Racing Engine Technology

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Racing Engine Technology Ethanol as a
Performance Racing Fuel
Robert L. Colesworthy
Advanced Engineering Technology Conference
12/3/07
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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

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Does rod length really affect engine torque?
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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
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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
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Are gear camshaft drives better than chain or
belt drives?

• Positives
• Durability
• Negatives
• Power loss
• Noise
• Time consumingto change timing

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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

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What Makes Horsepower?

• Formula
• HPTorque x RPMs/5252
• Increasing Torque
• Increase Engine Displacement
• Increase Cylinder Pressures
• Reduce Parasitic Losses
• Increasing RPMs
• Speed Costs Money!
• Component Selection/Matching

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Where to Spend Your Money

• Buy
• Quality matched components
• Great cylinder heads
• Titanium valves
• Stiff valve springs
• Avoid
• Titanium Rods
• Extrusion Hone or Home Portingof heads
  manifolds
• Bigger is Better syndrome

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Cool New Stuff!
Beehive Valve Springs
Oval PortRaptor Heads
Heart-Shaped Combustion Chamber
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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

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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

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Ethanol Blends Significantly Reduce Greenhouse
Gas Emissions Argonne National Labs.
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Michael Wang Argonne National Laboratory, Aug.
2005
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Power Making Fuel Characteristics

• Octane Rating
• Burning Rate
• Latent Heat of Vaporization
• Energy Value

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1. Octane

• Measures fuels resistance to pre-ignition and
  detonation, commonly called knocking
• Three common octane ratings for motor fuels
• Research Octane Number (RON)
• Motor Octane Number (MON)
• (RM/2) method

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1. Octane

• MON rating is most useful to racers because it is
  measured under high loads and at high RPMs
• High MON rated fuels allow the use of higher
  compression and advanced spark timing

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1. Octane

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

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2. Burning Rate

• The speed at which fuel burns and releases its
  heat energy
• There is less time for fuel to burn at high
  RPMs, so rapid burning fuel is a must in racing

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2. Burning Rate

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

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3. Latent Heat of Vaporization

• Measures a fuels ability to cool the intake
  charge and combustion chamber
• Measured in BTUs per gallon
• Higher rated fuels remove heat better

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3. Latent Heat of Vaporization

• 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

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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

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4. Energy Value

• A fuels 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

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4. Energy Value

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

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Fuel Comparison Chart
Fuel Octane (MON) Burning Rate (ms_at_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

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Fuel Rankings
Fuel Octane (MON) Burning Rate (ms_at_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
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Dave Slatten 540 CID Drag Race Engine Dyno
Results
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Dave Slatten 540 CID Drag Race Engine Dyno
Results
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Different Blends, Availability, and How E85 will
Fit the Future

• E10
• E85
• E100 (E-98)

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Application Specifics, a Review of Compatibility
of Parts, Corrosion, etc.

• E10
• Passenger car-compliant for decades. A simple
  replacement fuel
• Reduced emissions/oxygenate
• MTBE replacement
• Promotes clean fuel injectors
• Octane booster

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• E85
• Requires vehicle modifications
• Flex Fuel vehicle (FFV) identified by a gas
  cap insignia
• Ethanol-compatible fuel tank, pump, lines, etc.
• Modified air/fuel ratio enriched air/fuel ratio
  (approx. 25-28) or specialized sensors and
  computer programming
• Additional changes and race car handling
  considerations

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• E100 (E98)
• Contains 98 ethanol and 2 denaturing chemical
• Race-only fuel (IRL series)
• Extremely hygroscopic
• May require top oil and post-race pickling
  procedures.

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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

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• Know Your Fuel Determine Actual Ethanol Content
• The 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

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Six-Step Water Titration Method, for E85

• Step 1
• Fill the cylinder to the 50 ml. mark with the
  test fuel.

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Six-Step Water Titration Method, for E85

• Step 2
• Add 48 ml. of distilled water.

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Six-Step Water Titration Method, for E85

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

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Six-Step Water Titration Method, for E85

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

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Six-Step Water Titration Method, for E85

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

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• 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 13.58
• Percent 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

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Four-Step Water Titration Method
The ethanol/water level reads 88 ml. Subtract 10
ml. for the true ethanol content of 78, or E78.

• 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.

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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.

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Four-Step Water Titration Method
The ethanol/water level reads 88 ml. Subtract 10
ml. for the true ethanol content of 78, or E78.

• 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.

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• Fuel System Modifications
• To make your race vehicle E85 compatible, you
  must inspect the following and make any needed
  changes
• Correct fuel tank type size
• Vented gas cap
• Compatible fuel pump correct type and capacity
• Compatible carburetor/injectors

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• Engine Modifications
• Protect 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

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• Handling Storage
• Ethanol blends are hygroscopic. Once water has
  been introduced, corrosion will develop. Be sure
  to
• Store the fuel only in approved containers and
  keep it tightly capped at all times.
• All alcohols are very drying to skin. Avoid
  contact with skin and eyes.
• Follow all other normal fuel handling and storage
  recommendations.
• Inspect your motor oil for milking and change
  frequently.
• After racing, pickle the engine and vehicle.
  Drain all fuel from lines and use an appropriate
  anti-corrosive agent.

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• Racing with E85
• Not 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 (RM/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.

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Contact Information
Robert L. Colesworthy IQ Learning Systems,
Inc. 1833 Scherer Parkway Saint Charles, MO
63303 800-597-9747 www.iqlearningsystems.com
12/3/07