1. Biodiesel
Technical
Training
Course
BIO
3A:
Biodiesel
Engine
and
Fleet
Performance
Presented by the
National Biodiesel Board

2. Learning
Objec-ves
• Provide
access
to
industry
experts
for
more
detailed
ques-ons
and
answers
about
biodiesel
• Introduce
the
Na-onal
Biodiesel
Board’s
Diesel
Technician
Training
program
and
the
program
resources
to
the
audience
• Provide
informa-on
regarding
engine
performance
and
fleets
using
biodiesel
and
biodiesel
blends
across
the
US
2

3. Learning
Outcomes
• Be
able
to
iden-fy
which
public
and
private
fleets
use
biodiesel
and
why
• Be
able
to
explain
the
key
changes
made
to
a
fleet
preventa-ve
maintenance
program
when
switching
to
biodiesel.
• Be
able
to
properly
diagnose
and
make
recommenda-ons
regarding
biodiesel
use
and
vehicle
performance
3

4. Key
Resources
• Department of Energy (DOE)
• B100 & Blends
• Material Compatibility
• Engine Performance
• Diesel and Biodiesel Emissions

5. Fleet
Management
Experiences

6. Fuel
proper-es
effects
on
Common
Rail
FIE
Specified Fuel properties: chemical, contamination, physical
Density Aromatics Flash Pt Viscosity
Cetane # Sulfur
& Volatility • Leakage control
• Startability • Corrosion • Fire Hazard
• Pressure
• Accurate SOI control • Elastomeric • Acid oxidation • Spill • Pressure control
compatibility Hazard
• Controlled HR • Quantity • Catalyst poisoning • Durability/Fatigue
control • Cavitation • Spark
damage • Smoke & Particulates Hazard • Filter plugging
Hard Particle and ash Water Oxidation Fatty Acid
Lubricity
contamination contamination Stability Methyl Esters
• Wear
• Abrasive Wear • Rough running • Gumming, sticking • Gumming, sticking
(misfire) • Scuffing
• Deposits • Deposits
• Filter plugging • Corrosion • Seizure
• Filter plugging • Filter plugging
OTC and Refiner Additives • Wear
• Corrosion & Wear • Corrosion / Wear
• Anticorrosion
• Cetane improvers Refining process Distribution and storage process
contaminants contaminants
• Cold flow improvers • Catalysts • tank bottoms * pumps, pipes
• Lubricity improvers • Desulfurization agents • microbial * corrosion
• Conductivity improvers • Cross contamination • algae *varnish/sludge

7. Biodiesel
Delivers
Important
Diesel
Proper-es
• Auto-­‐igni-on
=
Cetane
Number
over
50
• BTU
Content
=
Similar
to
#1,
less
than
#2
• Viscosity
=
Values
in
diesel
fuel
range
• Cloud
Point
=
Current
biodiesel
higher
than
#2
• Lubricity
=
Naturally
high
in
lubricity
• Sulfur
=
Naturally
less
than
15
ppm
• Cleanliness
=
ASTM
specs
same
as
petrodiesel
• Stability
=
Spec
set
for
6
month
min.
shelf
life
• Emissions
significantly
less
for
PM,
HC,
CO

8. Biodiesel
and
Engine
Manufacturers
• A]er
the
first
passage
of
ASTM
D6751
in
2001,
even
though
engine
manufacturers
voted
posi-ve
at
ASTM
most
were
not
yet
willing
to
put
their
name
behind
B20
• Na-onal
Biodiesel
Board
set
forth
on
intensive
effort
to
work
with
OEM’s
to
address
any
issues
and
concerns
• B20
Fleet
Evalua-on
Team
Formed:
Interna'onal,
John
Deere,
Na'onal
Biodiesel
Board,
Na'onal
Renewable
Energy
Lab,
Parker
–
Racor,
Siemens
Diesel
Systems,
Stanadyne
Corp,
Volkswagen
AG,
Volvo
Truck,
Fleetguard,
Bosch,
Case
New
Holland,
Caterpillar,
Cummins,
DaimlerChrysler,
Delphi
Diesel
Systems,
Department
of
Defense,
Engine
Manufacturers
Associa'on,
Ford
Motor
Co,
General
Motors
• Develop
fact
based
informed
posi-on
on
B20
• B20
Failure
Mode
and
Effects
Analysis
(FMEA)
• Detailed
iden-fica-on
of
everything
that
can
go
wrong
when
using
B20
• Rank:
Severity,
Occurrence,
Detec-on
modes
• Develop
RIN:
Risk
Iden-fica-on
Number
• Develop
plan
to
address
high
RIN
areas

9. B20 FET - Technical Guidance
and Recommendations
• Ensure
the
B20
blend
meets
proper-es
for
ASTM
D
975,
Standard
Specifica-on
for
Diesel
Fuel
Oils
or
the
ASTM
specifica-on
for
B20
once
it
is
approved.
• Ensure
your
B20
supplier
provides
a
homogenous
product.
Avoid
long
term
storage
of
B20
to
prevent
degrada-on.
Biodiesel
should
be
used
within
six
months.
• Prior
to
transi-oning
to
B20,
it
is
recommended
that
tanks
be
cleaned
and
free
from
sediment
and
water.
Check
for
water
and
drain
regularly
if
needed.
Monitor
for
microbial
growth
and
treat
with
biocides
as
recommended
by
the
biocide
manufacturer.
See
the
NREL
Biodiesel
Storage
and
Handling
Guidelines
for
further
informa-on.

10. B20 FET - Technical Guidance
and Recommendations
• Fuel
filters
on
the
vehicles
and
in
the
delivery
system
may
need
to
be
changed
more
frequently
upon
ini-al
B20
use.
Biodiesel
and
biodiesel
blends
have
excellent
cleaning
proper-es.
The
use
of
B20
can
dissolve
sediments
in
the
fuel
system
and
result
in
the
need
to
change
filters
more
frequently
when
first
using
biodiesel
un-l
the
whole
system
has
been
cleaned
of
the
deposits
le]
by
the
petrodiesel.
• Be
aware
of
B20’s
cold
weather
proper-es
and
take
appropriate
precau-ons.
When
opera-ng
in
winter
climates,
use
winter
blended
diesel
fuel.
If
B20
is
to
be
used
in
winter
months,
make
sure
the
B20
cloud
point
is
adequate
for
the
geographical
region
and
-me
of
year
the
fuel
will
be
used.

11. B20 FET - Technical Guidance
and Recommendations
• Perform
regularly
scheduled
maintenance
as
dictated
by
the
engine
opera-on
and
maintenance
manual.
If
using
B20
in
seasonal
opera-ons
where
fuel
is
not
used
within
6
months,
consider
storage
enhancing
addi-ves
or
flushing
with
diesel
fuel
prior
to
storage.
• These
recommenda-ons
on
use
of
B20
are
preliminary
and
are
not
provided
to
extend
or
supplant
warranty
limita-on
provided
by
an
individual
engine
or
equipment
supplier.
Use
of
B20
blends
is
solely
at
the
discre-on
and
risk
of
the
customer
and
any
harm
effect
caused
by
the
use
of
B20
are
not
the
responsibility
of
the
engine
or
equipment
maker.

12. B20 FET - Technical Guidance
and Recommendations
• Biodiesel
is
the
pure,
or
100
percent,
biodiesel
fuel.
It
is
referred
to
as
B100
or
“neat”
biodiesel.
• A
biodiesel
blend
is
pure
biodiesel
blended
with
petrodiesel.
Biodiesel
blends
are
referred
to
as
BXX.
The
XX
indicates
the
amount
of
biodiesel
in
the
blend
(i.e.,
a
B20
blend
is
20
percent
by
volume
biodiesel
and
80
percent
by
volume
petrodiesel
).
• Ensure
the
biodiesel
meets
the
ASTM
specifica-on
for
pure
biodiesel
(ASTM
D
6751)
before
blending
with
petrodiesel.
Purchase
biodiesel
and
biodiesel
blends
only
from
companies
that
have
been
registered
under
the
BQ-­‐9000
fuel
quality
program.

13. Today’s Fleet examples
 B20
Fleet
Evalua-on
Team
NREL/NBB
B20
Bus
Fleet
Evalua-on
B20
Cummins
1000
hr.
Durability
Test
US
Postal
Service,
St.
Louis
Bus
System
Denver
Regional
Transit
Bus
System
Las
Vegas
Valley
Water
District
Clark
County,
NV
School
District
Connec-cut
DOT;
Keene,
NH;
NC
DOT;
Cedar
Rapids,
IA
Buses,
etc.
etc.
etc.

14. Cummins
1000
Hour
Durability
B20
Study
 The
objec-ve
was
to
operate
the
engine
for
1000
hr
using
B20
biodiesel
fuel,
and
do
a
compara-ve
analysis
with
engines
that
have
operated
under
the
same
type
of
condi-ons
using
#2D
diesel
fuel.
Accelerated, high-load
durability cycle
hr
0 25 50 125 1000

15. Test
Engine
 Cummins
prototype
2007
ISL
 Six
cylinder
8.9
liter
 Rated
power
of
330
BHP
 Peak
torque
of
1150
]•lb
at
1300
rpm
 Diesel
Oxida-on
Catalyst
(DOC)
 Diesel
Par-culate
Filter
(DPF)
 Post
injec-on
(in-­‐cylinder)
for
ac-ve
regenera-on
 Variable
geometry
turbocharger
 Exhaust
gas
recircula-on
(EGR)
with
cooler
 Cummins
fuel
injec-on
system

16. Test
Cycles
Durability
Tes-ng
 Accelerated
High Idle
 High-­‐load
Peak Low Idle
Power
 Transient
cycle
 Varying
load
and
speed
Peak
Torque
 Cycle
repeated
for
1000
hr
>70% of durability
cycle at full load
Emissions
Tes-ng
 Federal
Test
Procedure
(FTP)
 One
cold
start
transient
FTP
test
 Three
hot
start
transient
FTP
test
 One
SET
Ramped
Modal
Cycle

17. Durability
&
Emission
Results
 Approximately
17,000
gallons
of
B20
biodiesel
fuel
was
used
during
the
durability
test.
 Test
went
well
and
was
successful.
There
were
no
biodiesel
related
failures
during
the
test,
and
no
reported
significant
changes
in
performance
of
the
engine.
 Engine
performance
was
essen-ally
the
same
when
tested
at
125
&
1000
hr
of
accumulated
durability
opera-on.
 Emission
results
indicate
that
THC,
CO,
and
PM
levels
were
not
significantly
different
between
the
B20
and
ULSD.
~The
emission-­‐grade
B20
test
resulted
in
≈6%
higher
NOx
(within
expected
range)
 Fuel
consump-on
was
observed
to
be
≈3%
higher
than
the
2007
cer-fied
ULSD
test
(within
expected
range).

18. Overhead
Components
Top of cylinder head No Bottom of cylinder head
sludge deposits Deposits comparable to #2D
Results are typical for this type of
test with #2D diesel fuel
Intake Valves Exhaust Valves

19. Power
Transfer
Components
Component
Comments
Crancksha]
Gear
Meets
rebuild
spec
Cam
Gear
Meets
rebuild
spec
Cam
Bushing
Meets
rebuild
spec
Fuel
Pump
Gear
Meets
rebuild
spec
Crancksha]
Meets
rebuild
spec
During teardown, the crankshaft was found
Lower
&
Upper
Normal
wear
to be in very good condition, and results
Bearings
were comparable to #2D diesel fuel test.
Connec-ng
Rod
Meets
rebuild
spec
Connec-ng
Rod
Meets
rebuild
spec
Bushing

20. Power
Cylinder
Components
Crosshatch visible in all six cylinders.
Component
Comments
Minor staining
Piston
Normal
light
wear
and
deposits.
Cylinder
Liners
Normal
light
wear.
Ring Grooves
Anti-Thrust Side
Top
rings
Normal
uniform
face
wear.
Cylinder 1
Top
and
booom
side
look
typical.
Middle
rings
Normal
face
wear.
Top
and
booom
sides
OK,
and
light
Top Piston
carboning.
Piston Bowl Front
Cylinder 1
Oil
rings
Looked
good.
Very
liole
wear.
Results comparable to #2D diesel fuel test.

21. Cooling
and
Lube
Components
Cylinder 1 Top
Component
Comments
Cylinder 6 Bottom
Oil
pump
No
issues
Oil
cooler
head
No
issues
Oil
cooler
cover
No
issues
Bottom (Oil) Piston Rings
Oil
pressure
No
issues
regulator/bypass
There were no failures found on the
Piston
cooling
No
problems
due
to
cooling and lube components. The
nozzles
B20.
wear and deposits found on the parts
were normal and consistent with
Oil
Pan
Normal
findings found on parts that ran with #2
Oil
suc-on
tube
Gasket
showed
good
diesel fuel in similar tests.
imprint
of
seal
Turbo
coolant/oil
Normal
lines

22. Air
Handling
Components
Component
Comments
Exhaust
Manifold
No
issues.
EGR
Cooler
No
cracks,
light
coa-ng
of
soot
on
inlet
and
outlet
tubes.
No
soot
in
inlet
diffuser.
Findings
good
overall.
EGR
Valve
Looked
good.
Normal
soot
accumula-on.
EGR
gaskets,
hoses,
No
issues
found
due
to
Carbon deposit layer was generated on the
tubes,
shield,
moun-ng
running
with
B20.
passage and inside parts of the EGR valve, but
plate,
crossover
thickness was very thin and condition was dry
which is normal for this durability test.

23. A]ertreatment
Components
Component
Comments
Diesel
Oxida-on
Looked
good.
No
face
plugging.
Catalyst
(DOC)
Blockages
found
appeared
like
debris
and
substrate
material.
Debris
was
analyzed
under
Electron
Dispersive
Spectroscopy
(EDS),
and
all
debris
found
is
expected
in
a
typical
DOC
a]er
1000
hr
of
opera-on,
whether
fueled
with
ULSD
or
biodiesel.
Diesel
Par-culate
Inlet
face
showed
signs
of
ash
build
up,
but
similar
to
diesel
fuel
for
Filter
(DPF)
this
type
of
test.
Outlet
looked
good
with
no
signs
of
soot.
No
failure
found.
Inlet
and
outlet
Looked
good.
sec-on
Gaskets
Looked
good.

24. Fuel
System
Pictures
Stage 1 Plunger Needle
Plunger Needle – Top View
No marks on
needle
surface or
the edge.
Some slight staining.
Plunger Orifice
not clogged with oil
sludge or deposits Stage 2 Plunger Needle
has some wear, but
normal for this type of
aggressive test.

25. Fuel
System
Components
Rail
and
fuel
lines
Rail
–
No
abnormal
wear.
End
Fi?ng
–
No
unusual
wear.
HP
Fuel
Lines
–
No
visible
structural
deteriora-on
or
cracks
observed.
Mechanical
Dump
No
unusual
wear,
deteriora-on
or
sludge
buildup
observed
on
plungers,
Valve
(MDV)
plunger
seats
or
orifice.
1)
Stage
One
Plunger
–
No
wear
visible
on
the
needle
surface
or
the
edge.
Some
slight
staining
seen
on
plunger
base.
2)
Stage
Two
Plunger
–
Some
wear,
but
normal.
Plunger
orifice
not
clogged
with
oil
sludge
or
deposits.
Injectors
Injector
performance
test
and
photos
indicate
that
the
injectors
were
consistent
with
injectors
that
ran
with
#2D
diesel
fuel.
So]
Lines
No
visible
damage
to
any
sec-on
of
the
internal
wall
of
the
used
fuel
tubes
indica-ng
that
the
tubing
liner
material
is
resistant
to
the
B20
temperatures
and
pressures
during
the
engine
performance
test.
Overall
There
were
no
signs
of
severe
or
aggressive
corrosion
pirng
damage
on
any
of
the
surfaces.

26. Summary
 A
Cummins
2007
prototype
8.9
liter
ISL
diesel
engine
equipped
with
DOC,
DPF,
VGT,
and
EGR
with
cooler
was
operated
successfully
at
SwRI
using
a
high-­‐load
accelerated
durability
cycle
for
1000
hr
with
a
B20
blend
of
soy-­‐based
biodiesel
and
ULSD.
 During
the
durability
tes-ng,
no
biodiesel
related
failures
occurred.
 Engine
performance
was
essen-ally
the
same
when
tested
at
125
and
1000
hr
of
accumulated
durability
opera-on.
Emissions
measurements
indicate
the
HC,
CO,
and
PM
were
not
significantly
different
between
the
B20
and
ULSD
tests,
and
NOx
increased
with
B20
fuel.
Fuel
consump-on
also
increased
with
B20
fuel.
 A
thorough
engine
teardown
evalua-on
of
the
overhead,
power
transfer,
cylinder,
cooling,
lube,
air
handling,
gaskets,
a]ertreatment,
and
fuel
system
parts
was
performed.
 There
were
no
failures
found
on
the
engine
components
that
were
directly
aoributable
to
running
biodiesel
B20.
 The
wear
and
deposits
found
were
normal
and
consistent
with
findings
from
parts
that
ran
with
#2
diesel
fuel
in
similar
tests.

36. Biodiesel
Resources
 www.biodiesel.org
• Biodiesel
Training
Toolkit
• News
Releases
&
Informa-on
Resources
• Technical
Library,
Spec
Sheets
&
Videos
• OEM
Warranty
Posi-ons
on
Biodiesel
•
U.S.
Diesel
Vehicle
List
 www.BQ-­‐9000.org
Rachel
Burton
NBB
Diesel
Technician
Training
Prog
• Lis-ng
of
BQ-­‐9000
Cer-fied
Companies
wrenchwench@blast.com
Tel:
919-­‐444-­‐3495
 www.biotrucker.com
Call
NBB
at
1-­‐800-­‐841-­‐5849
• Lis-ng
of
BioTrucker
retail
sites
Visit
www.biodiesel.org
 www.biodieselautomoNve.org
36
• Dedicated to information exchange for biodiesel & diesel
technicians