US DOE Awards $4M for Renewable Systems Interconnection Support
ARB Delays Hearing on Modifying Test Procedures for HEVs and PHEVs

Alcohol Boosting Enables Significant Downsizing of Heavy-Duty Diesels to Smaller Gasoline Engines

Using a direct-injected alcohol fuel as a second, boosting fuel can allow a turbo-charged, high-compression ratio spark-ignited gasoline engine to replace larger diesels in certain heavy-duty applications, according to work being done by Ethanol Boosting Systems, LLC (EBS), a spin-off from MIT. (Earlier post.)

A study by EBS supported by Volvo Powertrain North America found that for a given engine size, an alcohol-boosted gasoline engine (spark-ignited, SI) could operate with about twice the torque and at higher horsepower than a baseline diesel. In a study presented at the DEER (Diesel Engine-Efficiency and Emissions Research) conference last week, EBS simulated a scaled, downsized 7-liter alcohol-boosted SI engine operating at a 14:1 compression ratio and found that it exhibited higher predicted efficiency than the baseline 11-liter diesel engine when operating over the boosted operating points.

The Ethanol Turbo Boost concept being developed by EBS uses the second boost fuel only under conditions of high torque, while operating on conventional gasoline throughout the rest of the engine map. This offers an alternative for heavy-duty vehicles that operate intermittently at high torque and within a bounded region, reducing the logistical issues of supplying the second fuel (e.g., a fleet, back-to-base application).

The ethanol boost technology uses direct injection (DI) of a knock-suppressing second fuel when the engine is prone to knock (usually at conditions of high torque). The cooling, which derives from the high latent heat of vaporization of the knock-suppressing fuel, typically a lower alcohol such as ethanol or methanol, is primarily responsible for this fact. Due to the charge cooling from the DI process, the effective octane rating greatly exceeds the chemical octane rating that these fuels would exhibit using conventional induction methods such as port fuel injection (PFI). In the ethanol-boosted concept, DI of the knock-suppressing fuel is used only in the amount required to prevent knock and gasoline is supplied to the cylinder by conventional PFI. Since the engine operates at stoichiometry (using a typical O2 feedback sensing system), a very high specific torque output can be produced while emissions can be maintained at low levels through the well proven and relatively simple three-way catalyst system without the use of EGR as a major diluent. The technology opens the possibility of a spark-ignited gasoline engine operating at high compression ratio (12 – 14) and high boost ratios of 2.0 – 2.5 times ambient pressure, which is sufficient to produce a torque output equivalent to or greater than more highly turbocharged heavy duty diesel engines operating lean with significant EGR.

—Blumberg et al. (2008)

The study evaluated E85 (85% ethanol blend) and M100 (100% methanol) as the knock-suppressing second fuels and found that the use of methanol reduces the storage requirements for the second fuel by about a factor of two. Other major conclusions of the study were:

  • The brake thermal efficiency of an ethanol-boosted 7-liter engine with premium gasoline as the primary fuel and E85 as the secondary fuel is comparable to the baseline 11-liter diesel. Using methanol as the direct-injection boost fuel does not materially affect the BTE comparison.

  • Volumetric fuel flows are higher (~30%) with the boosted 7-liter engine compared to the 11-liter diesel due to the lower density of gasoline and lower energy densities of the alcohol fuels relative to No. 2 diesel fuel.

  • CO2 emissions on a specific basis are less at all points with the EBS-conversion 7-liter engine as compared to the 11-liter diesel.

  • Emissions treatment (current and future) in EBS-conversion engines can be accomplished using the highly efficient and proven three-way catalyst system that is enabled by operation at stoichiometric air-fuel ratios.

  • In the absence of a knock-suppressing second fuel, premium gasoline can be used as the second fuel, allowing 50% of rated boost-torque.

  • As a result of the deletion of the high pressure fuel injection equipment, the use of a much simpler exhaust aftertreatment system and the reduction in the size of the engine, a significant reduction in up-front cost of the engine should be realizable.

To further improve the concept, EBS suggests that it may be possible to decrease substantially the amount of alcohol required through stratification of the alcohol injection, predominantly injecting the alcohol in those regions that will encompass the end gas. An additional concept would be to operate in the EBS mode under conditions of high torque, while operating in a more efficient mode at low torque. Relatively simple solutions such as operation with EGR can be used, EBS says, but they have not yet quantified the benefits. In addition, VVT or VCT can be used for minimization of the throttling losses.

EBS is also working with Ford and AVL on an optimized light-duty engine application targeted at the Ford F-Series trucks. The EBS engine is intended to demonstrate an improvement of fuel efficiency of 15-20% for E85. The approach here is to use a downsized, turbocharged, relatively high compression ratio V-8 with high low-end and mid-range torque, combined with an optimized transmission to support engine down-speeding at lower vehicle speeds. (Earlier post.)

Resources

Comments

Bill Young

High performance piston aviation engines have used water injection at high boost levels in the past to reduce knock and provide added cooling. How is this different other than using alcohol rather than water?

Bill

HarveyD

Ethanol dealers at work?

ToppaTom

This is not new astounding science, but Volvo capitalizing on their turbo experience.
Is the baseline 11 liter diesel engine NORMALLY aspirated?
Methanol has a very high octane rating and high evaporative cooling.
Much higher (on both counts) than ethanol and even more compared to “gas”. So this allows higher (diesel like) compression ratios.
When fuel economy was not an issue, durable diesel engines were still the choice even with their very low specific output, so now, durability and fuel economy are key.

arnold

If the 7liter alcohol version is using 30% more volumetric than a 50 % High turbo -BUT ALSO HIGH EGR - (there's the nub) larger diesel, then they are simply saying that the efficiencies "can" be optimised in an approximately equivalent fashion.
The high EGR gives cleaner emissions , while reducing power this is in part picked up by the turbo and efficiency regained partially by lean burn, but the clean burning alcohol engine needs only chase the bottom line, hence fewer penalties and equivalent output per emissions.

"which is sufficient to produce a torque output equivalent to or greater than more highly turbocharged heavy duty diesel engines operating lean with significant EGR."
arn

Roger Pham

Can these downsized gasoline engines last 1 million miles in comparison to their far beefier diesel brethens? Diesel fuel has superior lubricating property, and water or alcohol can dilute the lubricant film on the piston wall. The rapid combustion of pre-mixed charge in Otto-cycle engines won't help durability, either.

GreenPlease

This seems like a very promising approach to improving the fuel economy of ICE engines.

-This is all existing technology. Direct injection and ethanol are here now.
-I glanced through the material on EBS' website and didn't see anything that indicates that this technology is exclusive to acqueous ethanol. The ability to use acqueous or "wet" ethanol would improve the EROEI

Anyone care to speculate as to what sort of engine downsizing would be possible? E.g. would this boost technology allow for a move from a (gasoline) 3.0L V6 to a 1.0L I4 while maintaining power/torque? What sort of fuel savings would this represent? The smaller engine should have greatly reduced internal friction and pumping losses, not to mention that the BTE is higher witht the higher CR.

GreenPlease

@Roger

Do the engines NEED to last 1 million miles? For class 8 trucks the answer is yes. For LDVs, I would say half of that is perfectly reasonable.

Lad

@Roger:
Read where ULSD fuel has decided less lubrication qualities than high sulfur fuel...this could reduce the life of the diesel engine.

Henry Gibson

This is a second vote for pure water injection. But then the oil companies don't make it. Steam produced from engine cooling and superheated by the exhaust could also produce power boosts by the 100 year old Still system. ..HG..

kum dollison

They're backwards. I don't care if they are MIT; they're still backwards. Use a little gasoline injection to start the danged thing; and, then run straight ethanol, or e85.

GreenPlease

@kum dollison

Could you elaborate? What would the advantages be?

sjc

I like ethanol injection because you might be able to use wet ethanol which is less costly and time consuming to produce than dry ethanol.

arnold

Roger,
I'm sure I have no opinion one way or the other re alcohol fuels, but to do the article justice....
I know I can be as guilty as the next when reading (or not) these articles.
mostly dont balls up too badly (more by good luck than good measure .)

"To further improve the concept, EBS suggests that it may be possible to decrease substantially the amount of alcohol required through stratification of the alcohol injection, predominantly injecting the alcohol in those regions that will encompass the end gas."

kum dollison

Greenplease, oil is "going away;" thus, it's getting expensive. Ethanol, on the other hand, is going to get cheaper, and more plentiful. It's, also, more powerful than diesel when utilized in a high-compression engine.

It's weakness is cold-starts. It burns too cool. That's the only reason you need to mix it with gasoline. If you're going to do a dual-fuel injection, anyway, you might as well make ethanol your "Primary" fuel, and gasoline your secondary.

Andrey Levin

Roger:

Small portion of diesel charge, evaporated and mixed with air during ignition delay, undergoes explosive combustion (chemical oxidation with speed of sound, which at high pressure and temperature is close to 2000 m/s) and produces typical diesel “roar” and very high stress on mechanical parts. Hence diesel engines are built heavy, with tighter mechanical tolerances, and from better steel alloys. As a result, diesel engines are more expensive and last for very long time. It is not possible to produce diesel engine which lasts 100K miles: diesel knock will destroy it in a matter of hours. Combustion of the main portion of injected fuel in diesel engine is very slow, defined by speed of evaporation of diesel droplets and mixing with air (that’s why diesel cycle is generally termed “constant pressure” combustion).

Combustion of charge in gasoline engines is faster than combustion of main charge in diesel (generally “constant volume” combustion and cycle, with flame speed defined by chain reaction of oxidation of air/gasoline vapor at couple of m/s, increased by swirl of air in combustion chamber), but there is no explosion of any part of the charge. Stress on mechanical parts in gasoline engine is much lower than in diesel, and because of this gasoline engines are cheaper and could be built to last 50, 100, etc. K miles. If built according to diesel standards (and some industrial gasoline engines are), gasoline engine could last kinda forever.

Lubricating properties of diesel are important only to parts of high-pressure injectors. For compression rings and cylinder liners, diesel fuel is much worse than gasoline: carbon particles of diesel soot formed during diesel combustion are abrasive.

All in all, the only part of diesel engine which is cheaper and has lower stress than in gasoline engine is turbocharger (diesel exhaust is much cooler than gasoline).

If used only on rare occasions of full power (like in passenger vehicles), lubricating oil dilution and fracture of lubricating film on cylinder walls have negligible effect on engine wear, even if injected fluid is water.

yesplease

Looks like they're betting that in the future it would be cheaper to use ethanol from waste biomass to provide liquid fuel for HDVs than biodiesel from Soy/etc on cropland.

Franklin E. Fraitus

Don't forget diesel engines inject fuel into the combustion chamber right at the desired time, not before. This means no raw fuel reaches the cylinder walls, as the injection is timed when the piston is at or near TDC. This fuel is combusted right away. This is likely to be a major contributing factor in diesel engine lifespan.

Conventional gasoline engines ingest a fuel/air mixture. The result is a cylinder wall awash in fuel.

A variation of this "technology" is currently in use in the hot rod industry. It is common to inject water/methanol in high boost engines. This is often done right at the intake valve, to reduce or eliminate any evaporation taking place in the manifold. Also, toluene is used for the very same purpose. The results are very high specific hp/displacement.

GreenPlease

@kum

I see. This system would be able accomodate such a regime, though the ethanol fuel tank would probably have to be enlarged. In their literature, EBS states that the fraction ethanol used can be increased "...up to 100%."

GdB

This sounds great. I read the http://www.ethanolboost.com/EBS_Overview.pdf link. Seems like this could arrive to market much faster, given the low incremental cost and based on existing technology, low emmissions...

For heavy duty vehicles I doubt this system could approach the diesel operating cost.

One more comment. Downsizing really must not be forgotten, otherwise much of the efficiency will be squandered away. The V-8 should be shelved. The 330hp, 360ft*lb 1.9L engine would be plenty enough for midsize trucks etc. But I could see compacts using 100hp 800cc engines with this. And for small series HEV or PHEV a 250cc generator would be enough.

fred

Amazing. Buick had a 215 cu in high compression aluminum v8 with turbocharger and alcohol injection back in 1962 which was well ahead of its time. unfortunately people forgot to keep the alcohol tank filled and preignition killed quite a few engines. the rest ended up in sports car racing because it was a very strong engine with great reliability.Any time you do a dual fuel, even for water injection, you run the risk that the secondary fuel will be neglected.

Franklin E. Fraitus

The comment above by (no name given) is somewhat accurate. Downsizing the engine is a key factor in this scheme. However, a turbocharged 1.5L engine can make upwards of 1500HP with proper design and be reliable enough for F1 racing. At what point is the balance between power and truck like reliablity met? I suspect it is at a very low specific output.

Some here may not know what goes on inside an engine. For instance, the torsional stress on small crankshafts making big power reduce lifespan to mere hours. Aircraft piston engines of fairly low output, but high loading, (say 200HP) have massive crankshafts with dual torsional dynamic dampers to prevent certain destruction.

arnold

Lube oil contamination in deisel/carbon or volatile fuels will be a problem whenever injectors leak (dribble) or combustion is incomplete so as usual good maintainence and measure is always essential.
This is the reason for great benifit to gas fuels.

Roger Pham

Thanks, Franklin, for stating the much-needed response.

Heavy-duty diesel engine is already very much downsized in comparison to private automobiles. 11-liter engine for 60,000-80-000-lb gross vehicle weight rated. This, in comparison to a 7000-lb SUV having a 7-liter engine, meaning that the SUV is 7 times over-engined in comparison to a tractor-trailer rig. It is ridiculous to consider downsizing further a HDV diesel truck. When an engine is already working at high BMEP during cruise as in a HD truck engine, there will be nothing to be gained by further downsizing, while the reduction in durability and reliability will be certain.

The reason that big-bore truck engines are diesel and not gasoline is that big-bore gasoline engine would be much more susceptible to engine knocking (detonation) than smaller-bore automobile engines. The larger the SI engine bore, the higher likelyhood that a second flame front will be formed to collide with the one produced by the spark to produce engine knock. Piston aircraft engines have very low compression ratio of around 7-8, and require higher octane engine than 87 automotive engine, which is a lot more expensive, to prevent engine knocks. Water-alcohol injection was not new for WWII aircraft engines, and was used during takeoff and for War Emergency Power. This scheme is impractical for HDV use, since HDV engines frequently runs at maximum power during acceleration and during climbing even somewhat gradual grade, so, a lot of water or alcohol must be stored which would make it impractical.

Thanks, Andrey, for your input. Diesel's combustion is highly controlled and predictable, unlike SI engine's combustion which is highly unpredictable when susceptible to pre-ignition and detonation with tremendous stress on engine piston and conrod. Diesels are built sturdy due to the higher pressures involved, both from much higher compression ratio, resulted in higher combustion pressure. Gasoline SI engines have much lower compression ratio, hence much lower pressures involved and can be built lighter, but must be protected against detonation or pre-ignition which will destroy engine.

Fuel contamination of engine oil film is inevitable during engine start up, which requires a much richer mixture. Engine start up time is when most of engine wear will occur. The high lubricity of diesel fuel will help in this respect. Of course, gaseous fuels such as NG or H2 will eliminate this problem, however, data have shown that H2 has been hard on engine valve seats. Before more durable engine valve seat material was used, the lead used in gasoline has helped reduce engine valve seat wear.

The comments to this entry are closed.