Alternate Fuels For Diesel Engines Bill Richards, Director of Business Development

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1 Alternate Fuels For Diesel Engines Bill Richards, Director of Business Development The Tune-up for the 21st Century

2 Why AMRA/MAP Members Should Care about Diesels Growth in Passenger Vehicle use of Diesel Engines is all around us and its coming to North America

3 Expected to reach 7.5% of NA production by 2015 OEM Current offerings Future offerings AUDI A3 and Q7 A6 (2014), A8 (2013) and Q5 (2013) BMW X5 xdrive 35d and 335d (Canada only) 2.0L (3 Series and X1) 3.0L (X 3 and X5 New Engine) (2013) General Motors Chevrolet Express Van, Silverado 2500 & 3500 GMC Savana, Sierra 2500HD and 3500HD Chevrolet Cruze (2013) Cadillac ATS (2014) Chrysler Ram 2500 and 3500 Jeep Grand Cherokee (2013) Ford Super Duty F250/350 /450 and F550 Chassis Cab Ford Transit (2014) Mazda Mercedes Benz Porsche Volkswagen E350 BlueTec, ML350 BlueTec, R350 BlueTec (Canada Only), S350 BlueTec, GLK 350 BlueTec Sprinter (older versions are Dodge or Freightliner) Cayenne Beetle, Golf, Jetta, Jetta Wagen, Toureg and Passat 2.2L Skyactiv D (Mazda 6) 2013 and CX 5 Crossover (2014) GLK 250 (2013) and C Class (2014)

4 History of Diesel Engines Invented in 1890 s by Rudolph Diesel (patented in 1892) Based on Compression Ignition Compression Ratios can be as high as 25:1 Unlike Gas Engines, Diesel s can have varying air/fuel ratio s Under full loads air/fuel ratios can vary between 17:1 and 29:1 At idle it is possible to exceed 145:1

5 Rudolph Diesel s Original 1897 Engine

6 Technology Changes due to EPA regulations 1998 EGR 2002 Cooled EGR PM g/hp-hr 2007 Catalytic Particulate Filter Trap: Requires use of ULSD Fuel (Sulpher content limit 15ppm. Previous limit was 500ppm 2010 DEF/SCR systems

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8 Who Determines What the Fuels Characteristics Are? ASTM International (American Society for Testing and Materials) ASTM D975-12a ASTM D Depending on crude source and refinery, finished fuels can have a variety of colors Fuels may also cause differing engine and emission operation

9 ASTM D975-12a Diesel Specs. S-15 No. 2-D = Ultra-Low Sulfur Diesel ASTM D a sets the industry specification for diesel fuel. The EPA regulates only sulfur, aromatic content, and renewable fuel percentages. There are hundreds, perhaps thousands of components in diesel fuel and dozens of characteristics. Only a few are actually specified and measured. 81

10 What is Biodiesel Fuel Biodiesel (straight or B100) is fuel derived from Biomass--plants, seeds, algae, animal fats and waste cooking oils (many other sources) US Biodiesel Industry produced 1 Billion Gallon in 2012 (biodiesel.org) Fuel Grade Biodiesel Standard is ASTM 6751 BQ-9000 The amount allowed is determined by the EPA ASTM specs allow for up to 5% in all diesel motor fuels. Some states have a minimum requirement (%) for biodiesel--pa and 2%. Some states have created tax incentives to promote biodiesel B11, PA with domestically produced biodiesel.

11 ASTM D-6751 Biodiesel Specs. ASTM D-6751 is the standard for B100 (straight or neat) biodiesel. BQ-9000 is a standard created by the biodiesel industry to help members meet the ASTM through the production, storage, transportation, blending and use of biodiesel fuels. Biodiesel also any components and characteristics not covered by current specifications. Biodiesel blends typically range between 1% (B1) and 20% (B20). #2 Diesel may contain up to 5% biodiesel without any notification or marking. 83

12 Homemade Biodiesel 84

13 Biodiesel Issues Water from condensation accumulates in the fuel tank which allows bacteria to grow in the fuel. Biodiesel holds more water dissolved or in-suspension than does traditional diesel. This excess water has several detrimental effects, such as promoting bacterial and fungal growths in fuel. Untreated, this bacteria can eventually clog Filters and Injectors Contaminated Diesel Fuel Bacteria found in Diesel Fuel

14 Other Fuels Used in Diesel Engines Primarily used by buses, fleets and commercial vehicles E-Diesel Diesel or Biodiesel blended with up to 15% Ethanol Natural Gas o CNG Compressed Natural Gas o LNG Liquefied Natural Gas

15 Key s to Clean Diesel Common Rail Fuel Injection More precise fuel delivery EGR Reduce NOx by cooling combustion Turbo Charging Increase power and efficiency Exhaust Treatment Reduce Particulate Matter (Soot ) and NOx

16 Unit Injector There are 2 types of Unit Injectors Mechanical Unit Injector Mechanical operated by a cam lobe Hydraulic Electronic- referred to as HEUI HEUI Injector Ford 6.0 Powerstroke HEUI injectors are used in the Ford 6.0 L PowerStroke Engine Utilizes hydraulic oil pressure from a secondary pump from within the engine to boost pressure and a ECU to control opening and closing Injection pressures can be as high as 26,000 psi (1,800 BAR)

17 Common Rail Common Rail refers to a high pressure pump supplying fuel to an accumulator (common rail) which then distributes it as needed at operating pressure to the individual injectors. Solenoid type injectors offer another option for high pressure common rail systems. Piezoelectric injectors combined with ECU s can currently provide up to 9 injections per combustion event to quiet engines, reduce emissions, increase power, and improve fuel economy. 89

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19 EGR Operation NOx is formed at temperatures above 1600C (2900F) Diesel Engines have very high compression ratios and produce abnormally high amounts of NOx EGR is an emissions reduction technique Works by re-circulating a portion of an engine's exhaust gas back to the engine cylinders On Diesel Engines the exhaust gas replaces some of the excess oxygen in the pre-combustion mixture which cools the combustion temperature thereby reducing NOx

20 Cooled EGR Operation In an effort to cool the combustion chamber further, many OEM s utilize a Cooled EGR system Utilize engine coolant Designed to reduce Exhaust gas from 1100 F (593 C) to 300 F (149 C)

21 EGR Circuit Restriction EGR Valve/Cooler Intake Runners

22 Variable Geometry Turbo Stop and Go driving creates excess carbon build-up on the Turbo Charger vanes reducing their effectiveness Resulting in power loss and fuel economy Eventual Turbo failure Carbon Build up On Linkages

23 Particulate Filter Operation Exhaust Flow Inlet Diesel Particulate Filter Oxidation Catalyst Particulate Filter traps Soot & Ash Particles Filter Will Become Restricted and Will Need to be Cleaned or Regenerated Regeneration is the Process of Raising Exhaust Temperature to Burn Off Accumulated PM Particulate Matter Begins to Burn at 600º F (315º C)

24 Exhaust SCR Technology Small amounts of UREA (DEF) is added to the exhaust which converts it to an ammonia Ammonia reacts with the NOx stored in the NOx trap. The byproduct is nitrogen and water This technology is so effective that it allows for leaner air/fuel ratios, resulting in improved fuel economy

25 Particulate Filter Plugging. Reduces Performance and Fuel Economy, while Increasing Emissions

26 (Truck News March 17, 2013) Look no further than a $500,000 fine levied by EPA in January against Edge Products, an American company that sold more than 9,000 devices allowing owners of model year 2007 or later diesel pick-up trucks to operate without their factoryinstalled diesel particulate filters. The Department of Justice will continue to vigilantly protect America s health and environment through the enforcement of the Clean Air Act standards governing emissions from vehicles and engines, Ignacia Moreno, Assistant Attorney General for the Justice Department s Environment and Natural Resources Division announced in a press release, clearly intended to scare providers of such services. A Word of Warning on Delete Kits Ford 6.0 EGR Delete Kit DPF Delete Kit