Ruby Fieldmaster
Welcome Viafield Farmer Meeting March 15, 2011
CHS Energy A Division of CHS Inc.
Tank Maintenance/Filter Plugging Will become the #1 issue facing us
Fuel Filter Plugging • Biomass build up • Fuel filter blocking
Furnace Filter
Heavy Duty Diesel Truck Filter
Sock Filter GM light duty truck
JBC 11/1/01
3
Ultra Low Sulfur Diesel Fuel Transition from: History of Diesel Fuel -Beginning 5000ppm (High Sulfur) -1994 reduced to 500ppm (Low Sulfur) -2006 reduced to 15ppm (Ultra Low Sulfur) All of this is driven by the EPA EMISSIONS
Side effect of making ULSD Distillates have undergone progressively deeper hydrodesulphurization in order to meet lower S targets. The hydrotreating and hydrocracking processes remove naturally occurring polar fuel components which afforded relatively effective protection. The actual diesel cut also has an impact on the most important, active lubricity components.
As sulfur levels decrease
Result Pump & Injector Failures
Lubricity properties decrease
Q and A • Why is water in the tank harmful? • How often should tanks be cleaned? • How do “bugs” survive in fuel? • Why is ULSD more susceptible to bugs?
Importance of Proper Tank Maintenance Why is tank maintenance critical? One word, WATER. A significant amount of water in the tank will likely cause problems including, oxidative degradation (rust, scale), particulates and microbiological growth.
Water
Oxidative Degradation
Particulates
Microbiological growth
• Bugs cannot grow in diesel fuel alone – Require water, carbon and trace nitrogen for life, growth, & reproduction – Water bottoms • Bugs live at a fuel water interface – Any place a droplet of water is present
Diesel Fuel
Water
Dead Microbes
Microbes
Contaminants-Water • Water will; – Promote bugs – aids in rapid filter plugging – Induce corrosion – Interaction with certain lubricity additives – Degrade biodiesel – Negatively impact cold flow improvers • Helpful Hints – Check water separators daily – New (larger micron) fuel filters for winter operability – Don’t forget to check vehicle tank water levels often
Proper Tank Maintenance Tips
• Storage Tanks – Drain and remove all water and contaminants quarterly and or prior to winter season. – Change filters and clean pump screens – Use Hydrosorb Filters (Warm Temperatures) – Send in bottom sample from tank quarterly – Have tanks cleaned annually
Observed In-Vehicle Field Problems with Emission Controlled Vehicles
• • • • • •
Vehicle dependent fuel filter blocking Fuel pump gumming Fuel line corrosion Power loss, > 6% Fuel Economy deficits Not achieving oil filter PMI
Not specific to one engine manufacture Not specific to one injector manufacturer High degree of regionality
Shortened PMI Warranty Issue Warranty Issue Diminished drive ability ↑ CO2 , ↑ $$$ Fuel Spend Shortened PMI
Evolution of fuel injection pressures for heavy-duty Advanced high-pressure high-flexible FIE
Pressure at nozzle - bar
2500
2000
1500
Common rail
1000
Unit pump Unit injector
500
Inline pump 0
1991
source - Bosch SAE Oct. 2008
1994
1997
2000
2003
2006
2009
Typical HPCR fuel system Common Rail High pressure pump Pressure-side filter Lift pump
Injectors Injected fuel
Suction filter
Fuel tank
source - Cummins Inc. SAE Oct 2008
Return
Power Loss, Fuel Economy Deficits and Driveability Issues
HPFI
Conventional
Deposit Locales
• •
High incidence of “conventional” injector tip deposits Evidence of slight fouling on matched tolerance components causing significant power loss – –
•
Tolerance, 1 – 3 microns Even “tarnishing” causes problem
Widely reported in recent literature:- Bosch, Delphi, Siemens, etc.
Microns (μm) and HPCR tolerances •
A micron is 0.001 mm (1 μm)
•
Human hair 70μm
•
Smallest you can see – 40μm
•
Rust Inhibitor - 1μm
•
Bacteria – 1μm
•
Many tolerances are measured in microns – Spray hole diameters 150μm – Matched Clearance - 2μm ~ 7μm – Filter media (final) 4μm ~5μm (c)
source - Cummins Inc. SAE Oct 2008
-2μm ~ 7μm
Human hair 70μm
Fuel Filter Blocking - Illustration Black deposit ex injector internal 3624
Particles appear to be agglomerates of smaller, hydrogen rich carbonaceous particles
Fuel Filter Blocking - Illustration
•
Problems highlighted in medium duty urban fleets and mine vehicles
Highly Stressing Environments
Power Loss, Fuel Economy Deficits and Driveability Issues - “NonConventional” Injector Deposits
48 additional hours with antifoulant
166 hrs
0 hrs
166 hours without Additive
48 additional hours with antifoulant
50 hrs
48 hours with Additive
100 hrs
96 hours with Additive
What Vehicles are affected? •
• •
The problem is a function of ULSD, Modern Injection System Technology, not Vehicle Manufacturer. – All use High Pressure Direct Injection common rail technology (i.e. Higher Temps, Higher pressures, tighter tolerances) - Up to 2,000 Bar Latest generation engines are experiencing problems to some degree or other Severity related to:– Fuel – Additives – Fuel Rail Pressure – Duty Cycle – Engine Management ( time & temp of fuel soak)
Fleet users are becoming aware of systemic problems
What fuels are affected? Least affected ULSD
All OEMs
Most affected B5
B10
B15
B20
CHS Experience • End users reporting abnormal filter plugging problems and injector fouling issues (‘07) • OEMs discuss issue (SAE meeting Oct ‘08)
– Cummins, Deere, Detroit and Bosch • CHS arranges meeting with John Deere to discuss issues (End Oct ‘08) • Deere performs engine testing on Innospec’s additive (Jan ‘09)
– 2500 hr test • CHS participates in joint field test with Deere (Feb ’08)
Engine Stand Test using PL-2293D (2nd Gen Eco Clean formulation)
Using a B20 blend
Energy Division Mission • “High Quality” – CHS Energy will only provide products that meet or exceed industry standards. • “Solutions” – CHS Energy will search for and create effective solutions for our customers that create a strategic advantage. • “The Strength of the Cenex Brand – CHS Energy will be passionate about the protection and promotion of Cenex and related brands, allowing no compromise of its products or quality.
Ruby Fieldmaster “Quality Balanced System”
Ruby Fieldmaster & Roadmaster XL contains the following components, quality balanced for your area: • Detergents • High Cetane • Lubricity Enhancers • Water Demulsifiers • Corrosion Inhibitors • Fuel Stabilizers • Soy Enhanced • Tracer
Ruby Fieldmaster & Roadmaster XL Feature/Benefits
Feature: Ruby Fieldmaster & Roadmaster contain “Corrosion Inhibitors” to provide superior corrosion protection. Benefits:
1) 2) 3) 4) 5)
Prevents rust and corrosion formation on metal parts. Extends fuel life. Reduces engine wear. Reduces filter plugging. Reduces down time.
Ruby Fieldmaster & Roadmaster Feature/Benefits
Feature: Ruby Fieldmaster & Roadmaster contains “Aggressive Detergent Components” to keep fuel systems clean and performing at their optimum level. They achieved “Superior Pass” rating on the Cummins L-10 test. Benefits: 1) 2) 3) 4) 5)
Cleans up and keeps injectors clean. Reduces injector fouling and clogging. Maintains ideal injector fuel spray pattern. Optimizes power and fuel economy. Improves combustion
Ruby Fieldmaster & Roadmaster XL Feature/Benefits
•
Feature: “Cetane” enhances the ignition quality of a fuel.
– – – Benefits:
The higher the cetane number, the easier the fuel will ignite. Typical #2 diesel fuel cetane number: 41. Ruby Fieldmaster & CF Roadmaster cetane number: 47+
Quicker starts, especially in cold temperatures. Smoother starting, less engine noise. Less smoke during start-up. Reduces exhaust emissions during start-up. Reduces wear and tear on engine.
Ruby Fieldmaster & Roadmaster XL Feature/Benefits
Feature: Ruby Fieldmaster & Roadmaster contain a “Lubricity Component” that provides increased lubricity. Benefits:
1) 2) 3) 4) 5)
Protects injectors and injector pump against wear. Increases injector and injector pump life. Reduces maintenance costs. Reduces downtime. Improves lubricity of low sulfur diesel.
Ruby Fieldmaster & Roadmaster XL Feature/Benefits
Feature: Ruby Fieldmaster & Roadmaster include “Demulsifiers” for water shedding capabilities. Benefits: 1) Forces water to fall to bottom of tank to be drained. 2) Moisture will not be carried through the fuel system. 3) Reduces volume of moisture entering the combustion chamber. 4) Reduces sulfuric acid metal erosion. 5) Reduces filter plugging. 6) Extends engine life.
Ruby Fieldmaster & Roadmaster XL Feature/Benefits
Feature: Ruby Fieldmaster & Roadmaster contain “Stabilizer and AntiSludge” components to increase storage life. Benefits:
1) 2) 3) 4) 5) 6) 7)
Extends fuel life. Tolerates temperature extremes. Reduces varnish and gum build-up. Less filter plugging. Increases injector life. Provides maximum performance. Optimizes combustibility.
Field Test: Summary • Test Results of Ruby Fieldmaster over #2 diesel fuel:
– 4.5% increase in power over #2 fuel. – Easier, quicker starting with less smoke. – No visible wear on injection pump versus visible wear in 12 different areas with the #2. – Lower emissions: range from 2.6% to 9.1% less than #2 fuel.
Savings Calculations based on 4.5% improved power and fuel economy from field test
Fuel Price
4.5% Diff. Increase
Savings over #2 $.00/gal
$2.60/ gal $.117 $.05 $.067 $2.80/ gal $.126 $.05 $.076 $3.00/ gal $.135 $.05 $.085 $3.20/ gal $.144 $.05 $.094 $3.40/ gal $.153 $.05 $.103 $3.60/ gal $.162 $.05 $.112 $3.80/ gal $.171 $.05 $.121 Note: The higher the cost of the fuel, the greater the savings.
Thank you for your business!
CHS Energy A Division of CHS Inc.
Tank Maintenance/Filter Plugging Will become the #1 issue facing us
Fuel Filter Plugging • Biomass build up • Fuel filter blocking
Furnace Filter
Heavy Duty Diesel Truck Filter
Sock Filter GM light duty truck
JBC 11/1/01
3
Ultra Low Sulfur Diesel Fuel Transition from: History of Diesel Fuel -Beginning 5000ppm (High Sulfur) -1994 reduced to 500ppm (Low Sulfur) -2006 reduced to 15ppm (Ultra Low Sulfur) All of this is driven by the EPA EMISSIONS
Side effect of making ULSD Distillates have undergone progressively deeper hydrodesulphurization in order to meet lower S targets. The hydrotreating and hydrocracking processes remove naturally occurring polar fuel components which afforded relatively effective protection. The actual diesel cut also has an impact on the most important, active lubricity components.
As sulfur levels decrease
Result Pump & Injector Failures
Lubricity properties decrease
Q and A • Why is water in the tank harmful? • How often should tanks be cleaned? • How do “bugs” survive in fuel? • Why is ULSD more susceptible to bugs?
Importance of Proper Tank Maintenance Why is tank maintenance critical? One word, WATER. A significant amount of water in the tank will likely cause problems including, oxidative degradation (rust, scale), particulates and microbiological growth.
Water
Oxidative Degradation
Particulates
Microbiological growth
• Bugs cannot grow in diesel fuel alone – Require water, carbon and trace nitrogen for life, growth, & reproduction – Water bottoms • Bugs live at a fuel water interface – Any place a droplet of water is present
Diesel Fuel
Water
Dead Microbes
Microbes
Contaminants-Water • Water will; – Promote bugs – aids in rapid filter plugging – Induce corrosion – Interaction with certain lubricity additives – Degrade biodiesel – Negatively impact cold flow improvers • Helpful Hints – Check water separators daily – New (larger micron) fuel filters for winter operability – Don’t forget to check vehicle tank water levels often
Proper Tank Maintenance Tips
• Storage Tanks – Drain and remove all water and contaminants quarterly and or prior to winter season. – Change filters and clean pump screens – Use Hydrosorb Filters (Warm Temperatures) – Send in bottom sample from tank quarterly – Have tanks cleaned annually
Observed In-Vehicle Field Problems with Emission Controlled Vehicles
• • • • • •
Vehicle dependent fuel filter blocking Fuel pump gumming Fuel line corrosion Power loss, > 6% Fuel Economy deficits Not achieving oil filter PMI
Not specific to one engine manufacture Not specific to one injector manufacturer High degree of regionality
Shortened PMI Warranty Issue Warranty Issue Diminished drive ability ↑ CO2 , ↑ $$$ Fuel Spend Shortened PMI
Evolution of fuel injection pressures for heavy-duty Advanced high-pressure high-flexible FIE
Pressure at nozzle - bar
2500
2000
1500
Common rail
1000
Unit pump Unit injector
500
Inline pump 0
1991
source - Bosch SAE Oct. 2008
1994
1997
2000
2003
2006
2009
Typical HPCR fuel system Common Rail High pressure pump Pressure-side filter Lift pump
Injectors Injected fuel
Suction filter
Fuel tank
source - Cummins Inc. SAE Oct 2008
Return
Power Loss, Fuel Economy Deficits and Driveability Issues
HPFI
Conventional
Deposit Locales
• •
High incidence of “conventional” injector tip deposits Evidence of slight fouling on matched tolerance components causing significant power loss – –
•
Tolerance, 1 – 3 microns Even “tarnishing” causes problem
Widely reported in recent literature:- Bosch, Delphi, Siemens, etc.
Microns (μm) and HPCR tolerances •
A micron is 0.001 mm (1 μm)
•
Human hair 70μm
•
Smallest you can see – 40μm
•
Rust Inhibitor - 1μm
•
Bacteria – 1μm
•
Many tolerances are measured in microns – Spray hole diameters 150μm – Matched Clearance - 2μm ~ 7μm – Filter media (final) 4μm ~5μm (c)
source - Cummins Inc. SAE Oct 2008
-2μm ~ 7μm
Human hair 70μm
Fuel Filter Blocking - Illustration Black deposit ex injector internal 3624
Particles appear to be agglomerates of smaller, hydrogen rich carbonaceous particles
Fuel Filter Blocking - Illustration
•
Problems highlighted in medium duty urban fleets and mine vehicles
Highly Stressing Environments
Power Loss, Fuel Economy Deficits and Driveability Issues - “NonConventional” Injector Deposits
48 additional hours with antifoulant
166 hrs
0 hrs
166 hours without Additive
48 additional hours with antifoulant
50 hrs
48 hours with Additive
100 hrs
96 hours with Additive
What Vehicles are affected? •
• •
The problem is a function of ULSD, Modern Injection System Technology, not Vehicle Manufacturer. – All use High Pressure Direct Injection common rail technology (i.e. Higher Temps, Higher pressures, tighter tolerances) - Up to 2,000 Bar Latest generation engines are experiencing problems to some degree or other Severity related to:– Fuel – Additives – Fuel Rail Pressure – Duty Cycle – Engine Management ( time & temp of fuel soak)
Fleet users are becoming aware of systemic problems
What fuels are affected? Least affected ULSD
All OEMs
Most affected B5
B10
B15
B20
CHS Experience • End users reporting abnormal filter plugging problems and injector fouling issues (‘07) • OEMs discuss issue (SAE meeting Oct ‘08)
– Cummins, Deere, Detroit and Bosch • CHS arranges meeting with John Deere to discuss issues (End Oct ‘08) • Deere performs engine testing on Innospec’s additive (Jan ‘09)
– 2500 hr test • CHS participates in joint field test with Deere (Feb ’08)
Engine Stand Test using PL-2293D (2nd Gen Eco Clean formulation)
Using a B20 blend
Energy Division Mission • “High Quality” – CHS Energy will only provide products that meet or exceed industry standards. • “Solutions” – CHS Energy will search for and create effective solutions for our customers that create a strategic advantage. • “The Strength of the Cenex Brand – CHS Energy will be passionate about the protection and promotion of Cenex and related brands, allowing no compromise of its products or quality.
Ruby Fieldmaster “Quality Balanced System”
Ruby Fieldmaster & Roadmaster XL contains the following components, quality balanced for your area: • Detergents • High Cetane • Lubricity Enhancers • Water Demulsifiers • Corrosion Inhibitors • Fuel Stabilizers • Soy Enhanced • Tracer
Ruby Fieldmaster & Roadmaster XL Feature/Benefits
Feature: Ruby Fieldmaster & Roadmaster contain “Corrosion Inhibitors” to provide superior corrosion protection. Benefits:
1) 2) 3) 4) 5)
Prevents rust and corrosion formation on metal parts. Extends fuel life. Reduces engine wear. Reduces filter plugging. Reduces down time.
Ruby Fieldmaster & Roadmaster Feature/Benefits
Feature: Ruby Fieldmaster & Roadmaster contains “Aggressive Detergent Components” to keep fuel systems clean and performing at their optimum level. They achieved “Superior Pass” rating on the Cummins L-10 test. Benefits: 1) 2) 3) 4) 5)
Cleans up and keeps injectors clean. Reduces injector fouling and clogging. Maintains ideal injector fuel spray pattern. Optimizes power and fuel economy. Improves combustion
Ruby Fieldmaster & Roadmaster XL Feature/Benefits
•
Feature: “Cetane” enhances the ignition quality of a fuel.
– – – Benefits:
The higher the cetane number, the easier the fuel will ignite. Typical #2 diesel fuel cetane number: 41. Ruby Fieldmaster & CF Roadmaster cetane number: 47+
Quicker starts, especially in cold temperatures. Smoother starting, less engine noise. Less smoke during start-up. Reduces exhaust emissions during start-up. Reduces wear and tear on engine.
Ruby Fieldmaster & Roadmaster XL Feature/Benefits
Feature: Ruby Fieldmaster & Roadmaster contain a “Lubricity Component” that provides increased lubricity. Benefits:
1) 2) 3) 4) 5)
Protects injectors and injector pump against wear. Increases injector and injector pump life. Reduces maintenance costs. Reduces downtime. Improves lubricity of low sulfur diesel.
Ruby Fieldmaster & Roadmaster XL Feature/Benefits
Feature: Ruby Fieldmaster & Roadmaster include “Demulsifiers” for water shedding capabilities. Benefits: 1) Forces water to fall to bottom of tank to be drained. 2) Moisture will not be carried through the fuel system. 3) Reduces volume of moisture entering the combustion chamber. 4) Reduces sulfuric acid metal erosion. 5) Reduces filter plugging. 6) Extends engine life.
Ruby Fieldmaster & Roadmaster XL Feature/Benefits
Feature: Ruby Fieldmaster & Roadmaster contain “Stabilizer and AntiSludge” components to increase storage life. Benefits:
1) 2) 3) 4) 5) 6) 7)
Extends fuel life. Tolerates temperature extremes. Reduces varnish and gum build-up. Less filter plugging. Increases injector life. Provides maximum performance. Optimizes combustibility.
Field Test: Summary • Test Results of Ruby Fieldmaster over #2 diesel fuel:
– 4.5% increase in power over #2 fuel. – Easier, quicker starting with less smoke. – No visible wear on injection pump versus visible wear in 12 different areas with the #2. – Lower emissions: range from 2.6% to 9.1% less than #2 fuel.
Savings Calculations based on 4.5% improved power and fuel economy from field test
Fuel Price
4.5% Diff. Increase
Savings over #2 $.00/gal
$2.60/ gal $.117 $.05 $.067 $2.80/ gal $.126 $.05 $.076 $3.00/ gal $.135 $.05 $.085 $3.20/ gal $.144 $.05 $.094 $3.40/ gal $.153 $.05 $.103 $3.60/ gal $.162 $.05 $.112 $3.80/ gal $.171 $.05 $.121 Note: The higher the cost of the fuel, the greater the savings.
Thank you for your business!
