Boeing Biofuel Update

Bio-SPK (HRJ) Approval StatusJames D. Kinder, Ph.D.Technical FellowBoeing Commercial Airplanes

COPYRIGHT © 2009 THE BOEING COMPANY

Plant-Based Feedstocks Remove CO2 from the Atmosphere

Plant feedstocks re-absorb CO2 emissions as they grow

Petroleum releases CO2 that has been locked underground

Petroleum-based fuel Plant-based fuel

No CO2 removed

CO2 removed


Why Sustainable Biofuels? Challenges and Opportunities

Challenge:Fuel price and availability

Opportunity:Secure advantaged positionMitigate price volatilityMitigate risk from heavy crudes

Challenge:Greenhouse gas emissions

Opportunity:Reduce emissions cost-effectivelyPosition with stakeholders, customersMitigate exposure to regulation

Types of Alternative Fuels

Bio-OilsBiodiesel (FAME) Bio-SPK)

Synthesis Gas FT-SPK (CTL, GTL, BTL) Other (H2 Ethanol)

JatrophaJatropha

SPK = Synthetic Paraffinic Kerosene


The Chemistry of Typical Jet Fuel

H3C CH3

CH3

CH3

S

OH

Ideal Carbon Length C8Ideal Carbon Length C8--C16C16

ParaffinsNormal Paraffins Iso-paraffins Cyclic Paraffins

Aromatics

Olefins

Sulfur, Nitrogen, Oxygen ContainingCompounds

70%-85%

< 25%

(<5%)

Acids, phenols, etc

We desire fuels with composition similar to above (i.e. a replacement or “drop-in” fuel)

For BCA flights & engine tests:Paraffins were producedfrom plant oils and blended

with Jet A at 50% ratio.

Copyright © 2009 Boeing. All rights reserved. Page 6

Bio-SPK (HRJ) Approval Status


Certification Process – ASTM D 4054 Standard Practice for Qualification and Approval of New Aviation Turbine Fuels and Fuels Additives

Fuel Fuel Specification Specification

PropertiesProperties

FitFit--forfor--Purpose Purpose PropertiesProperties

Component or Component or Rig TestsRig Tests

Engine Engine Endurance TestEndurance Test

Test Program OEM Internal Review Specification Change

OEM OEM Internal Internal ReviewReview

FAA FAA ReviewReview

Reject or Reject or Additional Additional

Data as Data as RequiredRequired

Reject or Reject or Additional Additional

Data as Data as RequiredRequired

ASTM Review ASTM Review & Ballot& Ballot

ASTM ASTM SpecificationSpecification

Research ReportResearch Report

OEM ApprovalIncorporate into Fuel Specification with

FAA Consensus

Now ASTM D7566 as

well

http://www.airfinancejournal.com/docs/GE-logo(Blue-PMS7455).jpg

http://www.honeywell.com/

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ASTM Research ReportFuel ProducersBio-SPK: UOP, Syntroleum, Energy & Environmental Research Center

(EERC), ENEOS, Neste OilFT-SPK: Sasol, Shell, Syntroleum

FeedstocksJatropha, Camelina, Tallow, Algae, Halophytes, Soybean, Canola,

Palm, Coconut

Fit-For-Purpose tests were run on 100 %Bio-SPK, 100% FT-SPK and 50% jet fuel blends of Bio-SPK and FT-SPK blends

Research Report Prepared by Boeing, UOP and the US Air Force


"Chemistry" :Hydrocarbon chemistry

Hydrocarbon Types D2425 and GCxGCAromatics D1319 or ASTM D6379Hydrogen D5291 or D3701

Trace materialOrganics Carbonyls UOP 730 E 411

Alcohols UOP 656 or EPA 8015BEsters EPA 8260B

Phenols EPA 8270CInorganics: N D4629

Trace ElementsAl, Ca, Co, Cr, Cu, Fe, K, Mg, Mn, Mo, Na, Ni, UOP 389P, Pb, Pd, Pt, Sn, Sr, Ti, V, Zn"Bulk physical and performance properties" :Boiling point distribution D86Thermal stability breakpoint D3241 Appendix X.2Viscosity vs temperature D445Density vs temperature D4052Water solubility vs temperature D6304Flash Point D56/3828Freeze point D2386 and 5972Vapor-Liquid ratio D6378 Lubricity and response to lubricity improver D5001Specific heat vs temperature E1269Surface tension vs temperature D1331Bulk modulus vs temperature D6793Thermal conductivity vs temperature D2717Solubility of air (O2/N2) D2779

Fit-for-Purpose Tests


"Electrical properties" :Dielectric cste vs density D924Electrical Conductivity and response to static dissipator D2624"Compatibility" :With other additives and fuels D4054 Appendix BWith engines and airframe seals, coatings and metallics

"Ground handling / safety" :Effect on Clay Filtration D3948Flammability Limits E 681Autoignition Temperature DE 659

Filtration- coalescers filters and monitors (water fuses) API 1581 (// SAE J 1488)Storage Stability: - Peroxides D3703 - Potential gums D5304Toxicity DoD handbook Aerospace Fuels

Certification, Appendix E

Hot Surface Ignition Temperature FTS 791C method 6053 or ISO 20823

Fit-for-Purpose Tests

The CFM Engine Ground TestGround testing at Peebles, OH with a CFM56-7B development engine

Back-to-back runs comparing Jet A, 50%, and 25% biofuel blends

Performance testing consisted of measuring Specific Fuel Consumption (SFC) at several power settings from ground idle to take-off. SFC improved commensurate with the Net Heat of Combustion (NHC).

Operability testingStart times, Lean-blow out margin, and accel/decel times were within expected variationNo engine deterioration noted.

Emissions testing was conducted for regulated emissions species (NOx, CO, HC, smoke). Smoke number and NOxdecreased slightly, while CO and HC slightly increased.

Emissions ProbeEmissions ProbeInlet Turbulent Inlet Turbulent Control StructureControl Structure

Honeywell Engine Test ProgramGround tests run in Phoenix, AZ with 50% biofuel blend and baseline fuel

UOP Bio-SPK - jatropha & algae oil feedstock (CAL)

TFE731-5 turbofan enginePerformance, lean blowout margin, operability (accel/decel transients)

TPE331-10 turboprop enginePerformance and emissions

131-9 APU (Auxiliary Power Unit)Performance, operability, emissions

TFE731-5 combustor rig testPerformance, lean blowout, ignition (ground starting, altitude relight)

ObservationsNo fuel effect on engine performance and operability, lean blowout margin, ignition characteristics, minor changes in emissionsFuel flow & specific fuel consumption (SFC) reduced ~1% due to higher biofuel LHVHigh power smoke emissions reduced due to lower biofuel aromatic content

TFE731 Engine

Inlet Screen & Bellmouth

Air Inlet

Exhaust

TFE731 Comb Rig


Airline Air New Zealand Continental Airlines Japan Airlines

Aircraft Boeing 747-400 Boeing 737-800 Boeing 747-300

Engine Rolls-RoyceRB211-524G

CFM InternationalCFM56-7B

Pratt & WhitneyJT9D

Plant Feedstock 50% jatropha 47.5% jatropha, 2.5%algae 42% camelina,8% jatropha/algae

Flight date Dec 30, 2008 Jan 7, 2009 Jan 30, 2009

Engine Tests/Ground Run Results Comparison of fuel flow with expected heat of combustion

Engine Operability & Emissions Tests for various blend percentages

Engine Operability & Emissions for Neste- provided paraffins.

Flight Test Profile FL 350, accels/decel, engine windmill restarts, starter- assisted engine relights, simulated missed approach, suction feed test

FL390, accels/decels,engine windmill restarts, starter- assisted engine relights, simulated missed approach, suction feed test

FL390, accels/decels, engine windmill restarts, starter-assisted engine relights,

December 30th, 2008 January 7th, 2009 January 30th, 2009

Flight Test Program

http://www.susoils.com/index.php

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Bio-SPK Report Status

Fit-for-Purpose tests are complete for Bio-SPK FuelsAPU and Combustion Rig testing are completeCFMI Engine Test (Performance, Operability, and Emissions) Completed by GE/CFMEngine Tests (Performance, Operability, and Emissions) were performed by Honeywell. Data from the Bio-SPK test flights will be included in the report.Material compatibility data generated by AFRL OEM review completedReport will be sent for balloted this week.


Additional Bio-SPK Test Flights

KLM Royal Dutch AirlinesDate: November 23, 2009Airframe: 747-400Engine Company Partner: GEFeedstock: CamelinaVIP Passengers onboard

US Air Force A-10Date: March 25, 2010Airframe: A10Engine Company Partner: GEFeedstock: CamelinaBoth engines feed by a 50% Bio-SPK blend.


Additional Bio-SPK Test FlightsUS NavyDate: April 22, 2010Airframe: F/A-18Engine Partner: GEFeedstock: CamelinaSummary: Aggressive flight

profile. Both engines fed 50% Bio-SPK blend.

US Air ForceAirframes: C17, F15, F22Date: Summer/Fall 2010


D7566 Relationship to D1655

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

Specification Table for the blended

Specification Table for the pure Synthetic Component

•Currently D7566 only include fuel made from Synthesis gas (FT-SPK). We expect Bio-SPK to be included by the end of 2010


D7566 Specification

Key ProvisionsBody of Spec Applies to Finished Semi-Synthetic FuelAnnex for Each Class of Synthetic BlendingComponentAllow Re-Certification to D1655−

No need for separate trackingAnnex 1−

Hydroprocessed SPK−

Includes 50% FT FuelAnnex 2−

Bio-SPK−

Includes 50% Bio-SPK blends

Blend Comp’s Criteria and Blend % Limits

Annex 250% Bio-SPK

Annex 150% 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

We Have Published Biofuel Test Results

Paris Air Show Executive Summary – June 2009

AIAA Technical Conference Paper– September 2009


Hydroplane jet engine ran on 100 % Renewable Jet Fuel (Bio-SPK + Renewable Aromatics) Aug. 2009


Forever New Frontiers

http://www.newairplane.com/environment/

Documents

Boeing Biofuel Update