the role of ethanol in the future engines & institutional

The role of ethanol in the future engines

& institutional R&D partnerships

Dipl.- Ing. Dietmar Goericke

Managing Director

FVV e.V.

Research Association

for Combustion Engines

VDMA, Frankfurt, Germany

The Power of Joint Research

http://www.oopper.de/gr/frankfurt-p489.htm

Presentation of FVV e.V., Sao Paulo, Brasil, 2012-10-03/04

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Content

1. Introduction to FVV

Who we are

How we work

What is the benefit being a member

2. Project examples

Survey on “Future Fuels”

“Future Fuels SI Engines”


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FVV – Who we are

FVV – a clear focus on industrial needs

FVV …

is a non profit research association

is a spin off of German Engineering Federation (VDMA)

membership is exclusively for industry

covers all applications of combustion engines

members are paying yearly fees, in total 5 Mio. Euro in 2012

triples money from industry by other sources of funding

projects are pre-competitive and initiated by industry

projects are contracted mainly to universities

all members have free access to all activities and results


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FVV - Network

The FVV was founded in 1956 as a non-profit society for engineering and research in order to promote pre-competitive, joint research for combustion engines.

27 founding members

Today 150 members => including 2 US and 20 European corporations

Member companies are manufacturers of

combustion engines (motor vehicle and industrial engines)

components and systems for the automotive, industrial engine and turbomachinery industry

R&D service providers and engineering firms

turbomachinery (gas and steam turbines, superchargers, axial and radial compressors)

FVV - competence in research for more than 50 years


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FVV – Mission and Vision

FVV is the platform of the combustion engine and turbine

industry for joint research projects in Europe and the world

with its core competences

joint, strategic and pre-competitive research

fast and efficient transfer of research to industrial practice

qualified and practice oriented education & training of young scientists

a permanent and comprehensive network of corporate and industrial

competence

FVV – a strong and reliable network of competence


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iST GmbH

FVV - Members

http://www.atlascopco.de/dede/

http://www.johncrane.co.uk/productfinder.asp?r=de&l=de

http://www.sulzermetco.com/de/DesktopDefault.aspx/tabid-100/

http://www.renault.de/

http://huber-group.masie-online.de/

http://upload.wikimedia.org/wikipedia/de/2/24/Iveco_logo.svg

http://de.wikipedia.org/w/index.php?title=Datei:Continental-Logo.svg&filetimestamp=20080529190101


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Membership Structure

Suppliers and service providers represent 70%, mostly SMEs

FVV - covers the process chain

9%6%

7%

43%

35%

OEM

industrial engine manufacturers

turbomachinery manufacturers

suppliers

R&D service providers


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FVV – Sources of Research Funding

FVV – constant growth – excellent reputation in the industry

2011

Total Funding 16 Mio. Euro

BMWi 4,0

Fees by members 4,0

CO2-programm 1,0

Hardware 4,0

Other cooperation 3,0


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Main Areas of Research I

• potential evaluation of

• new technologies

• alternative drives and APU

• overall balance

• Recovery of lost energy recovery

• model based engine control and

management

• supercharging

Engines II. > mechanics and acoustics

• new materials and coolants

• tribology and coatings

• sliding fit

• additives and lubricants

• Engine mechanics and strength

• engine dynamics and acoustics

Engines III. > Combustion processes and fuel preparation

• HCCI (diesel/gasoline engine)

• hydrogen combustion

• variable valve control combined with direct injection

• downsizing concepts

• fuel distribution and preparation, high pressure injection

• modeling of combustion and emission generation (gasoline/ diesel engines)

Engines I. > complete Systems


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Main Areas of Research II

Engines IV. > fuels with the focus

on CO2 emissions

• biofuels

• synfuel

• hydrogen

• natural gas

Engines V. > exhaust gas recirculation

• catalytic converter modeling for reaction

kinetics

• local determination of emission states

(e.g. N20, NH3, H2S)

• high resolution online measurement

techniques for new combustion

processes

Turbomachinery

• aerodynamics

• materials

• optimization of components

• development tools Currently over 200 ongoing FVV

research projects (Sept. 2012)


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FVV – Research Partners

30 universities and research centres

80 research institutes

300 scientists involved in FVV-projects

3-5 BSc-, MSc-, PhD – thesis p. project

FVV- young scientist award

FVV – supports education of young scientists


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FVV - Transfer of Know How

Project related discussion groups and working committees

influence on the orientation / execution of projects

discussion of the latest project findings and direct transfer of know how

Planning groups

planning and control of research programs

setting priorities for new projects on the main areas of research

Scientific advisory board and general meeting of the members

determination and controlling of the overall program

Spring and fall conferences

status reports on ongoing research program

networking

ProMeta - the web based project center

document and software download, events and meetings, communication

FVV publications

complete final documentation of projects

Internet

The latest developments, newsletter, download of general documents.


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FVV – Project examples with focus on ethanol

1. „Future Fuels“ Preparation of a new research priority by a survey

with 130 participants from 150 members

2. “Future Fuels SI Engines”

3. „Fatigue in corrosive fuels“


Example 1: Inquiry „Future Fuels“

Importance and temporal relevance

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Which application areas are relevant?

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Application Area Passenger Car

Gasoline

Passenger Car

Diesel

Passenger Car

Gas

Truck Industrial

Engine

Off-Road Ship Railway Stationary

Engine

Methan (CNG)

Ethanol

Biodiesel

Poor Quality Diesel

Methan (LNG)

Additive

Poor Quality Gasoline

Paraffinic Diesel

Methan/H2 Blends

LPG

Methanol

Synthetic Gas

Pure H2

DME (Dimethylether)

OME (Oxymethylenether)

Butanol



Which fuel properties are of interest?

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Fuel Properties

Fuel Quality,

Fuel Variation

Aging

Resistance

Fuel

Blends

Fuel

Characteristic

Numbers

Emission

Characteristic

Material

Compatibility

System-

Sensitivity

Suitability of

Additives

Methan (CNG)

Ethanol

Biodiesel

Poor Quality Diesel

Methan (LNG)

Additive

Poor Quality Gasoline

Paraffinice Diesel

Methan/H2 Blends

LPG

Methanol

Synthetic Gas

Pure H2

DME (Dimethylether)

OME (Oxymethylenether)

Butanol



Results

The topic of fuel is of great interest in the FVV.

Methane, ethanol, biodiesel, additives and poor quality fuels are

particularly relevant.

In the next 5 years, results are needed.

All applications / engine types will be considered.

The following properties of the fuels are the focus:

Fuel quality, fluctuation, margin

Fuel key figures

Emission behavior

Material compatibility

System sensitivity (Components affected by new fuels)

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FVV – future fuels are becoming a research priority


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Determination of potential and challenges of new synthetic fuels as a basis for

premium gasoline fuels in outlook of the European biofuel share for 2020.

Participating companies

Daimler AG (Initiator), AFT Atlas, APC Advanced Pro, Audi, BMW, BASF, Bosch,

Continental,BP, Deutz, Federal-Mogul, FEV, Ford, IAV, IFPEN, Lurgi, Mahle, MAN,

Nedalco Alcohol, Opel, Porsche, PSA Peugeot, Renault, Sasol Solvents, Südzucker

AG, Total, ACS, Volkswagen

RTD-partner

RWTH Aachen University, VKA, Prof. Dr.-Ing. S. Pischinger

Project funding and budget

Public funding (BMWi) / 280.000 Euro (365.000 $)

Duration:

24 Month

Example 2: „Future Fuels SI Engines“


Determination of the maximum compression ratio increase of ethanol-

gasoline fuel blends in comparison to a conventional RON95 fuel.

Optical investigation of spray penetration and evaporation in a high pressure

chamber.

Experimental investigations using a turbocharged direct injection research

engine.

Part load testing was carried out to determine efficiency benefits.

Climate chamber testing was used to test low temperature starts.

E20 fuel evaporation is similar, sometimes better than conventional fuel

The higher knock resistance enables an increased compression ratio

E85 evaporates worse under all investigated boundary conditions.

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Example 2: Inquiry „Future Fuels SI Engines“

Workplan & Results


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Example 2: Inquiry „Future Fuels SI Engines“


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Development and experimental verification of a fatigue assessment method

for highly loaded engine components in corrosive fuels“

Participating companies

Robert Bosch (Initiator), AVL List, Benteler Automotive, BMW Group, Continental

Automotive, Daimler, L'Orange, Mahle, Opel, Porsche, Volkswagen AG

RTD-partner

Prof. Oechsner, Technische Universität (TU) Darmstadt, Institut für Werkstoffkunde

Prof. Zoch, Stiftung Institut für Werkstofftechnik (IWT), Bremen

Prof. Sonsino, Systemzuverlässigkeit und Maschinenakustik (SzM), TU Darmstadt

Project funding and budget

Funding: FVV in cooperation with DFG (German Research Foundation)

Budget: 875.000 Euro (≈1.135 Mio. US$)

Duration

36 months

Example 3: „Fatigue in corrosive fuels“


High pressure

section

Worldwide a variety of alternative fuels are increasingly used.

Fatigue in corrosive surroundings (e.g. ethanol fuel) leads to a number of

phenomena which at present are cleared only insufficiently.

Corrosion fatigue at simultaneous cyclical loads leads to a reduction of the

component strength.

Primary objective of the project is the

development of safe fatigue assessment

methods for highly loaded components

(fuel injection system) in corrosive media.

Challenges (for example)

Determination of the influence of the

corrosive media on the dynamic strength

Extrapolation of S-N(Wöhler)-curve to

the Very-High-Cycle-Fatigue (VHCF)

area beyond 1E7 load cycles

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Example 3: „Fatigue in corrosive fuels“

Workplan & Results


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FVV – Cooperation with Brazil

The challenges for the combustion engine industry are worldwide the same

Brazil is one of the major markets for FVV-member companies

Most of them are represented in Brazil

Excellent research capabilities in Brazil

Strong relations in RTD-cooperation between Brazil and Germany

This cooperation is strongly supported by both governments

Time seems to be right to cooperate

FVV – the power of joint research


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Forschungsvereinigung

Verbrennungskraftmaschinen e.V.

Lyoner Straße 18

60528 Frankfurt

Dietmar Goericke

Tel.: (+49 69) 6603 - 1821

Email: [email protected]

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