UNIVERSITI PUTRA MALAYSIA EXPERIMENTAL AND SIMULATED PERFORMANCE STUDY OF A SMALL-SCALE GAS TURBINE ENGINE USING JET A-1 AND PALM OIL BIODIESEL BLENDS

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1 UNIVERSITI PUTRA MALAYSIA EXPERIMENTAL AND SIMULATED PERFORMANCE STUDY OF A SMALL-SCALE GAS TURBINE ENGINE USING JET A-1 AND PALM OIL BIODIESEL BLENDS EZANEE BIN GIRES FK

2 EXPERIMENTAL AND SIMULATED PERFORMANCE STUDY OF A SMALL-SCALE GAS TURBINE ENGINE USING JET A-1 AND PALM OIL BIODIESEL BLENDS EZANEE BIN GIRES MASTER OF SCIENCE UNIVERSITI PUTRA MALAYSIA 2013

3 EXPERIMENTAL AND SIMULATED PERFORMANCE STUDY OF A SMALL-SCALE GAS TURBINE ENGINE USING JET A-1 AND PALM OIL BIODIESEL BLENDS By EZANEE BIN GIRES Thesis Submitted to the School of Graduate Studies, Universiti Putra Malaysia, in Fulfilment of the Requirements for the Degree of Master of Science January 2013

4 Abstract of thesis presented to the Senate of Universiti Putra Malaysia in fulfilment of the requirement for the degree of Master of Science EXPERIMENTAL AND SIMULATED PERFORMANCE STUDY OF A SMALL-SCALE GAS TURBINE ENGINE USING JET A-1 AND PALM OIL BIODIESEL BLENDS Chair: Abd Rahim Abu Talib, PhD Faculty: Engineering By EZANEE BIN GIRES January 2013 The experimental and simulated performance of an Armfield CM4 turbojet engine was investigated for conventional Jet A-1 fuel as well as its blends with palm oil biodiesel (PME), a form of fatty acid methyl ester (FAME). The volumetric blends of PME with Jet A-1 are 20, 50, 70 and 100% (B20, B50, B70 and B100). Fuel heating values (FHV) of each fuel mixture were obtained by calometric analysis and were used to estimate changes in CM4 performance which were verified experimentally. The experimental tests included performance tests for Jet A-1 and B20, while the performances of B50 to B100 were simulated using GasTurb 11 analytical software after verification of simulated and experimental results for Jet A-1 and B20. Values of thrust, fuel flow, temperature and pressure distribution along the engine and engine speed were available from experimental measurements, whereas other values of merit were calculated using parametric cycle analysis and one-dimensional flow assumptions. In terms of maximum measured thrust, Jet A-1 yielded the highest value of 216 N, decreasing by 0.77%, 4%, 8% and 12% with B20, B50, B70 and ii

5 B100 based on experimental and simulated results. It was found that B20 produced comparable results compared to the benchmark Jet A-1 tests, particularly with thrust and thermal efficiency. Slight performance penalties occurred due to the lower energy content of the biodiesel blend. The efficiency of the combustor improved with the addition of biodiesel while the other component efficiencies remained collectively consistent. The performance parameters of the CM4 engine were found to deteriorate with increased PME content in the simulations, particularly for volumetric blends of over 50% palm oil biodiesel. This research shows that for gas turbines, PME is suitable for use as an additive to Jet A-1, but not as a complete replacement fuel. iii

6 Abstrak tesis yang dikemukakan kepada Senat Universiti Putra Malaysia sebagai memenuhi keperluan untuk ijazah Sarjana Sains KAJIAN PRESTASI EKSPERIMEN DAN SIMULASI ENJIN TURBIN GAS SKALA KECIL MENGGUNAKAN JET A-1 DAN CAMPURAN BIODIESEL MINYAK SAWIT Pengerusi: Abd Rahim Abu Talib, PhD Fakulti: Kejuruteraan Oleh EZANEE BIN GIRES Januari 2013 Prestasi sebuah enjin turbojet Armfield CM4 telah dikaji secara eksperimen dan simulasi untuk bahan api pesawat udara konvensional Jet A-1 serta campurannya dengan biodiesel minyak kelapa sawit (PME), sejenis metil ester asid lemak (FAME). Isipadu campuran PME dengan Jet A-1 adalah dalam nisbah campuran isipadu 20, 50, 70 dan 100% (B20, B50, B70 dan B100). Kandungan tenaga bahan api (FHV) bagi setiap campuran minyak telah diperolehi melalui analisis kalorimetrik dan nilainya digunakan dalam anggaran perubahan prestasi CM4 yang telah disahkan melalui eksperimen. Kajian eksperimental merangkumi ujian prestasi bagi minyak Jet A-1 dan B20, manakala prestasi bagi B50, B70 dan B100 disimulasi dengan menggunakan perisian analisis GasTurb 11 selepas pengesahan keputusan simulasi B20 dan Jet A-1 dengan keputusan daripada eksperimen. Nilai-nilai tujahan, aliran bahan api, taburan suhu dan tekanan dalam enjin, serta pusingan per minit (rpm) enjin diperolehi daripada pengukuran eksperimen, manakala nilai-nilai merit yang lain dikira melalui analisis kitaran parametrik dan andaian aliran satu dimensi. Dari segi tujahan maksimum, Jet A-1 menghasilkan nilai tertinggi iaitu 216 N, dengan iv

7 nilai yang menurun sebanyak 0.77%, 4%, 8% dan 12% dengan B20, B50, B70 dan B100 berdasarkan keputusan eksperimen dan simulasi. Didapati bahawa B20 menghasilkan keputusan setanding dengan keputusan kajian menggunakan Jet A-1, terutamanya dalam tujahan dan kecekapan terma. Penalti prestasi yang kecil diakibatkan oleh kandungan tenaga B20 yang lebih rendah daripada Jet A-1. kecekapan seksyen pembakar enjin dipertingkatkan dengan pembakaran campuran biodiesel, manakala kecekapan komponen yang lain kekal konsisten. Parameter prestasi enjin CM4 didapati merosot dengan peningkatan kandungan PME dalam simulasi, terutamanya bagi campuran isipadu lebih daripada 50% biodiesel minyak sawit. Kajian ini menunjukkan bahawa bagi turbin gas, PME adalah sesuai untuk digunakan sebagai bahan tambahan kepada Jet A-1, tetapi bukan sebagai bahan api gantian yang lengkap. v

8 ACKNOWLEDGEMENTS My first show of thanks and appreciation is to my main supervisor, Assoc. Prof. Dr. Abd Rahim Abu Talib. To this day, he has shown the same high level of support, patience, encouragement and advice that he has given since the first time I set foot in the Faculty of Engineering. Most importantly, I am grateful for the level of freedom and autonomy that he has given since day one, allowing me to complete this project successfully. In that same vein, I also extend my thanks to my co-supervisor, Assoc. Prof. Lt. Col. (R) Mohamed Tarmizi Ahmad, whose presence in and around the Propulsion Laboratory provided advice and conversation throughout my study duration. I am also grateful for the backing of the Aerospace Engineering Department of UPM for their support for this research project, especially in the early stages of running the CM4 gas turbine. This work was significantly supported by the Universiti Putra Malaysia Research University Grant Scheme (RUGS) RU, which also allowed me to work as a research assistant for two years. The RUGS scheme also made it possible for Mr. Zulfikar and Mr. Radin to repair the CM4 whenever it broke down, and for whom I am highly indebted to. I am also extremely grateful for the friendships that had formed since the project began. To list down all of them would take the whole length of this thesis. However, special mention goes to Mr. Helmey Ramdhaney Mohd. Saiah, whose guidance, patience and insight has been invaluable. Similarly, I would like to thank Mr. Saffairus Saleh for his technical and moral support. I am also grateful for the friends that I had retained since before this project began. I feel that no acknowledgment would be complete without giving due to my beloved family. Through all of the easy and hard times they have been there for me, and so I thank my parents, Gires Usup and Asmat Ahmad, as well as my brother Adrian, his wife and son Ainul and Alfie, and my sister Jasmine. I only hope that I can one day fully repay their love and support beyond putting my thanks in writing. vi

9 I certify that a Thesis Examination Committee has met on 29 January 2013 to conduct the final examination of Ezanee bin Gires on his thesis entitled "Title of thesis" in accordance with the Universities and University Colleges Act 1971 and the Constitution of the Universiti Putra Malaysia [P.U.(A) 106] 15 March The Committee recommends that the student be awarded the degree of Master of Science. Members of the Thesis Examination Committee were as follows: Harijono Djojodihardjo, PhD Professor Ir Faculty of Engineering Universiti Putra Malaysia (Chairman) Kamarul Arifin Ahmad, PhD Associate Professor Faculty of Engineering Universiti Putra Malaysia (Internal Examiner) Surjatin Wiriadidjaja, PhD Associate Professor Faculty of Engineering Universiti Putra Malaysia (Internal Examiner) Mohammad Nazri Mohd Ja'afar, PhD Professor Faculty of Mechanical Engineering Universiti Teknologi Malaysia Malaysia (External Examiner) SEOW HENG FONG, PhD Professor and Deputy Dean School of Graduate Studies Universiti Putra Malaysia Date: 21 March 2013 vii

10 This thesis was submitted to the Senate of Universiti Putra Malaysia and has been accepted as fulfilment of the requirement for the degree of Master of Science. The members of the Supervisory Committee were as follows: Abd Rahim Abu Talib, PhD Associate Professor Faculty of Engineering Universiti Putra Malaysia (Chairman) Mohamed Tarmizi Ahmad Associate Professor Lt. Col. (R) Faculty of Engineering Universiti Putra Malaysia (Member) BUJANG BIN KIM HUAT, PhD Professor and Dean School of Graduate Studies Universiti Putra Malaysia Date: viii

11 DECLARATION I declare that the thesis is my original work except for quotations and citations which have been duly acknowledged. I also declare that it has not been previously, and is not concurrently, submitted for any other degree at Universiti Putra Malaysia or at any other institution. EZANEE BIN GIRES Date: 29 January 2013 ix

12 TABLE OF CONTENTS ABSTRACT ABSTRAK ACKNOWLEDGEMENTS APPROVAL DECLARATION LIST OF TABLES LIST OF FIGURES LIST OF SYMBOLS CHAPTER 1 INTRODUCTION 1.1 Historical Context 1.2 Scope of Study 1.3 Aims, Significance and Hypothesis of Study 1.4 Thesis Outline 2 REVIEW OF LITERATURE 2.1 The Need for Alternatives to Fossil Fuels 2.2 Alternative Fuels 2.3 Test Flights and Aero-Engine Tests Using Biofuel 2.4 Engine Tests Using Biofuels and Other Alternative Fuels Gas Turbine Engine Tests Diesel Engine Tests 2.5 Summary and Discussion of Previous Research Findings Effect of Alternative Fuels on Engine Performance Effect of Alternative Fuels on Emissions 3 METHODOLOGY 3.1 Description of Apparatus 3.2 Instrumentation 3.3 Test Facility 3.4 Test Fuels 3.5 Experimental Procedure 3.6 Jet Engine Cycle Analysis and Performance Parameters Page 4 ARMFIELD CM4 EXPERIMENTAL PERFORMANCE USING Jet A-1 AND A BIODIESEL BLEND 4.1 Operational Observations ii iii iv v vii ix x xiv x

13 4.2 Temperature and Pressure Properties Across Engine Stations 4.3 CM4 Measured Thrust Values for Jet A-1 and B Mass Flows Through CM4 Engine 4.5 Performance Analysis of CM4 Turbojet 4.6 CM4 Core Engine Efficiencies 4.7 CM4 Turbojet Component Analysis Inlet Compressor Burner Turbine Performance and Mechanical Efficiency CM4 Turbojet Efficiency Overview 4.8 CM4 Thermodynamic Analysis 4.9 Conclusions Regarding CM4 Performance on Jet A Summary of Armfield CM4 B20 Performance 5 SIMULATION OF ARMFIELD CM4 PERFORMANCE FOR FURTHER BIODIESEL BLENDS 5.1 Design of the Simulation Model 5.2 Comparison of GasTurb and Experimental Results for Jet A-1 and B Temperature and Pressure Distribution Thrust Mass Flows and Initial Engine Performance Parameters Engine and Component Efficiencies Summary of Comparison of GasTurb Results to Experimental Results 5.3 GasTurb 11 Simulation Results for all PME Biodiesel Blends Thrust Mass Flows Specific Thrust, Fuel-Air Ratio, and Thrust Specific Fuel Consumption Engine Efficiencies Component Efficiencies 5.4 Conclusions From GasTurb 11 Simulation 6 CONCLUSION AND RECOMMENDATIONS 6.1 Findings 6.2 Limitations and Recommendations REFERENCES 155 xi

14 APPENDICES A Detailed Calculation Methodology for Jet Engine Cycle Analysis B Verification of Load Cell Thrust Measurement 175 C Additional Notes Regarding the JFS100-13A Gas Turbine Engine BIODATA OF STUDENT LIST OF PUBLICATIONS AND PRESENTATIONS xii