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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Specification Requirements on Synthetic Diesel Fuelfrom the Perspective of a FIE Manufacturer
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
2
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Specification Requirements on Synthetic Diesel Fuelfrom the Perspective of a FIE Manufacturer
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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Specification Requirements on Synthetic Diesel Fuelfrom the Perspective of a FIE Manufacturer
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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Specification Requirements on Synthetic Diesel Fuelfrom the Perspective of a FIE Manufacturer
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.
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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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.
Design of Common Rail System (RB 3. Gen. )
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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.
Common Rail High Pressure Pump (RB CP3.2)
high pressure
low pressure
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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.
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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Specification Requirements on Synthetic Diesel Fuelfrom the Perspective of a FIE Manufacturer
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)
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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.
Specification Requirements on Synthetic Diesel Fuelfrom the Perspective of a FIE Manufacturer
Piezo actuator module
nozzle modulecoupling module
valve module
“Multiple Injection”
Common Rail Injector (RB Piezo Inline Injector)
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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.
Engine control with Common Rail System
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Specification Requirements on Synthetic Diesel Fuelfrom the Perspective of a FIE Manufacturer
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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Criteria for Good Diesel Fuel Quality (according to ACEAWorld-Wide Fuel Charter)
Specification Requirements on Synthetic Diesel Fuelfrom the Perspective of a FIE Manufacturer
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. 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
Specification Requirements on Synthetic Diesel Fuelfrom the Perspective of a FIE Manufacturer
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
Specification Requirements on Synthetic Diesel Fuelfrom the Perspective of a FIE Manufacturer
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.
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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Specification Requirements on Synthetic Diesel Fuelfrom the Perspective of a FIE Manufacturer
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.
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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Specification Requirements on Synthetic Diesel Fuelfrom the Perspective of a FIE Manufacturer
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.
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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Specification Requirements on Synthetic Diesel Fuelfrom the Perspective of a FIE Manufacturer
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.
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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Specification Requirements on Synthetic Diesel Fuelfrom the Perspective of a FIE Manufacturer
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
20
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205093/2 ; Diesel Fuel EN 590101/2 ; GTL 20%096/2 ; GTL 100%
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NOX,indi. [g/kW h]
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n=1130 rpm, q=115 mg/stroke (50% load), pInj=2000 bar, SOI=1° aTDC, max. EGR=36%
Specification Requirements on Synthetic Diesel Fuelfrom the Perspective of a FIE Manufacturer
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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NOX,indi. [g/kW h]
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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%
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.
lower soot emissionwith EGR
Specification Requirements on Synthetic Diesel Fuelfrom the Perspective of a FIE Manufacturer
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.
Specification Requirements on Synthetic Diesel Fuelfrom the Perspective of a FIE Manufacturer
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NOX,indi. [g/kW h]
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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
12
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.
Specification Requirements on Synthetic Diesel Fuelfrom the Perspective of a FIE Manufacturer
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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Specification Requirements on Synthetic Diesel Fuelfrom the Perspective of a FIE Manufacturer
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
13
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Summary / Conclusions
Specification Requirements on Synthetic Diesel Fuelfrom the Perspective of a FIE Manufacturer
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.
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