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2010 Annual Progress Report for Fuels Technologies

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2010 Annual Progress Report for Fuels Technologies 20annual progress 10report Fuels Technologies For more information DOE/EE-0725 January 2011 1-877-EERE-INFO (1.877.337.3463) Printed with a renewable-source ink on paper containing eere.energy.gov at least 50% wastepaper, including 10% post consumer waste. U.S. Department of Energy 1000 Independence Avenue, S.W. Washington, D.C. 20585-0121 FY 2010 PROGRESS REPORT FOR FUELS TECHNOLOGIES Energy Efficiency and Renewable Energy Vehicle Technologies Program Approved by Kevin Stork Team Leader, Fuels Technologies Vehicle Technologies Program February 2011 DOE-FT-2010AR FY 2010 Progress Report i Fuels Technologies Acknowledgement We would like to express our sincere appreciation to Alliance Technical Services, Inc. and Oak Ridge National Laboratory for their technical and artistic contributions in preparing and publishing this report. In addition, we would like to thank all the participants for their contributions to the programs and all the authors who prepared the project abstracts that comprise this report. Fuels Technologies ii FY 2010 Progress Report Table of Contents I. Introduction . 1 II. Fuels and Lubricants to Enable High Efficiency Engine Operation while Meeting 2007 - 2010 Standards. 19 II.1 Oak Ridge National Laboratory: Effects of Fuel and Lubricant Properties on Advanced Engine Emission Control; Development of Rapid Aging and Poisoning Protocols. 21 II.2 Oak Ridge National Laboratory: Non-Petroleum-Based Fuels: Effects on EGR System Performance . 27 II.3 Oak Ridge National Laboratory: Non-Petroleum-Based Fuels: Effects on Emissions Controls Technologies. 30 III. Fuel Property Effects on Advanced Combustion Regimes . 37 III.1 Oak Ridge National Laboratory: Fuel Effects on Advanced Combustion Engines . 39 III.2 Sandia National Laboratories: Optical-Engine Investigations of Fuel and Operating-Condition Effects on In-Cylinder Liquid-Phase Fuel Penetration. 45 III.3 Lawrence Livermore National Laboratory: Chemical Kinetic Modeling of Advanced Transportation Fuels . 51 III.4 Lawrence Livermore National Laboratory: Improving Advanced Fuel Utilization through Detailed Chemical Kinetic Combustion Modeling . 55 III.5 National Renewable Energy Laboratory: Advanced Petroleum-Based Fuels Research at NREL . 59 III.6 National Renewable Energy Laboratory: Fuels for Advanced Combustion Engines (FACE) – Development of Research Fuels Matrix . 64 III.7 Oak Ridge National Laboratory: Non-Petroleum Fuel Effects in Advanced Combustion Regimes. 70 III.8 Sandia National Laboratories: Alternative Fuels DISI Engine Research . 75 III.9 Oak Ridge National Laboratory: Enabling High-Efficiency Ethanol Engines . 80 III.10 Oak Ridge National Laboratory: CRADA with Reaction Design. 84 IV. Petroleum Displacement Fuels/Fuel Blending Components. 89 IV.1 National Renewable Energy Laboratory: Biodiesel Impact on Performance and Durability of DOC and DPF Systems. 91 IV.2 National Renewable Energy Laboratory: Biofuels Quality Surveys in 2010. 94 IV.3 National Renewable Energy Laboratory: Understanding Biodiesel Low Temperature Operability Issues . 99 IV.4 Oak Ridge National Laboratory: Advanced Chemical Characterization of Non-Petroleum-Based Fuels and Emissions for Understanding Effects on Combustion. 103 IV.5 National Renewable Energy Laboratory: Evaluating Compatibility of New and Legacy Infrastructure with E15. .106 IV.6 National Renewable Energy Laboratory: Headspace Flammability of Gasoline/Ethanol Blends. 109 IV.7 Oak Ridge National Laboratory: Mid-Level Ethanol Blends Vehicle Aging Program . 113 IV.8 General Motors Powertrain: The Use of Exhaust Gas Recirculation to Optimize Fuel Economy and Minimize Emissions in Engines Operating on E85 Fuel. 119 IV.9 MAHLE Powertrain LLC: Optimally Controlled Flexible Fuel Powertrain System . 123 IV.10 Ford Motor Company: E85 Optimized Engine . 128 IV.11 Robert Bosch LLC: Optimally Controlled Flexible-Fuel Powertrain System. .133 FY 2010 Progress Report iii Fuels Technologies Table of Contents IV. Petroleum Displacement Fuels/Fuel Blending Components (Continued) IV.12 Delphi: E85 Optimized Engine through Boosting, Spray-Optimized GDi, VCR and Variable Valvetrain . 140 IV.13 University of Illinois at Urbana-Champaign: Investigation of Biodiesel-Fueled Engines under Low-Temperature Combustion Strategies. .144 IV.14 Pacific Northwest National Laboratory: Unconventional Hydrocarbon Fuels. 150 IV.15 Pacific Northwest National Laboratory: Alternative Fuels Infrastructure Development. 153 IV.16 Pacific Northwest National Laboratory: Decision Analysis Tool to Compare Energy Pathways for Transportation. .156 V. New Projects. 161 V.1 National Renewable Energy Laboratory: Collaborative Lubricating Oil Study on Emissions (CLOSE) Project. 163 VI. Acronyms, Abbreviations and Definitions. .167 VII. Index of Primary Contacts. 171 Fuels Technologies iv FY 2010 Progress Report I. INTRODUCTION FY 2010 Progress Report 1 Fuels Technologies Fuels Technologies 2 FY 2010 Progress Report I. Introduction ADVANCED PETROLEUM-BASED, NON-PETROLEUM-BASED, AND RENEWABLE FUELS FOR A CLEAN AND SECURE HIGHWAY TRANSPORTATION SYSTEM On behalf of the Department of Energy’s Vehicle Technologies Program (VTP), we are pleased to introduce the Fiscal Year (FY) 2010 Progress Report for Fuels Technologies. The potential benefits of advanced fuels technologies include: • Energy security: Advanced fuels enable more efficient engines that reduce fuel use, and non- petroleum-based fuels reduce the demand for petroleum fuel, much of which is imported. • Environmental sustainability: Cleaner fuels enable efficient and durable emissions control technologies for reduced vehicle emissions. Advanced and non-petroleum-based fuels reduce the emissions of greenhouse gases. • Economic improvement: A more diverse portfolio of fuels in transportation will improve the economy by reducing price volatility and stimulating new market activity in areas such as renewable fuels. The Fuels Technologies subprogram supports fuels and lubricants research and development (R&D) to provide vehicle users with cost-competitive options that enable high fuel economy with low emissions, and contribute to petroleum displacement. Transportation fuels are anticipated to be produced from future refinery feedstocks that may increasingly be from non-conventional sources including, but not limited to, heavy crude, oil sands, shale oil, and coal, as well as renewable resources such as biomass, oils derived from plants and algae, and waste animal fats. The impact of changes in refinery feedstocks on finished fuels is an area of relatively new concern to engine manufacturers, regulators and users. Advanced engine technologies may be more sensitive to variations in fuel composition than were earlier engines, in addition to facing tightening emissions standards. The Fuels Technologies subprogram activities focus on the properties and quality of the finished fuels derived from these sources, not primarily on their production. The Fuels Technologies subprogram consists of two activities: Advanced Petroleum-Based Fuels, and Non-Petroleum-Based Fuels and Lubricants. The goals are: (1) to enable post-2010 advanced combustion regime engines and emission control systems to be more efficient while meeting future emission standards; and, (2) to reduce reliance on petroleum-based fuels through direct fuel substitution by non-petroleum-based fuels. These activities are undertaken to determine the impacts of fuel and lubricant properties on the efficiency, performance, and emissions of current engines as well as to enable emerging advanced internal combustion engines, and are coordinated with and supportive of the Environmental Protection Agency’s (EPA’s) fuels and emissions-related activities, as mentioned in their strategic plan. The Energy Independence and Security Act (EISA) of 2007 established aggressive goals for renewable fuel use that might require significant changes to the nation’s fueling infrastructure. The EISA mandates the use of as much as 36 billion gallons annually by 2022 of renewable fuels, which will mainly be ethanol. The U.S. vehicle fleet consumed almost 10.8 billion gallons of ethanol in the first 10 months of 2010 (compared to 11.0 billion gallons in all of 2009), nearly all in the form of E10 (10% ethanol, 90% gasoline) sold as gasoline at fueling stations. The nation’s 8.35 million flexible- fuel vehicles can operate on E85 (85% ethanol, 15% gasoline), but relatively few fueling stations are equipped to dispense E85. Because of E10 and E85’s limited ability to absorb increases in U.S. ethanol production to meet the EISA goal of 36 billion gallons of annual renewable fuel consumption by 2022, a solution would be to require vehicles to use intermediate ethanol blends such as E15 (15% ethanol, 85% gasoline) or E20 (20% ethanol, 80% gasoline). The Fuels Technologies subprogram is examining the impact of intermediate blends on passenger vehicles, outdoor equipment, and generator sets, with research focusing on regulated and unregulated tailpipe emissions, fuel economy, and emission system durability. Materials compatibility, evaporative emissions, and vehicle driveability are also being investigated. FY 2010 Progress Report 3 Fuels Technologies I. Introduction The Fuel Technologies subprogram is an integral part of the FreedomCAR government/industry partnership and a key means of pursuing the FreedomCAR mission to develop more energy-efficient and environmentally friendly highway transportation technologies that enable America to use less petroleum in transportation. The work in advanced
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