Specification Requirements on Synthetic Diesel Fuel from the Perspective of a FIE Manufacturer Dr. Heinz Stutzenberger DS/ENF Engineering Fuels Robert Bosch GmbH 1 07/03/2006 007-05 686 Robert Bosch GmbH reserves all rights even in the event of industrial property rights. We reserve all rights of disposal such as copying and passing on to third parties. Titelmasterformat Specificationdurch Requirements Klicken bearbeiten on Synthetic Diesel Fuel Contents 1. Introduction 2. Design of Common Rail System and components 3. Characteristics of typical Diesel fuels and impact on the fuel injection system 4. Impact on engine application and calibration 5. Summary and conclusions 2 1
Titelmasterformat Specificationdurch Requirements Klicken bearbeiten on Synthetic Diesel Fuel Contents 1. Introduction 2. Design of Common Rail System and components 3. Characteristics of typical Diesel fuels and impact on the fuel injection system 4. Impact on engine application and calibration 5. Summary and conclusions 3 Titelmasterformat Specificationdurch Requirements Klicken bearbeiten on Synthetic Diesel Fuel Contents 1. Introduction 2. Design of Common Rail System and components 3. Characteristics of typical Diesel fuels and impact on the fuel injection system 4. Impact on engine application and calibration 5. Summary and conclusions 4 2
Boundary conditions of Diesel high press. injection injection time injection characteristic injection pressure min. injection quantities injection frequency 1.5 ms mm 3 / crksft 2000 bar 1 mm 3 / stroke ^= 1.5 ms 16000 cycles/min. @ 250 Hz crksft 5 Specification Requirements on Synthetic Diesel Fuel Design of Common Rail System (RB 3. Gen. ) 6 07/03/2006 007-05 686 Robert Bosch GmbH reserves all rights even in the event of industrial property rights. We reserve all rights of disposal such as copying and passing on to third parties. 3
Common Rail High Pressure Pump (RB CP3.2) high pressure low pressure 7 07/03/2006 007-05 686 Robert Bosch GmbH reserves all rights even in the event of industrial property rights. We reserve all rights of disposal such as copying and passing on to third parties. Specification Requirements on Synthetic Diesel Fuel Common Rail High Pressure Pump (RB CP3.2) flange LP connector HP valve cone drive metering unit barrel tappet polygon plunger suction valve monobloc housing backflow connector HP connector gear pump 8 07/03/2006 007-05 686 Robert Bosch GmbH reserves all rights even in the event of industrial property rights. We reserve all rights of disposal such as copying and passing on to third parties. 4
Specification Requirements on Synthetic Diesel Fuel Common Rail Injector (RB CRI1) residual air gap 0.065 ± 0.010 mm = 65 µm ± 10 µm armature stroke 0.040 mm ± 0.004 = 40 ± 5 µm spray hole 0.150 ± 0.003 mm = 150 µm ± 5 µm 9 nozzle needle clearance plunger clearance 0.0018 0.0031 mm = 2-4 µm 0.00395 ± 0.00075 mm = 3.95 µm ± 0.7 µm DS/ENF 07/03/2006 007-5 686 en Robert Bosch GmbH reserves all rights even in the event of industrial property rights. We reserve all rights Titelmasterformat Klicken bearbeiten Specificationdurch Requirements on Synthetic Diesel Fuel Common Rail Injector (RB Piezo Inline Injector) Multiple Injection Piezo actuator module nozzle module coupling module valve module 10 07/03/2006 007-05 686 Robert Bosch GmbH reserves all rights even in the event of industrial property rights. We reserve all rights of disposal such as copying and passing on to third parties. 5
Engine control with Common Rail System 11 07/03/2006 007-05 686 Robert Bosch GmbH reserves all rights even in the event of industrial property rights. We reserve all rights of disposal such as copying and passing on to third parties. Titelmasterformat Specificationdurch Requirements Klicken bearbeiten on Synthetic Diesel Fuel Contents 1. Introduction 2. Design of Common Rail System and components 3. Characteristics of typical Diesel fuels and impact on the fuel injection system 4. Impact on engine application and calibration 5. Summary and conclusions 12 6
Criteria for Good Diesel Fuel Quality (according to ACEA World-Wide Fuel Charter) 1. For Combustion, Efficiency and Emissions Cetane number 55 Total aromatics 15 % Polycyclic aromatics 2 % Sulphur content 10 ppm 2. For Function and Durability of FIE Lubricity, HFRR 460 µm Dirt / Particles 10 mg/kg (total contamination) Water 200 mg/kg, no free water No admixtures (FAME > 5 %, alcohol,...) 13 Specification Requirements on Synthetic Diesel Fuel Overview of Standardized Fuel Characteristics properties unit Diesel EN 590 (2005) Diesel (typical german quality 2005/2006) SynFuels (Bosch investigated samples) FAME EN 14214 (2003) cetan number 51 49.6 53.3 58... 80 51 density 15 C kg/m³ 820... 845 821.3 838.2 770... 800 860 900 total aromatics % (m/m) - 18.1 26.5 < 0.1 - (< 0.1) poly aromatics % (m/m) 11 1.1 4.1 < 0.1 - (< 0.1) sulfur content mg/kg 50 2009: 10 4 17 2 10 water content mg/kg 200 7 114 7 26 500 oxidation stability - EN 12205 sludge g/m³ 25 1 5 1... 91 - - EN 14112 induction period h - 13 >48 13... >48 6.0 lubricity µm 460 205 434 330... 580 * - ( 460) viscosity 40 C mm²/s 2.0... 4.5 2.3 3.4 2.6... 3.5 3.5 5.0 FAME content % (v/v) 5.0 < 0.1 5.0 < 0.1 96.5 distillation see distillation curve * without lubricity additive 14 CR/ARA2/DS/ENF 07/03/2006 007-5 686 en Robert Bosch GmbH reserves all rights even in the event of industrial property rights. We reserve all rights 7
Distillation Curves of Synthetic Diesel Fuels 400,0 350,0 temperature [ C] 300,0 250,0 200,0 150,0 100,0 50,0 0,0 0 10 20 30 40 50 60 70 80 90 100 volume [%] Synfuel #A Synfuel #B Synfuel #C Synfuel #D Synfuel #E DK EN 590_low DK EN590_high RME 15 CR/ARA2/DS/ENF 07/03/2006 007-5 686 en Robert Bosch GmbH reserves all rights even in the event of industrial property rights. We reserve all rights Titelmasterformat Specificationdurch Requirements Klicken bearbeiten on Synthetic Diesel Fuel Impact of Fuel Properties on the Injection System (1) high cetane number shorter ignition delay* lower density fuel mass injected reduced by 5 % because of volume metering characteristic of Common Rail System partly compensated by 3 % higher energy content per mass (not standardized) operation set points in ECU shifted by 2 % with respect to injected fuel energy* * eventually to be compensated by changed calibration 16 8
Titelmasterformat Specificationdurch Requirements Klicken bearbeiten on Synthetic Diesel Fuel Impact of Fuel Properties on the Injection System (2) sludge too high in one sample (accompanied by high acidity) to be below EN590 standard to be replaced or complemented by induction period low lubricity to be adjusted to necessary level for wear avoidance by appropriate additivation higher distillation curve influence on evaporation and mixture formation in cylinder* * eventually to be compensated by changed calibration 17 Titelmasterformat Specificationdurch Requirements Klicken bearbeiten on Synthetic Diesel Fuel Impacts of non-standardized Fuel Properties risk of cavitation and wear by higher volatility and lower density fuel behaviour at low and high temperature acid formation during ageing process additive compatibility elastomer compatibility with used NBR-sealings of older vehicles 18 CR/ARA2/DS/ENF 07/03/2006 007-5 686 en Robert Bosch GmbH reserves all rights even in the event of industrial property rights. We reserve all rights 9
Titelmasterformat Specificationdurch Requirements Klicken bearbeiten on Synthetic Diesel Fuel Contents 1. Introduction 2. Design of Common Rail System and components 3. Characteristics of typical Diesel fuels and impact on the fuel injection system 4. Impact on engine application and calibration 5. Summary and conclusions 19 Specification Requirements on Synthetic Diesel Fuel Part Load Behaviour of a Modern CV Engine (1) n=1130 rpm, q=115 mg/stroke (50% load), p Inj =2000 bar, SOI=1 atdc, max. EGR=36% Soot indi. [g/kwh] HC indi. [g/kwh] 0.06 0.05 0.04 0.03 0.02 0.01 0.00 0.24 0.20 0.16 0.12 0.08 0.04 0.00 0 4 8 12 16 20 Sc0163.IPW Seite 1 093/2 ; Diesel Fuel EN 590 101/2 ; GTL 20% 096/2 ; GTL 100% lower HC emission NO X,indi. [g/kw h] lower isfc NO X,indi. [g/kw h] lower NOx w/o EGR 0 4 8 12 16 20 205 200 195 190 185 180 175 2.4 2.0 1.6 1.2 0.8 0.4 0.0 isfc [g/kwh] CO indi. [g/kwh] Alle Rechte bei Robert Bosch GmbH, auch für den Fall von Schutzrechtsanmeldungen. Jede Verfügungsbefugnis, wie Kopier- und Weitergaberecht, bei uns. 20 DS/ENF 007-4 686 07/03/2006 007-05 686 Robert Bosch GmbH reserves all rights even in the event of industrial property rights. We reserve all rights 10
Part Load Behaviour of a Modern CV Engine (2) n=1130 rpm, q=115 mg/stroke (50% load), p Inj =2000 bar, SOI=1 atdc, max. EGR=36% Soot indi. [g/kwh] 0.06 0.05 0.04 0.03 0.02 0.01 0.00 0 1 2 3 4 5 6 Sc0163.IPW Seite 12 lower soot emission with EGR NO X,indi. [g/kw h] 093/2 ; Diesel Fuel EN 590 101/2 ; GTL 20% 096/2 ; GTL 100% Alle Rechte bei Robert Bosch GmbH, auch für den Fall von Schutzrechtsanmeldungen. Jede Verfügungsbefugnis, wie Kopier- und Weitergaberecht, bei uns. 21 Specification Requirements on Synthetic Diesel Fuel Full Load Behaviour of a Modern CV Engine n=1710 rpm, q=213 mg/stroke (100% load), p Inj =2400bar, SOI=-1 atdc, max. EGR=30% Soot indi. [g/kwh] 0.06 0.05 0.04 0.03 0.02 0.01 0.00 0 1 2 3 4 5 6 Sc0165.IPW Seite 12 NO X,indi. [g/kw h] 092/2 ; Diesel Fuel EN590 100/2 ; GTL 20% 095/2 ; GTL 100% Alle Rechte bei Robert Bosch GmbH, auch für den Fallvon Schutzrechtsanmeldungen. Jede Verfügungsbefugnis, wie Kopier- und Weitergaberecht, bei uns. 22 11
ESC Test Result Estimation at NOx=1g/kWh 1.2 Diesel Fuel EN 590 GTL 20% GTL 100% 0.06 215 1.0-34% 0.05 210 0.8 0.04 205 NOx [g/kwh] 0.6-2,2% 0.03 soot [g/kwh] 200 isfc [g/kwh] 0.4 0.02 195 0.2 0.01 190 0.0 NOx soot isfc 0.00 185 23 Titelmasterformat Specificationdurch Requirements Klicken bearbeiten on Synthetic Diesel Fuel Contents 1. Introduction 2. Design of Common Rail System and components 3. Characteristics of typical Diesel fuels and impact on the fuel injection system 4. Impact on engine application and calibration 5. Summary and conclusions 24 12
Summary / Conclusions XtL Diesel Fuel exhibits properties largely in compliance with the demands of a modern fuel injection system, but partly different to Diesel according to EN590 (density) or field quality (cetane number) combustion related properties are better than those of conventional Diesel due to different molecular structure of components for optimum results an adaption of engine calibration is necessary when pure GtL is used for low blend rates no calibration adaption is necessary, but lower advantages to be expected under these conditions (preferred short and mid-term solution from Bosch point of view) for an area-wide release intensive fleet testing is necessary to assure long term durability of the injection equipment XtL to offer chance for comprehensive optimization of engine, FIE and fuel for homogeneous Diesel combustion processes 25 13