High Ethanol Fuel Endurance Advanced Engineering Project A study of the effects of running 15%...

High Ethanol Fuel Endurance Advanced Engineering Project

A study of the effects of running 15% ethanol concentration in current production 4-stroke engines and legacy 2-stroke engines.

Prepared By:Dave Hilbert

*Brunswick, Confidential*

OverviewThis project is a cooperative effort to assess the feasibility of increasing the allowable ethanol concentration in gasoline above the current legal limit of 10% for use in marine engines.

Objectives of this project:Run 300 hours of wide-open throttle endurance on 3 engine families and measure emissions at 0, 150, and 300 hours.9.9HP 4-stroke carbureted, 200HP 2.5L 2-stroke EFI (represents legacy product) and 300HP L6SC Verado engines were chosen.Two engines from each familyTest engine operated on E15Control engine run on pure gasoline


Test Engine Specifications

Sheet1

9.9HP 4-StrokeVerado200 EFI

Gas Exchange ProcessFour StrokeFour StrokeTwo Stroke

Power Rating at Prop9.9HP300HP200HP

Cylinder ConfigurationInline 2 CylinderInline 6 Cylinder60 Degree V-6 Cylinder

Displacement0.209 Liter2.59 Liter2.51L

Fuel Induction SystemSingle Carburetor w/Accelerator Circuit, 2 Valve per Cylinder, Single Overhead CamSupercharged Electronic Fuel Injected 4 Valve per Cylinder, Dual Overhead Cam, Electronic Boost Control, Electronic Knock Abatement StrategyElectronic Fuel Injected with Oil Injection, Loop Scavenged Porting, Crankcase Reed Induction, Electronic Knock Abatement Strategy

Dry Weight108 lbs / 49 kg635 lbs / 288 kg425 lbs / 193 kg

Fuel Requirement87 Octane R+M/2 Minimum Required92 Octane R+M/2 Recommended, 87 Octane R+M/2 Minimum Required87 Octane R+M/2 Minimum Required

Sheet2

Sheet3


Results SummaryVeradoInitial 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.

F9.9HPThe 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 StrokeE15 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-Continued4.3L V6 ECT MercruiserTwo 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.OverallThe 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.


Conclusions and Recommendations SummaryDespite the limited scope of project several significant issues were discovered.Durability FailuresEmissions Issues (elevated NOx, HC variability)Run Quality due to Lean OperationMore testing is necessary to understand effects on:Driveability- Ex. cold and hot start, transient accel/decel, boiloff, etc.Oil dispersion in 2 stroke enginesStorage (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


Fuel Comparison

Chart1

86.39.4

88.58.7

84.65

87.55.9

Motor Octane

Research Octane

Octane Number

Octane Measurement Comparison of Various Fuels

Sheet1

Fuel AnalysisE15 FuelEEE (10/8/10-Haltermann Data)87 Bulk Fuel (Sample 10-15-10)91 Bulk Fuel (Sample 10-15-10)91 Bulk Fuel (Sample 02-10-11)Pure Ethanol Boiling PointBoiling TempBoiling TempDistillation Class10% Max50% Min50% Max90% Max100% Max

Research OctaneRON95.797.289.693.4078172.40.10.50.50.91

Motor OctaneMON86.388.584.687.5178172.4ASTM D4814-09B: Distillation Class A (Summer)7077121190225

[R+M]/2AKI91.092.987.190.45ASTM D4814-09B: Distillation Class E (Winter)5077110185225

RON-MON Delta9.48.75.05.9

Density @ 15.5Ckg/L0.7520.744

API GravityAPI56.558.7

Ethanol Content (NREL/ASTM D5501)%18+/-1%

Ethanol Content (IROX analyzer @ NREL)%14%

Results from Petrospec analyzer at Mercury (E15 data ave. of 2 samples)

Ethanol Content%14.1%0000

RONRON95.795.889.492.991.5

MONMON84.787.783.387.285.4

[R+M]/2AKI90.291.786.490.188.5

Reid Vapor Pressure (Mercury analysis)PSI8.59.010.810.7

Distillation % Recovered

0%F98869282

5%F123106119104

10%F130121133116

20%F140144160146

30%F148170183180

40%F155202205198

50%F164223228214

60%F220235239227

70%F254247262242

80%F284268300272

90%F328320367346

95%F365338392402

100%F412392422430

Distillation % Evap% Evap

5%F11911494

10%F129130110

20%F139157139

30%F147181172

40%F154203194

50%F163226210

60%F216238224

70%F251260239

80%F282296265

90%F324360329

95%F359387376


0%C36.730.033.327.8% RecoveredAverage Summer RegularAverage Summer PremiumAverage Winter RegularAverage Winter Premium% RecoveredEmission Test EEEHaltermann High Endpoint HF 0112

5%C50.641.148.340.0%deg Cdeg Cdeg Cdeg C%deg Cdeg C

10%C54.449.456.146.70%36.1235.4228.4228.560%28.334.6

20%C60.062.271.163.35%48.7249.9136.8236.545%41.256.8

30%C64.476.783.982.210%55.8659.2242.744.6610%46.867.4

40%C68.394.496.192.220%65.2473.0852.7858.6615%52.176.7

50%C73.3106.1108.9101.130%75.4686.163.9874.6220%57.685.7

60%C104.4112.8115.0108.350%99.82108.3690.44103.3225%63.593.8

70%C123.3119.4127.8116.770%128.94127.82120.82124.1830%70100.9

80%C140.0131.1148.9133.390%169.54162.82161.28158.3435%77.3105.8

90%C164.4160.0186.1174.495%187.18179.48178.78175.2840%84.7109.8

95%C185.0170.0200.0205.6100%213.36208.04204.12201.645%92.4113.6

100%C211.1200.0216.7221.150%99.5117.4

55%105.7122.5

60%111129.1

65%116.2138

70%123.2152.2

75%131.1166.2

80%142.3176.7

85%156.6181.1

90%171.3190.6

100%211.4233.5

Sheet1

E15 Fuel

EEE (10/8/10-Haltermann Data)

91 Bulk Fuel (Sample 02-10-11)

ASTM D4814-09B: Distillation Class A (Summer)

Pure Ethanol Boiling Point

ASTM D4814-09B: Distillation Class E (Winter)

Percent Recovered (%)

Temperature (C)

Distillation Curve Comparison, ASTM D86

Sheet2

Motor Octane

Research Octane

Octane Number


Sheet3

Sheet1






Density @ 15.5Ckg/L0.7520.744






RONRON95.795.889.492.991.5

MONMON84.787.783.387.285.4

[R+M]/2AKI90.291.786.490.188.5



0%F98869282

5%F123106119104

10%F130121133116

20%F140144160146

30%F148170183180

40%F155202205198

50%F164223228214

60%F220235239227

70%F254247262242

80%F284268300272

90%F328320367346

95%F365338392402

100%F412392422430


5%F11911494

10%F129130110

20%F139157139

30%F147181172

40%F154203194

50%F163226210

60%F216238224

70%F251260239

80%F282296265

90%F324360329

95%F359387376




10%C54.449.456.146.70%36.1235.4228.4228.560%28.334.6

20%C60.062.271.163.35%48.7249.9136.8236.545%41.256.8

30%C64.476.783.982.210%55.8659.2242.744.6610%46.867.4

40%C68.394.496.192.220%65.2473.0852.7858.6615%52.176.7

50%C73.3106.1108.9101.130%75.4686.163.9874.6220%57.685.7

60%C104.4112.8115.0108.350%99.82108.3690.44103.3225%63.593.8

70%C123.3119.4127.8116.770%128.94127.82120.82124.1830%70100.9

80%C140.0131.1148.9133.390%169.54162.82161.28158.3435%77.3105.8

90%C164.4160.0186.1174.495%187.18179.48178.78175.2840%84.7109.8

95%C185.0170.0200.0205.6100%213.36208.04204.12201.645%92.4113.6

100%C211.1200.0216.7221.150%99.5117.4

55%105.7122.5

60%111129.1

65%116.2138

70%123.2152.2

75%131.1166.2

80%142.3176.7

85%156.6181.1

90%171.3190.6

100%211.4233.5

Sheet1

E15 Fuel







Temperature (C)


Sheet2

Motor Octane

Research Octane

Octane Number


Sheet3

Fuel AnalysisE15 FuelEEE 10/8/1087 Bulk Fuel 10-15-1091 Bulk Fuel 02-10-11

[R+M]/291.092.987.190.45


Fuel Comparison

Chart2

36.66666666673027.777777777833.3333333333707850

50.555555555641.11111111114048.3333333333777877

54.444444444449.444444444446.666666666756.1111111111121110

6062.222222222263.333333333371.1111111111190185

64.444444444476.666666666782.222222222283.8888888889225225

68.333333333394.444444444492.222222222296.1111111111

73.3333333333106.1111111111101.1111111111108.8888888889

104.4444444444112.7777777778108.3333333333115

123.3333333333119.4444444444116.6666666667127.7777777778

140131.1111111111133.3333333333148.8888888889

164.4444444444160174.4444444444186.1111111111

185170205.5555555556200

211.1111111111200221.1111111111216.6666666667

E15 Fuel








Temperature (C)


Sheet1






Density @ 15.5Ckg/L0.7520.744






RONRON95.795.889.492.991.5

MONMON84.787.783.387.285.4

[R+M]/2AKI90.291.786.490.188.5



0%F98869282

5%F123106119104

10%F130121133116

20%F140144160146

30%F148170183180

40%F155202205198

50%F164223228214

60%F220235239227

70%F254247262242

80%F284268300272

90%F328320367346

95%F365338392402

100%F412392422430


5%F11911494

10%F129130110

20%F139157139

30%F147181172

40%F154203194

50%F163226210

60%F216238224

70%F251260239

80%F282296265

90%F324360329

95%F359387376




10%C54.449.456.146.70%36.1235.4228.4228.560%28.334.6

20%C60.062.271.163.35%48.7249.9136.8236.545%41.256.8

30%C64.476.783.982.210%55.8659.2242.744.6610%46.867.4

40%C68.394.496.192.220%65.2473.0852.7858.6615%52.176.7

50%C73.3106.1108.9101.130%75.4686.163.9874.6220%57.685.7

60%C104.4112.8115.0108.350%99.82108.3690.44103.3225%63.593.8

70%C123.3119.4127.8116.770%128.94127.82120.82124.1830%70100.9

80%C140.0131.1148.9133.390%169.54162.82161.28158.3435%77.3105.8

90%C164.4160.0186.1174.495%187.18179.48178.78175.2840%84.7109.8

95%C185.0170.0200.0205.6100%213.36208.04204.12201.645%92.4113.6

100%C211.1200.0216.7221.150%99.5117.4

55%105.7122.5

60%111129.1

65%116.2138

70%123.2152.2

75%131.1166.2

80%142.3176.7

85%156.6181.1

90%171.3190.6

100%211.4233.5

Sheet1

E15 Fuel








Temperature (C)


Sheet2

Motor Octane

Research Octane

Octane Number


Sheet3

Fuel AnalysisE15 FuelEEE 10/8/1087 Bulk Fuel 10-15-1091 Bulk Fuel 02-10-11

[R+M]/291.092.987.190.45


F9.9HP 4-Stroke EmissionsVariability on E15 Engine is a concern.E15 fuel-zero hour and EEE-E0 fuel 150 hour checks are likely due to run-to-run variability.E15 fuel-300 hour variability is due primarily from Mode 5 (idle) HC emissions.Trends on EEE-E0 fuel are consistent between the 2 engines.


F9.9HP 4-Stroke EmissionsBoth engines had a tendency to run leaner at Modes 4 and 5 with increasing endurance time.The combination of the inherent leaner operation and the E15 fuel was enough to cause misfires/poor combustion at idle.The misfires caused the HC emissions to increase and become highly variable.


F9.9HP 4-Stroke EmissionsThe fact that the E15 fuel emissions tests show that HC emissions increase with leaner mixtures supports the misfire theory.The graph below shows HC vs. equivalence ratio at idle for every emissions test performed on engine 0R352904, which is the E15 engine.All E15 fuel emissions tests are shown in redAll EEE-E0 fuel emissions test are shown in blue


F9.9HP 4-Stroke Teardown and InspectionMore carbon deposits on intake valves of E15 engine.


F9.9HP 4-Stroke Teardown and InspectionMore carbon deposits on intake port of E15 engine.E15E0


F9.9HP 4-Stroke Teardown and InspectionMore carbon deposits on piston undercrown and rods of E15 engine.


F9.9HP 4-Stroke Teardown and InspectionThe gasket showed signs of deterioration on the E15 engine compared with the E0 engine. The gasket on the E15 engine had a pronounced ridge formed in the area that hinges when the check valve is in operationThe E15 gasket material in the area that seals the check valve also had signs of wear that were more advanced than the E0 gasket. E15E0


F9.9HP 4-Stroke Teardown and InspectionMaterial transfer from gasket to diaphragm in mechanical fuel pump. E15E0


Verado TestingSummary / ReviewVerado E15 Engine:Initial emissions tests on E15 fuel generated HC+NOx values in excess of the FEL set for this engine.Three-run average on E15 fuel: HC+NOx = 25.6 g/kw-hrFEL set to 22.0 g/kw-hrE15 engine failed the exhaust valves.High cycle fatigue due to elevated temperatures


Verado E15 Valve Failure InvestigationCylinder 3Top ValveCylinder 3Bottom ValveCylinder 6Top Valve


Verado E15 Valve Failure InvestigationCylinder 3 Bottom Valve


Verado E15 Valve Failure InvestigationThe failed valves were checked for hardness and the values were low.Valves from other E0 engines w/o failed valves were measured and the hardness values were within expected values.Brand new valves were also measured for comparison.

Sheet1

Valves

EngineRc HardnessRc AverageRA HardnessRc Average

1400 Heat3939.569.970.0

4070.1

1400 No Heat3434.567.667.7

3567.7Before (HRC)Before (HRA)After (HRC)After (HRA)

1500 Heat3434.56767.4140034.567.739.570

3567.7150034.567.434.567.7

1500 No Heat3534.567.967.716003366.72766.2

3467.517003366.7

High Ethanol Fuel Endurance Advanced Engineering Project A study of the effects of running 15%...

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