Biodiesel fleet case studies

Biodiesel Performance:Some Examples of Fleet use

&Field Durability Studies

National Biodiesel Board Diesel Technician Training Program

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Today’s Topics

B20 Fleet Evaluation Team NREL/NBB B20 Bus Fleet Evaluation USPS Biodiesel B20 Cummins 1000 hr. Durability Test Health Effects in Keene, NH North Carolina Dept. of

Transportation

Many detailed B20 Studies have been performed and published

• US Postal Service, St. Louis Bus System

• Denver Regional Transit Bus System• Las Vegas Valley Water District• Clark County, NV School District• Connecticut DOT; Keene, NH; NC DOT;

Cedar Rapids, IA Buses, etc. etc. etc.

Biodiesel and Engine Manufacturers• After the first passage of ASTM D6751

in 2001, even though engine manufacturers voted positive at ASTM most were not yet willing to put their name behind B20

• National Biodiesel Board set forth on intensive effort to work with OEM’s to address any issues and concerns

• B20 Fleet Evaluation Team Formed

B20 Fleet Evaluation Team• Develop fact based informed position on B20• Most major diesel engine and fuel injection

companies participated in this process• B20 Failure Mode and Effects Analysis (FMEA)

• Detailed identification of everything that can go wrong when using B20

• Rank: Severity, Occurrence, Detection modes• Develop RIN: Risk Identification Number• Develop plan to address high RIN areas

B20 Fleet Evaluation Members

• Bosch• Case New Holland• Caterpillar• Cummins• DaimlerChrysler• Delphi Diesel Systems• Department of

Defense• Engine Manufacturers

Association• Ford Motor Co• General Motors

• International• John Deere• National Biodiesel Board• National Renewable

Energy Lab• Parker - Racor• Siemens Diesel Systems• Stanadyne Corp• Volkswagen AG• Volvo Truck• Fleetguard

B20 FMEA Results• Most potential ‘problems’ are eliminated

if the B100 meets D6751 prior to blending

• More info is needed on after-treatment• More info is needed on stability/shelf life• More info is needed from field (materials

compatibility, un-anticipated issues)• Provide user advise to help trouble-free

use

• Biodiesel is the pure, or 100 percent, biodiesel fuel. It is referred to as B100 or “neat” biodiesel.

• A biodiesel blend is pure biodiesel blended with petrodiesel. Biodiesel blends are referred to as BXX. The XX indicates the amount of biodiesel in the blend (i.e., a B20 blend is 20 percent by volume biodiesel and 80 percent by volume petrodiesel ).

• Ensure the biodiesel meets the ASTM specification for pure biodiesel (ASTM D 6751) before blending with petrodiesel. Purchase biodiesel and biodiesel blends only from companies that have been registered under the BQ-9000 fuel quality program.

B20 FET - Technical Guidance and Recommendations

• Ensure the B20 blend meets properties for ASTM D 975, Standard Specification for Diesel Fuel Oils or the ASTM specification for B20 once it is approved.

• Ensure your B20 supplier provides a homogenous product. Avoid long term storage of B20 to prevent degradation. Biodiesel should be used within six months.

• Prior to transitioning to B20, it is recommended that tanks be cleaned and free from sediment and water. Check for water and drain regularly if needed. Monitor for microbial growth and treat with biocides as recommended by the biocide manufacturer. See the NREL Biodiesel Storage and Handling Guidelines for further information.


• Fuel filters on the vehicles and in the delivery system may need to be changed more frequently upon initial B20 use. Biodiesel and biodiesel blends have excellent cleaning properties. The use of B20 can dissolve sediments in the fuel system and result in the need to change filters more frequently when first using biodiesel until the whole system has been cleaned of the deposits left by the petrodiesel.

• Be aware of B20’s cold weather properties and take appropriate precautions. When operating in winter climates, use winter blended diesel fuel. If B20 is to be used in winter months, make sure the B20 cloud point is adequate for the geographical region and time of year the fuel will be used.


• Perform regularly scheduled maintenance as dictated by the engine operation and maintenance manual. If using B20 in seasonal operations where fuel is not used within 6 months, consider storage enhancing additives or flushing with diesel fuel prior to storage.

• These recommendations on use of B20 are preliminary and are not provided to extend or supplant warranty limitation provided by an individual engine or equipment supplier. Use of B20 blends is solely at the discretion and risk of the customer and any harm effect caused by the use of B20 are not the responsibility of the engine or equipment maker.


Department of Energy (DOE)B100 & BlendsMaterial CompatibilityEngine PerformanceDiesel and Biodiesel Emissions

Handling & Usage

Fleet Management Experiences

Cold weather can cloud and even gel any diesel fuel, including biodiesel.

Users of a B20 with #2 diesel will usually experience an increase of the cold flow properties (cold filter plugging point, cloud point, pour point) approximately 2 to 10° Fahrenheit.

Similar precautions employed for petroleum diesel are needed for fueling with 20 percent blends.

• blending with #1 diesel (kerosene)• using fuel heaters and parking indoors• and using a cold-flow improvement additive

User B20 Results Summary Similar fuel economy Similar maintenance costs Some initial filter clogging—’cleaning the

system’ Some cold weather filter clogging

Usually due to in-adequate blending or handling, ‘normal diesel issues, poor quality biodiesel or imposter biodiesel

Following established guidelines give trouble free use Positive driver and user experience—smell,

smoke

1000 Hour Durability B20 The objective was to operate the engine for

1000 hr using B20 biodiesel fuel, and do a comparative analysis with engines that have operated under the same type of conditions using #2D diesel fuel.

hr

0 25 50 125 1000

Accelerated, high-load durability cycle

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Test Engine

q Cummins prototype 2007 ISLq Six cylinder 8.9 literq Rated power of 330 BHPq Peak torque of 1150 ft•lb at 1300 rpmq Diesel Oxidation Catalyst (DOC)q Diesel Particulate Filter (DPF)q Post injection (in-cylinder) for active regenerationq Variable geometry turbochargerq Exhaust gas recirculation (EGR) with coolerq Cummins fuel injection system

Test Cyclesq Durability Testing

AcceleratedHigh-loadTransient cycle Varying load and speedCycle repeated for 1000 hr

q Emissions TestingFederal Test Procedure (FTP)One cold start transient FTP

testThree hot start transient FTP

testOne SET Ramped Modal Cycle

High IdleLow Idle

Peak Torque

Peak Power

>70% of durability cycle at full load

Durability & Emission Resultsq Approximately 17,000 gallons of B20 biodiesel fuel was used

during the durability test.q Test went well and was successful. There were no biodiesel

related failures during the test, and no reported significant changes in performance of the engine.

q Engine performance was essentially the same when tested at 125 & 1000 hr of accumulated durability operation.

q Emission results indicate that THC, CO, and PM levels were not significantly different between the B20 and ULSD. The emission-grade B20 test resulted in ≈6% higher NOx

(within expected range)q Fuel consumption was observed to be ≈3% higher than the

2007 certified ULSD test (within expected range).

Top of cylinder head No sludge deposits

Bottom of cylinder head Deposits comparable to #2D

Intake Valves Exhaust Valves

Results are typical for this type of test with #2D diesel fuel

Overhead Components

Power Transfer ComponentsComponent CommentsCranckshaft Gear Meets rebuild

specCam Gear Meets rebuild

specCam Bushing Meets rebuild

specFuel Pump Gear Meets rebuild

specCranckshaft Meets rebuild

specLower & Upper Bearings

Normal wear

Connecting Rod Meets rebuild spec

Connecting Rod Bushing

Meets rebuild spec

During teardown, the crankshaft was found to be in very good condition, and results were comparable to #2D diesel fuel test.

Power Cylinder Components

Component

Comments

Piston Normal light wear and deposits.

Cylinder Liners

Normal light wear.

Top rings Normal uniform face wear. Top and bottom side look typical.

Middle rings Normal face wear. Top and bottom sides OK, and light carboning.

Oil rings Looked good. Very little wear.

Crosshatch visible in all six cylinders.

Results comparable to #2D diesel fuel test.

Ring GroovesAnti-Thrust Side

Cylinder 1

Top PistonPiston Bowl Front

Cylinder 1

Minor staining

Cooling and Lube Components

Component CommentsOil pump No issuesOil cooler head No issuesOil cooler cover No issuesOil pressure regulator/bypass

No issues

Piston cooling nozzles

No problems due to B20.

Oil Pan NormalOil suction tube Gasket showed

good imprint of seal

Turbo coolant/oil lines

Normal

There were no failures found on the cooling and lube components. The wear and deposits found on the parts were normal and consistent with findings found on parts that ran with #2 diesel fuel in similar tests.

Bottom (Oil) Piston Rings

Cylinder 1 Top

Cylinder 6 Bottom

Air Handling ComponentsComponent Comments

Exhaust Manifold No issues.EGR Cooler No cracks, light

coating of soot on inlet and outlet tubes. No soot in inlet diffuser. Findings good overall.

EGR Valve Looked good. Normal soot accumulation.

EGR gaskets, hoses, tubes, shield, mounting plate, crossover

No issues found due to running with B20.

Carbon deposit layer was generated on the passage and inside parts of the EGR valve, but thickness was very thin and condition was dry which is normal for this durability test.

Aftertreatment ComponentsComponent

Comments

Diesel Oxidation Catalyst (DOC)

Looked good. No face plugging.Blockages found appeared like debris and substrate material. Debris was analyzed under Electron Dispersive Spectroscopy (EDS), and all debris found is expected in a typical DOC after 1000 hr of operation, whether fueled with ULSD or biodiesel.

Diesel Particulate Filter (DPF)

Inlet face showed signs of ash build up, but similar to diesel fuel for this type of test. Outlet looked good with no signs of soot.No failure found.

Inlet and outlet section

Looked good.

Gaskets Looked good.

Fuel System PicturesStage 1 Plunger Needle

No marks on needle surface or the edge.

Plunger Needle – Top View

Some slight staining.

Stage 2 Plunger Needle has some wear, but normal for this type of aggressive test.

Plunger Orifice not clogged with oil sludge or deposits

Fuel System Components

Rail and fuel lines

Rail – No abnormal wear. End Fitting – No unusual wear. HP Fuel Lines – No visible structural deterioration or cracks observed.

Mechanical Dump Valve (MDV)

No unusual wear, deterioration or sludge buildup observed on plungers, plunger seats or orifice.1) Stage One Plunger – No wear visible on the needle surface or the edge. Some slight staining seen on plunger base.2) Stage Two Plunger – Some wear, but normal. Plunger orifice not clogged with oil sludge or deposits.

Injectors Injector performance test and photos indicate that the injectors were consistent with injectors that ran with #2D diesel fuel.

Soft Lines No visible damage to any section of the internal wall of the used fuel tubes indicating that the tubing liner material is resistant to the B20 temperatures and pressures during the engine performance test.

Overall There were no signs of severe or aggressive corrosion pitting damage on any of the surfaces.

Summary A Cummins 2007 prototype 8.9 liter ISL diesel engine equipped with

DOC, DPF, VGT, and EGR with cooler was operated successfully at SwRI using a high-load accelerated durability cycle for 1000 hr with a B20 blend of soy-based biodiesel and ULSD.

During the durability testing, no biodiesel related failures occurred.

Engine performance was essentially the same when tested at 125 and 1000 hr of accumulated durability operation. Emissions measurements indicate the HC, CO, and PM were not significantly different between the B20 and ULSD tests, and NOx increased with B20 fuel. Fuel consumption also increased with B20 fuel.

A thorough engine teardown evaluation of the overhead, power transfer, cylinder, cooling, lube, air handling, gaskets, aftertreatment, and fuel system parts was performed.

There were no failures found on the engine components that were directly attributable to running biodiesel B20.

The wear and deposits found were normal and consistent with findings from parts that ran with #2 diesel fuel in similar tests.

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NCDOT emissions studiesNCDOT emissions studies

• A characterization study by NCDOT and NCSU using on-A characterization study by NCDOT and NCSU using on-board diagnostic equipment on 8 dump trucks found an board diagnostic equipment on 8 dump trucks found an average decrease in NO of about 10% with B20 versus average decrease in NO of about 10% with B20 versus petroleum diesel.petroleum diesel.

http://www.ncdot.org/doh/preconstruct/tpb/research/download/http://www.ncdot.org/doh/preconstruct/tpb/research/download/2004-18FinalReport.pdf2004-18FinalReport.pdf• A new DOT study is being conducted by NCSU’s Dr Chris A new DOT study is being conducted by NCSU’s Dr Chris

Frey to analyze emissions from construction equipment Frey to analyze emissions from construction equipment Study will utilize the Montana Portable On-Board Real Time Study will utilize the Montana Portable On-Board Real Time Emissions Recording System” manufactured by Clean Air Emissions Recording System” manufactured by Clean Air Technologies International, Inc. and evaluate B20 and low Technologies International, Inc. and evaluate B20 and low sulfer diesel emission on graders, loaders and back hoes. sulfer diesel emission on graders, loaders and back hoes. Final results expected July 2007Final results expected July 2007

http://www.ncdot.org/doh/preconstruct/tpb/research/download/2004-18FinalReport.pdf

http://www.ncdot.org/doh/preconstruct/tpb/research/download/2004-18FinalReport.pdf

Who Uses Biodiesel in NC?Who Uses Biodiesel in NC? State AgenciesState Agencies - NC Department of Transportation (DOT), - NC Department of Transportation (DOT),

the NC Zoothe NC Zoo MilitaryMilitary-Camp Lejuene Marine Corps Base-Camp Lejuene Marine Corps Base

AirportAirport -RDU International Airport -RDU International Airport Private BusinessPrivate Business - moving and construction companies - moving and construction companies

HospitalHospital - Pitt County Memorial Hospital - Pitt County Memorial Hospital Public School BussesPublic School Busses - Durham & Gaston County Schools - Durham & Gaston County Schools

Universities - UNC-CH, Duke, and NC State Universities - UNC-CH, Duke, and NC State Local governmentsLocal governments – over a dozen municipalities – over a dozen municipalities

Service stationsService stations 16 public stations selling B10- 16 public stations selling B10-B99 blends w 3 more expected to open in coming B99 blends w 3 more expected to open in coming

weeks!weeks!

B20 Fleet Resources

www.biodiesel.org• Technical Library• Biodiesel Bulletin• Educational Videos Available• Informational Resources• Technical Resources• On-line Database & Spec Sheets

• B20 Fleet Guide: http://www.biodiesel.org/buyingbiodiesel/

Documents

Biodiesel fleet case studies