Compendium of Synfuel End-Use Testing Programs


               United States                            cnnn
               Environmental Protection                     EPA-600/7-82-015
               Agency                             APRIL 1982
&EPA        Research  and
               Development
               A COMPENDIUM


               OF SYNFUEL END-USE


               TESTING PROGRAMS
               Prepared for




               EPA Program Offices

               EPA Regional Offices
               Prepared by

               Industrial Environmental Research
               Laboratory
               Research Triangle Park NC 27711

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                       600782035
                                              EPA-600/7-82-015
                                              APRIL 1982
            A COMPENDIUM OF
   SYNFUEL END USE TESTING PROGRAMS
                   by

     M. Ghassemi, S. Quinlivan and M. Haro
                 TRW
        ENVIRONMENTAL DIVISION
           Redondo Beach, CA 90278
         EPA Contract No. 68-02-3174
           Work Assignment No. 18
         Project Officer: J. McSorley

   Industrial Environmental Research Laboratory
Office of Environmental Engineering and Technology
       Research Triangle Park, N.C. 27711
               Prepared for:

 U.S. ENVIRONMENTAL PROTECTION AGENCY
      Office of Research and Development
           Washington, D.C. 20460

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                                  ABSTRACT


      This  "Compendium  of Synfuel End Use Testing Programs" provides informa-
 tion on major  recently-completed, current and planned synfuel end use testing
 projects.   The compendium  is  intended to promote flow of information among
 various synfuel  testing programs, thereby reducing chances for duplication  of
 effort and enabling  design and implementation of cost-effective and systematic
 approaches to  the  collection  of appropriate environmental data in conjunction
 with on-going  and  planned  performance testing projects.   It is EPA's intention
 to update  this compendium  to  include results from current and future testing
 programs.

      Projects  described in the compendium involve testing of shale-derived
 fuels,  SRC-II .middle distillates, EDS fuel oils, H-coal  liquids and methanol-
 indolene mixtures  in various  equipment such as utility boilers, steam genera-
 tors,  diesel engines (lab-scale and full-scale), auto engines, and various
 other  combustors.

     A  separate  "data  sheet"  is devoted to each of the major projects covered.
 In  general, each data  sheet provides the following information on a project:
 type of fuel tested  (both synfuel and the reference fuel), test equipment used,
 test site,  test  objectives, sponsoring agency, contractor, test conditions,
 environmental  monitoring,  project status, summary of results, and references.
 A table summarizing the information in the data sheets and an overview of the
 synfuel testing programs are also included.

     Based  on  the data  presented in this compendium, the thrust of the synfuel
 testing program which has  been carried out to date has been to assess equip-
 ment performance and fuel  handling characteristics.  Where some emissions
 monitoring  has been conducted, such efforts have been limited in scope and
 have primarily emphasized  measurement of criteria pollutants (NOX, SOX, par-
 ticulates,  etc.).  Essentially no data have been collected on emissions of
 non-criteria/non-regulated  pollutants.

     Published reports  on  various testing efforts and discussions with test
sponsors/contractors are the sources of data for the compendium.  Agencies/
organizations providing input include DOD, DOE, NASA, EPRI, private synfuel
developers, and engine  manufacturers.

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                                  CONTENTS

Abstract	      ii
Tables 	       v
Acknowledgments	      vi
    1.0  Introduction and Objectives of the Document 	       1
    2.0  Data Base Used and Data Presentation	       2
    3.0  Overview of Synfuel Testing Programs	      15
Appendix - Data Sheets on Individual Projects	    A-l
    Test 1.  Combustion Demonstration of SRC-II Fuel Oil in a
    Tangentially-Fired Boiler	    A-l
    Test 2.  Combustion and Emission Characteristics of Coal-Derived
    Liquid Fuels 	    A-6
    Test 3.  Characterization and Combustion of SRC-II Fuel Oil.  .  .  .    A-10
    Test 4.  Catalytic Combustion of Coal-Derived Liquid Fuels ....    A-14
    Test 5.  Gas Turbine Combustor Performance on Synthetic Fuels.  .  .    A-17
    Test 6.  Solvent Refined Coal Burn Test	    A-24
    Test 7.  Test and Evaluation of Methanol in a Gas Turbine System .    A-27
    Test 8.  Effect of Fuel Bound Nitrogen on Oxides of Nitrogen
    Emissions From a Gas Turbine Engine	    A-30
    Test 9.  Shale-Derived Fuel Oil Engine Suitability Investigation .    A-34
    Test 10.   Fuel  Property Effects on Combustion Performance	    A-37
    Test 11.   Shale Oil Fuel Particulate Emissions Measurement ....    A-42
    Test 12.   Diesel Engine Test	    A-44
    Test 13.   Navy CVA-60 Boiler Test	    A-48
    Test 14.   Navy DDG-15 Boiler Test	    A-53
    Test 15.   Navy FF-1040 Boiler Test	    A-61
    Test 16.   Evaluation of Shale-Derived JP-5 Type Fuel in an
    Allison T63-A-5A Engine	    A-67
    Test 17.   Development of Alternate Sources of JP-5 Fuel, Endurance
    and Emission Tests of a T63-A-5A Engine Using a Tar Sands Derived
    JP-5	    A-73
    Test 18.   U.S.  Army's Energy and Synthetic Fuels Program .....    A-80
                                     i i i

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                         CONTENTS  (Continued)


 Test  19.   Evaluation  of  Military  Fuels  Refined  From  Paraho-II
 Shale Oil	A'83
 Test  20.   Evaluation  of  Fuel  Character  Effects  on  F101  Engine
 Combustion System	A~94
 Test  21.   Evaluation  of  Fuel  Character  Effects  on  J79 Smokeless
 Combustor	A"97
 Test  22.   Evaluation  of  Fuel  Character  Effects  on  J79 Engine
 Combustion System	A-100
 Test  23.   Fuel  Character Effects  on Current, High  Pressure  Ratio,
 Can-Type  Turbine  Combustion Systems	A-103

 Test  24.   Low  NO   Heavy  Fuel  Combustor  Concept	A-106
                X
 Test  25.   Low  NOV Heavy  Fuel  Combustor  Concept	A-110
                /\
 Test  26.   Low  NO   Heavy  Fuel  Combustor  Concept	A-117
                X
 Test  27.   Low  NO   Heavy  Fuel  Combustor  Concept	A-123
                X
 Test  28.   Low  NO   Heavy  Fuel  Combustor  Concept	A-127
                X
 Test  29.   Small Scale Combustion  Testing of Synthetic Fuels. .  .  .   A-135

 Test  30.   Evaporative Emissions From Vehicles Operating on
 Methanol/Gasoline Blends  	   A-144
 Test  31.   Experimental Results Using Methanol and  Methanol/
 Gasoline  Blends as Automotive Engine Fuel. . 	   A-146

 Test  32.   Fleet Trials Using  Methanol/fiasoline  Blends	A-151

 Test  33.   Gasohol  Fleet  Operations  	   A-155

 Test  34.   Evaporative Emissions From Methanol/Gasoline  Blends.  .  .   A-157

 Test  35.   Performance Evaluation  of Alcohol-Gasoline Blends in
 Late  Model Automobiles 	   A-159

 Test  36.   Determination of Individual Aldehyde  Concentrations in
 The Exhaust of a  Spark Ignited Engine Fueled by Alcohol/Gasoline
 Blends	A-162

 Test  37.  Methanol As a Boiler Fuel	A-164

 Test  38.  Characterization of Emissions From Methanol and
 Methanol/Gasoline Blended Fuels	A-167

Test  39.  Comparative Mutagenicity of Combustion Emissions  of a
 High  Quality No.  2 Diesel Fuel Derived  From Shale  Oil and a
 Petroleum-Derived No.  2 Diesel Fuel	A-173

Test  40.  Report  on the Methanol-Powered Bank of America Vehicle
 Fleet in San Francisco and Los Angeles	A-176

Test  41.  Advanced Combustion Systems for Stationary Gas Turbine
Engines	A-178

                                  iv

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                            CONTENTS (Continued)
    Test 42.   Advanced Combustion Systems for Stationary Gas Turbine
    Engines	A-186
    Test 43.   Evaluation of NOX Emission Characteristics of Alcohol
    Fuels for Use in Stationary Combustion Systems	A-197
    Test 44.   The Control of Nitrogen Oxide Emissions From Package
    Boilers	A-204
    Test 45.   Impact of Gasohol  on Automobile Evaporative and Tail-
    pipe Emissions	A-209
                                   TABLES
Number
  1.      List of Organizations/Individuals Providing Information Used
         in the Development of the Compendium	
  2.      Synfuels-Combustion System Combinations Tested and Emissions
         Monitored 	       4
  3.      On-Going Synfuel  Testing Programs 	      11
  4.      Tentative Synfuel  Testing Programs	      14

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                               ACKNOWLEDGMENTS


     Gratitude Is expressed to the EPA Project Officer, Mr.  Joe McSorley, for
suggesting the subject study and for his advice and guidance during the course
of the effort.

     This compendium is based on information and documents provided to the
study by individuals/organizations engaged in synfuel  characterization and end
use testing; those on the project staff wish to express their gratitude to the
supporting individuals/organizations,  particularly to  those  listed in Table 1,
to whom the project is deeply indebted.

     Special thanks are due to Mrs.  Monique Tholke for typing the manuscript
and for her invaluable secretarial  support to the project.   Mr.  Robert Scofield
and Mrs.  Anne Takata assisted in the preparation of data sheets  on the projects
covered.
                                     VI

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               .0  INTRODUCTION AND OBJECTIVES OF THE DOCUMENT
     A recently-completed synfuel utilization background study  identified a
great need for better coordination among various agencies involved in synfuel
end use testing programs so as to promote more systematic approaches to the
collection of environmental data in connection with such programs and to
reduce chances for duplication of effort.  This compendium of synfuel end use
testing programs, which has been developed per recommendation of the back-
ground study, is intended as an information source on major recently-completed,
on-going, and planned synfuel  end use testing programs.   The dissemination of
the document among agencies/organizations engaged in various aspects of synfuel
production, testing, utilization, and regulation, coupled with holding regular
symposia/workshops on synfuel  utilization and end use testing, should greatly
enhance coordination and flow of information among various programs and, in
the long run, contribute to the goal  of more rapid establishment of an environ-
mentally acceptable commercial synfuel  industry in the U.S.  It is EPA's inten-
tion to periodically update this document to include the results from current
and future testing programs.
 M.  Ghassemi  and R.  Iyer, "Environmental  Aspects of Synfuel  Utilization", EPA
 Report No.  EPA-600/7-81-025, March 1981.

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                 2.0   DATA BASE USED AND DATA PRESENTATION


      Information  presented in this document on the recently-completed, on-going
 and  planned  synfuel  testing programs has been obtained from published documents
 and  via  telephone calls and/or interviews with organizations involved in the
 testing  programs.  The key individuals/agencies providing most of the reports
 and  data used  in  this document are listed in Table 1.

      A separate  "data sheet" has been devoted to each project covered in this
 compendium to  permit  periodic updating of the document to include additional
 projects and incorporation of further results from on-going studies.  The data
 sheets are grouped into four categories, covering projects for which the key
 sponsors/participants are Electric Power Research Institute (EPRI), Department
 of Defense (DOD), Department of Energy (DOE), and Miscellaneous agencies (e.g.,
 EPA).  Data sheets are presented for a total of 45 projects, of which 7 are in
 the  EPRI-sponsored category, 16 in the DOD category, 13 in the DOE category,
 and  9 in  the Miscellaneous category.

     Where data have been available,  each data sheet provides the following
 information on a test project:   type  of fuel tested (both synfuel and the re-
 ference  petrofuel, where indicated),  test equipment used, test site, test
 objectives, sponsoring agency,  contractor, test conditions, environmental
 monitoring, project status,  summary of results, and references (where a report
 or reports have been published  on a project).

     A summary of the data contained  in the data sheets is presented in Table
2.   Tables 3  and 4 present brief descriptions of some of the recently initiated
and tentatively planned  synfuel  testing programs.

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                TABLE 1.   LIST OF  ORGANIZATIONS/INDIVIDUALS  PROVIDING  INFORMATION
                              USED IN  THE DEVELOPMENT  OF  THE  COMPENDIUM
 Electric Power Research Institute
 3412 Hillview Drive
 Palo Alto, CA  94303
  Mr. Al Dolbec

 Air Force Wright Aeronautical
 Laboratory, Aero Propulsion Laboratory
 Wright-Patterson AFB/POSF
 Dayton, OH  45433
  Mr. Charles Delaney

 Navy Air Propulsion Center
 P. 0. Box 7176
 Trenton, NJ  08628
  Mr. C. J. Nowack

 David W. Taylor Naval Ship R&D Center
 Code 2705
 Annapolis, MD  21402
  Mr. Carl A. Hershner

 Army Mobility Equipment Research and
 Command Center - Attn:  DRDME-GL
 Ft. Belvoir, VA  22060
  Mr. F. Schaekel

 U.S. Air Force HQ AFESC/RDV
 Tyndall AFB
 Tyndall, FL  32403
  Major J. Tom Slankas

 DOE, Bartlesvllle Energy
 Technology Center
 P. 0. Box 1398
 Bartlesville, OK  74003
  Mr. Dan Gurney

 DOE, Conservation and Solar Energy  Div.
'Washington, D.C.  20585
  Mr. Gene Ecklund

 DOE, Office of Coal Utilization
 Fossil Energy Research Center
 Washington, D.C.  20454
  Mr. John Fairbanks
DOE, Laramie  Energy Technology Center
P.  0. Box 3395
Laramie,  WY  82071
  Dr. R.  Poulson

DOE, Pittsburgh Energy Technology
Center, Analytical Chemistry Division
Pittsburgh, PA  15236
  Mr. Curt White

National  Aeronautics and Space
Administration
Lewis Research Center
21000 Brook Park  Drive
Cleveland, OH 44135
  Mr. Rick Niedzwiecki

EPA, Special  Studies Branch
Industrial Environmental Research Lab.
Research  Triangle Park, NC  27711
  Mr. G.  Blair Martin

EPA, Motor Vehicle Emission Laboratory
2625 Plymouth Road
Ann Arbor, MI 48105
  Mr. Robert  Garbe

EPA, Combustion Research Branch
Industrial Environmental Research Lab.
Research  Triangle Park, NC  27711
  Mr. G.  Blair Martin

EPA, Office of Environmental
Engineering and Technology
Industrial Environmental Research Lab.
Research  Triangle Park, NC  27711
  Mr. W.  S. Lanler

EPA, Mobile Sources Laboratory
Research  Triangle Park, NC  27711
  Mr. Frank Black
Southwest Research  Institute
Automotive Research Division
6220 Culebra  Road
San Antonio,  TX  78284
  Mr.  Charles T. Hare

Southwest Research  Institute
Mobile Energy Division
6220 Culebra  Road
San Antonio,  TX  78284
  Mr.  John A. Russell

U.S. Department  of Transportation
Systems Center
Kendall Square
Cambridge, MA  02142
  Mr.  Joe Sturm

U.S. Department  of Energy and
Coordinating  Research Council
Atlanta,  GA  30309
  Mr.  Al  Zingle

Carson Associates for
Bank of America
4117 Robertson Boulevard
Alexandria, VA  22309
  Mr.  Gavin McGurdy

Energy and Environmental Research
Corporation
8001 Irvine Boulevard
Santa  Ana, CA  92705
  Mr.  Dave Pershing

Ford Motor Company
Scientific Research Laboratory
Dearborn, MI   48121
                                               Vulcan Cincinnati, Inc.
                                               2900 Vernon Place
                                               Cincinnati, OH  45219
                                                Mr. R. W. Duhl

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TABLE 2. SYNFUELS-COMBUSTION SYSTEM COMBINATIONS TESTED AND EMISSIONS MONITORED
Test No. Agency Synfuel
1 EPRI SRC-II fusl oil
2 EPRI SRC-II fuel oil
H-Coal
EDS oil
3 EPRI SRC-II fuel oil
4 EPRI SRC-II, H-Coal
Reference Fuel
No. 6 fuel oil
No. 6 and No. 2
fuel oils
No. 2 and No. 5
fuel oil
No. 2 diesel
fuel
Combustion System
Tangentially-fired
utility boiler
Scaled-down
utility boiler
Babcock & Wilcox
package boiler
Three catalytic
reactors
Emissions Monitored
NOX, CO, THC, S03,
POM, particulates,
particle size, par-
ticulate composition
NO, C02, CO, S02,
S03, THC, smoke,
particulates, par-
ticle size
NOX, CO, C02, S02,
hydrocarbons, 02,
and dust
NO and CO
General Conclusions
• No adverse boiler performance effects
with SRC-II fuel.
• NOX emissions nominally 70% higher than
No. 6 fuel.
t Higher fuel nitrogen content of SRC-II
fuels produced higher NO emissions than
reference fuels.
• NO emissions from H-Coal and EDS liquids
were lower than SRC-II.
• No unique differences in combustion or
emission characteristics of SRC-II fuel
blends.
t NOX emissions consistent with fuel nitro-
gen content.
• Combustion performance of SRC-II fuel oil
was similar to No. 2 and No. 5 fuel oils.
• Coal-derived liquids can be burned cata-
tytically but SRC-II, and to a lesser
dearee H-Coal , appeared to degrade reactc
EPRI
EPRI
Hydrogenated
shale oil and
various liquid
fuels for SRC-I,
H-Coal, EDS,
and SRC-II
Solvent refined
coal
No. 2 distillate
fuel
Full-scale and
sub-scale turbine
combustors
NOX, CO, UHC, par-
ticulates, and
smoke
Bituminous coal Utility boiler
EPRI
Jet-A fuel,
natural gas,
metHanoi
Two utility gas
turbines
NOX, S02. C02, par-
ticulates, particu-
late composition
NOX, CO, S02, THC,
POM, sulfates, par-
ticulates, aldehydes,
opacity
performance significantly as evidenced by
higher CO emissions.
i NOX emissions were consistent with fuel
nitrogen content.

• A selected number of coal liquids and
shale oil fuels can be used in current
turbines.
• Emission levels of CO, UHC, and particu-
lates for synfuels were about the same as
for No. 2 fuel - not.significant.
• Significant quantities of FBN are con-
verted to NOX causing emissions higher
than EPA limits.

• The boiler stayed much cleaner with SRC
than with coal, producing an equivalent
boiler efficiency as coal at full load.
• The quantity of SRC flyash was 10 to 15S
of that of coal flyash with no bottom ash
accumulation from SRC.
• Particulates,S02 and NOv emissions from
SRC were all under EPA limits.

• Methanol is a suitable fuel for gas tur-
bines; turbine performance and NOX and
particulate emissions are improved over
the other fuels.
(Continued)

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                                                                  TABLE 2.    (Continued)
             Test No.  Agency
    Synfuel
                     Reference  Fuel
                    Combustion  System
                                          Emissions Monitored
                                                                                                General Conclusions
                        DOD
                        DOD
                10      DOD
(Ji
                11       DOD
                12      DOD
              13-15     DOD
                16      OOD
                                 Shale-derived
                                 JP-5  and  blends
                                 with  petroleum
                                 JP-5
                                 Shale-derived DFM
                                                     Petroleum JP-5
                                 JP-5  from  oil
                                 shale,  coal, and
                                 tar  sands
                                 Shale  fuel  oil
Shale-derived
diesel fuel
                                 Shale-derived  DFM
Oil shale-derived
JP-5 fuel
                                                      Petroleum diesel
                                                      fuel
                                                      (MIL-F-16884G)
                     Jet-A,  JP-5,
                     diesel  marine
                     fuel ,  leaded
                     gasoline,  and
                     blends  of  the
                     above
                     Petroleum diesel
                     fuel  marine
                     (DFM)
Petroleum
distillate
                                                      Petroleum DFM
Petroleum-
derived JP-5
fuel
                                         DOD  helicopter
                                         engine:   Allison
                                         T63-A-5A  turbo-
                                         shaft
                                         U.S.  Navy  LM2500
                                         turbine  engine
                    Two high tempera-
                    ture/pressure
                    research combustors
                    Steam generator
                    diesel  engine
Lab-scale diesel
engine
                                                                         3 different types
                                                                         of prototype steam
                                                                         generators
DOD helicopter
engine:  Allison
T62-A-5A turbo-
shaft
                                          NOX,  CO, C02, and
                                          THC
                                          NOX,  CO, THC, and
                                          smoke
                      NOX,  CO,  UHC,  and
                      smoke
                      Particulates  and
                      particulate  compo-
                      sition
NOX, THC,  and smoke
                                                              NOX, S02, CO, C02,
                                                              THC, 02, and smoke
NOX> CO,  and THC
t  NOX emissions increased with increasing
   fuel  nitrogen content;  conversion effi-
   ciency was about 45%.
•  No significant effects  were noted on en-
   gine  performance or CO, C02, and THC
   emissions due to the presence of high
   levels of fuel bound nitrogen.

•  Combustor and engine operating  character-
   istics were identical  when using marine
   diesel or DFM shale oil; thus,  DFM shale
   oil would be suitable  for use in LM2500
   engines.
9  NOX emissions followed  fuel nitrogen con-
   tent; CO and THC levels were essentially
   the same for both fuels.

»  In all performance areas, the synfuels
   correlated in the same  manner as petro-
   leum-derived fuels except for NOX emis-
   sions from the shale oil fuel.
9  Smoke formation was dependent on hydrogen
   content;  combustion efficiency, CO,  and
   UHC depend more on higher boiling point
   components than fuel viscosity.

«  No significant differences between parti-
   culate emission products measured in the
   study from the combustion of DFM or  shale
   fuel  oil.

c  There was no significant difference  in
   performance or emissions with the shale-
   derived fuel.

•  There were no significant differences in
   measured pollutant emissions resulting
   from the combustion of petroleum DFM or
   shale-derived DFM on the CVA-60, DDG-15,
   and the FF-1040 boilers.  In each case,
   S02,  NOX, and smoke were below levels set
   by EPA.

«  Performance, CO, and THC emissions were
   equivalent for both fuels.
(  NOX emissions followed  fuel nitrogen con-
   tent.
                                                                                                                                                        (Continued)

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TABLE 2. (Continued)
Test No. Agency
17 DOD
18 DOD

19 DOD
Synfuel
Uniflned kerosene
derived from tar
sands
Distillate, avia-
tion, turbine, and
diesel fuels de-
rived from coal , tar
sands and oil shale
Shale-dHved JP-5,
JP-8, and DFM
Reference Fuel
Petroleum-
derived JP-5
fuel
Various petro-
leum-derived
fuels

JP-5, diesel
fuel No. 2, and
Jet A
Combustion System
DOD helicopter
engine: Allison
T63-A-5A turbo-
shaft
Wide variety of
Army power-plant
systems

DOD helicopter
engines : Allison
T-63 gas turbine,
Emissions Monitored
NOX, CO, and IJHC
Various pollutants

CO, NOX, unburned
hydrocarbons , and
smoke
General Conclusions
• Uni fined kerosene was a satisfactory sub-
stitute for petroleum JP-5 fuel.
• NOX emissions were slightly higher when
using unifined kerosene than with JP-5.
• Product quality of manv svnfuels tested
and other results are described in indivi-
dual abstracts.

• The carbon monoxide emissions followed the
same trend as combustion efficiency. At the
lower power points, DFM showed slightly
20-22
DOD
13 petroleum de-
rived fuels: JP-4,
JP-8, diesel No.
2 & various blends
Detroit Diesel 6V-
53T. LDT-465-1C
diesel engine,
Teledyne-Continenta1!
AVDS-1790 diesel
engine, and Detroit
Diesel 3-53
General Electric
F101 turbofan, J79-
17C turbojet, and
J79 turbojet engines
NOX, CO, UHC, and
smoke
higher CO than JP-5 and Jet A. There were
no fuel property effects on the emissions of
unburned hydrocarbons and NOX. The flame
radiation and exhaust smoke levels for the
synfuels were higher than those of Jet A and
are attributed to differences in hydrogen
content.
• The shale JP-5 in the DD6V-53T engine showed
a 6% average loss 1n maximum power output
when compared to the reference diesel fuel
which approximates the 6.5% oower loss obser-
ved in the same engine with petroleum-derived
JP-5. The shale-derived JP-5 and DFM per-
formed in the CUE-1790 engine like similar
petroleum-derived fuels. Evaluation of DFM
from shale in the LDT-465-1C engine resulted
in no difference between the maximum power
produced by this fuel and that of a oetroleum
No. 2 diesel fuel.
• The results from the 210-hour test in the DD
3-53 engine are indistinguishable from those
that may result from tests with conventional
petroleum-derived diesel fuel with similar
properties.
» Shale-derived fuels met virtually every mili-
tary specification with the exception of the
failure of JP-5 to meet copper corrosion re-
quirement and DFM to meet maximum pour point
limit.

e In all three engines, fuel hydrogen content
strongly affected smoke and NOX emissions.
NOX emissions were also highly dependent
upon combustor operating conditions.
(Continued)

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TABLE  2.   (Continued)
Test No. Agency Synfuel Reference Fuel
23 DOE * 12 petroleum-
derived fuels:
JP-4, JP-8, and
various blends

24 DOE SRC-II middle Low quality resi-
distillate dual oil, and
petroleum refe-
rence distillate
fuel
25 DOE SRC-II middle Petroleum
distillate distillate



26 DOE SRC-II middle Low quality
distillate residual oil and
distillate fuel



27 DOE SRC-II middle Low quality
distillate residual oil,
petroleum refe-
rence distillate
oil , and natural
gas



28 DOE SRC-II middle Low quality
distillate residual oil,
petroleum refe-
rence distillate
oil







Combustion System Emissions Monitored
TF41 turbofan com- NOX, CO, UHC, and
bustor smoke



Combustor sized NOX, CO, C02, THC,
for use with in- and smoke
dustrial gas
turbine

Various combustor NOX, smoke
concepts



Seven combustors NOX> smoke, CO, un-
of varying designs burned HC
for use in utility
gas turbine engines


Combustors for use NOX, CO, THC, smoke
in utility gas
turbine engines






Experimental com- NOX, CO, UHC, smoke
bustor for use
with utility gas
turbine engines








General Conclusions
• All pollutant emissions measured were
highly dependent upon ooerating conditions.
CO and smoke levels were also strongly
affected by hydrogen and aromatic content
of fuels.
a The combustor was able to achieve low NOX
with all fuels.
• CO and smoke varied directly with rich
zone equivalence ratio and inversely with
lean zone equivalence ratio.
» Values of NOX were reduced for the smaller
diameter quench zone and increased for
larger diameter quench zone.
c Rich-lean burn stage combustion system can
meet EPA emission standards.
» A lean-lean combustor has potential for
achieving ultra-low NOX emissions with
distillate, residual or other fuels con-
taining up to 0.25% (wt.) fuel nitrogen.
CO and smoke met program goals from this
combustor also.
• Lean-lean combustor NOX emission levels
were higher than emission goals using SRC-
II fuel. CO emissions remained low using
SRC-II fuel, while no smoke was detectable
and UHC levels were negligible throughout
these tests.
• Rich-lean combustor NOX emissions appeared
to reach a minimum below the NOX emission
goal for rich primary zone condition.
a Five combustors have been found adequate
for further development: rich-lean diffu-
sion flame venturi quench, burner ceramic
lined pipe lean burner, multiannular swirl
burner, Rolls-Royce combustor, and lean
catalytic combustor. These meet NOX emis-
sion limits set by EPA with petroleum
distillate and/or residual oils.
s SRC-II fuel NOx emissions were close to
meeting EPA limits in only two combustors:
rich-lean diffusion and ceramic lined pipe
lean burners.
                                                            (Continued)

-------
TABLE 2. (Continued)
CO
- - — • — — — —
Test No. Agency Synfuel
29 DOE SRC-II middle and
heavy distillate,
fuel oils & three
blends of the
above

30 DOE *

31 DOE *

32 DOE *

33-35 DOE *

36 DOE *

37 Vulcan *
Cincinnati

Reference Fuel
No. 2 and No. 6
petroleum- based
fuel oils

Indolene and 10%
methanol/90%
indolene
Unleaded gasoline
and methanol/
indolene mixtures

10% methanol/90%
gasoline blends

Ethanol ,
methanol, and
gasoline blends

Indolene, indo-
lene/methanol
blends and
ethanol/indolene
blends

No. 6 residual
oil, natural gas,
and methanol
Combustion System
A 20-hp Johnston,
fire-tube boiler

Two light duty
vehicles

Auto engines (10)

Auto engines (7)

Fleet vehicles

Pontiac 4-cylinder
modified engine

Small scale boiler
test stand and a
49 HW utility
Emissions Monitored
NOX, S02, CO, HC
and polynuclear
aromatic hydro-
carbons

Evaporative emissions
(hydrocarbons and
methanol )
NOX> CO, THC. alde-
hydes, and methanol

NOX, CO, and eva-
porative emissions
(HC and methanol)

Evaporative and
tailpipe hydrocarbon
emissions

Total aldehydes and
specific organics

NO,,, CO, and
aldehydes

General Conclusions
« The levels of NOX and 503 produced were pro-
portional to the amount of nitrogen and
sulfur in the fuel.
• There appear to be two sources of trace or-
ganics in the exhaust gases: small amounts
of the fuel Itself not burned during combus-
tion, and the products of combustion. For
the petroleum fuels, n-alkanes and polynuclear
aromatic hydrocarbons are seen in the exhaust
gas; for the SRC-II fuels, the alkanes are
absent or present at very low levels, and
polynuclear aromatic hydrocarbons not seen in
the petroleum exhaust gases are present.
• Using methanol 10% blend increased evapo-
rative emissions by 130% for short term
use and 220% for long term use.
• Aldehyde, methanol, and hydrocarbon emis-
sions increased with higher concentration
of methanol 1n the fuel.
• CO was reduced by the addition of methanol
to the base fuel .
B Data show consistent reduction in CO
emissions with use of methanol blends.
• Significant increases in evaporative
emissions with methanol blends.
• 75% increase in evaporative emissions with
methanol blends over a straight gasoline.
* Emissions were lower for vehicles fueled
with gasohol but data was inadequate to
conclude a significant difference.
t Total aldehydes increased 25% in going from
indolene to ethanol/indolene and methanol/
indolene blends.
» Formaldehyde is the largest component of
the total aldehydes (up to 90 mole percent
of the total).
• In the utility boiler, methanol NOX levels
were 7-14% of those measured during resi-
dual oil combustion.
boiler
CO emission levels of methanol were less
than 100 ppm and generally less than those
observed for the residual oil.
Aldehyde emissions during methanol com-
bustion were generally less than 1 opra.
(Continued)

-------
                                                           TABLE  2.    (Continued)
Test No.
38
39
Agency Synfuel
Ford *
Motor
Co.
DOT Shale-derived DFM
Reference Fuel
Methanol ,
indolene, and
blends\
No. 2 diesel
fuel
Combustion System
Ford 400 CID engine
and 1975 Ford LTD
with 400 Cin engine
VW Rabbit engine
Emissions Monitored
Total hydrocarbons
and specific
organics
NOX, CO, THC, parti-
culates, Ames test
 propane >
   isopropanol > alcohol  mixture > methanol.
   Although there was considerable scatter in
   the data, aldehyde concentrations  were
   around 10 ppm for methanol.
   NO emissions for all  fuels decreased with
   increasing fraction of flue gas recircula-
   tion.
   CO and hydrocarbon emissions were  always
   below 50 ppm and smoke was not observed
   for any fuel.
                                                                                                                                          (Continued)

-------
TABLE 2. (Continued)
Test No. Agency Synfuel
Reference Fuel
Combustion System Emissions Monitored
General Conclusions
44 EPA
45 EPA
No. 5 residual
oil, natural gas,
and methanol
Indolene and
ethanol blends
Industrial water-
tube and fire-tube
boilers
Two light duty
vehicles
NO,,
ethanol, and evapo-
rative emissions
Flue gas recirculation was capable of re-
ducing NOX emissions during methanol com-
bustion.
Methanol NOX emissions were significantly
lower than during residual oil combustion
and were also less than during natural
gas combustion.

The addition of ethanol to indolene re-
duced tailpipe emissions of THC and CO,
but increased NOX.
Use of gasohol increased evaporative
emissions substantially.
Because of the unavailability of synfuels, the fuels used in some of these programs were not "true" synfuels (e.g., methanol-derived from natural
gas was used instead of coal-derived methanol). These studies, however, are included in this report because they were conducted to show what
might be expected from the combustion of actual synfuels in the indicated combustion systems.

-------
TABLE 3. ON-GOING SYNFUEL TESTING PROGRAMS
Sponsoring Agency
Test Fuels
Schedule
Project Description
EPA. Motor Vehicle
Emission Laboratory
EPA, Combustion
Research Laboratory
Shale-derived dlesel fuel
and SRC-II fuel versus
National Average Baseline
Diesel Fuel, and Mobil-M
gasoline

EDS and H-coal liquids
SRC-II fuel
SRC-II middle and heavy
distillates, EDS middle
distillates, and shale-
derived No. 2 fuels
DOE, Bartlesville
Energy Technology Center;
Contractor/test site:

A. General Electric,
Erie, PA
Transamerica
Delaval,
Oakland, CA
SRC-II middle distillate
and oil shale distillate
H-coal liquids

SRC-II middle distillate
1981 to Volkswagen Rabbit diesel engine testing. Emissions
late 1982 monitored to Include particulates, N0x, C0/C02> hydro-
carbons, and aldehydes.
Late 1981 to Large standing diesel engines and a GE research engine.
September 1982 Emissions monitoring includes collection of particulates.

1982 Electronically controlled internal combustion engine at
Southwest Research Institute, San Antonio, TX.

November 1981- North American package boiler and Caterpillar Model D334
April 1982 stationary diesel engine testing. Package boiler repre-
sents small-to-medium sized fire-tube boiler for indus-
trial and commercial applications; boiler can be equipped
with low NOX burner which may be tested with synfuels.
The stationary diesel represents medium-sized industrial
and commercial engine used for backup power generation,
pumping and other applications. Emissions monitored in-
clude particulates, NO , CO/CO,, SO,, and hydrocarbons.
1981- Testing of GE EDI-8, 8-cylinder "V" configuration, 5344
early 1982 cu. in. standing diesel engine for electric power, rail
and marine applications. Parameters evaluated include:
starting ability, injection timing, fuel rate variation
effects and internal engine temperatures. Emissions
monitored include 0,, CO/CO,, NO , SO,, HC, H9SO., and
particulates. i * x ' ^ q

January to Limited testing with single cylinder diesel engine.
April 1982 Emissions monitored include 0,,, C0/C02> NO , SO,,, and HC.

1981- Testing of Delaval DSR 46, 6-cylinder in-line configura-
early 1982 tion, 28,600 cu. in. standing diesel engine for electric
power, compressor and marine aoplications. Performance
parameters being evaluated include starting ability,
precombustion chamber effects, ignition delay, and other
engine parameters. The engine has been operated at full
load using a pre-mixed blend of 60% SRC-II liquid and
40% diesel oil which had been injected into the combus-
tion chamber with no modification of the engine, followed
by increasing proportions of SRC-II liquid up to 100^.
Emissions monitored include 0,, CO/CO,, NO , SO,, THC,
and smoke.
x'
(Continued)

-------
TABLE 3. (Continued)
Sponsoring Agency
Test Fuels
Schedule
Project Description
C. A. 0. Little,
Beloit, WI
SRC-II middle distillate
ro
D. Energy and Envi-
ronmental Research,
Springfield, OH
E. Acurex,
Shoreham-by-the-Sea,
England
DOE, Conservation and
Solar Energy Division
DOE, Office of Coal
Utilization
Various H-coal and EDS
liquids
Shale-derived distillate
oil
Shale oil residuals
Various shale- and coal-
derived fuels

SRC-II distillates and
shale-derived JP-5 and
DFM mixed with powdered
carbon, sawdust, or other
cellulosic material
Coal-derived methanol
and gasohol

SRC-II and shale-derived
fuels
1981-1982 Fairbank-Morse 38 to 8-1/8, 6-cylinder opposed piston
design, 3108 cu. in. standing diesel engine for electric
power and marine applications, compressors and pumps
being tested. Parameters evaluated include effects of
load variations, combustion pressure vs. time, and engine
delay. Emissions monitored include C0/C02, NO, N0?, S02,
SO^, HC, PAH, particulates, and oxidants.
March to Testing of Fairbanks piston engine at NAVSSES test faci-
November 1982 lity, Philadelphia, PA. Emissions monitoring to include
gaseous pollutants and collection of sizable (i.e., 5 g)
quantities of particulate matter.

1981- Testing of Superior 6-cylinder in-line configuration
early 1982 turbo-charged 4120 cu. in. standing diesel engine for
use in compressors, pumping and electrical power genera-
tion. The purpose of the tests is to comoare engine
performance parameters during synfuel and conventional
fuel combustion. Tests with shale-derived distillate
oil and a baseline No. 2 diesel fuel include SASS train
sampling for PAH and particulates. Other emissions
monitored include CO, HC, N0x, and smoket.

1981- Testing of A.f'.E. Allen BSC 128 6-cylinder, in-line
early 1982 configuration, 5101 cu. in. standing diesel engine for
marine, pumping, compressor and electric power applica-
tions. Tests include injection, starting, combustion
duration and steadiness. Emissions monitored include
C0/C02, NO , N02, THC, and smoket.

1978-1984 Auto engine dynamometer testing being conducted at
SwRI. Particulates, NOX, CO/C02, hydrocarbons, and
aldehydes being monitored.
1981 to --- Slurry/fuel project involving diesel engine testing.
Particulates, NO , and other emissions being monitored.
1981 to --- Testing in 1,000 fleet vehicles; program currently
constrained for lack of fuel samples.

1980 to --- Medium speed diesel engine testing conducted by SEMT-
Pielstich, Paris; Baumester Wain, Copenhagen; rirandi
Motori Trieste, Trieste; and Selzer of Switzerland.
(Continued)

-------
TABLE 3. (Continued)
Sponsoring Agency
Test Fuels
Schedule
Project Description
DOE, Office of Coal
Utilization
(Continued)
DOE, Pittsburgh Energy
Technology Center
Air Force/Navy/FAA
(under the direction of
Capt. H. Cewell. USAF
Civil Engineering and
Services Center, Tyndall
AFB)

Department of
Transportation and
Rutgers University

Sandia Laboratories
Bank of America
SRC-II middle distillates, 1980 to ---
a 2.9 to 1 blend of SRC-II
middle and heavy distillate,
and shale-derived fuels
SRC-II middle distillate 1981 to ---
Biomass fuel, H-coal, 1981 to
Exxon Donor Solvent, October 1982
and shale fuel oils
Shale-derived JP-4 and 1982-1984
JP-8
Coal- and shale-derived 1981 to 1982
dlesel fuel
Petroleum-derived synfuel 1981 to —
simulation fuels, with
higher hydrocarbon/aroma-
tic content than conven-
tional fuels

Methanol/gasollne blends 1980 to ---
Program conducted at Norwegian Technical Institute in
various ships.
Continuation of low NOX fuel combustor concept program
(see Tests 24-28). Several combustors to be tested by
Westinghouse; staged combustor to be tested at several
operating loads at Detroit Diesel Allison; testing of 5
combustors planned at GE.

Continuation of small scale combustion of synthetic fuels
program (see Test 29). A 20-hp firetube boiler is to be
tested with the above synfuels using No. 2 and No. 6 fuel
oils as a baseline. The purpose of the program is to
assess the possible environmental impact of substituting
synfuels for petroleum in utility and industrial boilers.

Testing of CF-6 and CFM-56 turbine engines. Emissions
monitoring to include NOX, SOX, CO/CO?, hydrocarbons, and
particulates. Limited Ames mutagenicity testing to be
performed on particulate samples, as well as photochemi-
cal reactivity testing on exhaust gases.
Testing of a recently-designed and constructed one cylin-
der diesel engine, including collection of particulates
and other combustion products.

Testing being conducted in single cylinder diesel systems
and auto/truck engines from Cumins Engine Co. Emphasis
on measurement of flame fronts and other engine/burn
parameters. Limited emissions monitoring performed.
Testing being conducted in blends ranging from 2 to 18%
methanol in fleet vehicles, with emphasis on blends of 2
and 4%. CO, NO, and unburned hydrocarbons being moni-
tored.
The schedules and some of the activities listed under the Project Description are somewhat tentative and subject to modification.

fTest results obtained to date have Indicated that the performance of the shale-derived fuel was comparable to the No. 2 diesel
fuel, although easier atomization and lower fuel consumption were observed with the shale-derived fuel.

'The test engine satisfactorily burned residual shale oil when heated above the wax melting point and with agitation; emissions
were comparable to a No. 2 diesel fuel except for an Increase of cylinder deposits of fine carbon.