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Utilization of Waterless Coolantto Improve Fuel Economy

and Increase Engine Durability

Mark J StoneEvans Cooling Systems, Inc.

Federation of New York Solid WasteAssociations Conference & Trade Show

May 18, 2014

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Topics Covered

1. Why Waterless Coolants2. Properties Comparison3. Advantages of Waterless Coolant4. Applications of the Technology5. Meeting Industry Standards

Disclaimer: Specific properties and test results presented are based onwaterless coolant technologies developed by Evans Cooling Systems, Inc.

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Why Waterless Coolant?

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Water has been the choice for cooling engines for decadesbecause:

Positives of Water In a Coolant

• Water is cheap

• Water is available

• Water is non-toxic

• Water has superior thermal conductivity- In its liquid state

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Negatives of Water In a Coolant

• Water supports electrolysis and iscorrosive Electrical Conductivity (uS/cm)

• 50/50 Coolant/Water 3000• Waterless Coolant 700

• Water has a low boiling point Little margin between coolant operating temperature under

load and boiling point of water at the system pressure.

Failure temperature of the system is the boiling point ofwater – where free vapor is formed

Water retains just 4% of it’s thermal conductivity when itchanges to vapor

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What is Waterless Coolant

• Components: (One example)

Proprietary base blend, additives, and No water

• Properties: Water Content, wt%: <0.5 Specific Gravity @ 20/20C: 1.12 Pour Point, °C/°F: <-40 Viscosity, Pa·s @ - 40°C/- 40°F: 2.0 Boiling point, °C/°F: 191/375 Thermal Conductivity, W/m·K 0.27

@ 100°C/212°F

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Properties Comparison

Waterless Coolantvs

Ethylene Glycol/Water

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Boiling Point Comparison

50/50 EG/Water – 1 atmosphere /15 psi gauge

Water – 1 atmosphere / 15 psi gauge

Waterless Coolant – No pressure

Boiling point of water is the failure temperatureof the system, at the system pressure

Elevation (Meters)

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Boiling Point Safety Margin

Waterless Coolant creates a large separation between its boilingpoint and the operating temperature of the system

• An engine operating temperature of 230°F/110°C is much colderthan the boiling point of Waterless Coolant (375°F/191°C)

• Cooling system continues to function under load and aftershutdown:

Coolant continues safely absorbing heat from the metal No vapor generation at high temperature/low pressure areas No after-boil with abrupt shutdown Can restart the engine at any time

The boiling point of water is no longer the limitation

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Thermal Conductivity

Waterless Coolant – Liquid

EG/Water:50/50 - Vapor

Water: 0.68EG/Water:50/50 – Liquid

0.43

0.27

0.024

Liquid and Vapor Phases of50/50 EG/Water vs. Waterless Coolants

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Heat Transfer Failure of Water Vapor

With Waterless Coolant, Metal Temperatures Are Controlled

A = Waterless Coolant B = Water-Based Coolant

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Vapor Pressure With Waterless Coolant, System is Not Pressurized

Only 1.4 g of water are needed to produceenough vapor to open the pressure cap

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Advantages

of Waterless Coolant

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Benefits of Waterless Coolant Technology

• Enhances Engine Efficiency Enables Fuel Savings Strategies Helps Reduce Emissions

• Improves Engine Durability andReduces Maintenance Costs Reduces component failures Minimizes coolant replacement

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Enables Fuel Savings Strategies

Large boiling point safety margin enables system to safely run at ahigher operating temperature while controlling metal temperatures

Two strategies to capitalize on this:

1.Reduce fan-on time by raising fan-on temperature Fans on heavy duty diesel engines draw up to 70 HP Minimizing fan operation yields significant fuel savings 40-60+% fan-on time reduction in some tests

2.Combine strategy 1 with a higher temperaturethermostat for better thermal efficiency

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Fuel Economy Tests - Waterless CoolantCompany/Test Vehicle Method Improvement Notes

Veolia Waste Collection Truck – 2009Mack AI 350 ASET 12 L 350 HP

Road Test- 110 C Fan-On 3.5% - Fuel Economy

- Oil Analysis

Veolia Waste Collection Truck – 2011Mack MP7 11 L 330 HP

Road Test- 110 C Fan-On 4.4 – 8.5% - Fuel Economy

- Oil Analysis

USA Hauling Waste Collection TruckMack E7 350 HP

Road Test- 110 C Fan-On 5.5 – 8.6% - Fuel Economy

- Oil Analysis

NYC Waste Collection Truck- 2009Mack MP7 11 L 330 HP

Chassis Dyno- 110 C Fan-On 4.4 - 6.1% - Fuel Economy

- Emissions

UPS Delivery TruckCummins ISX

Road Test- 110 C Fan-On- 96 C T-Stat

>3%- Fuel Economy- Used Telematics

Perdue Farms Fleet TruckInternational Max Force 13 L

Road Test-110 C Fan-On 5.5% - Fuel Economy

Murphy Brown Fleet TruckMack MP8 13 L 390 HP

Road Test- On-Road Emiss.- 110 C Fan-On

4.0%- Fuel Economy- Emissions by SEMTECH-DS

mobile analyzer

Program for Advanced VehicleEvaluation (PAVE)Detroit Diesel 14 L 435 HP Series 60

Road Test102 C T-Stat >3.0%

Run at Auburn University- Fuel Economy by

SAE/J1321 Type II

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Tests in NYC Department of Sanitation Truck

Body Type RefuseCollection

Weight (ton) 25.8(net18.5)

No. of Axles 3

Engine Size 10.8 L

Horsepower 330Fuel Type Diesel

After Treatment DPF

2009 MY Mack MP7

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Tests in NYC Department of Sanitation Truck

New York City Garbage Truck Cycle Central Business District

Test Cycles

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Tests in NYC Department of Sanitation Truck

Test Results1 ─ 230F/110C Fan-OnParameter 50/50 EG/Water Waterless Change

Fuel Economy (mpg) 1.28 1.34 4.7%

BSFC (gal/hp-hr) 0.055 0.050 -9.1%

Coolant Temperature (℃)- Engine Inlet 91.0 98.7 7.7℃Coolant Temperature (℃)- Engine Outlet 95.5 103.9 8.4℃Engine Oil Temperature (℃) 83.9 85.9 2.0℃CO2 (g/hp-hr) 0.560 0.511 -8.8%

PM (g/hp-hr) 0.0023 0.0018 -21.7%

NOx (g/hp-hr) 2.29 2.53 10.5%1 NYCGTC Test Cycle

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Improved Durability/Reduced Maintenance Costs

• Lower potential for corrosion and electrolysis• Protection against water pump cavitation and cavitation erosion• Minimal wet sleeve cylinder liner cavitation erosion• Significantly reduced potential for EGR cooler failures• Less stress on hoses and gaskets• Minimal coolant loss/makeup

Water-based: New Trucks – 5 gal/yrOlder Trucks – 12 gal/yr

• Non-SCA formula avoids potential foradditive deposits or plugged filters

Excessive Additive Buildup

No water + higher boiling point + low system pressure translatesinto:

WaterlessCoolant

Poor-PerformingWater-Based Coolant

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Cylinder Liner Protection

• John Deere Engine Cavitation Test is a real-world predictor ofcoolant protection to wet sleeve liners 250 Hours Speed/Load Cycling

• Waterless Coolant tested bySouthwest Research Institute

Results were 70% better thanthe best water-based coolant tested Pass = ≤ 200 pits Best 50/50 Glycol/Water = 70 pits Waterless Coolant = 21 pits

ASTM D7583 Engine Cavitation Test

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EGR Cooler Failures

• Significant Issue in the Industry E.g., Replacement Every 2 Years @ $2000 – 3000 each

• Coolers see gas inlet temperature of 1100–1200+F (593-649C)

• Heat load: Must Drop >700 degrees in ~2 feet

• More Severe With Natural Gas

Gas is 180F (100C) hotter

Causes 18% higher stress Failures can happen 2x

faster than with diesel

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EGR Cooler Failures

• Failure mode is tube crackingdue to Thermal cycling/stress Vibration Corrosive condensate (gas side)

• Thermal stress likely exacerbatedby vapor film on coolant side Analogous to cylinder head

Fatigue Break Points

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Applicationsof the Technology

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Technology Applications - Land, Air, Marine

• Validated in many applications worldwide:

Cars, aircraft, generators, wind turbines,mining, off-road, and heavy duty vehicles

• Most installations answer challenging enginecooling problems not solved by conventionalcoolants

• Waterless Coolant technology offers ability todrive operating efficiency and durability

A two-year fuel economy study with Veolia Environmental Servicesshowed an improvement with Evans Waterless Coolant of more than 5%.

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Veolia Fuel Savings

• Frequently operate at/near rated capacity while producing power from landfillmethane and delivering it to the power grid.o Designed to operate at full load for extended periods without interruption.

• When shutdown is needed, engine should be operated at reduced load,allowing the engine to cool off.

• Reality is often operators don’t get a chance to run a cool-down cycle beforethe engine abruptly shuts down.

• When this happens, water-based coolant cannot absorb residual heat from thecylinder heads of the engine.

• Violent after-boil / expulsion of coolant from the heads causes stress, andsometimes cracks the heads.

• Repeated abrupt shutdowns cause build-up of baked-on coolant additives andcarbonized glycol in cylinder head coolant passages.o Must remove residues to prevent formation of an insulating layer between

the cylinder head wall and the coolant.

Downtime was very costly to Ameresco!27

Problems with Ameresco Landfill Generators

Waterless Coolant is Never Near its Boiling Point

• Waterless coolant is operated at conventional or slightlyelevated temperatures, but nowhere near its boiling pointof 375⁰F.

• Waterless Coolant prevents after-boil, regardless ofabrupt shut-downs, by having the capacity to absorbresidual cylinder head heat without boiling, making vapor,or displacing liquid coolant from the coolant jackets.

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Solution - Waterless Coolant

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Waterless Coolants Allows Landfill Methane GasUnits to Run Without Interruption

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Other Technology Applications

Prevents Overheating Of RotaxEngines In Predator UAV

Made Generators In Iraq Reliable At140oF On The Tarmac

Helped Increase Fuel EconomyIn Prototype Bullet Truck

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MeetingIndustry Standards

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New Technology, New Standards

• Waterless Coolant meets many ASTM standardsdeveloped for water-based coolants.

• Some standards are not relevant to waterless coolantsbecause they require the addition of water.

• New ASTM sub-committee (D15.22) established todevelop new standards and specifications appropriate forwaterless engine coolants Standards currently being developed and balloted

• New task group formed within TMC1 to develop aRecommended Practice (RP) for waterless coolants

1 Technology & Maintenance Council of the American Trucking Association

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Thank you!