specification requirements on synthetic diesel fuel · pdf filepiezo actuator module ......

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Specification Requirements on Synthetic Diesel Fuelfrom the Perspective of a FIE Manufacturer

07/03/2006 | 007-05 686 | © Robert Bosch GmbH reserves all rights even in the event of industrial property rights. We reserve all rights ofdisposal such as copying and passing on to third parties.

Specification Requirements onSynthetic Diesel Fuel from the

Perspective of a FIE Manufacturer

Dr. Heinz StutzenbergerDS/ENF Engineering FuelsRobert Bosch GmbH

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DS/ENF | 07/03/2006 | 007-05 686 | © Robert Bosch GmbH reserves all rights even in the event of industrial property rights. We reserve all rightsof disposal such as copying and passing on to third parties.

1. Introduction

2. Design of Common Rail System and components

3. Characteristics of typical Diesel fuels and impact onthe fuel injection system

4. Impact on engine application and calibration

5. Summary and conclusions

Contents

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3



1. Introduction





Contents


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1. Introduction





Contents

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2000 bar1.5 ms 1 mm3/stroke

injectiontime

injectioncharacteristic

injectionpressure

min. injectionquantities

injectionfrequency

16000cycles/min.@ 250 Hz

°crksft

mm3/°crksft

= 1.5 ms^

Boundary conditions of Diesel high press. injection

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Design of Common Rail System (RB 3. Gen. )

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Common Rail High Pressure Pump (RB CP3.2)

high pressure

low pressure

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Common Rail High Pressure Pump (RB CP3.2)

metering unit

polygon

cone drive

suction valve

HP valve

plunger

LP connector

HP connector

backflowconnector

monobloc housing

flange

barrel tappet

gear pump

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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 allrights of disposal such as copying and passing on to third parties.

armature stroke0.040 mm ± 0.004

= 40 ± 5 µm

residual air gap0.065 ± 0.010 mm= 65 µm ± 10 µm

plunger clearance0.00395 ± 0.00075 mm

= 3.95 µm ± 0.7 µm

nozzle needle clearance0.0018 – 0.0031 mm

= 2 - 4 µm

spray hole0.150 ± 0.003 mm= 150 µm ± 5 µm

Common Rail Injector (RB CRI1)


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 ofdisposal such as copying and passing on to third parties.


Piezo actuator module

nozzle modulecoupling module

valve module

“Multiple Injection”

Common Rail Injector (RB Piezo Inline Injector)

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Engine control with Common Rail System


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1. Introduction





Contents

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Criteria for Good Diesel Fuel Quality (according to ACEAWorld-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, ...)

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properties unitDiesel

EN 590 (2005)Diesel

(typical germanquality 2005/2006)

SynFuels(Bosch investigated

samples)

FAMEEN 14214 (2003)

cetan number ≥ 51 49.6 … 53.3 58 ... 80 ≥ 51density 15°C kg/m³ 820 ... 845 821.3 … 838.2 770 ... 800 860 … 900total 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: ≤ 104 … 17 ≤ 2 ≤ 10

water content mg/kg ≤ 200 7 … 114 7 … 26 ≤ 500oxidation 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 … 5.0FAME content % (v/v) ≤ 5.0 < 0.1 … 5.0 < 0.1 ≥ 96.5distillation see distillation curve


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. Wereserve all rights of disposal such as copying and passing on to third parties.

Overview of Standardized Fuel Characteristics

* without lubricity additive

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volume [%]0 10 20 30 40 50 60 70 80 90 100



Distillation Curves of Synthetic Diesel Fuels400,0

350,0

300,0

250,0

200,0

150,0

100,0

50,0

0,0

tem

pera

ture

[°C

]

Synfuel #ASynfuel #BSynfuel #CSynfuel #DSynfuel #EDK EN 590_lowDK EN590_highRME


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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

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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


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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

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1. Introduction





Contents

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HC

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.[g

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0.00

0.04

0.08

0.12

0.16

0.20

0.24

NOX,indi. [g/kW h]

0 4 8 12 16 20

isfc

[g/k

Wh]

175

180

185

190

195

200

205093/2 ; Diesel Fuel EN 590101/2 ; GTL 20%096/2 ; GTL 100%

CO

indi

.[g

/kW

h]

0.0

0.4

0.8

1.2

1.6

2.0

2.4

NOX,indi. [g/kW h]

0 4 8 12 16 20

n=1130 rpm, q=115 mg/stroke (50% load), pInj=2000 bar, SOI=1° aTDC, max. EGR=36%


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. Wereserve all rights of disposal such as copying and passing on to third parties.

lower isfclower NOxw/o EGR

lower HC emission

Part Load Behaviour of a Modern CV Engine (1)

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0.00

0.01

0.02

0.03

0.04

0.05

0.06

NOX,indi. [g/kW h]

0 1 2 3 4 5 6

093/2 ; Diesel Fuel EN 590101/2 ; GTL 20%096/2 ; GTL 100%

n=1130 rpm, q=115 mg/stroke (50% load), p Inj=2000 bar, SOI=1° aTDC, max. EGR=36%


lower soot emissionwith EGR


Part Load Behaviour of a Modern CV Engine (2)

22 DS/ENF | 07/03/2006 | 007-05 686 | © Robert Bosch GmbH reserves all rights even in the event of industrial property rights. We reserve all rightsof disposal such as copying and passing on to third parties.



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0.00

0.01

0.02

0.03

0.04

0.05

0.06

NOX,indi. [g/kW h]

0 1 2 3 4 5 6

092/2 ; Diesel Fuel EN590100/2 ; GTL 20%095/2 ; GTL 100%

n=1710 rpm, q=213 mg/stroke (100% load), pInj=2400bar, SOI=-1° aTDC, max. EGR=30%

Full Load Behaviour of a Modern CV Engine

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23 DS/ENF | 07/03/2006 | 007-05 686 | © Robert Bosch GmbH reserves all rights even in the event of industrial property rights. We reserve all rightsof disposal such as copying and passing on to third parties.


NO

x[g

/kW

h]

0.0

0.2

0.4

0.6

0.8

1.0

1.2

NOx soot isfc

Diesel Fuel EN 590GTL 20%GTL 100%

isfc

[g/k

Wh]

185

190

195

200

205

210

215

soot

[g/k

Wh]

0.00

0.01

0.02

0.03

0.04

0.05

0.06

ESC Test Result Estimation at NOx=1g/kWh

-34%

-2,2%


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1. Introduction





Contents

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Summary / Conclusions



XtL Diesel Fuel exhibits properties largely in compliance with the demands ofa modern fuel injection system, but partly different to Diesel according toEN590 (density) or field quality (cetane number)

combustion related properties are better than those of conventional Dieseldue to different molecular structure of components

for optimum results an adaption of engine calibration is necessary when pureGtL is used

for low blend rates no calibration adaption is necessary, but lower advantagesto be expected under these conditions (preferred short and mid-term solutionfrom Bosch point of view)

for an area-wide release intensive fleet testing is necessary to assure longterm durability of the injection equipment

XtL to offer chance for comprehensive optimization of engine, FIE and fuel forhomogeneous Diesel combustion processes

specification requirements on synthetic diesel fuel · pdf filepiezo actuator module ......

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