Racing Engine Technology & Ethanol as a Performance Racing Fuel

Racing Engine Technology&

Ethanol as a Performance Racing Fuel

Robert L. Colesworthy

12/3/07 Advanced Engineering & Technology Conference

Racing Engine Technology Speaker, Robert L. Colesworthy

Does rod length really affect engine torque? Are aluminum blocks better than cast iron? Are aluminum heads better than cast iron? Are gear camshaft drives better than chain

or belt drives? Is fuel injection better than carburetion? What makes horsepower? Where to spend your money

800-597-9747 www.iqlearningsystems.com

Does rod length really affect engine torque?


Piston Depth vs Crankshaft Rotation4" Stroke

0.00000

0.50000

1.00000

1.50000

2.00000

2.50000

3.00000

3.50000

4.00000

4.50000

1 7 13

19

25

31

37

43

49

55

61

67

73

79

85

91

97

10

3

10

9

11

5

12

1

12

7

13

3

13

9

14

5

15

1

15

7

16

3

16

9

17

5

18

1

Rotation Angle

Pis

ton

De

pth

6.135 Rod

6.385 Rod

6.535 Rod


Are aluminum blocks better than cast iron?

Positives: Weight Repairablity Heat dissipation

Negatives: Expansion rate differentials Lower strength Cylinder sleeves

Dart “Big M” ferrous block


Are aluminum heads better than cast iron?

Positives: Weight Ease of porting Repairablity

Negatives: Expansion rate differentials Lower strength Heat dissipation

Reher-Morrison “Raptor” BBC Head


Are gear camshaft drives better than chain or belt drives?

Positives: Durability

Negatives: Power loss Noise Time consuming

to change timing

Crank Gear

Idler Gears

Cam Gear


Is fuel injection better than carburetion?

Fuel Injection Advantages: Fuel Mileage Lower Emissions Cold Startup/Driveablity

Carburetor Advantages: More Horsepower (nat. asp.) Lower Cost Easier to Adjust & Service


What Makes Horsepower?

Formula: HP=Torque x RPM’s/5252Increasing Torque: Increase Engine Displacement Increase Cylinder Pressures Reduce Parasitic LossesIncreasing RPM’s: Speed Costs Money! $$$ Component Selection/Matching


Where to Spend Your MoneyBuy: Quality matched components Great cylinder heads Titanium valves Stiff valve springs

Avoid: Titanium Rods Extrusion Hone or “Home Porting”

of heads & manifolds “Bigger is Better” syndrome


Cool New Stuff!

Oval Port`“Raptor” Heads

“Beehive” Valve Springs

Heart-Shaped Combustion Chamber

Ethanol as a Racing Fuel Winning on Ethanol - Why it works

and what is driving racing to go to it Different blends, availability, and how

E85 will fit the future Application specifics, a review of

compatibility of parts, corrosion, etc. How to optimize for effective use of

ethanol as a performance fuel


Winning on Ethanol - What is Driving Racing to Go to It? Environmentally-friendly fuel Favorable political climate Safety Low cost and increasing

availability Power-making potential




-2% -2%-6%

-23%

-17%

-64%

-80%

-60%

-40%

-20%

0%

E10 GV: DMCorn EtOH

E10 GV: WMCorn EtOH

E10 GV: Cell.EtOH

E85 FFV: DMCorn EtOH

E85 FFV: WMCorn EtOH

E85 FFV:Cell. EtOH

“Ethanol Blends Significantly Reduce Greenhouse Gas Emissions” Argonne National Labs.


Michael Wang – Argonne National Laboratory, Aug. 2005

Power Making Fuel Characteristics

1. Octane Rating

2. Burning Rate

3. Latent Heat of Vaporization

4. Energy Value


1. Octane Measures fuel’s resistance to pre-

ignition and detonation, commonly called “knocking”

Three common octane ratings for motor fuels: Research Octane Number (RON) Motor Octane Number (MON) (R+M/2) method


1. Octane MON rating is most useful to racers

because it is measured under high loads and at high RPM’s

High MON rated fuels allow the use of higher compression and advanced spark timing


1. Octane


E85 delivers MON octane ratings equal to, or better than, most gasolines

2. Burning Rate

The speed at which fuel burns and releases its heat energy

There is less time for fuel to burn at high RPM’s, so rapid burning fuel is a must in racing


2. Burning Rate

Peak horsepower and engine efficiency are realized if fuel is almost completely burned by 20 degrees after Top Dead Center (TDC)



Measures a fuel’s ability to cool the intake charge and combustion chamber

Measured in BTU’s per gallon Higher rated fuels remove heat better



E85 promotes better cooling: Making the intake charge more dense,

thereby packing more energy (per volume) into the engine

Helping to control detonation Reducing temperatures in the engine

and oiling system components


4. Energy Value

The total heat energy contained in a given amount of fuel – BTUs/lb.

Horsepower generation depends on “Net Energy Value” - Equal to the energy value multiplied by the amount of fuel that can be burned


4. Energy Value

A fuel’s “stoichiometric” defines its ideal air/fuel ratio

Lower stoichiometric fuels allow more fuel to be burned which, in turn, increases the Net Energy Value of the fuel


4. Energy Value


The lower stoichiometric of E85 provides the fuel with a higher Net Energy Value than most gasolines

Fuel Comparison Chart


Fuel Octane(MON)

Burning Rate(ms@stoic.)

Latent Heat(BTU/gal)

Energy Value

BTU/lbs

Power Stoic.

Net Energy Value

(MJ/kg)

Pure Ethanol 102 .39 396 12,800 6.5/1 3.00

Pure Methanol 103 .43 503 9,750 5/1 3.08

Pump Gasoline 80-90 .34

150(avg.)

18,700-19,100

12.5/1 2.92

Racing Gasoline 99 N/A

160(est.)

18,500(est.)

12.5/1 2.90

E30 87-94 .36 337 17,178 10.7/1 2.94

E85 99-100 .38 359 14,021 7.4/1 2.99

Fuel Rankings


Fuel Octane(MON)

Burning Rate(ms@stoic.)

Latent Heat(BTU/gal)

Net Energy Value

(MJ/kg)

Pure Ethanol 2 5 2 2

Pure Methanol 1 6 1 1

Pump Gasoline 6 2 6 5

Racing Gasoline 4 1 5 6

E30 5 3 4 4

E85 3 4 3 3


Gasoline vs Ethanol STP Trq

600.0

620.0

640.0

660.0

680.0

700.0

720.0

740.0

760.0

4500 5000 5500 6000 6500 7000 7500

RPM

ST

P T

rq

Gasoline Ethanol

Dave Slatten – 540 CID Drag Race Engine Dyno Results


Gasoline vs Ethanol STP Hp

550.0

600.0

650.0

700.0

750.0

800.0

850.0

900.0

950.0

1000.0

4500 5000 5500 6000 6500 7000 7500

RPM

ST

P H

p

Gasoline Ethanol

Dave Slatten – 540 CID Drag Race Engine Dyno Results

Different Blends, Availability, and How E85 will Fit the Future

E10 E85 E100 (E-98)


Application Specifics, a Review of Compatibility of Parts, Corrosion, etc. E10:1. Passenger car-compliant for decades. A

simple replacement fuel

2. Reduced emissions/oxygenate

3. MTBE replacement

4. Promotes clean fuel injectors

5. Octane booster


E85:1. Requires vehicle modifications

2. “Flex Fuel” vehicle (FFV) – identified by a gas cap insignia

3. Ethanol-compatible fuel tank, pump, lines, etc.

4. Modified air/fuel ratio: enriched air/fuel ratio (approx. 25-28%) or specialized sensors and computer programming

5. Additional changes and race car handling considerations


E100 (E98):1. Contains 98% ethanol and 2% denaturing

chemical

2. Race-only fuel (IRL series)

3. Extremely hygroscopic

4. May require “top oil” and post-race “pickling” procedures.


How to Optimize for Effective Use of Ethanol as a Performance Fuel

Know Your Fuel – Determine Actual Ethanol Content

Fuel System Modifications Engine Modifications Handling and Storage Racing E85 Fuel


Know Your Fuel – Determine Actual Ethanol ContentThe actual ethanol content of E85 varies widely by the time of year and pump-to-pump. For our easy Four-Step Titration Method, you will need:1. 100 ml. graduated cylinder & stopper

2. Sample of test E85 fuel

3. Distilled water


Step 1:

Fill the cylinder to the 50 ml. mark with the test fuel.


10

20

30

40

50

60

70

80

90

100

Six-Step Water Titration Method,for E85

Step 2:

Add 48 ml. of distilled water.


10

20

30

40

50

60

70

80

90

100


Step 3:Put stopper in top of cylinder. Shake vigorously to mix the water and fuel. Allow it to stand.


10

20

30

40

50

60

70

80

90

100



10

20

30

40

50

60

70

80

90

100


Step 4:Pull stopper out slightly to allow pressure buildup to escape. Reseal and allow to stand for 15 min.


10

20

30

40

50

60

70

80

90

100

Water/Ethanol

Gasoline

Volume B = 86 mlVolume A = 93 ml


Step 5:Write down the overall Volume A and the separation line Volume B.


Step 6:Apply this formula to determine gasoline content: Percent Gasoline = 2.1 + 1.94 (Volume A – Volume B)2.1 + 1.94 (93-86)2.1 + 1.94 (7)2.1 + 13.58Percent Gasoline = 15.68%To find the ethanol content, subtract the percentage

gasoline content (15.68) from 100:

100 – 15.68 = 84.32% or approx. E85

02/20/09 Advanced Engineering & Technology Conference, 2007

43

Step 4:

Read the level of the ethanol/water at the bottom. Subtract 10 ml. (the amount of added water). This is your true ethanol percentage.


10

20

30

40

50

60

70

80

90

100

110

88 ml.

The ethanol/water level reads 88 ml. Subtract 10 ml. for the true ethanol content of 78%, or E78.

Four-Step Water Titration Method

Step 3:Put stopper in top of cylinder. Shake vigorously to mix the water and fuel. Allow it to stand. The ethanol/water mix will fall to the bottom of the cylinder.


10

20

30

40

50

60

70

80

90

100

110


Step 4:

Read the level of the ethanol/water at the bottom. Subtract 10 ml. (the amount of added water). This is your true ethanol percentage.


10

20

30

40

50

60

70

80

90

100

110

88 ml.

The ethanol/water level reads 88 ml. Subtract 10 ml. for the true ethanol content of 78%, or E78.


Fuel System ModificationsTo make your race vehicle E85 compatible, you must inspect the following and make any needed changes:1. Correct fuel tank type & size2. Vented gas cap3. Compatible fuel pump – correct type

and capacity4. Compatible carburetor/injectors


Engine ModificationsProtect your engine and take full advantage of the power-making capability of E85 fuel:1. Utilize ethanol-compatible motor oil

2. Increase engine static compression ratio

3. Increase engine dynamic compression

4. Adjust air/fuel ratio

5. Adjust spark timing

6. Experiment with spark timing correction


Handling & StorageEthanol blends are hygroscopic. Once water has been introduced, corrosion will develop. Be sure to:

1. Store the fuel only in approved containers and keep it tightly capped at all times.

2. All alcohols are very drying to skin. Avoid contact with skin and eyes.

3. Follow all other normal fuel handling and storage recommendations.

4. Inspect your motor oil for “milking” and change frequently.

5. After racing, “pickle” the engine and vehicle. Drain all fuel from lines and use an appropriate anti-corrosive agent.


Racing with E85Not only does E85 vary in ethanol content by the time of year and from pump to pump, but the 15% gasoline portion also affects engine performance and fuel system requirements.

While pump E85 has a nominal octane rating of 105 (R+M/2 method), we strongly recommend that you find a supplier of “E85 Racing Fuel”. The fuel should have a consistent and high (85%) ethanol content and the gasoline should also be a high grade racing fuel. This will protect your engine from varying octane levels and air/fuel mixture requirements.


Contact Information:

12/3/07

Robert L. ColesworthyIQ Learning Systems, Inc.1833 Scherer ParkwaySaint Charles, MO 63303

800-597-9747www.iqlearningsystems.com

Documents

Racing Engine Technology & Ethanol as a Performance Racing Fuel