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Minnesota E-20 Fuel Waiver Test Program

Minnesota E-20 Fuel Waiver Test Program. Technical Presentation Dr. Ranajit (Ron) Sahu, Consultant Phone: (626) 382 0001 sahuron@earthlink.net. Topics. Off-Road Characteristics Equipment Engines Fuel Systems EPA’s Exhaust Regulations Impact on Air-Fuel Ratio Settings

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Minnesota E-20 Fuel Waiver Test Program

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  1. Minnesota E-20 Fuel Waiver Test Program Technical Presentation Dr. Ranajit (Ron) Sahu, Consultant Phone: (626) 382 0001 sahuron@earthlink.net

  2. Topics • Off-Road Characteristics • Equipment • Engines • Fuel Systems • EPA’s Exhaust Regulations • Impact on Air-Fuel Ratio Settings • Summary of Existing E-20 Studies

  3. Topics (cont.) • General Testing Issues to Meet Waiver Criteria • Creating technology categories to respond to diversity • Existing and newly regulated products • Engine technologies/materials/components • Statistically valid data • Pass/Fail criteria • Testing Evaluations/Criteria • Impact on exhaust and evaporative emissions • Impact on materials compatibility • Impact on drivability/functionality

  4. Topics (cont.) • Illustrative Example – Handheld Engines • Fuel Specification Issues • Additional Technical Slides/Discussion

  5. Off-Road Characteristics

  6. Equipment • Diversity • Components, materials, and uses • Key design issues differ by category • Lawn and garden vs. snow vs. marine etc. • Seasonal use • Consumers • Minnesotans own and rely on millions of off-road engines, vehicles and equipment • Exposed to potential hazards if engine/equipment operates outside of normal expected conditions

  7. Engines • Air or Water Cooled • Operator in Close Proximity to Hot Engine/Exhaust System • 2-Stroke and 4-Stroke – With Variations • Various Fuel Introduction Technologies • Mostly carbureted with variations • Some fuel injected

  8. Engines (cont.) • Various Engine “Control” Technologies • Mostly open loop with no feedback • Few closed loop • Various Emissions Reduction Strategies/Technologies

  9. Fuel Systems • Wide variety of tank and hose materials • Different evaporative control strategies • Permeation, tank venting, etc. • Multi-positional operational requirements • Storage-stability issues due to seasonal usage • Safety constraints • EPA evaporative/permeation regulations

  10. EPA’s Exhaust Regulations: Impact on Air-Fuel Ratio Settings

  11. Regulations Summary

  12. Impact • EPA’s exhaust emission regulations have resulted in enleanment of the engine’s air-fuel calibration to functional limits • Fuel management systems cannot effectively manage E0 through E20 fuels interchangeably • Modification of existing fuel management systems to operate on E-20 would require tampering with an emission control device and thus violate Federal Law

  13. Limit for Acceptable Operation Limit for Emission Compliance Acceptable Operating Range Operation on E20 Gasoline Operation on E10 Gasoline Operation on Neat Gasoline Lean Air:Fuel Ratio Rich

  14. 1350 1300 Change in CO for fuel change from certification to E22 - Engine M44 1250 CaRFG PH2 Fuel Exhaust Gas Temperature - Degrees F 1200 E22 Fuel 1150 1100 0.00 1.00 2.00 3.00 4.00 5.00 6.00 7.00 8.00 9.00 CO % Exhaust Gas Temperature vs. Fuel Change

  15. Summary of Existing E20 Experience and Studies

  16. E-20’s Impact on Current, Exhaust- Emission Compliant Small Engines • Exhaust temperatures up 100°F • Peak cylinder pressures higher • Combustion deposits • Cylinder head gasket burned & failed • Exhaust valve burned • Cylinder bore scored • 25 hours light duty emissions testing • Lost cylinder compression • Lost 20% power

  17. E-20 Implications on Engine Durability Cylinder head gasket burned Lost seal Exhaust leak out

  18. E-20 Implications on Engine Durability Cylinder head gasket burned Lost seal

  19. E-20 Implications on Engine Durability Cylinder Bore scoring Deposits

  20. Engine Durability Implications with E-20 1 6 8 2 3 4 5 7 1 Head bolts discolored due to heat and carbon build up from exhaust gas blowing past bolt.

  21. Engine material compatibility Implications with E-20 Carburetor bowl mounting screw gasket attacked by E20 in few hours. Fuel containment seal. Bowl gasket swelled & lost seal.

  22. Engine material compatibility Implications with E-20 Carburetor welch plug epoxy attacked by E20 in 17 wks. Fuel containment seal.

  23. Engine material compatibility Implications with E-20 Fuel Cap gasket swelled & warped by E20 in 1 wk. Fuel containment seal & tank venting.

  24. Brazilian Experience • During 1970s and 1980s, blends ranging from E14 – E24 used in Brazilian fuel supply (pre-emission compliant products) • OPEI Member Experience (2-Stroke engines) • Lean air fuel ratio delivery resulting in • higher engine temperatures • engine seizures • Poor acceleration performance • Cold start problems • Phase-separation due to water uptake leading to water in carburetor • Formation of deposits blocking carburetor nozzles • Corrosion of engine parts, crankcase, bearings, crankshaft, etc. • Had to develop unique products with different carburetor settings, fuel system materials, etc.

  25. Orbital 2002 and 2004; NREL 2002 • E20 requires resizing/recalibration of existing open loop engines (i.e., changed A/F ratio) to prevent • enleanment, resulting in temperature increase, and engine malfunctions • detrimental impacts on safety • Detrimental impacts of phase-separation due to presence of water in E-20 – potential engine stall – esp. at cold temperatures • Poor (Cold) Start performance (esp. important for hand-start engines) • Hot and Cold performance degraded

  26. Publication SAE 920164 • Concluded that ethanol has an adverse effect on evaporative permeation emissions from current fuel tanks and hoses

  27. Summary of E-20 Studies • Causes corrosion of metals and resulting impacts on engine components • Distorts elastomers and causes resulting impacts on fuel system components • Causes loss of lubricity due to “cylinder wall wash” • Loosens deposits in existing equipment – leading to plugged fuel filters etc. • Damage to painted parts • Adverse impact on exhaust and evaporative emissions and on engine/equipment performance

  28. General Testing Issues to Meet Waiver Criteria

  29. Waiver Issues and Test Criteria 1. Exhaust emissions 2. Evaporative emissions 3. Materials compatibility • Drivability/Operational Performance and “Tampering” Risk • EPA must determine whether and when new fuels could cause “failures” in each of these categories • Data must be derived from unmodified engines, vehicles, and equipment that are EPA-certified, as applicable • Waiver applicant must evaluate carbureted-engine configurations with their existing air:fuel ratios set for EPA certification fuels

  30. Testing - Product Categories • Since emissions regulations are changing, off-road engines/equipment groups to be tested should include mix of: • Existing, pre-compliant equipment • Existing, EPA compliant equipment • New • In-use • Future, prototypical new equipment designed to meet EPA evaporative and exhaust regulations anticipated before 2015

  31. Testing - Representativeness Via Technology Categories • Need to identify and test “representative” mix of engines/equipment • Must test different “Technology Categories”, based on • Engine combustion cycle (2 Stroke and 4 Stroke) • Fuel delivery / control systems • Exhaust emission controls/strategies • Evaporative emissions controls/strategies • Equipment use profile

  32. Technology Categories - Fuel Delivery Systems • Carburetion • Float type • Diaphragm type • Single vs. multi-circuit • Fuel Injection • Open loop • Closed loop

  33. Technology Categories – Exhaust Emissions Controls / Strategies • Various Engine Designs and Modifications • 2 Cycle vs. 4 Cycle • Side vs. overhead valve configurations • Ignition timing changes • Air/Fuel preparation and delivery systems • Stratification • Compression wave technology • Catalysts • Hybrids (2/4 Strokes)

  34. Illustration of 2005 Exhaust Diversity – EPA Non-Road Small SI Engines[Additional Illustrations at End of Presentation]

  35. Technology Categories – Evaporative Materials • Permeation from • Fuel Tanks made of: • Metal • HDPE • Barrier Treated HDPE (fluorinated, sulfonated) • Selar • Nylons (various grades) • Coextruded (various types) • Other materials • Fuel Hoses made of: • NBR • FKM • Other materials • Venting Emissions from • Uncontrolled venting systems • Carbon Canisters

  36. Testing – Statistically Valid Data • EPA will consider the data’s statistical validity and how well the program represents the product universe • How many different products should be tested? • How many replicate products and repeat measurements? • How will test data quality be controlled? • Which data points provide statistically significant results? Which are outliers? • Which statistical tests should be used? etc. • Statistical expertise helpful in designing the test program and analysis of the results

  37. Testing Evaluations/Criteria

  38. Testing – Pass/Fail Criteria • How will pass/fail criteria be established? • Comparison with EPA standards and procedures • exhaust emissions • evaporative emissions • Criteria need to be developed for: • materials compatibility tests • drivability/operability tests

  39. Testing Exhaust and Evaporative Emissions • Goal – Evaluate E-20’s impacts on compliance with emissions standards: • Criteria pollutants (NOx, HC, CO, PMx) • Test Protocols • EPA exhaust emission test protocols • EPA evaporative emission test protocols • EPA durability/aging provisions • Pass/Fail criteria – compliance with EPA compliance levels • Air toxics • e.g, aldehydes, etc.

  40. Testing Materials Compatibility • Goal – Assess Short and Long Term E-20 compatibility with • Metals • Zinc, brass, cast iron, lead, aluminum, magnesium, nickel, etc. • Non-metallics • NBR, polyurethane, nylons, Viton, Teflon, nitrile, mylar, silicon sealants, felt, etc. • Adhesives used for labels and decals • Test Protocols – Need to be developed for various test types below: • Coupon tests • Engine/equipment soak tests under non-operational conditions • Durability tests under nominal operating conditions • Laboratory (bench) tests • Field tests • Durability tests under off-nominal operating conditions • Pass/Fail Criteria – Need to be developed for tests above.

  41. Testing “Drivability” • Goal - How does E-20 impact normal operation or expected normal operation? Specifically, tests should examine • Cold start ability (in all applicable ambient environments) • Load pickup • Acceleration • Hot restartability • Vapor lock • Maximum power operation • Fuel switching: from E-20 to Baseline fuel and vice versa • Impact on safe equipment operation • Test Protocols – Need to be developed • Pass/Fail Criteria – Need to be developed

  42. Illustrative Example: Handheld Engines

  43. Test Categories

  44. Test Parameters To Be Measured • Startability • Multipositional stability (@idle, @WOT) • Acceleration • Emissions (new and deteriorated) • Exhaust • Evaporative/Permeation (Tanks, Lines) • Power and Torque • Fuel consumption • Plug Seat Temperatures • Exhaust Temperatures • Materials Compatibility Indicators • Crankshaft assembly (Corrosion) • Cylinder (Corrosion) • Carburetor components (Corrosion/Distortion) • Fuel tanks / Fuel lines / Seals (Distortion) • Safety Feature Performance

  45. Fuel Specification Issues

  46. Testing – Fuel Specifications • The exact composition of E20 needs to be defined across all appropriate parameter ranges (e.g., ethanol content) • The exact choices for baseline fuels need to be defined

  47. Additional Technical Slides (future discussion)

  48. 2005 Diversity - Snowmobiles

  49. 2005 Diversity – ATV’s

  50. 2005 Diversity – Off Road MC’s

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