Environmental Technology Verification
Test Report of Mobile Source Emission
Control Devices
Flint Hills Resources, LP
CCD15010 Diesel Fuel Formulation with HJTEC4121 Additive
Prepared by
Southwest Research Institute RTI International
HRTI
INTERNATIONAL
Under a Cooperative Agreement with
U.S. Environmental Protection Agency
oEPA
EW ET
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THE ENVIRONMENTAL TECHNOLOGY VERIFICATION
PROGRAM
oERA ™/ fijRTT
U.S. Environmental Protection Agency T^^^T^^l ^fl_JL^^__M_ M
INTERNATIONAL
ETV Joint Verification Statement
TECHNOLOGY TYPE: MOBILE DIESEL ENGINE AIR POLLUTION
CONTROL
APPLICATION: CONTROL OF EMISSIONS FROM MOBILE DIESEL
ENGINES IN HIGHWAY USE WITH DIESEL FUEL
FORMULATION
TECHNOLOGY NAME: CCD15010 FUEL WITH HITEC4121 ADDITIVE
COMPANY: FLINT HILLS RESOURCES, LP
ADDRESS: 4111 EAST 37™ STREET NORTH
WICHITA, KS 67220
PHONE: (316) 828-5002
FAX: (316) 828-4905
WEB SITE: http://www.fhr.com/
E-MAIL: Charley.Selvidge@fhr.com
The U.S. Environmental Protection Agency (EPA) has created the Environmental Technology
Verification (ETV) Program to facilitate the deployment of innovative or improved
environmental technologies through performance verification and dissemination of information.
The goal of the ETV Program is to further environmental protection by accelerating the
acceptance and use of improved and cost-effective technologies. ETV seeks to achieve this goal
by providing high-quality, peer-reviewed data on technology performance to those involved in
the design, distribution, financing, permitting, purchase, and use of environmental technologies.
ETV works in partnership with recognized standards and testing organizations; stakeholder
groups, which consist of buyers, vendor organizations, permitters, and other interested parties;
and with the full participation of individual technology developers. The program evaluates the
performance of innovative technologies by developing test plans that are responsive to the needs
of stakeholders, conducting field or laboratory tests (as appropriate), collecting and analyzing
data, and preparing peer-reviewed reports. All evaluations are conducted in accordance with
rigorous quality assurance (QA) protocols to ensure that data of known and adequate quality are
generated and that the results are defensible.
The Air Pollution Control Technology Verification Center (APCT Center), one of six centers
under the ETV Program, is operated by RTI International (RTI), in cooperation with EPA's
National Risk Management Research Laboratory. The APCT Center has evaluated the
performance of an emissions control system consisting of a fuel formulation and additive.
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ETV TEST DESCRIPTION
All tests were performed in accordance with the Test/QA Plan for the Verification Testing of
Alternative or Reformulated Liquid Fuels, Fuel Additives, Fuel Emulsions, and Lubricants for
Highway andNonroad Use Heavy Duty Diesel Engines and Light Duty Gasoline Engines and
Vehicles and the Test-Specific Addendum to ETV Mobile Source Test/QA Plan for Flint Hills
Resources for the CCD15010 Diesel Fuel Formulation. These documents are written in
accordance with the applicable generic verification protocol and include requirements for quality
management, QA, procedures for product selection, auditing of the test laboratories, and test
reporting format.
The mobile diesel engine air pollution control fuel formulation was tested October 18-27, 2006,
at Southwest Research Institute. The performance verified was the percentage emission
reduction achieved by the fuel formulation for particulate matter (PM), nitrogen oxides (NOX),
hydrocarbons (HC), and carbon monoxide (CO) relative to the performance of the same baseline
engine with standard ultra-low sulfur diesel (ULSD) fuel. Operating conditions were
documented and ancillary performance measurements were also made. A summary description
of the ETV test is provided in Table 1.
Table 1. Summary Description of the ETV Test
Test type
Engine family
Engine make-model year
Service class
Engine rated power
Engine displacement, type
Technology
Technology description
Test cycle or mode
description
Baseline fuel description
Critical measurements
Ancillary measurements
Highway Transient Federal Test Procedure
Emissions Test (SET)
(FTP) and Supplemental
MDD12.7FZAK
Detroit Diesel Corp (DDC) - 1991 Series 60
, 6067GU60
Highway, heavy-duty diesel engine
365 bhp@ 1800 rpm
12.7 L, six-cylinder
CCD15010with HITEC4121
Diesel fuel formulation with additive
One cold-start and three hot-start tests plus
tests according to FTP test
supplemental emissions
Ultra-low-sulfur diesel (ULSD) fuel with 15 ppm sulfur maximum
PM, NOX, HC, and CO
Carbon dioxide, exhaust backpressure, and
fuel consumption
VERIFIED TECHNOLOGY DESCRIPTION
This verification statement describes the performance of the tested technology, CCD15010 diesel
fuel formulation with H1TEC4121 additive, on the diesel engine identified in Table 1.
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VERIFICATION OF PERFORMANCE
The CCD15010 fuelformulation with HiTEC4121 additive achieved the reduction in tailpipe
emissions shown in Table 2 compared to baseline operation without the additive.
Table 2. Verified Emissions Reductions
Technology
CCD15010+HITEC4121
Mean
Emissions Reduction (%)
PM
-0.74 a
NOx
8.2
HC
17
CO
9.6
95% Confidence Limits
on the Emissions Reduction (%)
PM
b
NOx
7.3 to 9.0
HC
b
CO
5.3 to 14
Negative reduction indicates increase in emissions.
b The emissions reduction can not be distinguished from zero with 95% confidence.
The APCT Center QA officer has reviewed the test results and quality control data and has
concluded that the data quality objectives given in the generic verification protocol and test/QA
plan have been attained. EPA and APCT Center QA staff have conducted technical assessments
of the test laboratory and of the data handling. These assessments confirm that the ETV tests
were conducted in accordance with the EPA-approved test/QA plan.
This verification statement verifies the emissions characteristics of the CCD15010 fuel
formulation with HHEC4121 additive for the stated application. Extrapolation outside that range
should be done with caution and an understanding of the scientific principles that control the
performance of the technology. This verification focuses on emissions. Potential technology
users may obtain other types of performance information from the manufacturer.
In accordance with the generic verification protocol, this verification statement is valid,
commencing on the date below, indefinitely for application of the CCD 15010 fuel formulation
with HiTEC4121 additive within the range of applicability of the statement.
Original signed by S. Gutierrez
5/16/07 Original signed by A. R. Trenholm 5/14/07
Sally Gutierrez
Director
National Risk Management Research
Laboratory
Office of Research and Development
United States Environmental Protection
Agency
Date
Andrew R. Trenholm
Director
Air Pollution Control Technology
Verification Center
Date
in
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Environmental Technology Verification
Report
Mobile Source Emission Control Devices
Flint Hills Resources, LP
CCD15010 Diesel Fuel Formulation
withHiTEC4121 Additive
Prepared by
RTI International
Southwest Research Institute
EPA Cooperative Agreement No. CR831911 -01 -1
EPA Project Manager:
Michael Kosusko
Air Pollution Prevention and Control Division
National Risk Management Research Laboratory
Office of Research and Development
U.S. Environmental Protection Agency
Research Triangle Park, NC 27711
May 2007
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Notice
This document was prepared by RTI International (RTI) and its subcontractor, Southwest
Research Institute (SwRI), with partial funding from Cooperative Agreement No. CR831911-
01-1 with the U.S. Environmental Protection Agency (EPA). The document has been submitted
to RTFs and EPA's peer and administrative reviews and has been approved for publication.
Mention of corporation names, trade names, or commercial products does not constitute
endorsement or recommendation for use of specific products.
11
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Foreword
The Environmental Technology Verification (ETV) Program, established by the U.S.
Environmental Protection Agency (EPA), is designed to accelerate the development and
commercialization of new or improved technologies through third-party verification and
reporting of performance. The goal of the ETV Program is to verify the performance of
commercially ready environmental technologies through the evaluation of objective and quality-
assured data in order to provide potential purchasers and permitters an independent, credible
assessment of the technology they are buying or permitting.
The Air Pollution Control Technology Verification Center (APCT Center) is part of the EPA's
ETV Program, and is operated as a partnership between RTI International (RTI) and EPA. The
APCT Center verifies the performance of commercially ready air pollution control technologies.
Verification tests use approved protocols, and verified performance is reported in verification
statements signed by EPA and RTI officials. RTI contracts with Southwest Research Institute
(SwRI) to perform verification tests on engine emission control technologies.
Fuel formulations and additives used to control emissions from mobile diesel engines are among
the technologies evaluated by the APCT Center. The center developed (and EPA approved) the
Generic Verification Protocol for Determination of Emissions Reductions Obtained by Use of
Alternative or Reformulated Liquid Fuels, Fuel Additives, Fuel Emulsions, and Lubricants for
Highway andNonroad Use Diesel Engines and Light Duty Gasoline Engines and Vehicles to
provide guidance on the verification testing of specific products that are designed to control
emissions from diesel engines.
The following report reviews the performance of the Flint Hills Resources, LP, CCD15010
diesel fuel formulation with HiTec4121 additive. ETV testing of this technology was conducted
in October 2006 at SwRI. All testing was performed in accordance with an approved test/QA
plan that implements the requirements of the generic verification protocol at the test laboratory.
in
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Availability of Report
Copies of this verification report are available from:
• RTI International
Engineering and Technology Unit
P.O. Box 12194
Research Triangle Park, NC 27709-2194
• U.S. Environmental Protection Agency
Air Pollution Prevention and Control Division (E343-02)
109 T. W. Alexander Drive
Research Triangle Park, NC 27711
Web site: http://www.epa.gov/etv/verifications/verification-index.html (.pdf format)
IV
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Table of Contents
Section Page
Notice ii
Foreword iii
Availability of Report iv
List of Figures vi
List of Tables vi
Acronyms/Abbreviations vii
Acknowledgments ix
Section 1.0 Introduction 1
Section 2.0 Product Description 2
Section 3.0 Test Documentation 4
3.1 Engine Description 4
3.2 Engine Fuel Description 5
3.3 Summary of Emissions Measurement Procedures 5
3.4 Deviations from the Test/QAPlan 7
3.5 Documented Test Conditions 7
Section 4.0 Summary and Discussion of Emission Results 10
Section 5.0 References 16
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List of Figures
Figure Page
Figure 1. Sealed drums of Flint Hills Resources diesel fuels 2
Figure 2. Schematic of emissions sampling system at SwRI 6
Figure 3. Torque map of 1991 DDC Series 60 engine using ULSD baseline fuel 7
List of Tables
Table Page
Table 1. Selected Fuel Properties and Specifications 3
Table 2. Engine Identification Information 4
Table 3. Overview of Verification Test Sequence 5
Table 4. Test Engine Baseline Emissions Requirement for 1991 DDC Series 60 6
Table 5. Brake-Specific Fuel Consumption (by Carbon Balance) for Highway FTP Tests 8
Table 6. Brake-Specific Fuel Consumption (by Carbon Balance) for SET Tests 9
Table 7. Summary of Fuel Consumption Reduction 9
Table 8. Emissions Data from Highway Transient Tests 10
Table 9. Emissions Data from Baseline Supplemental Emissions Tests (SET) 11
Table 10. Emissions Data from Candidate Supplemental Emissions Tests (SET) 12
Table 11. Combined Emission Rates (U.S. Common Units) 14
Table 12. Combined Emission Rates (Metric Units) 14
Table 13. Summary of Verification Test Data (U.S. Common Units) 14
Table 14. Summary of Verification Test Data (Metric Units) 15
Table 15. Summary of Verification Test Emission Reductions 15
VI
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Acronyms/Abbreviations
APCT Center
bhp
bhp-hr
BSFC
C-B
CFR
cm
CO
C02
CVS
DDC
EPA
ETV
FHR
FTP
ft
g
HC
HDDE
hp
kW
kWh
L
Ib
Ib-ft
m
mm
NCDC
NOX
OTAQ
PM
Air Pollution Control Technology Verification Center
brake horsepower
brake horsepower-hour
brake-specific fuel consumption
carbon balance
Code of Federal Regulations
centimeter(s)
carbon monoxide
carbon dioxide
constant volume sampler
Detroit Diesel Corporation
U.S. Environmental Protection Agency
Environmental Technology Verification
Flint Hills Resources, LP
Federal Test Procedure
foot (feet)
gram(s)
hydrocarbon(s)
heavy duty diesel engine
horsepower
kilowatt(s)
kilowatt hour(s)
liter(s)
pound(s)
pound foot (feet)
meter(s)
millimeter(s)
National Clean Diesel Campaign
nitrogen oxides
Office of Transportation and Air Quality
particulate matter
vn
-------
QA quality assurance
QC quality control
rpm revolutions per minute
RTI RTI International
SET supplemental emissions test
SwRI Southwest Research Institute
TCEQ Texas Commission on Environmental Quality
ULSD ultra-low sulfur diesel
Vlll
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Acknowledgments
The authors acknowledge the support of all of those who helped plan and conduct the
verification activities. In particular, we would like to thank Michael Kosusko, Project Manager,
and Paul Groff, Quality Assurance Manager, both of the U.S. Environmental Protection
Agency's (EPA's) National Risk Management Research Laboratory in Research Triangle Park,
NC. We would also like to acknowledge the assistance and participation of all Flint Hills
Resources, LP, personnel who supported the test effort.
For more information on the CCD15010 diesel fuel formulation and HiTEC4121 additive,
contact:
Mr. Charley Selvidge
Flint Hills Resources, LP
4111 East 3 7th Street North
Wichita, KS 67220
Telephone: (316)828-5002
Fax: (316)828-4905
Email: Charley.Selvidge@fhr.com
Web site: http://www.fhr.com
For more information on verification testing of mobile sources air pollution control devices,
contact:
Ms. Jenni Elion
RTI International
P.O. Box 12194
Research Triangle Park, NC 27709-2194
Telephone: (919) 541-6253
Email: jme@rti.org
ETV Web site: http://www.epa.gov/etv/
IX
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Section 1.0
Introduction
This report reviews the performance of the CCD15010 diesel fuel formulation, containing the
additive H1TEC4121, submitted for testing by Flint Hills Resources, LP (FHR). Environmental
technology verification (ETV) testing of this technology was conducted October 18-27, 2006,
during a series of tests by Southwest Research Institute (SwRI), under contract with the Air
Pollution Control Technology Verification Center (APCT Center). The APCT Center is
operated by RTI International (RTF/ in partnership with the U.S. Environmental Protection
Agency's (EPA) ETV Program. The objective of the APCT Center and the ETV Program is to
verify, with high-quality data, the performance of air pollution control technologies, including
those designed to control air emissions from diesel engines. With the assistance of a technical
panel of experts assembled for the purpose, RTI has established an air pollution control
technology program area specifically to evaluate the performance of alternative fuels, additives,
emulsions, and lubricants as control technologies for mobile diesel engines. Based on the
activities of this technical panel, the Generic Verification Protocol for Determination of
Emissions Reductions Obtained by Use of Alternative or Reformulated Liquid Fuels, Fuel
Additives, Fuel Emulsions, and Lubricants for Highway andNonroad Use Diesel Engines and
Light Duty Gasoline Engines and Vehicles1 was developed. This protocol was chosen as the best
guide to verify the immediate performance effects of the CCD15010 fuel formulation with
HiTEC4121 additive. To determine these effects, emissions results from a highway heavy-duty
diesel engine using ultra-low sulfur diesel (ULSD) fuel were compared to emissions results
obtained operating the same engine under the same conditions but with the CCD15010 fuel
formulation containing the HiTEC4121 additive. The specific test/quality assurance (QA) plan
addendum for the ETV test of the technology submitted by FUR was developed and approved in
August 2006.2 The goal of the test was to measure the emissions control performance of the
CCD15010 fuel formulation with HiTEC4121 additive and its emissions reduction relative to the
same engine using ULSD fuel.
A description of the FUR fuel formulation is presented in Section 2. Section 3 documents the
procedures and methods used for the test and the conditions under which the test was conducted.
The results of the test are summarized and discussed in Section 4, and references are presented in
Section 5.
This report contains only summary data and the verification statement. Complete documentation
of the test results is provided in a separate test report3 and audit of data quality report4. These
reports include the raw test data from product testing and supplemental testing, equipment
calibration results, and QA and quality control (QC) activities and results. Complete
documentation of QA/QC activities and results, raw test data, and equipment calibration results
are retained in SwRI's files for 7 years.
This verification statement describes the performance of the tested technology, CCD15010 diesel
fuel formulation with HiTEC4121 additive, on the tested diesel engine. Testing was conducted
in October 2006 at SWRI.
RTI International is a trade name of Research Triangle Institute.
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Section 2.0
Product Description
The FHR CCD15010 diesel fuel formulation has an aromatic content below the nationwide
average diesel fuel. It contains the H1TEC4121 additive with cetane-improving components.
Emissions were quantified with two separate diesel fuels, a baseline fuel and a candidate fuel.
FHR palletized approximately 200 gallons of both fuels for transport to SwRI in sealed 55-gallon
drums. As shown in Figure 1, drums of baseline fuel were labeled "NatAvBaseline" (coded by
SwRI as EM-6049-F), and drums of candidate fuel were labeled "CCD15010" (coded by SwRI
as EM-6048-F). SwRI extracted a one-gallon sample of the baseline and candidate fuels for
chemical analyses. The composition and properties of the CCD15010 fuel and the composition
and concentration of the HiTEC4121 additive in the fuel are proprietary and will be provided to
the EPA National Clean Diesel Campaign (NCDC) and to the Texas Council on Environmental
Quality (TCEQ) as confidential business information. The properties of the baseline fuel are
given in Table 1.
Figure 1. Sealed drums of Flint Hills Resources diesel fuels
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Table 1. Selected Fuel Properties and Specifications
Cetane number
Cetane index
Distillation range:
Initial boiling point, °C (°F)
10% Point, °C(°F)
50% Point, °C (°F)
90% Point, °C (°F)
End point, °C (°F)
Gravity (American Petroleum Institute)
Specific gravity
Total sulfur, ppm
Hydrocarbon composition:
Aromatics (minimum), %
Paraffins, naphthenes, and olefins, %
Flash point (minimum), °C (°F)
Viscosity, centistokes at 40 °C
Code of Federal Regulations
(CFR) Specification3
ASTM
D613
D976
D86
D86
D86
D86
D86
D287
—
D2622
D5186
D5186
D93
D445
Type 2D
40-50
40-50
171-204(340-400)
204-238 (400-460)
243-282 (470-540)
293-332 (560-630)
321-366(610-690)
32-37
—
7-15
27
e
54(130)
2.0-3.2
Test Fuel
EM-6049-F
(baseline)
45.1
b
194(382)
215(419)
256 (492)
316(601)
352 (666)
b
0.8542 c
5.1d
36.4
b
b
40 CFR 86.1313-2007(b)(2) for the year 2007 and beyond for heavy-duty diesel engines.
Not tested
Measured per ASTM D1298.
Measured per ASTM D7039. This method is an acceptable substitute for ASTM D2622.
Remainder of the hydrocarbons
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Section 3.0
Test Documentation
The ETV testing took place during October 2006 at SwRI under contract to the APCT Center.
Testing was performed in accordance with:
• Generic Verification Protocol for Determination of Emissions Reductions Obtained by Use
of Alternative or Reformulated Liquid Fuels, Fuel Additives, Fuel Emulsions, and Lubricants
for Highway andNonroad Use Diesel Engines and Light Duty Gasoline Engines and
Vehicles1
• Test/QA Plan for the Verification Testing of Alternative or Reformulated Liquid Fuels, Fuel
Additives, Fuel Emulsions, and Lubricants for Highway andNonroad Use Heavy Duty Diesel
Engines and Light Duty Gasoline Engines and Vehicles5
• Test-Specific Addendum to ETV Mobile Source Test/QA Plan for Flint Hills Resources for
the CCD15010 Diesel Fuel Formulation2
The applicant reviewed the generic verification protocol and had an opportunity to review the
test/QA plan prior to testing.
3.1 Engine Description
The ETV testing was performed on an inline six-cylinder, 12.7 L, 1991 model year, Detroit
Diesel Corporation (DDC) Series 60 highway heavy-duty diesel engine (model 6067GU60, SN:
06RE001123). The rating of this model engine is 272 kW (365 bhp) in "prime" power service at
1800 rpm. The engine was owned by SwRI and has been used in a number of test programs at
SwRI. Table 2 provides the engine identification details. The engine belongs to on-highway
engine family box OH-4 as categorized by EPA.
Table 2. Engine Identification Information
Engine serial number
Make
Model year
Model
Engine displacement and configuration
Service class
EPA engine family identification
Certification standards (g/hp-hr)
Rated power
Rated torque
Certified emission control system
Aspiration
Fuel system
06RE001123
Detroit Diesel Corp. (DDC)
1991
Series 60, 6067GU60
12.7 L, six-cylinder
Highway heavy-duty diesel engine (HDDE)
MDD12.7FZAK
HC 1.30/CO 15.50/NOx5.00/PM 0.250
365 bhp@ 1800 rpm
1 400 lb-ft@ 1200 rpm
Detroit Diesel electronic control (DDEC)-II
Turbocharger and laboratory charge air cooler
Direct injection
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3.2 Engine Fuel Description
All baseline emissions testing was conducted with ULSD fuel meeting the 40 CFR §86.1313-
2007 specification for emissions certified fuel.6 Baseline testing was conducted using fuel from a
single batch identified as EM-6049-F. All candidate emissions testing was conducted with FHR
CCD15010 diesel fuel formulation, containing the HiTEC4121 additive, from a single batch
identified as EM-6048-F.
In accordance with SwRI standard operating procedures, each fuel change included thoroughly
flushing fuel lines, heat exchangers, and the day tank. To fully purge the engine, the Series 60
was run with its return-fuel diverted into a slop container as new fuel was supplied. After the
previous fuel was fully purged and the engine was running on the selected fuel, a set of fresh fuel
filters was installed and the return-fuel was routed into the day tank. Each fuel change effort
consumed approximately 16 gallons of diesel fuel.
3.3 Summary of Emissions Measurement Procedures
The ETV tests consisted of baseline tests with ULSD fuel and candidate tests with the fuel
formulation. Engine operation and emissions sampling adhered to techniques developed by EPA
in 40 CFR, Part 86, Subpart N.7 Emissions were measured over triplicate runs of the highway
transient test cycle and the supplemental emissions test (SET) for the baseline and candidate
exhaust configurations. Baseline testing is conducted at the beginning and end of the verification
series, and the complete test sequence is repeated for the candidate fuel, as shown in Table 3.
Table 3. Overview of Verification Test Sequence
Description
Baseline 1
Candidate 1
Candidate 2
Baseline 2
Fuel
EM-6049-F a
EM-6048-F b
EM-6048-F
EM-6049-F
Engine
1991 DDC Series 60 HDDE
1991 DDC Series 60 HDDE
1991 DDC Series 60 HDDE
1991 DDC Series 60 HDDE
Test Sequence
Cold + 3 hots + SET
Cold + 3 hots + SET
Cold + 3 hots + SET
Cold + 3 hots + SET
FHR fuel identified as "NatAvBaseline" conforming to 40 CFR §86.1313-2007
b CCD15010 fuel formulation with HITEC4121 additive
The DDC Series 60 engine was operated in an engine dynamometer test cell, with exhaust
sampled using full-flow dilution constant volume sampling (CVS) techniques to measure
regulated emissions of hydrocarbon (HC), carbon monoxide (CO), nitrogen oxides (NOX), and
particulate matter (PM), as well as carbon dioxide (CO2). In addition to results presented in this
report, raw data were gathered at the rate of one series of measurements per second over each
test to record the engine speed, torque value, concentration of selected emissions, exhaust
temperature, and various pressures. Figure 2 depicts the sampling system and related
components. The system is designed to comply with the requirements of 40 CFR, Part 86.7
-------
HC
Analyzer
NOx
fn alyzer
Poat^e
Displacement
Rjrnp
(PCP)
Figure 2. Schematic of emissions sampling system at SwRI.
The verification protocol requires that engines used for verification testing must not exceed
110% of the certification standards for emissions from that engine category.8 For 1991-1992
highway engines, the certification standards are defined in EPA's on-highway engine family box
OH-49. Furthermore, the Office of Transportation and Air Quality (OTAQ) assumes 5%
reduction in PM emissions due to the use of ULSD fuel.
Therefore, the criteria established to indicate that the test engine was acceptable and that the
verification testing could proceed were that the baseline emissions from the engine using ULSD
fuel could not exceed 110% of OH-4 (1.1 x OH-4) for HC, CO, and NOX, and also could not
exceed 110% of [(OH-4)-5%], or (1.045 x OH-4) for PM. Table 4 presents the required
emission performance of the test engine, as well as the certification standards and baseline
results for comparison.
Table 4. Test Engine Baseline Emissions Requirement for 1991 DDC Series 60
OH-4
Acceptance criteria
Baseline results
H
g/kWh
1.74
1.92
0.07
C
g/hp-hr
1.30a
1.43
0.05
C
g/kWh
20.79
22.86
3.67
0
g/hp-hr
15.50a
17.05
2.74
INK
g/kWh
6.71
7.38
6.91
3x
g/hp-hr
5.00a
5.50
5.15
P
g/kWh
0.335
0.350
0.240
M
g/hp-hr
0.250a
0.261
0.179
40 CFR §86.091-11, Certification standards for EPA engine family box OH4 for 1991-1992 highway engines
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3.4 Deviations from the Test/QA Plan
There was one deviation from the test/QA plan. Following the initial baseline testing, an erratic
NOx signal was noted on several subsequent tests. These tests were voided and not included in
the results. Diagnostic tests indicated that the NOx pump's motor-to-pump coupling had allowed
the pump to turn, usually without interruption, but occasionally slipped, producing intermittent
flow losses that resulted in an erratic analyzer response. The coupling was replaced and testing
resumed without incident after a stable NOx signal was achieved.
3.5 Documented Test Conditions
Engine Performance
Figure 3 shows torque map information measured on the DDC Series 60 engine using the ULSD
fuel.
Ib-ft -
- - -hp
1600
400
500 750
0
1000 1250 1500 1750 2000
Engine Speed, rpm
Figure 3. Torque map of 1991 DDC Series 60 engine using ULSD baseline fuel.
Engine Exhaust Backpressure
The engine backpressure for the 1991 DDC Series 60 engine was set in accordance with the
engine manufacturer specifications before the first baseline test. Maximum backpressure
observed during testing did not exceed the manufacturer's specifications.
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Brake Specific Fuel Consumption
The fuel consumption was not measured explicitly during the engine testing. Rather, a
calculated "carbon-balance" (C-B) fuel consumption rate was determined based on the measured
exhaust flow rate and the carbon content (i.e., the CO and the CO2) in the exhaust gas analysis.
The weighted brake-specific fuel consumption (BSFC) calculations are similar to the weighted
emissions calculations explained in Section 4.0. Tables 5 and 6 show the weighted BSFC
calculations for the highway Federal Test Procedure (FTP) and SET. Table 7 summarizes the
results of these calculations and compares the fuel consumption during the baseline ULSD runs
with that measured during the candidate CCD15010 tests. (The weighting for BSFC in Table 7
is the same as that for the combined emissions rates in Tables 11 and 12. A more detailed
explanation is given in Section 4.)
Table 5. Brake-Specific Fuel Consumption (by Carbon Balance) for Highway FTP Tests
Test Number
Test
Type
Test Date
BSFC
Ib/bhp-hr
kg/kWh
Weighted BSFC
Ib/bhp-hr | kg/kWh
BASELINE 1
FHR49-C2
FHR49-H4
Cold-start
Hot-start
10/18/2006
10/18/2006
0.408
0.390
0.248
0.237
0.393
0.239
FHR49-H5
Hot-start
10/18/2006
0.404
0.246
0.405
0.246
FHR49-H6
Hot-start
10/18/2006
0.391
0.238
0.394
0.239
CANDIDATE 1
FHR48-C6
FHR48-H19
Cold-start
Hot-start
10/25/2006
10/25/2006
0.399
0.383
0.243
0.233
0.385
0.234
FHR48-H20
Hot-start
10/25/2006
0.380
0.231
0.383
0.233
FHR48-H21
Hot-start
10/25/2006
0.377
0.229
0.380
0.231
CANDIDATE 2
FHR48-C7
Cold-start
10/26/2006
0.424
0.258
FHR48-H22
Hot-start
10/26/2006
0.385
0.234
0.391
0.237
FHR48-H23
Hot-start
10/26/2006
0.384
0.233
0.389
0.237
FHR48-H24
Hot-start
10/26/2006
0.382
0.232
0.388
0.236
BASELINE 2
FHR49-C3
FHR49-H7
Cold-start
Hot-start
10/27/2006
10/27/2006
0.405
0.384
0.246
0.233
0.387
0.235
FHR49-H8
Hot-start
10/27/2006
0.381
0.232
0.385
0.234
FHR49-H9
Hot-start
10/27/2006
0.381
0.232
0.385
0.234
-------
Table 6. Brake-Specific Fuel Consumption (by Carbon Balance) for SET Tests
Test Number
FHR49-SET-4
FHR48-SET-4
FHR48-SET-6
FHR49-SET-5
Test Type
Baseline 1
Candidate 1
Candidate 2
Baseline 2
Weighted BSFC
Ib/bhp-hr
0.334
0.324
0.320
0.332
kg/kWh
0.203
0.197
0.195
0.202
Table 7. Summary of Fuel Consumption Reduction
Combined weighted BSFC
Ib/bhp-hr
kg/kWh
BASELINE
B1
B2
B3
B4
B5
B6
MEAN
0.384
0.394
0.385
0.379
0.377
0.377
0.383
0.233
0.240
0.234
0.230
0.229
0.229
0.233
CANDIDATE
C1
C2
C3
C4
C5
C6
MEAN
0.376
0.374
0.372
0.380
0.379
0.378
0.377
0.229
0.227
0.226
0.231
0.230
0.230
0.229
% Reduction
95% Confidence Limits
1.58
1.58 to 1.59
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Section 4.0
Summary and Discussion of Emission Results
Table 8 reports the emissions from cold- and hot-start tests that were conducted with the baseline
and candidate fuels. The concentration measurements were converted to units of total grams per
test for all species.
Table 8. Emissions Data from Highway Transient Tests
Test Number
Test Type
PM
NOX
HC
CO
g
CO2
kg
Work
kWh (bhp-hr)
BASELINE ULSD Fuel on a 1991 DDC Series 60 Engine
FHR49-C2
FHR49-H4
FHR49-H5
FHR49-H6
Cold-start
Hot-start
Hot-start
Hot-start
4.46
4.49
4.40
4.45
145
121
123
122
2.03
1.32
1.38
1.12
82.4
67.2
67.3
67.4
14.4
13.6
14.1
13.7
18.4(24.7)
18.2(24.4)
18.2(24.4)
18.2(24.4)
CANDIDATE CCD15010 Fuel and HITEC4121 Additive on a 1991 DDC Series 60 Engine
FHR48-C6
FHR48-H19
FHR48-H20
FHR48-H21
Cold-start
Hot-start
Hot-start
Hot-start
4.39
4.32
4.33
4.46
130
112
110
111
1.12
0.875
0.778
0.805
70.1
56.7
56.5
57.3
14.1
13.4
13.3
13.2
18.4(24.7)
18.2(24.4)
18.2(24.4)
18.2(24.4)
CANDIDATE CCD15010 Fuel and HITEC4121 Additive on a 1991 DDC Series 60 Engine
FHR48-C7
FHR48-H22
FHR48-H23
FHR48-H24
Cold-start
Hot-start
Hot-start
Hot-start
4.34
4.54
4.64
4.59
132
111
111
114
1.34
1.37
0.892
1.11
68.7
60.1
61.0
59.4
15.0
13.4
13.4
13.4
18.4(24.7)
18.2(24.4)
18.2(24.4)
18.2(24.4)
BASELINE ULSD Fuel on a 1991 DDC Series 60 Engine
FHR49-C3
FHR49-H7
FHR49-H8
FHR49-H9
Cold-start
Hot-start
Hot-start
Hot-start
4.40
4.23
4.35
4.30
146
125
122
122
1.37
1.07
0.919
0.982
77.8
62.9
62.6
62.0
14.3
13.4
13.3
13.4
18.5(24.8)
18.2(24.4)
18.2(24.4)
18.2(24.4)
Tables 9 and 10 report the emissions from the 13-mode steady-state SET tests that were
conducted with the baseline and candidate fuels. The concentration measurements were
converted to units of grams per hour for all species. The "bhp from Work" (the integrated
measured power during each test period) values are also shown in these tables.
10
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Table 9. Emissions Data from Baseline Supplemental Emissions Tests (SET)
Test Number
FHR49-SET-4
FHR49-SET-5
Mode
1
2
3
4
5
6
7
8
9
10
11
12
13
1
2
3
4
5
6
7
8
9
10
11
12
13
Target
%
(idle)
100
50
75
50
75
25
100
25
100
25
75
50
(idle)
100
50
75
50
75
25
100
25
100
25
75
50
Weighting
Factor
0.15
0.08
0.10
0.10
0.05
0.05
0.05
0.09
0.10
0.08
0.05
0.05
0.05
0.15
0.08
0.10
0.10
0.05
0.05
0.05
0.09
0.10
0.08
0.05
0.05
0.05
PMa
NOx
HC
CO
g
5.24
5.39
3.28
41.1
47.7
56.2
19.7
23.3
12.9
59.4
30.7
57.9
16.8
31.2
25.7
3.08
40.9
47.2
56.3
19.7
25.1
12.9
58.8
30.6
57.9
16.6
30.9
25.6
0.113
0.163
0.130
0.138
0.0577
0.0777
0.0794
0.230
0.172
0.171
0.105
0.0871
0.0839
0.0723
0.150
0.0795
0.102
0.0374
0.0729
0.0581
0.163
0.131
0.120
0.0780
0.0638
0.0620
1.20
47.1
2.28
10.4
1.45
12.7
0.734
25.6
1.77
9.36
1.18
2.19
0.892
1.08
46.1
2.14
9.67
1.46
12.6
0.732
23.4
1.78
8.89
1.13
2.02
0.867
CO2
kg
0.210
3.17
2.33
3.39
1.01
1.52
0.564
4.04
1.31
3.73
0.711
1.72
1.22
0.230
3.14
2.29
3.38
1.02
1.63
0.567
4.01
1.31
3.71
0.710
1.74
1.22
Work
kWh (bhp-hr)
0.0218(0.0292)
5.02 (6.73)
3.67 (4.92)
5.49 (7.36)
1.58(2.12)
2.38(3.19)
0.798(1.07)
6.56(8.80)
1.83(2.45)
6.03(8.08)
0.947(1.27)
2.83(3.79)
1.88(2.52)
0.0218(0.0292)
5.03 (6.74)
3.66(4.91)
5.48(7.35)
1.58(2.12)
2.61 (3.50)
0.798(1.07)
6.55(8.79)
1.81 (2.43)
6.05(8.11)
0.947(1.27)
2.82(3.78)
1.88(2.52)
PM is not reported mode-by-mode.
11
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Table 10. Emissions Data from Candidate Supplemental Emissions Tests (SET)
Test Number
FHR48-SET-4
FHR48-SET-6
Mode
1
2
3
4
5
6
7
8
9
10
11
12
13
1
2
3
4
5
6
7
8
9
10
11
12
13
Target
%
(idle)
100
50
75
50
75
25
100
25
100
25
75
50
(idle)
100
50
75
50
75
25
100
25
100
25
75
50
Weighting
Factor
0.15
0.08
0.10
0.10
0.05
0.05
0.05
0.09
0.10
0.08
0.05
0.05
0.05
0.15
0.08
0.10
0.10
0.05
0.05
0.05
0.09
0.10
0.08
0.05
0.05
0.05
PMa
NOx
HC
CO
g
4.41
4.97
3.26
40.2
43.7
54.9
18.8
22.5
11.4
58.9
26.6
57.5
14.3
30.5
23.8
3.06
39.2
44.1
54.2
18.4
22.0
11.0
57.6
26.3
59.3
14.3
30.0
23.6
0.0808
0.147
0.0912
0.133
0.0569
0.0822
0.0482
0.187
0.117
0.162
0.0787
0.0788
0.0696
0.00
0.107
0.0533
0.0733
0.0164
0.0447
0.0202
0.161
0.0588
0.111
0.0560
0.0553
0.0438
0.959
46.6
2.12
9.19
1.38
11.2
0.675
23.1
1.56
7.97
0.953
1.92
0.858
0.652
45.4
2.16
10.0
1.39
12.2
0.570
24.9
1.36
9.22
0.853
2.02
0.783
CO2
kg
0.214
3.06
2.24
3.32
0.995
1.47
0.557
3.95
1.27
3.60
0.670
1.71
1.18
0.191
3.03
2.24
3.28
0.977
1.45
0.529
3.89
1.26
3.75
0.668
1.68
1.17
Work
kWh (bhp-hr)
0.0224(0.0301)
5.00(6.71)
3.66(4.91)
5.50(7.37)
1.59(2.13)
2.39(3.21)
0.805(1.08)
6.57(8.81)
1.84(2.47)
6.00(8.04)
0.932(1.25)
2.82(3.78)
1.88(2.52)
0.0312(0.0418)
4.99 (6.69)
3.65 (4.89)
5.50(7.37)
1.58(2.12)
2.39(3.20)
0.790(1.06)
6.56(8.80)
1.84(2.47)
6.33(8.49)
0.940(1.26)
2.83(3.79)
1.89(2.54)
PM is not reported mode-by-mode.
For each cold/hot-start test combination, the composite-weighted transient emission rate for each
pollutant was then calculated following the fractional calculation for highway engines as follows:
— • EcOLD ~\ • \EiHOT )m
7 1 C^-1)
1 ,,, 6
— • WCOLD -\
7 7
where
ECOMP = composite-weighted transient emissions rate, g/bhp-hr
m = one, two, or three hot-start tests
ECOLD = cold-start mass emissions level, g
EHOT = hot-start mass emissions level, g
WCOLD = cold-start brake horsepower hour, bhp-hr
WHOT = hot-start brake horsepower hour, bhp-hr.
12
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For the SET, the emission rate for each pollutant was calculated by applying a weighting factor,
specified in 40 CFR 86.136010, to the emission rate and work measured at each mode as follows:
(Eq. 2)
/ , Ji * "MODEt
i=\
where ESET = emissions rate for SET, g/bhp-hr
/ = mode weighting factor from 40 CFR 86.1360
EMODEJ = pollutant emissions rate during mode /', g
WMODEI = brake horsepower hour during mode /', bhp-hr.
The composite-weighted highway transient emission rate for each pollutant, ECOMP, was then
combined with a single SET emission rate as follows to obtain the combined emission rate, Et,
for each pollutant for each of the n tests at the test point:
Et = 0.85*EcoMp, + 0.15'EsET (Eq. 3)
where Et = combined emission rate, g/bhp-hr
ECOMP = composite-weighted transient emissions rate, g/bhp-hr
ESET = emission rate for supplemental emissions test
/ = 1 to n tests required at test point
These combined emissions rates are shown in Tables 11 and 12 and were used to calculate the
mean and standard deviations for the baseline and controlled emissions rates. These data were in
turn used to calculate mean emissions reductions and 95% confidence limits. These calculations
are based on the generic verification protocol1 and test/QA plan.2 Equations 4-15 show how the
data from Tables 8, 9, and 10, identified by test number, were weighted to provide the combined
emissions rates.
Bl = (0.85)[(1/7)(FHR49-C2) + (6/7)(FHR49-H4)] + (0.15)(FHR49-SET-4) (Eq. 4)
B2 = (0.85)[(1/7)(FHR49-C2) + (6/7)(FHR49-H5)] + (0.15)(FHR49-SET-4) (Eq. 5)
B3 = (0.85)[(1/7)(FHR49-C2) + (6/7)(FHR49-H6)] + (0.15)(FHR49-SET-4) (Eq. 6)
B4 = (0.85)[(1/7)(FHR49-C3) + (6/7)(FHR49-H7)] + (0.15)(FHR49-SET-5) (Eq. 7)
B5 = (0.85)[(1/7)(FHR49-C3) + (6/7)(FHR49-H8)] + (0.15)(FHR49-SET-5) (Eq. 8)
B6 = (0.85)[(1/7)(FHR49-C3) + (6/7)(FHR49-H9)] + (0.15)(FHR49-SET-5) (Eq. 9)
Cl = (0.85)[(1/7)(FHR48-C6) + (6/7)(FHR48-H19)] + (0.15)(FHR48-SET-4) (Eq. 10)
C2 = (0.85)[(1/7)(FHR48-C6) + (6/7)(FHR48-H20)] + (0.15)(FHR48-SET-4) (Eq. 11)
C3 = (0.85)[(1/7)(FHR48-C6) + (6/7)(FHR48-H21)] + (0.15)(FHR48-SET-4) (Eq. 12)
C4 = (0.85)[(1/7)(FHR48-C7) + (6/7)(FHR48-H22)] + (0.15)(FHR48-SET-6) (Eq. 13)
C5 = (0.85)[(1/7)(FHR48-C7) + (6/7)(FHR48-H23)] + (0.15)(FHR48-SET-6) (Eq. 14)
C6 = (0.85)[(1/7)(FHR48-C7) + (6/7)(FHR48-H24)] + (0.15)(FHR48-SET-6) (Eq. 15)
13
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Table 11. Combined Emission Rates (U.S. Common Units)
Combined
Emissions Rate
PM
NOx
HC
CO
CO2
g/bhp-hr
BASELINE ULSD Fuel on a 1991 DDC Series 60 Engine
B1
B2
B3
B4
B5
B6
0.171
0.169
0.170
0.163
0.167
0.165
5.56
5.62
5.58
5.66
5.57
5.58
0.0542
0.0559
0.0481
0.0419
0.0376
0.0394
2.75
2.75
2.76
2.58
2.57
2.55
550
564
551
543
540
540
CANDIDATE CCD15010 Fuel with HiTEC4121 Additive on a 1991 DDC Series 60 Engine
C1
C2
C3
C4
C5
C6
0.163
0.164
0.167
0.171
0.174
0.173
5.16
5.10
5.10
5.13
5.12
5.20
0.0354
0.0326
0.0333
0.0498
0.0355
0.0419
2.35
2.35
2.36
2.46
2.48
2.43
539
536
533
544
543
542
Table 12. Combined Emission Rates (Metric Units)
Combined
Emissions Rate
PM
NOx
HC
CO
CO2
g/kW-hr
BASELINE ULSD Fuel on a 1991 DDC Series 60 Engine
B1
B2
B3
B4
B5
B6
0.229
0.227
0.228
0.219
0.224
0.221
7.46
7.54
7.48
7.59
7.47
7.48
0.0727
0.0750
0.0645
0.0562
0.0504
0.0528
3.69
3.69
3.70
3.46
3.45
3.42
738
756
739
728
724
724
CANDIDATE CCD15010 Fuel with HiTEC4121 Additive on a 1991 DDC Series 60 Engine
C1
C2
C3
C4
C5
C6
0.219
0.220
0.224
0.229
0.233
0.232
6.92
6.84
6.84
6.88
6.87
6.97
0.0475
0.0437
0.0447
0.0668
0.0476
0.0562
3.15
3.15
3.16
3.30
3.33
3.26
723
719
715
730
728
727
The combined emission rates from Tables 11 and 12 are the key values for the verification test.
Tables 13 and 14 summarize that information. The first line shows the baseline engine results;
the emissions in all categories are below the Table 3 threshold.
Table 13. Summary of Verification Test Data (U.S. Common Units)
Test Type
BASELINE
CANDIDATE
Fuel
ULSD
CCD15010+HITEC4121
Mean Composite Weighted Emission Value
PM
NOx
HC
CO
C02
g/bhp-hr
0.179
0.183
5.15
4.68
0.0496
0.0412
2.74
2.46
561
553
14
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Table 14. Summary of Verification Test Data (Metric Units)
Test Type
BASELINE
CANDIDATE
Fuel
ULSD
CCD15010+HITEC4121
Mean Composite Weighted Emission Value
PM
NOx
HC
CO
C02
g/kW-hr
0.240
0.245
6.91
6.28
0.0665
0.0553
3.67
3.30
752
742
Table 15 summarizes the emissions reductions that were achieved by the use of the CCD15010
fuel formulation with H1TEC4121 additive. These are the "verified emissions reductions"
reported in Table 2 of the ETV Joint Verification Statement.
Table 15. Summary of Verification Test Emission Reductions
Technology
CCD15010+HITEC4121
Mean
Emissions Reduction (%)
PM
-0.74 a
NOx
8.2
HC
17
CO
9.6
95% Confidence Limits
on the Emissions Reduction (%)
PM
_ b
NOx
7.3 to 9.0
HC
_ b
CO
5.3 to 14
Negative reduction indicates increase in emissions.
b The emissions reduction can not be distinguished from zero with 95% confidence.
4.1 Quality Assurance
The environmental technology verification of the CCD15010 fuel formulation with H1TEC4121
additive for highway heavy-duty diesel engines was performed in accordance with the approved
test/QA plan and the test-specific addendum.2 An audit of data quality included the review of
equipment, personnel qualifications, procedures, record keeping, data validation, analysis, and
reporting. Preliminary, in-process, and final inspections, and a review of 10% of the data
showed that the requirements stipulated in the test/QA plan5 were achieved. The SwRI, APCT
Center, and EPA quality managers reviewed the test results and the QC data and concluded that
the data quality objectives given in the generic verification protocol were attained. EPA and RTI
QA staff conducted audits of SwRI's technical and quality systems in April 2002 and found no
deficiencies that would adversely impact the quality of results. The equipment was appropriate
for the verification testing, and it was operating satisfactorily. SwRI's technical staff was well
qualified to perform the testing and conducted themselves in a professional manner.
15
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Section 5.0
References
1. RTI International. 2003. Generic Verification Protocol for Determination of Emissions
Reductions Obtained by Use of Alternative or Reformulated Liquid Fuels, Fuel Additives,
Fuel Emulsions, and Lubricants for Highway andNonroad Use Diesel Engines and Light
Duty Gasoline Engines and Vehicles. Research Triangle Park, NC, September. Available:
http://www.epa.gov/etv/pdfs/vp/05_vp_fuel.pdf
2. RTI International. 2006. Test-Specific Addendum to ETV Mobile Source Test/QA Plan for
Flint Hills Resources for the CCD15010 Diesel Fuel Formulation. Research Triangle
Park, NC, September 22.
3. Southwest Research Institute. 2006. Environmental Technology Verification of Diesel Fuel
Formulation FHR-CCD15010. Final Report. San Antonio, TX, December.
4. Southwest Research Institute. 2006. Audit of Data Quality for Environmental Technology
Verification of Diesel Fuel Formulation FHR-CCD15010. San Antonio, TX, December.
5. RTI International. 2006. Test/QA Plan for the Verification Testing of Alternative or
Reformulated Liquid Fuels, Fuel Additives, Fuel Emulsions, and Lubricants for Highway
andNonroad Use Heavy Duty Diesel Engines and Light Duty Gasoline Engines and
Vehicles. Research Triangle Park, NC, September. Available:
http://www.epa.gov/etv/pdfs/vp/05_tp_diesel.pdf.
6. 40 CFR §86.1313-2007 (Protection of Environment: Control of Emissions from New and
In-Use Highway Vehicles and Engines, Fuel Specifications), Table N07-2. Available:
http://www.epa.gov/epahome/cfr40.htm (updated September 6, 2006).
7. 40 CFR, Part 86 (Protection of Environment: Control of Emissions from New and In-Use
Highway Vehicles and Engines), Subpart N.
8. RTI International. 2003. Generic Verification Protocol for Determination of Emissions
Reductions from Selective Catalytic Reduction Control Technologies for Highway,
Nonroad, and Stationary Use Diesel Engines. Research Triangle Park, NC, September.
Available: http://www.epa.gov/etv/pdfs/vp/05_vp_emissions.pdf.
9. 40 CFR §86.091-11 (Protection of Environment: Control of Emissions from New and In-
Use Highway Vehicles and Engines, Emission standards for 1991 and later model year
diesel heavy-duty engines). Available: http://www.epa.gov/epahome/cfr40.htm (updated
June 26, 2006).
10. 40 CFR §86.1360-2007 (Protection of Environment: Control of Emissions from New and
In-Use Highway Vehicles and Engines, Supplemental emission test; test cycle and
procedures). Available: http://www.epa.gov/epahome/cfr40.htm (updated June 26, 2006).
16
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