Fuel systems

There always is a relation between fuel composition and that of hydrocarbon emissions to the atmosphere, whether it concerns hydrocarbon emissions from evaporative losses from the fuel system, or from exhaust gases. This is the reason that environmental protection regulations include monitoring the composition of motor and heating fuels. We will describe here the regulations already in existence and the work currently underway in this area with its possible effects on refining. 

Revised fuel system materials for methanol compatibility... 

In the United States, the Clean Air Act of 1970 imposed limitations on composition of new fuels, and as such methanol-containing fuels were required to obtain Environmental Protection Agency (EPA) waivers. Upon enactment of the Clean Air Act Amendments of 1977, EPA set for waiver unleaded fuels containing 2 wt % maximum oxygenates excluding methanol (0.3 vol % maximum). Questions regarding methanol s influence on emissions, water separation, and fuel system components were raised (80). 

Owing to its properties, methanol is not recommended for aircraft or marine fuel uses. Methanol caimot be used in conventional diesel-powered vehicles without modifications to the fuel system and engine. Simple methanol—diesel blends are not possible because of insolubiUty. Heavy-duty diesel engines have been adapted to use neat methanol by many U.S. manufacturers, and several are being used in field demonstrations (82) (see Alcohol fuels). 

Basic oxides of metals such as Co, Mn, Fe, and Cu catalyze the decomposition of chlorate by lowering the decomposition temperature. Consequendy, less fuel is needed and the reaction continues at a lower temperature. Cobalt metal, which forms the basic oxide in situ, lowers the decomposition of pure sodium chlorate from 478 to 280°C while serving as fuel (6,7). Composition of a cobalt-fueled system, compared with an iron-fueled system, is 90 wt % NaClO, 4 wt % Co, and 6 wt % glass fiber vs 86% NaClO, 4% Fe, 6% glass fiber, and 4% BaO. Initiation of the former is at 270°C, compared to 370°C for the iron-fueled candle. Cobalt hydroxide produces a more pronounced lowering of the decomposition temperature than the metal alone, although the water produced by decomposition of the hydroxide to form the oxide is thought to increase chlorine contaminate levels. Alkaline earths and transition-metal ferrates also have catalytic activity and improve chlorine retention (8). 

Flare noise (roar of combustion) is the most serious because it is elevated and the sound carries. The flare can be located at a remote distance from the operating unit or surrounding community. Noise of steam injection into the burner can be reduced by using multiple no22les. Furnace noise from air intake, fuel systems, and combustion blower forced draft/induced draft (FD/ID) fans can be reduced by acoustics. The plot plan should be evaluated for noise generation and to find the means of alleviating or moving noise to a less sensitive area. 

The fuel systems of ground-based turbiaes are far less critical, siace coolants other than fuel can be used and fuel lines can be well iasulated. The tendency for deposit formation ia fuel is not a concern ia ground systems. 

The reactive species that iaitiate free-radical oxidatioa are preseat ia trace amouats. Exteasive studies (11) of the autoxidatioa mechanism have clearly estabUshed that the most reactive materials are thiols and disulfides, heterocycHc nitrogen compounds, diolefins, furans, and certain aromatic-olefin compounds. Because free-radical formation is accelerated by metal ions of copper, cobalt, and even iron (12), the presence of metals further compHcates the control of oxidation. It is difficult to avoid some metals, particularly iron, ia fuel systems. 

Compatibility and Corrosion. Gas turbine fuels must be compatible with the elastomeric materials and metals used in fuel systems. Elastomers are used for O-rings, seals, and hoses as well as pump parts and tank coatings. Polymers tend to swell and to improve their sealing abiUty when in contact with aromatics, but degree of swell is a function of both elastomer-type and aromatic molecular weight. Rubbers can also be attacked by peroxides that form in fuels that are not properly inhibited (see Elastomers, synthetic Rubber, natural). 

NASA is also considering a more advanced aircraft such as Mach 5 to cut Pacific travel time to about three hours, but in this case kerosene fuel is no longer acceptable, and Hquefted natural gas or Hquefted hydrogen would be needed to provide the necessary cooling and stabiUty. However, a completely new fueling system would be required at every international airport to handle these cryogenic fluids. 

Transportation end uses are expected to become a significant outlet. Products under development include an engine valve cover, as are various housings such as those for od pumps, water pumps, starter motors, and certain transmission parts. These end uses employ PPS because it resists high temperatures and is also chemically resistant. Fuel system parts can employ the excellent chemical resistance of PPS, replacing nylon, if alcohol-based fuels are adopted to reduce emissions. 

Evaporative Emission. Fumes emitted from stored fuel or fuel left in the fuel dehvery system are also regulated by U.S. EPA standards. Gasoline consists of a variety of hydrocarbons ranging from high volatility butane (C-4) to lower volatility C-8 to C-10 hydrocarbons. The high volatility HCs are necessary for cold start, and are especially necessary for temperatures below which choking is needed to start the engine. Stored fuel and fuel left in the fuel system evaporates into the atmosphere. 

NFPA 57 Standard for Liquefied Natural Gas (LNG) Fuel Systems. National Fire Protection Association, Quincy, MA. 

Fuel systems can cause many problems, and fuel nozzles are especially susceptible to trouble. A gaseous fuel system consists of fuel filters, regulators, and gauges. Fuel is injected at a pressure of about 60 psi (4 Bar) above the compressor discharge pressure for which a gas compression system is needed. Knockout drums or centrifuges are recommended, and should be implemented to ensure no liquid carry-overs in the gaseous system. 

Liquid fuels require atomization and treatment to inhibit sodium and vanadium content. Liquid fuels can drastically reduce the life of a unit if not properly treated. A typical fuel system is shown in Figure 4-7. The effect of fuels on gas turbines and the details of types of fuel handling systems is given in Chapter 12. 

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