Diesel Fuel Additive Heavy Duty Applications. December 2011

Transcription

1 Diesel Fuel Additive Heavy Duty Applications December 2011

2 Diesel Fuel Additives Long term performance Long term benefits have been measured in both light duty and heavy duty vehicles with respect to; Emissions Fuel Economy Power Acceleration Down-Time/Maintenance Data generated through both vehicle trials, dyno-testing and test engines

3 Innospec High Performance Deposit Control Additive Fuel Additive prevents formation of, and removes existing, deposits caused by fuel decomposition results in optimal fuel spray pattern being maintained Performance Benefits better fuel economy improved vehicle driveability Power Loss, Acceleration reduced vehicle emissions (40-50%) improved fuel stability

4 Vehicle Testing Mileage Accumulation Fuel Injector Nozzles Base Vehicle (Fouled) Additive Vehicle (Clean) B2 G2 B2.1 G microns

5 Field Trial - Fuel Economy Measurements performed at the end of the 15,000 km test Innospec Fuel additives improve vehicle fuel economy by more than 4% >10% if start with dirty engine simply by cleaning up existing deposits Fuel Economy Improvement, % Urban Sub-urban Total Additive Car Additive Car with CNI

6 Nozzle Fouling Heavy duty (keep clean) Photographs of Cummins L10 plungers Basefuel Fuel treated with Additive

7 Nozzle Fouling - Heavy keep clean Scanning electron photographs of typical DI plungers - Basefuel - Fuel treated with Detergent

8 Heavy Duty Field Trial - fuel economy Fuel economy testing Improvements measured at the end of 100,000km test period in matched pairs improved fuel consumption by up to 4% through additive use Fuel Economy Improvement, % Urban Motorway Suburban Truck 1 Truck 2 Total

9 Smoke testing Long term performance Smoke reduction 50 Base vehicle smoke Additised vehicle smoke Use of Innospec diesel additive can reduce engine smoke by as much as 108% under cold start conditions Smoke benefits with additive use, % Cold start Warm idle Constant

10 Performance Benefits Total Single Package Fuel Economy Increased Power / Better Acceleration Less Down-Time Lower Emissions Full No Harm testing Engine

11 Fuel Economy Benefits of Additised Fuel Keep Clean Original design specification gine Fuel onomy Fuel Saving/Economy (1-6%) Additised Fuel Un-additised Fuel 0 Km / hours Km / hours Benefit is direct result of reduced deposits throughout the whole fuel injection and engine combustion system

12 Fuel Economy Benefits of Additised Fuel Clean-Up Original design specification gine Fuel onomy Un-additised Fuel Additised Fuel Fuel Saving/ Economy Switch from Un-additised Fuel to addiitsed fuel 0 Km / hours Km / hours Benefit is direct result of reduced deposits throughout the whole fuel injection and engine combustion system

13 Fuel Economy Benefits of Additised Fuel Conclusions The most effective additive option to improve fuel economy is by using deposit control additives. Generally known as Detergent Additives Keeping engines clean or cleaning them up is the most effective way to improve fuel economy. It is very well established technology

14 ECOCLEAN Background Injector Technology has changed. Newer high pressure fuel injectors (HPFI) or high pressure common rail (HPCR) systems create PSI and temperatures that have never been seen before ~36,000 psi on inlet side of injector Temperatures F Fuel is unstable at these extremes Fuel breaks down, forms particulate (asphaltene)

15 ECOCLEAN Background Problems are manifested as: Fuel filter plugging prematurely at a rate of up to 5x PM Injectors varnish, misfire, fail Lube oil (CJ4) filters plugging prematurely Extended lube oil drain intervals shortened EGR valve sticking and failures Fuel economy detriment All lead to high expenses and downtime

16 Injector Fouling in Heavy Duty Engines Injector Fouling, Internal and Injector Tip Filter Plugging Power Loss Economy Deficits Shortened PMI Diminished drivability Increased $$$ fuel Modern fuel injection technologies are designed to facilitate compliance with ever more stringent emission targets Smaller orifices Tighter tolerances Greatly increased pressures (30,000 psi!) are required to generate adequate fuel flow through reduced dimension labyrinth.

17 Typical HPCR fuel system High pressure pump Common Rail Pressure-side filter Lift pump Injectors Injected fuel Suction filter Fuel tank Return source - Cummins Inc. SAE Oct 2008

18 Deposit Location HPFI Conventional Deposit Locales

19 Engine Technology Summary HPCR engine technology have increased operating temperatures and pressure within the injector typical pressure of bar or 30,000 psi Typical temperatures of o C or 500 o F HPCR engines have much tighter tolerances between 2-7 µm, the smallest particles visible to the human eye is 40 microns Fuel filters are plugged when degradated fuel is recirculated back to the fuel tank and back through the fuel system Advanced HPCR engine technology needs to operate on a high quality fuel on a year round basis

20 Microns (µm) and HPCR Tolerances A micron is mm (1 µm) Human hair 70µm Smallest you can see 40µm Rust Inhibitor - 1µm Bacteria 1µm Many tolerances are measured in microns Spray hole diameters 150µm Matched Clearance - 2µm ~ 7µm Filter media (final) 4µm ~5µm (c) -2µm ~ 7µm Human hair 70µm source - Cummins Inc. SAE Oct 2008

21 Winter Solution to Injector Fouling ECOCLEAN Winter Power Plus Maintains clean Fuel Injectors Increases Cetane Number up to 4 Improved emissions, less smoke, better start-up Prevents Corrosion Contains De-Icer Removes and prevents deposits which can deteriorate fuel economy and emissions Fuel does not gel

22 Tank Maintenance/Fuel Quality Testing Program Many issues are created by poor tank maintenance. Water will plug filters in both the summer and winter. Water will also promote microbial contamination. Regular tank testing will help prevent and maintain product quality and provide asset protection (corrosion issues).

23 Fuel Analysis/Testing Program Quarterly Bottom Samples Water/Sediment bottoms Microbial Contamination Find problems before they become one Winter Nozzle Samples Cloud Point Cold Filter Plugging Point (3,820) Pour Point Water Check for operability Testing and Kits Provided at NO CHARGE

24 Syncrude Mine Trial with ECOCLEAN A short summary of a 2-year+ mine trial with ECOCLEAN at Syncrude s Fort McMurray Oil Sands Mine facility December 2010

25 New ECOCLEAN Diesel Technology from Innospec ECOCLEAN Innospec Technology high pressure, high temperature antifoulant/detergent chemistry Outstanding keep clean and clean-up capability Excellent high temperature, high pressure fuel stabilization performance Engine systems are moving to high pressure, high temperature operations Tier II and higher up to 60,000 psi. Fuel cleanliness is absolutely critical to the operation of many present and most future diesel engines. Mine trial 2 year+ Major Canadian mining operation Heavy Duty equipment large mine haulers including HPCR units (high pressure common rail) Examples: Liebherr 282B tonne haul unit CAT 797B 400 tonne haul unit Focus on equipment integrity expansion Fuel Injection system Fuel Filters Fuel Pumps

26 Filter Life Typical filter life is 500 hours PMI every 500 hours with major maintenance interval at 2500 hours Filters with new Innospec Technology Very clean after full 2500 hours of operation No visible deposits, no sludge etc

27 Filter after 2500 hours with Innospec ECOCLEAN Fuel Filter Liebherr 282B

28 Filter after 2500 hours with Innospec ECOCLEAN Fuel Filter Caterpillar 797B

29 Filter after 2500 hours with Innospec ECOCLEAN Fuel Filter Liebherr 282B

30 Fuel Pump Life Typical mine haul unit like a CAT 797B or LIEBHERR 282B engine life is about 15K to 18K hours Fuel pump life is expected to be ½ engine life or about 7K 9K hours Pre-trial pump life ~2000 hours Trial pump life ~ hours

31 Fuel Injection System Life Single largest fault driver to engine failure is malperforming fuel injectors In rugged mine haul operations for Tier II systems FI temperatures are in the o F. However temperatures under certain load conditions can reach 1200 o F. Fuel Injectors can actually break apart inside the combustion cylinder and cause damage. Engine Cost $400K - $800K. Fuel injection problems have been reduced to non-issue status during the trial at peak treat rates.

32 Future Work Very good success with new ECOCLEAN technology Mine trial will continue till June 2011 Designed a package to enable a fuel to meet European 50 Cetane Number Major emissions reduction performance

33 ECOCLEAN Trial at Pepsi- Frito-Lay Fleet -On Road HD Fleet- Summer 2008

34 Progression of filters from start to finish of trial. To the far right is a new unopened clean filter for reference. Start of trial begins to the right Filters become progressively cleaner with the continued use of ECOCLEAN Trial was run by Pepsi and permission given to Innospec to use these pictures Pepsi agrees to endorse performance of ECOCLEAN Improvement with ECOCLEAN

35 With ECOCLEAN

36

37 Series of filters taken at various junctions of fleet trial. Filters depict cleanup action of ECOCLEAN After week 1, filter on far left is completely plugged. After week 5, filter on far right is still very clean, clearly showing the positive effects of the use of ECOCLEAN

38 With ECOCLEAN in the fuel the filter runs very clean. Pepsi noted that the same picture was very dark and the filter was almost black previous to the use of ECOCLEAN

39 Fuel runs very clean with ECOCLEAN!!