Minnesota E-20 Fuel Waiver Test Program

1
Minnesota E-20 Fuel Waiver Test Program

• Technical Presentation
• Dr. Ranajit (Ron) Sahu, Consultant
• Phone [phone]
• sahuron_at_earthlink.net

2
Topics

• Off-Road Characteristics
• Equipment
• Engines
• Fuel Systems
• EPAs Exhaust Regulations
• Impact on Air-Fuel Ratio Settings
• Summary of Existing E-20 Studies

3
Topics (cont.)

• General Testing Issues to Meet Waiver Criteria
• Creating technology categories to respond to
  diversity
• Existing and newly regulated products
• Engine technologies/materials/components
• Statistically valid data
• Pass/Fail criteria
• Testing Evaluations/Criteria
• Impact on exhaust and evaporative emissions
• Impact on materials compatibility
• Impact on drivability/functionality

4
Topics (cont.)

• Illustrative Example Handheld Engines
• Fuel Specification Issues
• Additional Technical Slides/Discussion

5
Off-Road Characteristics
6
Equipment

• Diversity
• Components, materials, and uses
• Key design issues differ by category
• Lawn and garden vs. snow vs. marine etc.
• Seasonal use
• Consumers
• Minnesotans own and rely on millions of off-road
  engines, vehicles and equipment
• Exposed to potential hazards if engine/equipment
  operates outside of normal expected conditions

7
Engines

• Air or Water Cooled
• Operator in Close Proximity to Hot Engine/Exhaust
  System
• 2-Stroke and 4-Stroke With Variations
• Various Fuel Introduction Technologies
• Mostly carbureted with variations
• Some fuel injected

8
Engines (cont.)

• Various Engine Control Technologies
• Mostly open loop with no feedback
• Few closed loop
• Various Emissions Reduction Strategies/Technologie
  s

9
Fuel Systems

• Wide variety of tank and hose materials
• Different evaporative control strategies
• Permeation, tank venting, etc.
• Multi-positional operational requirements
• Storage-stability issues due to seasonal usage
• Safety constraints
• EPA evaporative/permeation regulations

10
EPAs Exhaust Regulations Impact on Air-Fuel
Ratio Settings
11
Regulations Summary
EQUIPMENT/ ENGINE TYPE CURRENT EFFECTIVE REGULATIONS FUTURE ADOPTED STANDARDS ANTICIPATED FUTURE REGULATIONS
Small Spark Ignition Lawn Garden Other Exhaust Revised Exhaust / New Evaporative
Small Spark Ignition Lawn Garden Other 40 CFR Part  90
Large Spark-Ignition Engines Exhaust / Evaporative Exhaust/Evaporative  
Large Spark-Ignition Engines 40 CFR Part 1048 2007  
Marine Engines Exhaust / Evaporative Exhaust / Evaporative Exhaust / Evaporative
Marine Engines 40 CFR Part  91 2006, 2007 Inboard / Stern-drive
Recreational / Vehicles Snowmobiles ATVs Off-Road Motorcycles Exhaust / Evaporative Exhaust / Evaporative  
Recreational / Vehicles Snowmobiles ATVs Off-Road Motorcycles 40 CFR Part 1051 2006, 2007, 2008, 2010, 2012  
12
Impact

• EPAs exhaust emission regulations have resulted
  in enleanment of the engines air-fuel
  calibration to functional limits
• Fuel management systems cannot effectively manage
  E0 through E20 fuels interchangeably
• Modification of existing fuel management systems
  to operate on E-20 would require tampering with
  an emission control device and thus violate
  Federal Law

13
Lean AirFuel Ratio
Rich
14
Exhaust Gas Temperature vs. Fuel Change
15
Summary of Existing E20 Experience and Studies
16
E-20s Impact on Current, Exhaust- Emission
Compliant Small Engines

• Exhaust temperatures up 100F
• Peak cylinder pressures higher
• Combustion deposits
• Cylinder head gasket burned failed
• Exhaust valve burned
• Cylinder bore scored
• 25 hours light duty emissions testing
• Lost cylinder compression
• Lost 20 power

17
E-20 Implications on Engine Durability
Cylinder head gasket burned Lost
seal Exhaust leak out
18
E-20 Implications on Engine Durability
Cylinder head gasket burned Lost seal
19
E-20 Implications on Engine Durability
Cylinder Bore scoring Deposits
20
Engine Durability Implications with E-20
1
6
8
7
5
4
3
2
1
Head bolts discolored due to heat and carbon
build up from exhaust gas blowing past bolt.
21
Engine material compatibility Implications with
E-20
Carburetor bowl mounting screw gasket attacked by
E20 in few hours. Fuel containment seal.
Bowl gasket swelled lost seal.
22
Engine material compatibility Implications with
E-20
Carburetor welch plug epoxy attacked by E20 in 17
wks. Fuel containment seal.
23
Engine material compatibility Implications with
E-20
Fuel Cap gasket swelled warped by E20 in 1 wk.
Fuel containment seal tank venting.
24
Brazilian Experience

• During 1970s and 1980s, blends ranging from E14
  E24 used in Brazilian fuel supply (pre-emission
  compliant products)
• OPEI Member Experience (2-Stroke engines)
• Lean air fuel ratio delivery resulting in
• higher engine temperatures
• engine seizures
• Poor acceleration performance
• Cold start problems
• Phase-separation due to water uptake leading to
  water in carburetor
• Formation of deposits blocking carburetor nozzles
• Corrosion of engine parts, crankcase, bearings,
  crankshaft, etc.
• Had to develop unique products with different
  carburetor settings, fuel system materials, etc.

25
Orbital 2002 and 2004 NREL 2002

• E20 requires resizing/recalibration of existing
  open loop engines (i.e., changed A/F ratio) to
  prevent
• enleanment, resulting in temperature increase,
  and engine malfunctions
• detrimental impacts on safety
• Detrimental impacts of phase-separation due to
  presence of water in E-20 potential engine
  stall esp. at cold temperatures
• Poor (Cold) Start performance (esp. important for
  hand-start engines)
• Hot and Cold performance degraded

26
Publication SAE 920164

• Concluded that ethanol has an adverse effect on
  evaporative permeation emissions from current
  fuel tanks and hoses

27
Summary of E-20 Studies

• Causes corrosion of metals and resulting impacts
  on engine components
• Distorts elastomers and causes resulting impacts
  on fuel system components
• Causes loss of lubricity due to cylinder wall
  wash
• Loosens deposits in existing equipment leading
  to plugged fuel filters etc.
• Damage to painted parts
• Adverse impact on exhaust and evaporative
  emissions and on engine/equipment performance

28
General Testing Issues to Meet Waiver Criteria
29
Waiver Issues and Test Criteria

• 1. Exhaust emissions
• 2. Evaporative emissions
• 3. Materials compatibility
• Drivability/Operational Performance and
  Tampering Risk
• EPA must determine whether and when new fuels
  could cause failures in each of these
  categories
• Data must be derived from unmodified engines,
  vehicles, and equipment that are EPA-certified,
  as applicable
• Waiver applicant must evaluate carbureted-engine
  configurations with their existing airfuel
  ratios set for EPA certification fuels

30
Testing - Product Categories

• Since emissions regulations are changing,
  off-road engines/equipment groups to be tested
  should include mix of
• Existing, pre-compliant equipment
• Existing, EPA compliant equipment
• New
• In-use
• Future, prototypical new equipment designed to
  meet EPA evaporative and exhaust regulations
  anticipated before 2015

31
Testing - Representativeness Via Technology
Categories

• Need to identify and test representative mix of
  engines/equipment
• Must test different Technology Categories,
  based on
• Engine combustion cycle (2 Stroke and 4 Stroke)
• Fuel delivery / control systems
• Exhaust emission controls/strategies
• Evaporative emissions controls/strategies
• Equipment use profile

32
Technology Categories - Fuel Delivery Systems

• Carburetion
• Float type
• Diaphragm type
• Single vs. multi-circuit
• Fuel Injection
• Open loop
• Closed loop

33
Technology Categories Exhaust Emissions
Controls / Strategies

• Various Engine Designs and Modifications
• 2 Cycle vs. 4 Cycle
• Side vs. overhead valve configurations
• Ignition timing changes
• Air/Fuel preparation and delivery systems
• Stratification
• Compression wave technology
• Catalysts
• Hybrids (2/4 Strokes)

34
Illustration of 2005 Exhaust Diversity EPA
Non-Road Small SI EnginesAdditional
Illustrations at End of Presentation
Category Non-Road SI (Handheld and Ground Supported)
Emission Classes I-A, I-B, I, II, III, IV, V
Displacement (cc) 20 - 1000
Useful Life 50-1000 hrs
Engine Cycle 2S, 4S
Fuel Introduction  
2S Carbureted, EFI, SFI
4S Carbureted, EFI, SFI
Control Open Loop, O2S/ECM
Valve Location  
2S Piston Port (most), Reed
4S Side Valve, Overhead Valve
Emissions Reduction Phase 1, Phase 2
2S EM, EM/TWC, OC, OC-2, TWC, TWC/OC
4S EM, ECM, ECM/O2S, EM/TWC, TWC
35
Technology Categories Evaporative Materials

• Permeation from
• Fuel Tanks made of
• Metal
• HDPE
• Barrier Treated HDPE (fluorinated, sulfonated)
• Selar
• Nylons (various grades)
• Coextruded (various types)
• Other materials
• Fuel Hoses made of
• NBR
• FKM
• Other materials
• Venting Emissions from
• Uncontrolled venting systems
• Carbon Canisters

36
Testing Statistically Valid Data

• EPA will consider the datas statistical validity
  and how well the program represents the product
  universe
• How many different products should be tested?
• How many replicate products and repeat
  measurements?
• How will test data quality be controlled?
• Which data points provide statistically
  significant results? Which are outliers?
• Which statistical tests should be used? etc.
• Statistical expertise helpful in designing the
  test program and analysis of the results

37
Testing Evaluations/Criteria
38
Testing Pass/Fail Criteria

• How will pass/fail criteria be established?
• Comparison with EPA standards and procedures
• exhaust emissions
• evaporative emissions
• Criteria need to be developed for
• materials compatibility tests
• drivability/operability tests

39
Testing Exhaust and Evaporative Emissions

• Goal Evaluate E-20s impacts on compliance with
  emissions standards
• Criteria pollutants (NOx, HC, CO, PMx)
• Test Protocols
• EPA exhaust emission test protocols
• EPA evaporative emission test protocols
• EPA durability/aging provisions
• Pass/Fail criteria compliance with EPA
  compliance levels
• Air toxics
• e.g, aldehydes, etc.

40
Testing Materials Compatibility

• Goal Assess Short and Long Term E-20
  compatibility with
• Metals
• Zinc, brass, cast iron, lead, aluminum,
  magnesium, nickel, etc.
• Non-metallics
• NBR, polyurethane, nylons, Viton, Teflon,
  nitrile, mylar, silicon sealants, felt, etc.
• Adhesives used for labels and decals
• Test Protocols Need to be developed for various
  test types below
• Coupon tests
• Engine/equipment soak tests under non-operational
  conditions
• Durability tests under nominal operating
  conditions
• Laboratory (bench) tests
• Field tests
• Durability tests under off-nominal operating
  conditions
• Pass/Fail Criteria Need to be developed for
  tests above.

41
Testing Drivability

• Goal - How does E-20 impact normal operation or
  expected normal operation? Specifically, tests
  should examine
• Cold start ability (in all applicable ambient
  environments)
• Load pickup
• Acceleration
• Hot restartability
• Vapor lock
• Maximum power operation
• Fuel switching from E-20 to Baseline fuel and
  vice versa
• Impact on safe equipment operation
• Test Protocols Need to be developed
• Pass/Fail Criteria Need to be developed

42
Illustrative Example Handheld Engines
43
Test Categories
Engine/Control Technology Product Type Product Type Product Type Product Type Product Type Product Type
(current and future) Blower Chainsaw Chainsaw Chainsaw Trimmer/ Brushcutter Trimmer/ Brushcutter
  Pro Pro Consumer Farmer Pro Farmer
2S w/cat Y   Y Y   Y
Stratified Y Y  N N  Y N 
Stratified w/cat      N Y  N N 
Compression Wave     Y      
4S Y    N N  Y N 
2S w/tuned exhaust Y Y        
44
Test Parameters To Be Measured

• Startability
• Multipositional stability (_at_idle, _at_WOT)
• Acceleration
• Emissions (new and deteriorated)
• Exhaust
• Evaporative/Permeation (Tanks, Lines)
• Power and Torque
• Fuel consumption
• Plug Seat Temperatures
• Exhaust Temperatures
• Materials Compatibility Indicators
• Crankshaft assembly (Corrosion)
• Cylinder (Corrosion)
• Carburetor components (Corrosion/Distortion)
• Fuel tanks / Fuel lines / Seals (Distortion)
• Safety Feature Performance

45
Fuel Specification Issues
46
Testing Fuel Specifications

• The exact composition of E20 needs to be defined
  across all appropriate parameter ranges (e.g.,
  ethanol content)
• The exact choices for baseline fuels need to be
  defined

47
Additional Technical Slides (future discussion)
48
2005 Diversity - Snowmobiles
Category Recreation Vehicle - Snowmobile
Emission Classes -
Displacement (cc) 120 - 1500
Useful Life 400 hrs // 5 yrs // 8000 km
Engine Cycle 2S, 4S
Fuel Introduction  
2S Carb, TBI, Indirect Inj
4S Carb, TBI, Indirect Inj, Port Fuel Inj., EC
Control Open Loop
Valve Location  
2S Reed (most), Piston Ported
4S OHV
Emissions Reduction  
2S EM
4S EM
49
2005 Diversity ATVs
Category Recreational Vehicle - ATV
Emission Classes
Displacement (cc) 50-800
Useful Life 1000 hrs, 10000 km, or 5 years
Engine Cycle 2S, 4S
Fuel Introduction  
2S Carb
4S Carb, Inj
Control Open Loop
Valve Location  
2S Reed, Piston Ported
4S OHV
Emissions Reduction  
2S EM
4S EM
50
2005 Diversity Off Road MCs
Category Recreational Vehicle Off Road Motorcycle
Emission Classes
Displacement (cc) 50-650
Useful Life Earlier of 10000 km or 5 yrs
Engine Cycle 2S, 4S
Fuel Introduction
2S Carb
4S Carb
Control Open Loop
Valve Location
2S Reed Valve, Piston Port
4S OHV
Emissions Reduction
2S EM
4S EM
51
2005 Diversity - Marine
Category Marine
Emission Classes -
Displacement (cc) 60 - 3600
Useful Life PWC/Outboard 350 hrs/10 yrs, Inboard/Stern Drive 480 hrs/10 yrs
Engine Cycle 2S, 4S
Fuel Introduction  
2S Carb, DI, DI/EC, Indirect Inj/EC, TBI, MPI
4S Carb, Carb/EC, DI, MPI, MPI/EC, Indirect Inj.
Control  
Valve Location  
2S Reed, PP
4S OHV
Emissions Reduction  
2S EM, DFI, Cat, ECM/DFI
4S EM, ECM, SFI, MFI, Cat
52
2005 Diversity Large SI
Category LSI
Emission Classes -
Displacement (cc) 1000 - 6000
Useful Life 7 yrs / 5000 hrs
Engine Cycle 4S
Fuel Introduction
2S n/a
4S Carb, TBI, MPI
Control Open loop, closed loop
Valve Location
2S n/a
4S OHV
Emissions Reduction
2S n/a
4S EM, TWC
53
Specific Test Issues For Fuel Specification

• What is the specification for E-20?
• Ethanol should meet ASTM 4806
• Fuel as a whole should meet ASTM 4814
• Additional denatured ethanol standards
  (presumably like CA) need to be met (per RFA)
• Specific denaturant specs need to be met
  (presumably like CA, per RFA)
• Additives should be specified ignition
  improvers, detergents, corrosion inhibitors,
  anti-foaming agents, demulsifiers, lubricity
  additives, biocides, etc.
• Finally, certain additional specs (RVP?,
  distillation curve?, octane?) may need to be met

54
Fuels Baseline Testing

• What Baseline fuel(s) should be used?
• Seasonal/regional baseline fuel blends?
• Emissions and emission control systems tests need
  to use EPA certification fuels.
• For determination of drivability and
  operability differences, tests need to use E10 as
  baseline fuel.

55
Fuel Test Specifications

• Fuel Characteristics (all Baseline fuels and
  E-20)
• Ethanol concentration
• RVP, boiling curve, Drivability Index
• Mixability of oil in fuel
• Gum formation
• Water content, Corrosion
• Octane (RON, MON)
• Storability
• Autoignition temperature, flash point
• Flammability limits
• All properties per ASTM 4806 and ASTM 4814
• All additional specifications per CARB (and MN,
  if applicable)