak soot volume fraction for both flames occurs but the peak volume fraction of soot in the iso-octane flame is 40% higher than that in the FT flame. This peak in the iso-octane flame occurs closer to the center (r=2.25 mm) than the peak in the FT flame (r=2.75 mm). At 40 mm and 45 mm above the burner, shown in Figure 10(c), the radial profiles match quite well for both fuels but the peak soot volume fraction for the iso-octane flame is higher (8.4 ppm) as compared to the FT flame (5.46 ppm). Finally, at downstream locations of 50 mm and 55 mm, also shown in Figure 10(c), the soot volume fraction in the central region has decreased for the FT fuel due to oxidation but it is still significant for the iso-octane flame. This is consistent with Figure 8, where the integrated soot volume fraction for iso-octane is greater than the FT flame for a non-dimensional height greater than 0.8. Figure 10(d) shows a comparison of radial profiles for both fuels at an equivalence ratio of 6. The overall profiles are quite similar in terms of their radial distribution. The FT flame has a slightly higher peak soot volume fraction in a lower part as compared to the iso-octane flame. Further downstream at 40 mm above the burner, the iso-octane flame has a higher peak soot volume fraction in the central part of the flame. 10 114RK-0014 Reaction Kinetics Figure 10: Comparison of half profiles for FT vs i-C8 (a) phi=Inf, 15mm, 20mm, 25mm HAB, (b) phi=Inf, 30mm, 35mm HAB, (c) phi=Inf, 40mm, 45mm, 55mm HAB, (d) phi=6, all HAB. 3.4 Residence Times The residence time of soot in the non-premixed and premixed flame was calculated using the velocity field obtained from solving a Navier-Stokes based , two-dimensional simulation package known as UNICORN (Unsteady Ignition and Combustion using Reactions) [31-33]. The velocity along the centerline of the flame as a function of downstream distance for both the non-premixed and premixed flame is shown in Figure 11. Since the flames are buoyancy driven, the velocity profiles do not change much due to premixing [27]. The velocity fields were used to track particle 11 114RK-0014 Reaction Kinetics residence time along seven streamlines starting at different radial locations from the centerline of the tube. Figure 11: Velocity along centerline for phi=Inf and phi=6. Figure 12 shows the streamlines originating at these radial locations for a premixed (left) and non-premixed (right) flame. The streamlines for the non-premixed flame are more curved inside the flame as compared to the premixed flame. This is because less secondary air is required for the premixed flame as compared to the non-premixed. Figure 12: Streamline originating at different radial location for non-premixed flame (right) and equivalence ratio of 6 (left). The residence time along the seven streamlines as a function of downstream distance is plotted in Figure 13(a) and 13(b) from simulation of the premixed and non-premixed cases, respectively. A total of 1901 and 1471 points were obtained along each streamline for non-premixed and 12 114RK-0014 Reaction Kinetics premixed cases, respectively. The distance between two adjacent points and the velocity from the closest grid point were used to calculate the residence time between two points. Figure 13 shows that the total residence time of a particle decreases from the r=0 mm streamline to the r=4 mm streamline. This trend is driven by the temperature field; the temperature is lower along the centerline in lower part of the flame, resulting in a longer residence time in the buoyancy-driven flow. The residence time along the r=6 mm streamline is longer than the time along the r=5 mm and r=4 mm streamline. The trends in residence time variation for the premixed flame, in Figure 13(a), are similar to those in the non-premixed flame in Figure 13(b). The residence time along a particular streamline for the premixed flame is smaller compared to corresponding streamlines in the non-premixed flame. (a) (b) Figure 13: Variation of residence along the streamlines as a function of downstream distance (a) phi=6 flame (b) phi=Inf flame This residence time information can help explain the soot results from the premixed and nonpremixed flames. Soot volume fraction results in Figures 8-10 indicate that premixing has a significant impact on soot formation. First, oxygen in the premixed mixture could increase the fuel pyrolysis, thereby increasing soot formation. Simultaneously, soot oxidation also increases in the presence of oxygen. The overall effect of these two phenomena is reduced soot volume fraction in a premixed flame [34, 35]. Additionally, the time available for surface growth affects the soot volume fraction in a flame and could be another reason that the soot volume fraction is less in premixed flames [36]. The experimental results in Figure 9(b) and Figure 8 shows that for the premixed flame, soot inception occurs later at a non-dimensioned height of 0.4 compared to nondimensional height of 0.2 for the non-premixed flame. Table 4 quantifies the time required for a fluid particle to traverse the flame height; it is clear that the time is less for a premixed flame at any given streamline. As a result, soot in a premixed flame has less residence time available for surface growth as compared to soot in a non-premixed flame. The soot surface area available, which depends on soot number density, would also affect the overall growth of the soot. A greater surface area and higher residence time would result in faster soot growth. In future, the relative impact of residence time and surface area on soot surface growth needs to be investigated. 13 114RK-0014 Reaction Kinetics Table 4. Time to travel to flame tip for all streamlines for non-premixed and premixed flame. Time [ms] Streamline 0 1 2 3 4 5 6 106 102 94 86 80 79 85.6 Phi=Inf 64 63 60 57.5 56 58.7 64.3 Phi=6 4. Conclusions This paper presents a set of temperature and soot volume fraction data for iso-octane and FT fuels under non-premixed and rich-premixed conditions. The peak temperatures in the iso-octane and FT flames are almost the same in the lower part of the flame under non-premixed and premixed conditions. Also, radial and centerline temperature field are quite similar for both fuels. The integrated soot volume fraction in the iso-octane flame is similar to that of the FT flame for both non-premixed and premixed conditions. 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Dept. of Mechanical Engineering, Pennsylvania State University, University Park, PA., 1996. 16 114RK-0014 Reaction Kinetics 7. Supplementary material: Table 5: FT fuel (coal- Sasol) composition Number of C 11 10 9 12 13 9 8 11 10 14 9 Number of H 24 22 20 26 28 18 18 24 22 30 20 Class iso-C11 iso-C10 iso-C09 iso-C12 iso-C13 monocyclo-C09 iso-C08 n-C11 n-C10 iso-C14 n-C09 17 Mole Fraction 0.316 0.314 0.156 0.116 0.040 0.017 0.010 0.009 0.008 0.008 0.003
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