BIO3.1 Biodiesel Fleet and Case Studies

Biodiesel Technical Training Course

BIO3.1 Fleet Studies on Biodiesel

Presented by the National Biodiesel

Board

National Biodiesel Board

• The National Biodiesel Board (NBB) is the trade association for the U.S. Biodiesel Industry

• Receives funding from 3 sources:– Soybean Check-off program (i.e. farmers)– Government Grants and programs– Biodiesel Producer contributions

• Technical, Regulatory, Marketing and Lobbying• Over $100MM over last 15 years

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Learning Objectives

Provide access to industry experts for more detailed questions and answers about biodiesel

Introduce the National Biodiesel Board’s Diesel Technician Training program and the program resources to the audience

Provide information regarding fleets using biodiesel and biodiesel blends across the US

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Learning Outcomes

• Be able to identify which public and private fleets use biodiesel and why

• Be able to explain the key changes made to a fleet preventative maintenance program when switching to biodiesel.

• Be able to properly diagnose and make recommendations regarding biodiesel use and vehicle maintenance

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B20 Fleet Evaluation TeamNREL/NBB B20 Bus Fleet EvaluationUSPS BiodieselB20 Cummins 1000 hr. Durability TestHealth Effects in Keene, NHNorth Carolina Dept. of Transportation

Today’s Fleet examples

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 & Blends•Material Compatibility•Engine Performance•Diesel 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.

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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 Cycles

q Durability TestingAcceleratedHigh-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 Results

q 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 Components

Component CommentsCranckshaft Gear Meets rebuild spec

Cam Gear Meets rebuild spec

Cam Bushing Meets rebuild spec

Fuel Pump Gear Meets rebuild spec

Cranckshaft Meets rebuild spec

Lower & 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 ComponentsComponent 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 Comments

Oil pump No issues

Oil cooler head No issues

Oil cooler cover No issues

Oil pressure regulator/bypass

No issues

Piston cooling nozzles

No problems due to B20.

Oil Pan Normal

Oil 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 Components

Component 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 Components

Component 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 Pictures

Stage 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 studies

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

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

• A new DOT study is being conducted by NCSU’s Dr Chris Frey to analyze emissions from construction equipment Study will utilize the Montana Portable On-Board Real Time Emissions Recording System” manufactured by Clean Air Technologies International, Inc. and evaluate B20 and low sulfer diesel emission on graders, loaders and back hoes. Final results expected July 2007

Fleet Use of Biodiesel

• Some of the many major truck fleets using biodiesel blends include:

• Double D Express• JB Hunt• Sysco Corporation• U.S. Food Service• U.S. Postal Service• Volkswagen Jetta TDI Cup Transport Team

• Visit http://www.biotrucker.org/testimonials/ for more input from biodiesel users

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B20 vs. Diesel: In the shop

• With in-spec B20 and lower, the issues you can expect to see in your shop are the same as you will see with petrodiesel

• Except:– Expect to see less lubricity related issues– Expect to see less problems with after-treatment– Filter related issues may be related to cleaning effect upon

first use, or are likely normal diesel issues or out of spec or imposter biodiesel

– Less black smoke from exhaust!

Biodiesel Resources

www.biodiesel.org•Biodiesel Training Toolkit

•News Releases & Information Resources

•Technical Library, Spec Sheets & Videos

•OEM Warranty Positions on Biodiesel

• U.S. Diesel Vehicle List

www.BQ-9000.org •Listing of BQ-9000 Certified Companies

www.biotrucker.com•Listing of BioTrucker retail sites

www.biodieselautomotive.org•Dedicated to information exchange for biodiesel & diesel technicians

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Thank You!Questions…?

Rachel BurtonOEM Diesel Technician Training [email protected]: 919-444-3495

Call NBB at 1-800-841-5849Visit www.biodiesel.org

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Technology

BIO3.1 Biodiesel Fleet and Case Studies