8 march 2004 ethanol as fuel for recreational boats engs 190/engg 290 final report sponsor:...
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8 March 2004
Ethanol as Fuel for Recreational Boats
ENGS 190/ENGG 290 Final ReportSponsor: Professor Charles Wyman
Group Members:Erik Dambach, Adam Han, Brian Henthorn
www.dartmouth.edu/~ethanolboat
www.mercurymarine.com
Ethanol as Fuelfor Recreational Boats
Presentation Outline
• Need Statement and Background
• Engine Choice and Modifications
• Specifications and Testing
• Marketability
• Conclusions
• Acknowledgements
Ethanol as Fuelfor Recreational Boats
Need Statement
Due to the potential for environmental contamination by gasoline in recreational boating, fuel ethanol is a potential solution
to reduce pollution associated with recreational boating.
Ethanol as Fuelfor Recreational Boats
Why Ethanol?
• Recreational boating with gasoline as a fuel is a major source of pollution for both water and air
• Ethanol, unlike gasoline, is biodegradable and low in toxicity
• Ethanol is comprised of much fewer chemicals than gasoline
• As an additive, the use of ethanol as a fuel has the ability to allow for cleaner combustion and to lower air emissions
• Ethanol is a renewable source of energy
Ethanol as Fuelfor Recreational Boats
State of the Art
• The use of ethanol as a fuel has mainly been focused on the automotive industry
• There are limited studies of ‘alternative fuels’ in boating applications
• Fuel ethanol has never been researched for recreational boating
• Ethanol was investigated along with other ‘alternatives’ in use to strengthen fuel choice
Ethanol as Fuelfor Recreational Boats
Alternative Fuels for Gasoline Marine Engines
Ethanol as Fuelfor Recreational Boats
California Case Study
• US fuel prices and regulations vary by region
• Toughest emission regulations in country
• High price of gasoline• Supportive of alternative
fuel technology• Phase-out of MTBE
replaced with EtOH• 2nd most registered
number of boats in US• Discourages the use of
carbureted two-strokes
Ethanol as Fuelfor Recreational Boats
California Case StudyProjected Price Range* for Ethanol
Sale in California at Marinas Production Cost $1.020
Price Incentive $0.050
Transportation/handling costs $0.146 ─ $0.187
Excise Tax Rate $0.090
Mark-up $0.350
Projected California Price Range $1.656 ─ $1.697
Gasoline Equivalent Price Range $1.441 ─ $2.562
*Price per gallon of ethanol
Ethanol as Fuelfor Recreational Boats
Engine Overview
• 2000 Mercury 5 hp Four-Stroke Outboard
• Four-stroke for smaller needs (<90hp)
• Necessary Modifications– Materials Compatibility– A/F ratio– Cold-start
Ethanol as Fuelfor Recreational Boats
Materials Compatibility• Rubber Tubing, O-Rings
– Soaked in EtOH– Tubing replaced with
Viton B– O-rings replace with Butyl
Dupont Dow Elastomers Chemical Resistance Guide
Ethanol as Fuelfor Recreational Boats
Replacement of Rubberin Fuel System
Tubing
Drainage screw o-ring
Fuel pumpo-ring
Intake manifold o-ring
Ethanol as Fuelfor Recreational Boats
Materials Compatibility• Rubber Tubing, O-Rings
– Soaked in EtOH– Tubing replaced with
Viton B– O-rings replace with Butyl
• Fuel Filter– Soak in EtOH– Not needed to be replaced
• Metal Corrosion– Determine primary metal in
Fuel System using EDS on SEM
Dupont Dow Elastomers Chemical Resistance Guide
Ethanol as Fuelfor Recreational Boats
Energy-dispersive X-Ray Spectroscopy (EDS)
Main Jet - Brass Fuel Pump – Aluminum
Ethanol as Fuelfor Recreational Boats
Carburetor
Source: Mercury Service Manual, 4/5/6HP 4-Stroke
Ethanol as Fuelfor Recreational Boats
Carburetor Modifications• Enlarge Main Jet inner diameter by 20-40%
– (.033”, .036”,.039”)
Main JetMain Nozzle
Ethanol as Fuelfor Recreational Boats
Cold-start Solutions
Cold Start Method Portability Availability Fuel Cost Retrofit CostEffectiveness (single start) Repeatability
Environ. Impact Ease of Use TOTAL TOTAL weighted
Gasoline 5 5 3 4 4 1 8 4 34 77Propane 6 6 4 5 4 1 7 5 38 88Natural Gas 7 7 2 6 4 1 4 6 37 94Hydrogen Gas 1 1 0 8 1 1 3 7 22 66Diethyl Ether (EtOH) 1 1 0 7 2 1 5 7 24 68Diethyl Ether (Starting Fluid) 4 4 1 1 2 1 5 1 19 39Electric Heater (outlet) 8 8 0 2 7 1 1 1 28 74Electric Heater (battery) 1 3 0 3 7 7 1 1 23 66
Ethanol as Fuelfor Recreational Boats
Other Important Modifications
• Ignition Timing– Advance ignition timing for EtOH– Unfortunately, not possible with Mercury
outboard engine
• Compression Ratio – Increase (8.5:1~11:1)– Extremely expensive– Can only be drastically altered at production
stage
Ethanol as Fuelfor Recreational Boats
Target SpecificationsArea Quantification Justification Test
Environmental
NOx + HC emissions 1770.8 PPM 2008 CARB Exhaust Emissions Standard
Snap-on MT3505 Emissions Analyzer at Vermont Technical College
CO emissions 0.85% (reduction by 10%) The reduction is acceptable or ethanol to be preferred over gasoline.
Same as above
Performance
Horsepower 5 hp (100% of running on gasoline)
Maximum power output of gasoline engine
Torque, RPM, horsepower relationship
Efficiency At least 0.0140 gal/hr-hp (at least 66.7% of gasoline)
Energy content ratio of gasoline to ethanol
Run known volume of fuel until engine stopped
Cold-start Must start above 30°F Minimum starting temperature of gasoline engine
Start at cold temperature
Weight < 62.7 lbs. (110% of original engine weight)
According to Fairlee Marine Scale
Economics
Overall cost to retrofit (excluding labor)
$250 (25% of engine value maximum)
Alternative Fuel Data Center vehicle cost analysis
Economic analysis
Ethanol as Fuelfor Recreational Boats
Testing Methodology
Ethanol as Fuelfor Recreational Boats
Testing Methodology
Ethanol as Fuelfor Recreational Boats
Testing Setup
• Preparation for testing– Construct test stand– Break in engine
• Fuel Used– Gasoline: Shell 87 Octane
Unleaded– Ethanol: Ethanol with
Natural Gasoline Denaturant (2-5%)
• Testing Facilities– Emissions testing at
Vermont Technical College– Thayer School Ice Lab– Thayer School Loading
Dock
Ethanol as Fuelfor Recreational Boats
Emissions Testing
• Snap-on MT3505 Emissions Analyzer
• Emissions Analyzed– Hydrocarbons– NOx– CO
– CO2
• Tested at each throttle range (idle, mid, full)
• Tested at each jet size (.028”, .033”, .036”, .039”)
Ethanol as Fuelfor Recreational Boats
Emissions Testing Results
• Full and Mid-throttle testing– Idle is
independent of main jet size
• EtOH had dramatic reductions in emissions at .033” jet size
Hydrocarbon and NOx Emissions
3825
819.5
19532481
241.25 89.5314.25 403
0500
10001500200025003000350040004500
Gas EtOH (.033) EtOH (.036) EtOH (.039)
Fuel (Jet diameter in inches)
PP
M Full Throttle
Mid Throttle
Ethanol as Fuelfor Recreational Boats
Emissions Testing Results
• CO emissions– Increase using
EtOH
• Engine not optimized for EtOH combustion– Lower CO2 values
• .033” jet similar to gas emissions
CO and CO2 Emissions
0.00%
2.00%
4.00%
6.00%
8.00%
10.00%
12.00%
14.00%
Gas EtOH(.033)
EtOH(.036)
EtOH(.039)
Fuel (Jet diameter in inches)
%
Full Throttle CO%
Full Throttle CO2%
Mid Throttle CO%
Mid Throttle CO2%
Ethanol as Fuelfor Recreational Boats
Power Testing
• Power Calculated using:
• Torque = 4.22ft-lb at full throttle running on gasoline
• ~5 horsepower– .033” jet– .036” jet
Maximum Power Output
4.5
4.6
4.7
4.8
4.9
5
5.1
Gasoline EtOH - 0.028" diam. jet EtOH - 0.033" diam. jet EtOH - 0.036" diam. jet EtOH - 0.039" diam. jet
Fuel and Jet Size
hp
RPM
hplbfttorque
5252)(
Ethanol as Fuelfor Recreational Boats
Fuel efficiency testing
• Put in known amount of fuel (500 mL)
• Run until the engine stopped– Record run duration
time
• Measure amount of remaining fuel
Ethanol as Fuelfor Recreational Boats
Fuel Efficiency with Power
• Divide fuel efficiency by power output
• .036” jet size– closest to gasoline
efficiency
• .028” jet size (original optimized for gasoline)– Did not sustain
combustion of EtOH
Full-Throttle Efficiency with Power
0.093
0.1340.142
0.122
0.203
0
0.05
0.1
0.15
0.2
0.25
Gasoline EtOH - 0.028" diam. jet EtOH - 0.033" diam. jet EtOH - 0.036" diam. jet EtOH - 0.039" diam. jet
Fuel and Jet Size
gal
/hr-
hp
Ethanol as Fuelfor Recreational Boats
Cold-start Testing
• Gasoline Benchmark– Location: Cold room in ice lab, – Engine temperature monitored
with Fluke IR Thermometer– Cold room initially at 20°F– Warm cold room and engine
gradually
• Results– Below 30°F, engine did not
start– At 30°F, engine started with
much difficulty, requiring 15 pulls of recoil starter rope
• EtOH Testing– Location: Loading dock– Minimized difference between
• Results– Engine would not start at 30°F
without cold-start assist– Ether-assist achieved ignition
in four applications (pull of starter rope couple with ether spray into carburetor)
– EtOH engine with cold-start achieved ignition quicker than gasoline-powered engine
Ethanol as Fuelfor Recreational Boats
Determination of Optimal Jet Size
• .033” and .036” jet sizes determined optimal air-fuel ratio– .033” preferred due to reduced emissions,
slightly reduced efficiency
Jet Diameter (in.) Emissions Efficiency Power Total
0% (0.028) 4 4 4 12
20% (0.033) 1 2 1 4
30% (0.036) 2 1 1 4
40% (0.039) 3 3 3 9
Ethanol as Fuelfor Recreational Boats
Engine Economic Analysis
• Actual modification cost relatively minor– Rubber replacements
relatively inexpensive
• Labor costs significant, but within specification
• EtOH fuel costs for 60gal/yr increase from $101 to $141 compared to gasoline
Modification Cost without Labor Cost with Labor
Tubing $25.00 $25.00
O-ring $9.06 $9.06
Labor $0.00 $45.00
Jet Size $0.00 $0.00
Labor $0.00 $60.00
TOTAL $34.06 $139.06
Ethanol as Fuelfor Recreational Boats
Target vs. Actual SpecificationsArea Target Specification Actual Specification % Deviation from
Specification (if does not satisfy)
Environmental
NOx + HC emissions <1770.8 PPM 819.5 PPM
CO emissions <0.85% (reduction by 10%) 1.03% 21.2%
Performance
Horsepower >5 hp (100% of running on gasoline – no compression ratio change)
5.06 hp
Efficiency At least 0.140 gal/hr-hp (at least 66.7% of gasoline)
0.142 gal/hr-hp 1.4%
Cold-start Must start above 30°F Started above 30°F
Weight < 62.7 lbs. (110% of original engine weight)
57 lbs.
Economics
Overall cost to retrofit (excluding labor)
<$250 (25% of engine value maximum)
$34.06
Ethanol as Fuelfor Recreational Boats
Engine Marketability
“The buying public always looks towards mainstream success for their purchasing decision. If a product has had success and proven to perform at or near that of a
gasoline powered engine, they will most certainly consider it. “
-Randy Stratton, The Stratton Group
Although there are a lot of environmentally-conscious people, they are often unwilling to pay anything extra.
-Chris Virgo, mechanic at North Tahoe Marina
Ethanol as Fuelfor Recreational Boats
Timeline for ENGS 190 TASKS 1 2 3 4 5 6 7
Environmental
Background Research
Investigate fate and transport for gasoline and ethanol
Investigate effects of gasoline and ethanol in lakes
Investigate regulations
Economic Case Study
Background Research
Determine most applicable location
Investigate infrastructure for introducing fuel ethanol
Investigate cost associated with infrastructure
Determine retail cost of ethanol on lakes
Technical
Background Research
Determination of engine type for modification
Investigate adaptation of engines for ethanol
Investigate cold start technologies
Evaluate literature research
Search for and secure an engine
Written Proposal
Oral Proposal
Written Progress Report
Oral Progress Report
Ethanol as Fuelfor Recreational Boats
Timeline for ENGG 290TASKS 1 2 3 4 5 6 7 8
Pre-testing procedure and preparation
Design retrofit for engine
Benchmark testing for gasoline
Materials acquisition for retrofit
Construct prototype for ethanol
Test ethanol prototype for performance
Test ethanol prototype for emissions
Cost analysis of retrofitted engine
Investigate marketability of engine
Investigate implementation of engine
Implementation report via website
Oral Progress Report
Written Final Report
Oral Final Report
Ethanol as Fuelfor Recreational Boats
Project Conclusions
• Ethanol was found to out-perform gasoline environmentally for water and air pollution in recreational boating applications
• Ethanol as a fuel has high potential given the infrastructure, fuel cost, and environmental policy trends
• A four-stroke outboard engine was successfully modified to run on ethanol fuel
• Testing of the engine running on ethanol showed similar performance in terms of power, varied for emissions, and decreased fuel efficiency
• Website: www.dartmouth.edu/~ethanolboat
Ethanol as Fuelfor Recreational Boats
Recommendations
• Obtain dynamometer for engines of low hp to strengthen existing data
• Determine optimal jet size between 20% and 30%
• Alter compression ratio/timing to further optimize the engine at manufacturer level
• Research effects of ethanol materials and potential long-term replacements to increase longevity of engine
• Use findings to further ethanol-fueled engine research
Ethanol as Fuelfor Recreational Boats
AcknowledgementsAt Thayer School:Prof. Charles WymanProf. John CollierProf. Robert GravesDoug FraserGary DurkeeThayer School Instrument RmThayer School Machine ShopPaula BergProf. Benoit Cushman-RoisinProf. Horst RichterJoan LevyCathy FollensbeeWilliam CoteBin YangDaniel IliescuDaniel Cullen
Outside sources:Fairlee Marine Betsy Dorries and Steve Belitsos at Vermont
Technical CollegeRoberta NicholsTerry Jaffoni and Jackie Fee of CargillMichael O'Keefe and Professor Phil Malte at
University of WashingtonDon Mathey at Donlee Pump Company California Air Resources BoardEnvironmental Protection Agency (especially Stout
Alan)Edward Nelson at Wisconsin Department of Natural
ResourcesTom Durbin at University of California RiversideWarren H. Hunt of the Aluminum AssociationGarland Lewis at TohatsuJohn Cruger-Hansen Jeff Schloss at University of New HampshireJack Hull at Rainbow Rubber ExtrusionsJay Kidwell at The Carburetor Shop, Inc. and Mile
High PerformanceBones Gate FraternityZeta Psi Fraternity