Boat Builder Regulatory Update

ABYC Standards Week

H24 Fuel Standard

John McKnight

Marine Regulations

• California Evaporative Emission Update• Canada Marine Engine and Evaporative

Emission Update• EU Update

For more information, or a copy of today’s presentation, please visit

www.nmma.org/government/issues/environmental.aspx

How will the US fuel supply affect the boats you build?

• What do we now know about ethanol in fuel at amounts >10%?

• What do we know about alternatives to ethanol enhanced fuels?

• What are the US and California Governments doing about this?

Results Summary• Verado

– Initial E15 engine generated HC+NOx emissions in excess of FEL when operated on E15 fuel.

– E15 engine failed exhaust valves. Metlab analysis showed excessive metal temperatures caused a reduction in fatigue strength.

• F9.9HP– The E15 engine on E15 fuel showed high HC variability at the post-endurance emissions

testing. It is believed that this engine was misfiring at idle due to the lean operation.– The E15 engine showed evidence of hotter metal temperatures due to carbon deposits, etc.– The E15 engine showed signs of gasket deterioration on the fuel pump.

• 200HP EFI 2.5L 2 Stroke– E15 engine showed no difference in emission deterioration.– E15 engine failed the rod bearing. Root cause is indeterminate due to the degree of damage.

• How does ethanol affect oil dispersion in two stroke engines?

– Other than the bearing failure, the end of test teardown and inspection did not show any significant difference between the 2 engines

Results Summary-Continued• 4.3L V6 ECT Mercruiser

– Two emissions tests were performed on a 4.3L catalyzed sterndrive engine to compare the E0 fuel and the E15 fuel. No durability testing was completed on the 4.3L engine with E15 fuel.

– This testing was not part of the contract, but was performed due to the fact that the E15 test fuel and a catalyzed engine were readily available on the dyno. Also, it compliments the testing on a 4.3L carbureted engine done by Volvo Penta.

– EGT increased ~20C and catalyst temperatures increased ~32C at Mode 1 (WOT).• Valvetrain durability and catalyst system deterioration concerns.

– Fuel consumption increased by ~5% (mass-based fuel flow) in closed loop operation.– Aside from HC and CO reductions at Mode 1 (open loop), the E15 fuel afforded no real

benefit to reduced emissions overall.• NOx increased at Mode 1, but not as much as HC decreased for a slight overall reduction.• HC, NOx and CO in closed loop operation are essentially unchanged between the 2 fuels.

• Overall– The CO emissions were lower on all engines with E15 fuel due to leaner running (as

would be expected).– Fuel analysis showed the E15 fuel that was used in testing was in line with expectations.

F9.9HP 4-Stroke Teardown and Inspection

More carbon deposits on intake valves of E15 engine.

F9.9HP 4-Stroke Teardown and Inspection

• More carbon deposits on intake port of E15 engine.

E15E0

F9.9HP 4-Stroke Teardown and Inspection

• More carbon deposits on piston undercrown and rods of E15 engine.

Verado E15 Valve Failure Investigation

Cylinder 3Top Valve

Cylinder 3Bottom Valve

Cylinder 6Top Valve

Verado E15 Valve Failure Investigation

Cylinder 3 Bottom Valve

200HP EFI E15 Engine-Bearing Failure• Root cause of bearing failure is unknown.

• 283 total engine hours, 256 WOT endurance hours

• No rollers were recovered.

Remaining Pieces from Cyl 3 Rod Bearing Cage

Undamaged Rod Rod from Cyl 3

Undamaged Bearing

Conclusions and Recommendations Summary

• Despite the limited scope of project several significant issues were discovered.– Durability Failures– Emissions Issues (elevated NOx, HC variability)– Run Quality due to Lean Operation

• More testing is necessary to understand effects on:– Drivability- Ex. cold and hot start, transient accel/decel, “boil off”, etc.– Oil dispersion in 2 stroke engines– Storage (phase separation, corrosion, etc.)

• Test program was a cursory look at the effects of E15.– Sample size was insufficient to have statistical significance.– WOT operation only-masks effects of true customer duty cycle

So we had to put some the great minds in the boating industry to think about this

And at the end of the day we decided to test this

new type of biofuel called isobutanol

What is Butanol?• A four carbon alcohol (C4H9OH), colorless, neutral liquid of

medium volatility with a characteristic banana-like odor.• Can be biologically derived from biomass in a

fermentation process using microorganisms – Biobutanol • Biobutanol fermentation differs from bioethanol mainly in

the use of bacteria.• An existing ethanol plant can be converted to make

butanol

Butanol Properties:

• Butanol 99,800 BTU/gallon

• Gasoline 116,000 BTU/gallon

• Approximately 86% of the energy content of gasoline

• Ethanol 76,300 BTU/gallon (68% of the energy content of gasoline)

Butanol Properties:• Phase Separation

• As water enters a boat fuel system containing ethanol-extended fuels, phase separation may occur creating an ethanol/water fuel mixture.

• Butanol does not phase-separate as shown in the cylinder on the right

Figure 1. Effect of adding 10% water by volume to 85% ethanol

and 10% water by volume to 85% butanol

Butanol Introduction:• Less susceptible to phase separation means

butanol could be successfully delivered in existing pipelines

• Eliminates need for splash-blending

• Least corrosive of alcohols

• Higher energy content – can be blended into gasoline at higher percentages than ethanol

Energy Content:• 16.1% butanol by volume is equivalent to 10%

ethanol by volume

• ~3% O2 Energy Content of Butanol-Extended and Ethanol-Extended Fuels

16500

16750

17000

17250

17500

17750

18000

18250

18500

18750

19000

0 2 4 6 8 10 12 14 16 18 20

Alcohol by volume

En

erg

y C

on

ten

t [B

TU

per

lb]

Isobutanol

Ethanol

Gasoline

Purpose of Testing:

• To evaluate the effect of butanol-extended fuels in a harsh marine environment and to see if there is a better alternative to ethanol-extended fuels

Test Set-up:

• On-water emissions testing using the Marine Portable Bag Sampling (MPSS) unit developed for the EPA/NMMA green house gas study.

The Capture

The Boats & Crew

The Boats & Crew

Tests Conducted:• On-water emissions testing • Emissions data reported using EPA certification fuel

(non-oxygenated) and 16.1% isobutanol-extended fuel.

• Values reported in grams per ICOMIA hour:– Total Hydrocarbons– Nitrogen Oxides– Carbon Monoxide

Test Results:

ETEC 175 HC, NOx, CO grams per ICOMIA hour Indolene Fuel vs. 16.1% Isobutanol Extended Fuel

224.257.5

3725.3

230.386.4

3086.7

0

500

1000

1500

2000

2500

3000

3500

4000

THC NOx CO

gra

ms

/ IC

OM

IA h

ou

r

Indolene Isobutanol

Evinrude E-TEC 175 Stratified Charged Direct Fuel Injection Two-Stroke on water emissions evaluation [HC, NOx, CO] – 18' Mako Boat. Comparison between Indolene fuel and 16.1% isobutanol extended

fuel. Values in grams per ICOMIA hour average of two tests per fuel type

HC + NOx emissions are virtually the same

between the two fuels. CO is reduced using

isobutanol (as expected)

Test Results:

JETBOAT HC, NOx, CO grams per ICOMIA hour Indolene Fuel vs. 16.1% Isobutanol Extended Fuel

114.0208.0

3470.7

73.7

247.9

2235.9

0

500

1000

1500

2000

2500

3000

3500

4000

THC NOx CO

gra

ms

/ IC

OM

IA h

ou

r

Indolene Isobutanol

Jet-boat on water emissions evaluation [HC, NOx, CO] – Rotax 1503 Supercharged Four-stroke engine. Comparison between Indolene fuel and 16.1% isobutanol extended fuel. Values in grams per ICOMIA

hour average of two tests per test fuel.

HC decreased slightly and NOx increased slightly using

isobutanol…but the total HC+NOx was virtually the same

between the two fuels. CO is reduced using isobutanol (as

expected)

Product Testing

Vintage Tank Testing…..

Coupon testing

31

E10/E15 as Certification Fuel?

• EPA is expecting to propose a new certification fuel for cars and light-trucks at the end of 2011– Likely to propose a 15% ethanol/gasoline (E15) blend– EPA recently approved a waiver for E15 and expects use to grow

significantly in coming years

• EPA is considering proposing the new certification fuel for all nonroad categories that use gasoline– Apply to Marine SI, Small SI, Large SI, and Rec Vehicles– Apply to both exhaust and evaporative emissions

32

E10/E15 as Certification Fuel?• For marine engines, EPA has explored three options

– E15

– E10 initially, then move to E15 after market review indicates E15 is a “significant” fraction of fuel sold

– E10

• EPA would allow multiple years for manufacturers to re-certify their products on the new fuel

– Open to allowing carryover of existing CE10/E10 data from fuel tank and fuel line permeation testing

• No decisions have been made yet• Proposal will be available on EPA website after signature

– http://www.epa.gov/otaq/hwy.htm

The Ongoing Debate

“Recent claims from some marine engine

manufacturers that E15 ethanol blends will ruin

marine engines are meant solely to incite fear and not

meaningful discussion.”

David Hilbert, Thermodynamic Engineer for Mercury Marine

November 2, 2011

Jeff Wasil, Engineer, Emissions and Compliance for Bombardier

Recreational ProductsJuly 7, 2011

Congressional Testimony

What’s Next? • Continue to lobby Congress

to revisit the Energy Independence Act of 2007– Freeze the blend wall at 2011

levels– Variable legal challenge to the

EPA E15 partial waiver

• DOE is helping with funding for additional butanol testing:– Four in-water boats

• Water ski boat• Boat with Yamaha 08 engine• Center console with Johnson 2 stroke• Runabout with VolvoPenta engine

– Laboratory testing at BRP• Durability• Cold Starting• Emissions