Waste Oil Alternative Fuels Waste Minimisation Fund Project: WMF 223

Transcription

1 Waste Oil Alternative Fuels Waste Minimisation Fund Project: WMF 223 Page 1 of 23 Final Project Report WMF 223 Version 001 Dec 2014

2 Page 2 of 23 Final Project Report WMF 223 Version 001 Dec 2014

3 Introduction Since 2006 the Wellington Institute of Technology (WelTec) has provided support to a number of research and development entities which have been undertaking projects in the area of alternative fuels. This was an area of research and development of interest to WelTec as the training of Automotive Technicians is a significant part of the institution s extensive trade training portfolio. As a result, WelTec has a body of staff and students who have an interest in what form future vehicles may take and the propulsion systems they will use. Through working with these Research and Development entities and engagement with and support from the Hutt City Council through a joint waste assessment and minimisation project known as Silver Lining, WelTec became aware of the issues associated with the collecting and disposal of small dispersed amounts of waste lubrication oils [ULO]. Because of the dangers ULOs pose to New Zealand s underground water and above ground water systems such as streams, rivers and lakes through the effect even a small amount of waste oil has on entering any of these water systems by potentially rendering these water sources unusable as drinking / potable water for years, an application was made to the Waste Minimisation Fund for funding to support a project into the collection and recycling / re-use of these small dispersed quantities of ULOs. As WelTec s School of Engineering Technology offers a Water and Waste speciality for the Bachelor of Engineering Technology and is launching a new Graduate Diploma in Engineering in Water and Waste in 2015, this project would make a positive contribution to WelTec s R&D activities being undertaken by staff and students within this specialist area. Proposed Objectives In the Project Plan the following objectives were set. These were: Create a stable low emission alternative fuel that reuses / recycles hazardous waste oil as part of a blended fuel for use in diesel vehicles Test the efficiency of the blended fuel in accelerated stability tests. Create a local system (i.e. development and establishment of a plant at a single site) for the production and supply of the alternative blended fuel sufficient for use by a fleet of at least 20 diesel vehicles typical of those used by local authorities. Demonstrate the reliable use of the alternative blended fuel in a diesel vehicle by running the vehicle on the alternative blended fuel for 6 months, and regularly testing and inspecting the engine for excessive wear and tear. Develop a local waste oil collection system / scheme that is collecting at least 10,000 litres of waste oil per month Page 3 of 23 Final Project Report WMF 223 Version 001 Dec 2014

4 Produce a guideline information kit on the development of sustainable, locally-based, low emission waste oil alternative fuels for use in diesel vehicles and a final report for use by the Ministry for the Environment, local authorities and other organisations that sets out how an estimated million litres of hazardous waste oil can be effectively recycled and reused as part of an alternative blended fuel. The Project To meet these Objectives the Project Team set out to determine whether the Smart Mix process which had been developed by one of the R&D entities that WelTec had been supporting was a:: An economic, practical and sustainable methodology that could be utilised to drive the capture of significantly larger amounts of these small dispersed quantities of waste ULOs An option that would allow this collected ULO to be re-processed into a usable fuel that could be used in unmodified diesel engines and generators as close as possible to its point of collection thereby minimising the contamination risk involved when bulked up amounts of ULO are transported for recycling or disposal. Activities Undertaken The expectation at the start of the project had been that it would be relatively straight forward to create a collection system which would allow individuals to safely and effectively re-cycle these small quantities of waste lube oil, Because it was thought that the close proximity and accessibility would be key factors in encouraging people to recycle these small volumes of ULO, the team spoke to a number of commercial entities about their interest in being involved in such a collection /re-cycling scheme. From these conversations it became very obvious that without a means of generating a return to the commercial entity for establishing and running the necessary collection facilities, the chances of establishing a long term, hazard free and sustainable system were not promising. As a result of these findings and the fact that the failure to establish such a collection system would cause significant delays in achieving the objective the team had set itself in the Project Proposal in respect to the capture and re-cycling of such ULOs, the Project Team determined that there were two key things that needed to be done so that long term, hazard free and sustainable collection systems could be established.. These were to: Investigate what existing methods were being used to collect small dispersed quantities of waste lube oil [ULO] so that if needed an alternative Waste ULO Collection Unit could be developed so that it could be located alongside a Smart Mix processing plant Ensure that the Smart Mix process developed by one of the R&D entities WelTec was providing support for was tested against a recognised standard to ensure that it could produce blended / mixed fuels that included a % of ULO which could safely be run in unmodified diesel engines or generators. Page 4 of 23 Final Project Report WMF 223 Version 001 Dec 2014

5 If it could be proven that the Smart Mix process produced stable alternative fuels that could be used in unmodified diesel engines and generators then there would be a solution available which would produce returns for commercial entities investing in such a system and it would allow collected quantities of ULO to be processed on site soon after they had were collected. ( 1 ) Current collection methods for small dispersed quantities of ULO The investigation into how small dispersed quantities of waste lube oil [ULO] were currently collected, revealed that a wide range of approaches being used, but of particular concern were the type of collection facilities where individuals could drop off quantities of waste oil which was brought to the sites in a wide range of containers. The ULO in these containers were often then emptied into a bulk storage tank, in some cases by the individuals themselves without supervision, which immediately increases the hazards posed by this environmentally damaging substance In small amounts ULO poses a problem, but when bulked up in one place the risk it presents increases exponentially. Photos of two current collection sites are shown on the following pages. Page 5 of 23 Final Project Report WMF 223 Version 001 Dec 2014

6 This site did ask individuals bringing containers of waste ULO to the site to please see the attendant which was positive and did have the collection tank sitting in a covered bunded area, however there were signs of obvious oil seepage around the site in spite of this. Page 6 of 23 Final Project Report WMF 223 Version 001 Dec 2014

7 This site was out in the open with no containment or covering structures in place under and over the collection point. As at the other site shown there was also evidence of oil seepage on the site. Outcome of Activity 1 As a result of the findings of this investigation, it was seen that there was a clear need for the development of a standardised collection unit which would allow the safe collection, storage and initial processing of these small batch quantities of ULO. Working with an oil industry expert, WelTec has developed a concept for a unit which would allow all the above criteria plus ensure that in the finalised design all current environmental and health and safety regulations currently in place could be met. Drawings of concept ULO Collection Units are shown on the following pages. Page 7 of 23 Final Project Report WMF 223 Version 001 Dec 2014

8 Concept design 1 for a ULO Collection Unit: Fixed Location This was the first concept developed which was in line with current practice, but it was a site specific solution as it had to constructed on site. Page 8 of 23 Final Project Report WMF 223 Version 001 Dec 2014

9 Concept design 2 for a ULO Collection Unit: Transportable This concept moved to using a container so that the unit could be built inside the container and then moved to wherever it was needed. This approach gives greater flexibility and security in the unit can be closed up when unattended. Page 9 of 23 Final Project Report WMF 223 Version 001 Dec 2014

10 Concept design 2 for a ULO Collection Unit: Transportable Page 10 of 23 Final Project Report WMF 223 Version 001 Dec 2014

11 Concept design 2 for a ULO Collection Unit: Transportable Page 11 of 23 Final Project Report WMF 223 Version 001 Dec 2014

12 ( 2 ) Testing of a blended fuel which had a 5% ULO component. This activity set out to ensure that the new Smart Mix process developed by one of the R&D entities WelTec was supporting was tested against a recognised standard to ensure that it could produce blended / mixed fuels that included a % of ULO which could safely be run in unmodified diesel engines and / or generators. When the project had been first scoped it had initially been decided to run a vehicle for a period of six months on a blended / mixed fuel produced using the Smart Mix process. It was however later determined that an alternative method which would test the fuel produced by the process in an engine under the conditions set by the Engine Manufacturers Association would be a more preferable approach as this would allow replication of the test with this fuel and other fuels as they were developed. With the approval of the Ministry for the Environment this was the approach used. Using the Engine Manufacturers Association s 200 Hour Test protocols a new diesel engine was run on a blended fuel which had a 5% ULO content. The engine used was a Mitsubishi 4D56T turbo diesel Page 12 of 23 Final Project Report WMF 223 Version 001 Dec 2014

13 Specifications for the Engine used. Page 13 of 23 Final Project Report WMF 223 Version 001 Dec 2014

14 Scope of EMA 200 Hour Test Undertake an Engine Manufactures Association 200 hour test on a waste oil blended fuel in accordance with the project plan and to deliver a final report as per previous reports for the project. Quote from original contract. Demonstrate the reliable use of the alternative fuel on a diesel vehicle by running the vehicle on the alternative blended fuel for six months (six months later changed to EMA 200 hour test) and regularly testing and inspecting the engine for excessive wear and tear. Methodology Used A blended hybrid fuel was formulated, characterized and evaluated as a fuel in an indirect injection, turbocharged, 4 cylinder Mitsubishi diesel engine during an EMA 200 hour cycle laboratory screening endurance test. Engine set up on dynamometer for EMA 200 Hour Test programme. Page 14 of 23 Final Project Report WMF 223 Version 001 Dec 2014

15 The engine was run on Mobil Diesel for fifty hours to prepare it for the EMA 200 Hour Test on the Alternate Fuel. The testing and the report produced concentrates on the engine wear and any damage that may be caused by the use of the Smart Mix fuel and fuel consumption as compared to straight Diesel fuel as Emissions and Performance testing had been completed, and reported in previous reports. Data gathered during the testing can be categorized as either Dynamic or Static Static Data such as Cylinder leakage testing and oil sampling along with engine strip down and measure are to establish Engine Wear over the test duration. These measurements are taken whilst engine is not running (Static), This is considered critical data under the scope of this test Dynamic data is taken whilst the engine is running and under control of the Dynamometer. The purpose of Dynamic data is to observe trends over the test duration (e.g.: is power trending up or down and how does it compare to Diesel). Engine oil sampling was carried out every 30 hours of run time (24 hours of test time) to monitor Engine wear, oil degradation and viscosity changes due to contamination from 6 the combustion of the test fuel and to highlight wear metals that may indicate excessive engine wear. Oil testing results showed normal engine wear and oil degradation Cylinder leakage tests were carried out every 30 hours of runtime and oil consumption was monitored. Cylinder leak down showed a higher cylinder blow by than expected for the first two tests and then constant leak down results for the rest of the test with no changes or deterioration in leak down percentages for the rest of the test, indicating that the engine was not fully run until test cycle 3 Oil consumption remained constant through the test with the top up volume being equal to the oil volume removed for sampling. The engine was stripped down and measured before and after the test. No significant or undue wear or changes were observed or measured. The next pages show a number of Pre and Post-test photos of key components which were inspected and measured as part of the EMA 200 Hour Test. Page 15 of 23 Final Project Report WMF 223 Version 001 Dec 2014

16 Turbo Photos below are of the exhaust turbine. Observations should include the level of deposits on venturi and the turbine blades especially at the tips. Note: There is little difference in the deposits on the blades of the turbine Pre-Test Post Test Page 16 of 23 Final Project Report WMF 223 Version 001 Dec 2014

17 Piston Pre-test photo is of the crown only as pistons were not removed pre-test. Observations should include Gumming and deposits at ring groves (post-test), excessive carbon build up, signs of heat stress and pitting on crown. Note: piston was removed and inspected by an independent engine builder and deemed to show normal wear with no excessive or unusual deposits on crown or within the ring groves Pre-Test # 4 piston crown Post Test # 4 piston crown - no excessive deposits are observed Page 17 of 23 Final Project Report WMF 223 Version 001 Dec 2014

18 Post Test: Ring grove The two photos below were taken of the piston rings and ring groves. They show no signs of ring gumming or excessive carbon deposit formation Page 18 of 23 Final Project Report WMF 223 Version 001 Dec 2014

19 Cylinder Head and pre combustion port Observations should include excessive build-up of deposits at the Pre combustion chamber port and valve seat damage or recession. Note: No signs of excessive deposits were present Pre-test Post test Page 19 of 23 Final Project Report WMF 223 Version 001 Dec 2014

20 Conclusions: After careful analysis of the dynamometer data and the engine measurements and visual condition, it was concluded that there was no significant wear and tear on the test engine as a result of undergoing the EMA 200 hour test using the alternative blended fuel. Outcome of Activity 2 The reported results drawn from the outcome of the EMA 200 Hour Test which was undertaken have since been independently reviewed by a suitably qualified and experienced practitioner, who has verified the validity of the results obtained and reported. Page 20 of 23 Final Project Report WMF 223 Version 001 Dec 2014

21 Next steps in the journey Following the successful testing of a blended fuel with a 5%ULO component produced using the Smart Mix Process the Research & Development entity is in the process of commercialising the technology and discussions are being held with possible early adopters both in New Zealand and Internationally. The successful completion of any one of these discussions would allow WelTec to consider undertaking the detailed design of the Standardised ULO Collection Unit so that one could be built and deployed on-site at the New Zealand first user s facility. This would then allow a collection programme in the surrounding community to be initiated which could be measured overtime to establish how successful it is, thereby fulfilling one of the original objectives set in the Project Proposal submitted. The R&D entity will also be continuing its long term development programme as it has been found that the Smart Mix Process appears to be able to produce blended stable and engine safe fuels using not only ULO but also other types of waste oils and bio-fuels. At least one overseas University and a Scientific Research Centre have approached the R&D entity to discuss future joint research, something that will provide additional benefits to New Zealand. Page 21 of 23 Final Project Report WMF 223 Version 001 Dec 2014

22 Appendix 1: Glossary of Terms Term ULO MAP Premix Kg / hour RPM EGT λ Load PSI TP Main Test Condition Cycle Diesel/ AGO WOT SM SVO Pre test Post test Explanation Used Lubrication Oil Manifold absolute pressure A propriety blend of chemicals required to stabilise the fuel Kilogram per hour (fuel consumption as Mass instead of litres) Revolutions per minute Exhaust gas temperatures Lambda (oxygen % calculated by the Lambda probe) Torque produced by the engine at a given RPM and throttle position An Imperial unit of pressure pounds per square inch Percentage of throttle opening. Throttle position and RPM settings for a test. Expressed as A,B,C or D The completion of Test condition A,B,C,D combined Automotive Gas Oil / Diesel fuel as taken from the fuel station. Intended for use in a Diesel vehicle. Wide Open Throttle Smart Mix fuels Rated by the % of oils other than Diesel EG: SM5 = % 5 other oils ( ULO) & % 95 Diesel Straight Vegetable Oil Pre the start of the EMA200 hour test. Run on diesel but not on Blended fuel as yet Post the EMA 200 hour test. Run Diesel then Blended fuel for the 200 hour EMA test duration Page 22 of 23 Final Project Report WMF 223 Version 001 Dec 2014

23 Page 23 of 23 Final Project Report WMF 223 Version 001 Dec 2014