Upload
phamxuyen
View
217
Download
2
Embed Size (px)
Citation preview
1
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
2
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.
4
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
5
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
6
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
8
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)
9
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
10
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
11
Heat Transfer Failure of Water Vapor
With Waterless Coolant, Metal Temperatures Are Controlled
A = Waterless Coolant B = Water-Based Coolant
12
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
14
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
15
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
16
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
17
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
18
Tests in NYC Department of Sanitation Truck
New York City Garbage Truck Cycle Central Business District
Test Cycles
19
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
20
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
21
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
22
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
23
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
25
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%.
26
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.
28
Solution - Waterless Coolant
30
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
32
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