National Biodiesel Conference, February 4, 2008

Crankcase Oil Dilution Using Alternative Diesel Fuels

Stuart Johnson Engineering and Environmental Office Volkswagen Group of America

Volkswagen Group of America, EEO, February 4, 2008

Agenda
Diesel Engine Progress Emission Requirements Exhaust Gas Aftertreatment Post Injection Oil Dilution Concerns Oil Dilution Test Results Discussion

Volkswagen Group of America, EEO, February 4, 2008

Social Mobility Issues

Energy Greenhouse Gases CO2

Exhaust Emissions CO, NOX, HC, PM

1995 2000 2005 2010 2015 2020 2025 2030

Volkswagen Group of America, EEO, February 4, 2008

Environmental Goals in Vehicle Development

Production: save resources (energy, materials) low GHG impact build durable products Vehicle Characteristics: clean emissions good fuel economy low GHG impact examine alternative fuels consider renewable fuels

Volkswagen Group of America, EEO, February 4, 2008

Volkswagen Golf Diesel

First Diesel Golf I 1976 Recent Diesel Golf V 2003

Cylinder number Displacement Power Rational speed Maximum torque Maximum speed 0-100 km/h Consumption Curb weight

4 1.5L 50 HP 5000 rpm 84 Nm 140 km/h 18 sec 6.5 l/100km 780 kg

4 2.0L 140 HP 4200 rpm 320 Nm 203 km/h 9.3 sec 5.5 l/100km 1400 kg

Volkswagen Group of America, EEO, February 4, 2008

Diesel/Gasoline Comparison

Gasoline 2.0l Max. Power Max. Torque Max. Speed Acceleration 0 62 mph Acceleration 50 75 mph Mileage

Diesel 2.0l TDI

130 hp (96 kW) 140 hp (103 kW) at 5700 rpm at 4000 rpm 144 lb*ft (195 Nm) 235 lb*ft (320 Nm) at 3300 rpm at 1750-2500 rpm 131 mph 130 mph (210 km/h) (209 km/h) 9.9 s 13.5 s 30 mpg 9.5 s 11.4 s 42 mpg

Volkswagen Group of America, EEO, February 4, 2008

North American Region Emission Results

Emission regulation trends in North America Compared to the VW Jetta TDI

Volkswagen Group of America, EEO, February 4, 2008

Optimization of Combustion
Air and flow quality Number/layout of valves Timing/degree of delivery Rest gas and EGR Inlet/swirl Compression/inner flow Tumble Tightened flow Turbulence/3D flow field Injection pressure Injection pattern Nozzle inner flow Jet spread Jet speed Droplet current density Droplet diameter Intrusion depth Fuel quantity

Air

Fuel

Combustion chamber
Jet intensity Wall influence Evaporation Ignitable mixture Advanced reactions Ignition delay/self ignition Premixed combustion Diffusion combustion Flame spread Volkswagen Group of America, EEO, February 4, 2008

Diesel development for passenger cars in U.S.

Limit at 120,000 miles

0.10 0.08 0.06 0.04 0.02 0 0

Particulates [g/mi] TIER 2 /BIN 10 BIN 9

opt. injection opt. comb. process opt. air management opt. oxi-cat opt. fuel new combustion process

Basis DPF 0.2 0.3 0.4 0.5 NOx emission [g/mi]

Volkswagen Group of America, EEO, February 4, 2008

BIN 8 BIN 5 DeNOx

0.6

After-Treatment Components
Differential pressure sensor Diesel Oxidation Catalyst DOC Oxygen-Sensor Diesel Particulate Filter DPF EGR Filter H2S Slip Catalyst NOx- Storage Catalyst NSC Temperature sensors Exhaust throttle valve Oxygen-Sensor

Volkswagen Group of America, EEO, February 4, 2008

Fuel Properties and Their Influences

Injection
Viscosity Metals Additive package

Combustion
Boiling range, Cetane number, energy content

Exhaust gas Recirculation Boiling range, Cetane number, biodiesel content

Oxidation Catalyst
Sulfur content Phosphouros content Cetane number

Particulate Trap
Sulphur content Biodiesel content Ash precursors,

DeNOx

Sulfur content Phosphouros content

Volkswagen Group of America, EEO, February 4, 2008

Combustion of Diesel and Biodiesel

Longer ignition delay

Less fuel burnt in diffusion combustion

Mineral fuel RME (Biodiesel)

Energy/time

More fuel burnt in homogenous combustion

Post combustion phase

Time
Volkswagen Group of America, EEO, February 4, 2008

Temperatures in Front of the Particulate Trap

330 300 270 240 Temperature increase by engine management

Torque [Nm]

210 160 150 120 90 60

Soot combustion by temperature

CRT

Soot accumulation
30 0 1000 Particle filter system 1500 2000 2500 3000 3500 Engine Speed [1/min] Volkswagen Group of America, EEO, February 4, 2008 4000 4500

DPF Regeneration Mode

Volkswagen Group of America, EEO, February 4, 2008

Effect of Misuse with 350 ppm Sulphur Fuel

14

Effect of misuse
Sulphur loading on NSC [g] 12 10 8 6 4 2 0 0 5000 10000 Mileage [mi] 15000 20000
15 ppm 15 ppm, 50l 350 ppm

compliance with BIN 5 standard

Volkswagen Group of America, EEO, February 4, 2008

Boiling Range of Different Diesel Fuels

100% 90% 80% Evaporated [%] 70% 60% 50% 40% 30% 20% 10% 0% 0 50 100 150 200 250 300 350 400 450 500 Temperature [C] Mineral DF FAME (Biodiesel) Coc. derived -Methylester HVO BTL

Volkswagen Group of America, EEO, February 4, 2008

Oil Dilution During Particulate Trap Regeneration

Trap regenration

Biodiesel Fuel dilution Mineral Diesel

mileage
Volkswagen Group of America, EEO, February 4, 2008

Crankcase Oil Dilution Versus Fuel Blend Rate

typical: 60% Biodiesel 150%
Oil dilution (relative)

125% 100% 75% 50% 25% Neat Diesel 0 5 Biodiesel Content in the Fuel [%]
Volkswagen Group of America, EEO, February 4, 2008

typical: 45% Biodiesel

10

Consequences of Oil Dilution From Biodiesel

Oil coking, piston ring sticking

Volkswagen Group of America, EEO, February 4, 2008

Pre Results of DGMK Study 686

10 9 8 7 Fuel in Oil [Vol%] 6 5 4 3 2 1 0 One regeneration 12 Regenerations in 50 h 50 h high load run (without Regeneration)

B0 B10 Biodiesel

Volkswagen Group of America, EEO, February 4, 2008

DGMK 686: Concentrations of the end of the run

3 Concentration at the end of the Test Cycle [%] 2,5 2 1,5 1 0,5 0
el ie s FA M E VO l1 C oc D H h C .M E

Conclusions B10 FAME leads to high levels of biodiesel in the crankcase oil HVO Blends are at least compatible to Diesel Fuels with low boiling end are much better

is Sw ed

10

10

Volkswagen Group of America, EEO, February 4, 2008

10

Long Term Strategy of Volkswagen

Electricity renewable Hydrogen (regenerative) SunFuel Cellulose-Ethanol Natural Gas SynFuel Hybrid

Electrotraction Fuel cell

CCS

Crude Oil

Diesel Fuel Gasoline

TDI/TSI

Volkswagen Group of America, EEO, February 4, 2008

Thank you

Questions?
Volkswagen Group of America, EEO, February 4, 2008