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High Ethanol Fuel Endurance Advanced Engineering Project
A study of the effects of running 15% ethanol concentration in current production 4-stroke engines and legacy 2-stroke engines.
Prepared By:Dave Hilbert
*Brunswick, Confidential*
OverviewThis project is a cooperative effort to assess the feasibility of increasing the allowable ethanol concentration in gasoline above the current legal limit of 10% for use in marine engines.
Objectives of this project:Run 300 hours of wide-open throttle endurance on 3 engine families and measure emissions at 0, 150, and 300 hours.9.9HP 4-stroke carbureted, 200HP 2.5L 2-stroke EFI (represents legacy product) and 300HP L6SC Verado engines were chosen.Two engines from each familyTest engine operated on E15Control engine run on pure gasoline
*Brunswick, Confidential*
Test Engine Specifications
Sheet1
9.9HP 4-StrokeVerado200 EFI
Gas Exchange ProcessFour StrokeFour StrokeTwo Stroke
Power Rating at Prop9.9HP300HP200HP
Cylinder ConfigurationInline 2 CylinderInline 6 Cylinder60 Degree V-6 Cylinder
Displacement0.209 Liter2.59 Liter2.51L
Fuel Induction SystemSingle Carburetor w/Accelerator Circuit, 2 Valve per Cylinder, Single Overhead CamSupercharged Electronic Fuel Injected 4 Valve per Cylinder, Dual Overhead Cam, Electronic Boost Control, Electronic Knock Abatement StrategyElectronic Fuel Injected with Oil Injection, Loop Scavenged Porting, Crankcase Reed Induction, Electronic Knock Abatement Strategy
Dry Weight108 lbs / 49 kg635 lbs / 288 kg425 lbs / 193 kg
Fuel Requirement87 Octane R+M/2 Minimum Required92 Octane R+M/2 Recommended, 87 Octane R+M/2 Minimum Required87 Octane R+M/2 Minimum Required
Sheet2
Sheet3
*Brunswick, Confidential*
Results SummaryVeradoInitial E15 engine generated HC+NOx emissions in excess of FEL when operated on E15 fuel.E15 engine failed exhaust valves. Metlab analysis showed excessive metal temperatures caused a reduction in fatigue strength.
F9.9HPThe E15 engine on E15 fuel showed high HC variability at the post-endurance emissions testing. It is believed that this engine was misfiring at idle due to the lean operation.The E15 engine showed evidence of hotter metal temperatures due to carbon deposits, etc.The E15 engine showed signs of gasket deterioration on the fuel pump.
200HP EFI 2.5L 2 StrokeE15 engine showed no difference in emission deterioration.E15 engine failed the rod bearing. Root cause is indeterminate due to the degree of damage. How does ethanol affect oil dispersion in two stroke engines?Other than the bearing failure, the end of test teardown and inspection did not show any significant difference between the 2 engines
*Brunswick, Confidential*
Results Summary-Continued4.3L V6 ECT MercruiserTwo emissions tests were performed on a 4.3L catalyzed sterndrive engine to compare the E0 fuel and the E15 fuel. No durability testing was completed on the 4.3L engine with E15 fuel.This testing was not part of the contract, but was performed due to the fact that the E15 test fuel and a catalyzed engine were readily available on the dyno. Also, it compliments the testing on a 4.3L carbureted engine done by Volvo Penta.EGT increased ~20C and catalyst temperatures increased ~32C at Mode 1 (WOT).Valvetrain durability and catalyst system deterioration concerns.Fuel consumption increased by ~5% (mass-based fuel flow) in closed loop operation.Aside from HC and CO reductions at Mode 1 (open loop), the E15 fuel afforded no real benefit to reduced emissions overall.NOx increased at Mode 1, but not as much as HC decreased for a slight overall reduction.HC, NOx and CO in closed loop operation are essentially unchanged between the 2 fuels.OverallThe CO emissions were lower on all engines with E15 fuel due to leaner running (as would be expected).Fuel analysis showed the E15 fuel that was used in testing was in line with expectations.
*Brunswick, Confidential*
Conclusions and Recommendations SummaryDespite the limited scope of project several significant issues were discovered.Durability FailuresEmissions Issues (elevated NOx, HC variability)Run Quality due to Lean OperationMore testing is necessary to understand effects on:Driveability- Ex. cold and hot start, transient accel/decel, boiloff, etc.Oil dispersion in 2 stroke enginesStorage (phase separation, corrosion, etc.)Test program was a cursory look at the effects of E15.Sample size was insufficient to have statistical significance.WOT operation only-masks effects of true customer duty cycle
*Brunswick, Confidential*
Fuel Comparison
Chart1
86.39.4
88.58.7
84.65
87.55.9
Motor Octane
Research Octane
Octane Number
Octane Measurement Comparison of Various Fuels
Sheet1
Fuel AnalysisE15 FuelEEE (10/8/10-Haltermann Data)87 Bulk Fuel (Sample 10-15-10)91 Bulk Fuel (Sample 10-15-10)91 Bulk Fuel (Sample 02-10-11)Pure Ethanol Boiling PointBoiling TempBoiling TempDistillation Class10% Max50% Min50% Max90% Max100% Max
Research OctaneRON95.797.289.693.4078172.40.10.50.50.91
Motor OctaneMON86.388.584.687.5178172.4ASTM D4814-09B: Distillation Class A (Summer)7077121190225
[R+M]/2AKI91.092.987.190.45ASTM D4814-09B: Distillation Class E (Winter)5077110185225
RON-MON Delta9.48.75.05.9
Density @ 15.5Ckg/L0.7520.744
API GravityAPI56.558.7
Ethanol Content (NREL/ASTM D5501)%18+/-1%
Ethanol Content (IROX analyzer @ NREL)%14%
Results from Petrospec analyzer at Mercury (E15 data ave. of 2 samples)
Ethanol Content%14.1%0000
RONRON95.795.889.492.991.5
MONMON84.787.783.387.285.4
[R+M]/2AKI90.291.786.490.188.5
Reid Vapor Pressure (Mercury analysis)PSI8.59.010.810.7
Distillation % Recovered
0%F98869282
5%F123106119104
10%F130121133116
20%F140144160146
30%F148170183180
40%F155202205198
50%F164223228214
60%F220235239227
70%F254247262242
80%F284268300272
90%F328320367346
95%F365338392402
100%F412392422430
Distillation % Evap% Evap
5%F11911494
10%F129130110
20%F139157139
30%F147181172
40%F154203194
50%F163226210
60%F216238224
70%F251260239
80%F282296265
90%F324360329
95%F359387376
Distillation % Recovered
0%C36.730.033.327.8% RecoveredAverage Summer RegularAverage Summer PremiumAverage Winter RegularAverage Winter Premium% RecoveredEmission Test EEEHaltermann High Endpoint HF 0112
5%C50.641.148.340.0%deg Cdeg Cdeg Cdeg C%deg Cdeg C
10%C54.449.456.146.70%36.1235.4228.4228.560%28.334.6
20%C60.062.271.163.35%48.7249.9136.8236.545%41.256.8
30%C64.476.783.982.210%55.8659.2242.744.6610%46.867.4
40%C68.394.496.192.220%65.2473.0852.7858.6615%52.176.7
50%C73.3106.1108.9101.130%75.4686.163.9874.6220%57.685.7
60%C104.4112.8115.0108.350%99.82108.3690.44103.3225%63.593.8
70%C123.3119.4127.8116.770%128.94127.82120.82124.1830%70100.9
80%C140.0131.1148.9133.390%169.54162.82161.28158.3435%77.3105.8
90%C164.4160.0186.1174.495%187.18179.48178.78175.2840%84.7109.8
95%C185.0170.0200.0205.6100%213.36208.04204.12201.645%92.4113.6
100%C211.1200.0216.7221.150%99.5117.4
55%105.7122.5
60%111129.1
65%116.2138
70%123.2152.2
75%131.1166.2
80%142.3176.7
85%156.6181.1
90%171.3190.6
100%211.4233.5
Sheet1
E15 Fuel
EEE (10/8/10-Haltermann Data)
91 Bulk Fuel (Sample 02-10-11)
ASTM D4814-09B: Distillation Class A (Summer)
Pure Ethanol Boiling Point
ASTM D4814-09B: Distillation Class E (Winter)
Percent Recovered (%)
Temperature (C)
Distillation Curve Comparison, ASTM D86
Sheet2
Motor Octane
Research Octane
Octane Number
Octane Measurement Comparison of Various Fuels
Sheet3
Sheet1
Fuel AnalysisE15 FuelEEE (10/8/10-Haltermann Data)87 Bulk Fuel (Sample 10-15-10)91 Bulk Fuel (Sample 10-15-10)91 Bulk Fuel (Sample 02-10-11)Pure Ethanol Boiling PointBoiling TempBoiling TempDistillation Class10% Max50% Min50% Max90% Max100% Max
Research OctaneRON95.797.289.693.4078172.40.10.50.50.91
Motor OctaneMON86.388.584.687.5178172.4ASTM D4814-09B: Distillation Class A (Summer)7077121190225
[R+M]/2AKI91.092.987.190.45ASTM D4814-09B: Distillation Class E (Winter)5077110185225
RON-MON Delta9.48.75.05.9
Density @ 15.5Ckg/L0.7520.744
API GravityAPI56.558.7
Ethanol Content (NREL/ASTM D5501)%18+/-1%
Ethanol Content (IROX analyzer @ NREL)%14%
Results from Petrospec analyzer at Mercury (E15 data ave. of 2 samples)
Ethanol Content%14.1%0000
RONRON95.795.889.492.991.5
MONMON84.787.783.387.285.4
[R+M]/2AKI90.291.786.490.188.5
Reid Vapor Pressure (Mercury analysis)PSI8.59.010.810.7
Distillation % Recovered
0%F98869282
5%F123106119104
10%F130121133116
20%F140144160146
30%F148170183180
40%F155202205198
50%F164223228214
60%F220235239227
70%F254247262242
80%F284268300272
90%F328320367346
95%F365338392402
100%F412392422430
Distillation % Evap% Evap
5%F11911494
10%F129130110
20%F139157139
30%F147181172
40%F154203194
50%F163226210
60%F216238224
70%F251260239
80%F282296265
90%F324360329
95%F359387376
Distillation % Recovered
0%C36.730.033.327.8% RecoveredAverage Summer RegularAverage Summer PremiumAverage Winter RegularAverage Winter Premium% RecoveredEmission Test EEEHaltermann High Endpoint HF 0112
5%C50.641.148.340.0%deg Cdeg Cdeg Cdeg C%deg Cdeg C
10%C54.449.456.146.70%36.1235.4228.4228.560%28.334.6
20%C60.062.271.163.35%48.7249.9136.8236.545%41.256.8
30%C64.476.783.982.210%55.8659.2242.744.6610%46.867.4
40%C68.394.496.192.220%65.2473.0852.7858.6615%52.176.7
50%C73.3106.1108.9101.130%75.4686.163.9874.6220%57.685.7
60%C104.4112.8115.0108.350%99.82108.3690.44103.3225%63.593.8
70%C123.3119.4127.8116.770%128.94127.82120.82124.1830%70100.9
80%C140.0131.1148.9133.390%169.54162.82161.28158.3435%77.3105.8
90%C164.4160.0186.1174.495%187.18179.48178.78175.2840%84.7109.8
95%C185.0170.0200.0205.6100%213.36208.04204.12201.645%92.4113.6
100%C211.1200.0216.7221.150%99.5117.4
55%105.7122.5
60%111129.1
65%116.2138
70%123.2152.2
75%131.1166.2
80%142.3176.7
85%156.6181.1
90%171.3190.6
100%211.4233.5
Sheet1
E15 Fuel
EEE (10/8/10-Haltermann Data)
91 Bulk Fuel (Sample 02-10-11)
ASTM D4814-09B: Distillation Class A (Summer)
Pure Ethanol Boiling Point
ASTM D4814-09B: Distillation Class E (Winter)
Percent Recovered (%)
Temperature (C)
Distillation Curve Comparison, ASTM D86
Sheet2
Motor Octane
Research Octane
Octane Number
Octane Measurement Comparison of Various Fuels
Sheet3
Fuel AnalysisE15 FuelEEE 10/8/1087 Bulk Fuel 10-15-1091 Bulk Fuel 02-10-11
[R+M]/291.092.987.190.45
*Brunswick, Confidential*
Fuel Comparison
Chart2
36.66666666673027.777777777833.3333333333707850
50.555555555641.11111111114048.3333333333777877
54.444444444449.444444444446.666666666756.1111111111121110
6062.222222222263.333333333371.1111111111190185
64.444444444476.666666666782.222222222283.8888888889225225
68.333333333394.444444444492.222222222296.1111111111
73.3333333333106.1111111111101.1111111111108.8888888889
104.4444444444112.7777777778108.3333333333115
123.3333333333119.4444444444116.6666666667127.7777777778
140131.1111111111133.3333333333148.8888888889
164.4444444444160174.4444444444186.1111111111
185170205.5555555556200
211.1111111111200221.1111111111216.6666666667
E15 Fuel
EEE (10/8/10-Haltermann Data)
91 Bulk Fuel (Sample 02-10-11)
87 Bulk Fuel (Sample 10-15-10)
ASTM D4814-09B: Distillation Class A (Summer)
Pure Ethanol Boiling Point
ASTM D4814-09B: Distillation Class E (Winter)
Percent Recovered (%)
Temperature (C)
Distillation Curve Comparison, ASTM D86
Sheet1
Fuel AnalysisE15 FuelEEE (10/8/10-Haltermann Data)87 Bulk Fuel (Sample 10-15-10)91 Bulk Fuel (Sample 10-15-10)91 Bulk Fuel (Sample 02-10-11)Pure Ethanol Boiling PointBoiling TempBoiling TempDistillation Class10% Max50% Min50% Max90% Max100% Max
Research OctaneRON95.797.289.693.4078172.40.10.50.50.91
Motor OctaneMON86.388.584.687.5178172.4ASTM D4814-09B: Distillation Class A (Summer)7077121190225
[R+M]/2AKI91.092.987.190.45ASTM D4814-09B: Distillation Class E (Winter)5077110185225
RON-MON Delta9.48.75.05.9
Density @ 15.5Ckg/L0.7520.744
API GravityAPI56.558.7
Ethanol Content (NREL/ASTM D5501)%18+/-1%
Ethanol Content (IROX analyzer @ NREL)%14%
Results from Petrospec analyzer at Mercury (E15 data ave. of 2 samples)
Ethanol Content%14.1%0000
RONRON95.795.889.492.991.5
MONMON84.787.783.387.285.4
[R+M]/2AKI90.291.786.490.188.5
Reid Vapor Pressure (Mercury analysis)PSI8.59.010.810.7
Distillation % Recovered
0%F98869282
5%F123106119104
10%F130121133116
20%F140144160146
30%F148170183180
40%F155202205198
50%F164223228214
60%F220235239227
70%F254247262242
80%F284268300272
90%F328320367346
95%F365338392402
100%F412392422430
Distillation % Evap% Evap
5%F11911494
10%F129130110
20%F139157139
30%F147181172
40%F154203194
50%F163226210
60%F216238224
70%F251260239
80%F282296265
90%F324360329
95%F359387376
Distillation % Recovered
0%C36.730.033.327.8% RecoveredAverage Summer RegularAverage Summer PremiumAverage Winter RegularAverage Winter Premium% RecoveredEmission Test EEEHaltermann High Endpoint HF 0112
5%C50.641.148.340.0%deg Cdeg Cdeg Cdeg C%deg Cdeg C
10%C54.449.456.146.70%36.1235.4228.4228.560%28.334.6
20%C60.062.271.163.35%48.7249.9136.8236.545%41.256.8
30%C64.476.783.982.210%55.8659.2242.744.6610%46.867.4
40%C68.394.496.192.220%65.2473.0852.7858.6615%52.176.7
50%C73.3106.1108.9101.130%75.4686.163.9874.6220%57.685.7
60%C104.4112.8115.0108.350%99.82108.3690.44103.3225%63.593.8
70%C123.3119.4127.8116.770%128.94127.82120.82124.1830%70100.9
80%C140.0131.1148.9133.390%169.54162.82161.28158.3435%77.3105.8
90%C164.4160.0186.1174.495%187.18179.48178.78175.2840%84.7109.8
95%C185.0170.0200.0205.6100%213.36208.04204.12201.645%92.4113.6
100%C211.1200.0216.7221.150%99.5117.4
55%105.7122.5
60%111129.1
65%116.2138
70%123.2152.2
75%131.1166.2
80%142.3176.7
85%156.6181.1
90%171.3190.6
100%211.4233.5
Sheet1
E15 Fuel
EEE (10/8/10-Haltermann Data)
91 Bulk Fuel (Sample 02-10-11)
87 Bulk Fuel (Sample 10-15-10)
ASTM D4814-09B: Distillation Class A (Summer)
Pure Ethanol Boiling Point
ASTM D4814-09B: Distillation Class E (Winter)
Percent Recovered (%)
Temperature (C)
Distillation Curve Comparison, ASTM D86
Sheet2
Motor Octane
Research Octane
Octane Number
Octane Measurement Comparison of Various Fuels
Sheet3
Fuel AnalysisE15 FuelEEE 10/8/1087 Bulk Fuel 10-15-1091 Bulk Fuel 02-10-11
[R+M]/291.092.987.190.45
*Brunswick, Confidential*
F9.9HP 4-Stroke EmissionsVariability on E15 Engine is a concern.E15 fuel-zero hour and EEE-E0 fuel 150 hour checks are likely due to run-to-run variability.E15 fuel-300 hour variability is due primarily from Mode 5 (idle) HC emissions.Trends on EEE-E0 fuel are consistent between the 2 engines.
*Brunswick, Confidential*
F9.9HP 4-Stroke EmissionsBoth engines had a tendency to run leaner at Modes 4 and 5 with increasing endurance time.The combination of the inherent leaner operation and the E15 fuel was enough to cause misfires/poor combustion at idle.The misfires caused the HC emissions to increase and become highly variable.
*Brunswick, Confidential*
F9.9HP 4-Stroke EmissionsThe fact that the E15 fuel emissions tests show that HC emissions increase with leaner mixtures supports the misfire theory.The graph below shows HC vs. equivalence ratio at idle for every emissions test performed on engine 0R352904, which is the E15 engine.All E15 fuel emissions tests are shown in redAll EEE-E0 fuel emissions test are shown in blue
*Brunswick, Confidential*
F9.9HP 4-Stroke Teardown and InspectionMore carbon deposits on intake valves of E15 engine.
*Brunswick, Confidential*
F9.9HP 4-Stroke Teardown and InspectionMore carbon deposits on intake port of E15 engine.E15E0
*Brunswick, Confidential*
F9.9HP 4-Stroke Teardown and InspectionMore carbon deposits on piston undercrown and rods of E15 engine.
*Brunswick, Confidential*
F9.9HP 4-Stroke Teardown and InspectionThe gasket showed signs of deterioration on the E15 engine compared with the E0 engine. The gasket on the E15 engine had a pronounced ridge formed in the area that hinges when the check valve is in operationThe E15 gasket material in the area that seals the check valve also had signs of wear that were more advanced than the E0 gasket. E15E0
*Brunswick, Confidential*
F9.9HP 4-Stroke Teardown and InspectionMaterial transfer from gasket to diaphragm in mechanical fuel pump. E15E0
*Brunswick, Confidential*
Verado TestingSummary / ReviewVerado E15 Engine:Initial emissions tests on E15 fuel generated HC+NOx values in excess of the FEL set for this engine.Three-run average on E15 fuel: HC+NOx = 25.6 g/kw-hrFEL set to 22.0 g/kw-hrE15 engine failed the exhaust valves.High cycle fatigue due to elevated temperatures
*Brunswick, Confidential*
Verado E15 Valve Failure InvestigationCylinder 3Top ValveCylinder 3Bottom ValveCylinder 6Top Valve
*Brunswick, Confidential*
Verado E15 Valve Failure InvestigationCylinder 3 Bottom Valve
*Brunswick, Confidential*
Verado E15 Valve Failure InvestigationThe failed valves were checked for hardness and the values were low.Valves from other E0 engines w/o failed valves were measured and the hardness values were within expected values.Brand new valves were also measured for comparison.
Sheet1
Valves
EngineRc HardnessRc AverageRA HardnessRc Average
1400 Heat3939.569.970.0
4070.1
1400 No Heat3434.567.667.7
3567.7Before (HRC)Before (HRA)After (HRC)After (HRA)
1500 Heat3434.56767.4140034.567.739.570
3567.7150034.567.434.567.7
1500 No Heat3534.567.967.716003366.72766.2
3467.517003366.7
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