Compatibility of Tier 4 Diesel Engines with JP-8

OUSD (R&E) CRITICAL TECHNOLOGY AREA(S): Sustainment OBJECTIVE: Develop a solution or set of solutions that will enable the use of JP-8 in current Tier 4 diesel engines without adverse effects. The solution should apply as broadly as possible to multiple systems and engine types. DESCRIPTION: Navy expeditionary forces require equipment compatible with JP-8 to meet DoD level guidance prescribing JP-8 as the single fuel for expeditionary operations. JP-8 is an aviation fuel with up to 3000 ppm of sulfur. Current Tier 4 diesel engines are unable to meet the JP-8 compatibility requirement due to these engines requiring the use of ultra low sulfur diesel (ULSD) with a 15 ppm limit on sulfur. The use of ULSD is needed both to meet Tier 4 emissions requirements, but also to prevent degradation or damage to the engine and the emission components. Emissions components in Tier 4 engines such as catalysts and particulate filters are sulfur sensitive, they clog or are destroyed if JP-8 or high sulfur diesel fuels are used. Navy expeditionary forces currently satisfy this JP-8 requirement via the use of Tier 3 or lower or export market engines. These engines are becoming increasingly obsolete and progressively more difficult to procure and sustain. Increased procurement costs result from the need to source and integrate these engines into commercial items that are designed to be EPA compliant with Tier 4 engines for the U.S. market. Performance Requirements: The solution or solution set will need to allow for the fielding of commercial items using standard Tier 4 engines. The solution will need to allow for operation with both ULSD fuel supplies while in CONUS and JP-8 fuel supplies during expeditionary operations. The solution will need to result in no net increase in lifecycle cost and not negatively impact the performance of the engine beyond what is expected when using JP-8 in Tier 3 or lower engines. This includes power output, fuel efficiency, and ability to run throughout the range of worldwide environmental conditions. Lifecycle cost calculations will assume quantities of 100 for a single unique end item. The solution should apply as broadly as possible to multiple system and engine types (including different makes and models, both on and off-highway engines) and sizes of diesel engines ranging from small 10hp pony motors through large commercial truck engines. Demonstrate the solution via instrumented testing. Current equipment operates under an EPA exemption for national security. Any solution is permitted to result in exhaust emissions that no longer meet Tier 4 requirements. Exhaust emissions should meet or exceed the requirements of the equivalent Tier 3 engine. PHASE I: Define, design, and establish the feasibility of a concept that will result in the ability to procure equipment with current Tier 4 engines and operate this equipment during expeditionary operations with JP-8 fuel supplies. Produce a prototype engineering design with major components identified as either existing commercial items or those requiring no further development under Phase II. Ensure that any development components should be of sufficient maturity such that a full-scale prototype can be developed and demonstrated under Phase II. Identify and calculate expected procurement and sustainment costs for the concept. Identify any potential limitations or impacts to the system resulting from the concept, which could include any limitations on application (e.g., horsepower limitation) or increases in weight, among other possible characteristics. Provide a Phase II plan. PHASE II: Produce and demonstrate a prototype of the concept developed under Phase I. Include a minimum of 50 hours (threshold), preferably 100 hours or greater (objective), of run time using JP-8 or the CONUS equivalent F-24 as the supplied fuel. Demonstrate the prototype on an engine that is, of a minimum, in the 19-56 kW category (Threshold) to the 56-130 kW (or higher) category with a diesel exhaust fluid (DEF) system (Objective). Perform any small-scale demonstrations or testing of developmental components, as needed, to increase the maturity of the technology in support of a physical prototype of the Phase I concept. Perform any instrumented tests needed to validate the performance requirements of the prototype (e.g., dynamometer, instrumentation of the engine, or exhaust analysis). PHASE III DUAL USE APPLICATIONS: The end goal of Phase II is expected to be a design that, with further engineering development and testing to refine the design and develop manufacturing, would result in an end item the government can procure or component(s) and/or modifications that vendors of end items can incorporate into their systems that are procured by the expeditionary Navy. Phase III would concentrate on that additional engineering and commercialization effort required to prepare the solution(s) for a successful transition. The final solution(s) would be applied across the full spectrum of future equipment within the expeditionary Navy, such as civil engineering support equipment, construction equipment, and tactical and light ground vehicles. The solution would also be made available and socialized with the joint services, including the Army, Air Force, and Marine Corps. Any solutions developed under this SBIR topic which have potential commercial applications will be communicated to potential commercialization partners, such as engine manufacturers. These include any sulfur reduction filters or sulfur tolerate emissions components which could be applied to improve emissions in diesel engines in markets with high sulfur diesel. REFERENCES: 1. 40 CFR Part 1039, PART 1039 CONTROL OF EMISSIONS FROM NEW AND IN-USE NONROAD COMPRESSION-IGNITION ENGINES. https://www.ecfr.gov/current/title-40/part-1039 2. 40 CFR 1068.225, 1068.225 Exempting engines/equipment for national security. https://www.ecfr.gov/current/title-40/section-1068.225 3. Rohrbach, Ron et al. Desulfurization Fuel Filter. Honeywell, 24 August 2006, pp.1-22. https://www.energy.gov/eere/vehicles/articles/desulfurization-fuel-filter 4. Tran, D.T.; Palomino, J.M. and Oliver, S.R.J. Desulfurization of JP-8 jet fuel: challenges and adsorptive materials. RSC Advances, 8(13), February 2018, pp. 7301-7314. doi: 10.1039/c7ra12784g. PMID: 35540312; PMCID: PMC9078402. KEYWORDS: JP-8; diesel; engine; Expeditionary; Tier 4; sulfur