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Fuel 101

23K views 21 replies 10 participants last post by  McCoy  
#1 · (Edited)
Re: Fuel Tech Section

I was going to add more to this segment before dropping it here, but I think that this will suffice for now. I would like to find some pictures online of different flame fronts after ignition so that detonation and burn can both be better described.


Some good definitions for future use...
http://www.eng-tips.com/viewthread.cfm?qid=34183&page=33
Glossary on Explosion Dynamics
Some of the language used to describe explosions is very precise and scientific; other terms, including the very nature of an explosion itself, are quite ambiguous. The following list of terms is not intended to be exhaustive but simply to provide an explanation for some of the most commonly used concepts.

Blast or Blast Wave This is the rapid change in air pressure that propagates away from the region of an explosion. A sharp jump in pressure is known as a shock wave and a slow rise is known as a compression wave. Weak pressure waves propagate with the speed of sound and shock waves always travel supersonically, faster than the speed of sound. A blast wave is produced by an explosion because the explosive event displaces the surrounding air rapidly.

Burning speed This is the speed with which a smooth (laminar) flame advances into a stationary mixture of reactants. Burning speeds in hydrocarbon fuels mixed with air are typically less than 0.5 m/s. The burning speed is a function of the concentration of the fuel, temperature, and pressure of the mixture.

Deflagration This is a propagating flame that moves subsonically (the flame speed is less than the speed of sound) in a mixture of fuel and oxidizer.

Deflagration to Detonation Transition (DDT) In certain circumstances, a flame may accelerate to high velocities (greater than 1000 m/s) and suddenly become a detonation instead of a deflagration. The circumstances involve a sufficiently sensitive mixture (very rapid chemical reaction) in a geometrical configuration that is favorable to flame acceleration - this usually requires confinement and obstructions or obstacles in the path of the flame. Such mixtures are characterized by a small detonation cell width, high flame speed, and high volume expansion ratio.

Detonation This is a supersonic combustion wave. Detonations in gases propagate with velocities that range from 5 to 7 times the speed of sound in the reactants. For hydrocarbon fuels in air, the detonation velocity can be up to 1800 m/s. The ideal detonation speed, known as the Chapman-Jouguet velocity, is a function of the reactant composition, initial temperature and pressure.

Detonation cell width This is the characteristic width of the cellular pattern that is created by the instabilities that plague all propagating gaseous detonation waves. The cell width is measured by a sooted sheet or foil of metal inserted inside a tube used for detonation experiments. Detonation cell widths are used to characterize the sensitivity or susceptibility of a mixture to detonation. Sensitive mixtures (acetylene-oxygen) have cell sizes less than 1 mm; insensitive mixtures (methane-air or any lean hydrocarbon-air mixture) can have cell sizes of up to 1 m.

Explosion There is no fixed definition of an explosion. Events that are described as explosions include a rupturing water boiler, a flash of light created by an electrical short circuit, detonation of a high explosive, deflagration of a tank containing an explosive fuel-air mixture, or the shock wave, fireball, and debris cloud produced by a thermonuclear detonation. The AIChE suggests that an explosion is "A release of energy that causes a blast". Perhaps the best definition was given by Joseph Needham, "An explosion may be defined as a loud noise accompanied by the sudden going away of things from the places where they were before." - see p. 110 of The Gunpowder Epic, Vol 5, Part 7, Science and Civilization in China.

Fire This is a flame that is produced over a stationary fuel source such as a liquid hydrocarbon pool or solid such as wood.

Flame This is a thin zone of combustion in which diffusion plays a dominant role. Flames in hydrocarbon fuels and air are less than 0.1 mm thick for stoichiometric mixtures.

Flame speed This is the speed with which a flame, possibly turbulent, appears to move relative to a stationary observer. The flame speed can be much larger than the burning velocity due to expansion of the combustion products, instability, and turbulent deformation of the flame. Flame speeds of 10-100 m/s are commonly observed for hydrocarbon-air mixtures and it is possible under exceptional circumstances to have speeds up to 1000 m/s.

Flammability A fuel-air mixture is flammable when combustion can be started by an ignition source. The main fact is the proportions or composition of the fuel-air mixture. A mixture that has less than a critical amount of fuel, known as the Lean Flammability Limit (LFL), or greater than a critical amount of fuel, known as the rich or Upper Flammability Limit (UFL), will not be flammable. For example, the lean flammability limit for Jet A (aviation kerosene) in air at sea level is a concentration (by volume or partial pressure) of about 0.7%. The rich flammability limit is about 4.8% by volume or partial pressure. Flammability limits are not absolute, but depend on the type and strength of the ignition source. Previous studies on flammability limits of hydrocarbon fuels have shown that the stronger the source of the ignition stimulus, the leaner the mixture that can be ignited. Flammability limits also depend on the type of atmosphere (for example, limits are much wider in oxygen than in air), the pressure, and the temperature of atmosphere.

Flash point This is the minimum temperature at which the vapor above a liquid fuel will first support a combustion transient or "flash". The flash point is measured by a standardized test using a small quantity (50 cc) of liquid that is slowly heated (about 1 deg C/minute) until a flash is observed when an open flame is dipped down into a covered vapor space. The legal description of flammable is used for all liquids with a flash point less than 100 deg C, and the term combustible is used for liquids with a flash point in excess of 100 deg C.

Fuel-air mass ratio This is the ratio of the mass of fuel to the mass of air in the reactants. The fuel-air ratio is a method of measuring the composition of a potentially flammable mixture.

Lean mixture This is a mixture containing less than the stoichiometric amount of fuel. Combustion of a lean mixture will result in excess oxidizer remaining in the products.

Minimum Ignition Energy This is the lowest possible energy that will result in the ignition of a flammable mixture by an electrical discharge. The minimum ignition energy depends on the composition of the mixture and can be as low as 200 microJoules for many common hydrocarbon fuels.

Overpressure This is the pressure in excess of the ambient value that is created by the explosion process. The peak overpressures associated with deflagrations inside closed vessels can be as high as 10 times the initial pressure.

Partial pressure This is the pressure created by one component of gas mixture. The partial pressure of fuel vapor in a well-mixed ullage over a liquid fuel layer is equal to the vapor pressure of the liquid under those conditions. Strictly speaking, this is the case only for a single component fuel (such as hexane) but is also valid for multicomponent fuels like kerosene as long as sufficient liquid is present.

Pool Fire This is a flame over a puddle or pool of liquid fuel. The heat released by the combustion of the vapor fuel supplies the energy to vaporize the liquid.

Reactants This is the mixture of Fuel and Oxidizer molecules that are burned in the combustion process.

Rich mixture This is a mixture containing more than the stoichiometric amount of fuel. Combustion of a rich mixture will result in excess decomposed fuel (hydrogen and carbon monoxide for hydrocarbon fuels) remaining in the products.

Stoichiometric ratio The proportions of fuel and oxidizer that will result in optimal combustion are known as a stoichiometric ratio. The optimal ratio is determined by finding the amount of air that will result in the products of the combustion reaction containing only water and carbon dioxide with no left over oxygen. A stoichiometric mixture of Jet A and air contains about 1.2% fuel by volume or partial pressure.

Ullage This is the volume in a liquid fuel tank that is not occupied by liquid fuel. This is sometimes referred to as the vapor space since it is filled with a mixture of fuel vapor and a cover gas, air in the case of commercial airplanes.
 
#2 ·
Re: Fuel Tech Section

What is gasoline?
Most automotive fuels are comprised primarily of Hydrocarbons (about 14% Hydrogen and 86% Carbon by weight) and aromatics. Hydrocarbon molecular structure has a drastic affect on the properties of the fuel. Below are some different classes of hydrocarbons

Alkane
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Alkanes, also known as paraffins, are chemical compounds that consist only of the elements carbon (C) and hydrogen (H) (i.e., hydrocarbons), wherein these atoms are linked together exclusively by single bonds (i.e., they are saturated compounds) without any cyclic structure (i.e., loops). Alkanes belong to a homologous series of organic compounds in which the members differ by a constant relative atomic mass of 14.
Each carbon atom must have 4 bonds (either C-H or C-C bonds), and each hydrogen atom must be joined to a carbon atom (H-C bonds). A series of linked carbon atoms is known as the carbon skeleton or carbon backbone. In general, the number of carbon atoms is often used to define the size of the alkane (e.g., C2-alkane).


Alkene
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In organic chemistry, an alkene, olefin, or olefine is an unsaturated chemical compound containing at least one carbon-to-carbon double bond. [1] The simplest acyclic alkenes, with only one double bond and no other functional groups, form a homologous series of hydrocarbons with the general formula CnH2n. [2]
The simplest alkene is ethylene (C2H4), which has the International Union of Pure and Applied Chemistry (IUPAC) name ethene. Alkenes are also called olefins (an archaic synonym, widely used in the petrochemical industry). Aromatic compounds are often drawn as cyclic alkenes, but their structure and properties are different and they are not considered to be alkenes.[2]


Alkyne
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Alkynes are open chain unsaturated hydrocarbons that have at least one triple bond between two carbon atoms, with the formula CnH2n-2. The alkynes are traditionally known as acetylenes or the acetylene series, although the name acetylene is also used to refer specifically to the simplest member of the series, known as ethyne (C2H2) using formal IUPAC nomenclature.


Cycloalkane
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Cycloalkanes (also called naphthenes, especially if from petroleum sources) are types of alkanes which have one or more rings of carbon atoms in the chemical structure of their molecules. Alkanes are types of organic hydrocarbon compounds which have only single chemical bonds in their chemical structure. Cycloalkanes consist of only carbon (C) and hydrogen (H) atoms and are saturated because there are no multiple C-C bonds to hydrogenate (add more hydrogen to). A general chemical formula for cycloalkanes would be CnH2(n+1-g) where n = number of C atoms and g = number of rings in the molecule. Cycloalkanes with a single ring are named analogously to their normal alkane counterpart of the same carbon count: cyclopropane, cyclobutane, cyclopentane, cyclohexane, etc. The larger cycloalkanes, with greater than 20 carbon atoms are typically called cycloparaffins.
Cycloalkanes are classified into small, normal and bigger cycloalkanes, where cyclopropane and cyclobutane are the small ones, cyclopentane, cyclohexane, cycloheptane are the normal ones, and the rest are the bigger ones.


Aromatic hydrocarbon
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An aromatic hydrocarbon (abbreviated as AH) or arene [1] is a hydrocarbon, the molecular structure of which incorporates one or more planar sets of six carbon atoms that are connected by delocalised electrons numbering the same as if they consisted of alternating single and double covalent bonds. The term 'aromatic' was assigned before the physical mechanism determining aromaticity was discovered, and was derived from the fact that many of the compounds have a sweet scent. This sweet scent actually came from impurities in the compounds (which are not actually aromatic in the sense initially described). The configuration of six carbon atoms in aromatic compounds is known as a benzene ring, after the simplest possible aromatic hydrocarbon, benzene. Aromatic hydrocarbons can be monocyclic or polycyclic.


Alcohols
Ethane
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Ethanol
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Ethanol is considered an Alcohol. In these molecules one hydroxyl (-OH) group is substituted for one hydrogen atom. This is visible above as Ethane is changed to Ethanol (Ethyl Alcohol) by adding an oxygen atom. The same is true for Methane and Methanol.
 
#3 ·
Re: Fuel Tech Section

How is Octane determined?
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Excerpt from:
Heywood, John B. Internal Combustion Engine Fundamentals
McGraw-Hill Book Co. 1988

The Octane number (ON) is based on two hydrocarbons which define the ends of the scale. By definition, normal heptane (n-heptane) has a value of zero and isooctane has an octane number of 100. These hydrocarbons were chosen because of the great difference in their ability to resist knock and the fact that isooctane had a higher resistance to knock than any of the gasolines available at the time the scale was established. Blends of these two hydrocarbons define the knock resistance of intermediate octane numbers: e.g., a blend of 10% n-heptane and 90% isooctane has an octane number of 90. A fuel's octane number is determined by measuring what blend of these two hydrocarbons matches the fuel's knock resistance. For fuels below 100 ON, the primary reference fuels are blends of isooctane and n-heptane; the percent by volume of isooctane in the blend is the octane number. For fuels above 100 ON, the antiknock quality of the fuel is determined in terms of isooctane plus milliliters of the antiknock additive, tetraethyl lead, per U.S. gallon.
Several octane rating methods for fuels have been developed. Two of these-the research method (ASTM D-2699) and the motor method (ASTM D-2700)-are carried out in a standardized single-cylinder engine. In the motor method the engine operating conditions are more severe; i.e., the conditions are more likely to produce knock. The engine used in the ASTM research and motor methods is a single-cylinder developed under the auspices of the Cooperative Fuel Research Committee in 1931-the CFR engine. This test engine is a robust four-stroke overhead-valve engine with an 82.6mm (3.25") bore and 114.3mm (4.5") stroke. The compression ratio can be varied from 3 to 30while the engine is operating, with a mechanism which raises or lowers the cylinder and cylinder head assembly relative to the crankcase. A special valve mechanism maintains constant tappet clearance with the vertical adjustment of the head. The engine is equipped with multi-bowl carburetors so two reference fuels (usually blends of n-heptane and isooctane) and the fuel being rated can be placed in separate bowls. By means of a selector valve, the engine can be operated on any of the three fuels. The engine operating conditions of the research and motor methods are summarized below.



From: http://www.faqs.org/faqs/autos/gasoline-faq/part3/preamble.html
The conditions of the Motor method represent severe, sustained high speed,
high load driving. For most hydrocarbon fuels, including those with either
lead or oxygenates, the motor octane number (MON) will be lower than the
research octane number (RON).

Test Engine conditions-------------Motor Octane
Test Method------------------ASTM D2700-92 [104]
Engine------------------Cooperative Fuels Research ( CFR )
Engine RPM--------------------------900 RPM
Intake air temperature ----------------38 C
Intake air humidity------------3.56 - 7.12 g H2O / kg dry air
Intake mixture temperature-----------149 C
Coolant temperature------------------100 C
Oil Temperature-----------------------57 C
Ignition Advance - variable-----Varies with compression ratio ( eg 14 - 26 degrees BTDC )
Carburettor Venturi------------------14.3 mm



The Research method settings represent typical mild driving, without
consistent heavy loads on the engine.

Test Engine conditions----------Research Octane
Test Method-------------------ASTM D2699-92 [105]
Engine--------------------Cooperative Fuels Research ( CFR )
Engine RPM--------------------------600 RPM
Intake air temperature-------Varies with barometric pressure ( eg 88kPa = 19.4C, 101.6kPa = 52.2C )
Intake air humidity-------------3.56 - 7.12 g H2O / kg dry air
Intake mixture temperature-------------52 C
Coolant temperature------------------100 C
Oil Temperature------------------------57 C
Ignition Advance - fixed------------13 degrees BTDC
Carburettor Venturi-----------Set according to engine altitude ( eg 0-500m=14.3mm, 500-1000m=15.1mm )


All fuels have a different RON and MON number. The difference in these numbers for a fuel is the Fuel Sensitivity.
Fuel Sensitivity = RON - MON
Fuel sensitivity varies with the source of the crude petroleum and refining process used. The primary reference fuels themselves, by definition, have the same octane numbers by both the research and motor methods.
Fuels that high sensitivity generally, but not always, have lower road octane ratings (i.e., octane ratings determined in cars in on-the-road use) than do low sensitivity fuels of the same research octane number. Regular grade unleaded gasoline typically has a RON of about 91 and a MON of about 83 giving it a sensitivity of 8.

An antiknock index which is the mean of the research and motor octane numbers is used in the United States to characterize antiknock quality.
Antiknock index = (RON + MON) / 2
 
#7 · (Edited)
How much fuel do I need to meet my power goals?

Before you buy a pump, fuel lines, fuel pressure regulator, and injectors you should have an idea of your target power. This will help you determine what components you will need to use in your fuel set up.
There is one other thing you need as well, and this is the Brake specific fuel consumption (BSFC). BSFC is a measure of an engine's efficiency. It is the rate of fuel consumption divided by the rate of power production. BSFC is specific for the reciprocating engine. It is not weather dependent.(1) The formula for gasoline powered reciprocating naturally aspirated engines is 0.5 lb/(hp·h). Generally, SFC within a particular class of engine will decrease when the compression ratio is increased.(2) That is to say, less energy from fuel will be lost to heat, making the engine more efficient.
A good general rule of thumb for gasoline engines is:
* For naturally aspirated estimate BSFC to be 0.4 to 0.5
* For nitrous estimate BSFC to be 0.5 to 0.6
* For forced induction estimate BSFC to be 0.6 to 0.7
(3)
Remember, Engine size is not important in this calc, engine compression is. If you are using stock pistons and staying NA you would use 0.5, infact, that is the lowest I would go. 0.52-0.55 will add some margin of error.

So, now that we have the hard part out of the way we can start figuring out our fuel needs.

Lets go with a target horse power of 260. This will be approx 245-250 at the wheels.
260HP x 0.5lbs fuel/1HP an Hour = 130 lbs fuel/hour
This is the fuel requirement of the motor at this power. Running at 100% is not good for the components though, and it is best to have room to grow. A fuel pump that can provide more fuel would be desirable.

Well, we have the total fuel needed, how big do the injectors need to be?
Injectors are rated at a specific pressure. 43.5psi is pretty much the standard, but be sure to ask the manufacturer prior to purchasing a set. Upping the psi does add more fuel, but it can also stress the pump more. Infact, as pressure rises, pump flow capacity decreases substantially. Furthermore, because injector rating is a measure of the max volume the injector can flow at that psi, it is the same as 100% duty cycle. This is not ideal as the injector will become overdriven and could eventually fail. Not only that but the ECU programs the pulse width (time between injector opening and closing) with cylinder firing order and cam timing. Having the injector pour fuel into a closed intake port is not good at all.So keeping all of this in mind.
Now, lets get some basic numbers going.

Our total fuel is 130 lbs fuel/hour. We are using 4 injectors, so each must flow:
130 lbs fuel/hour / 4 injectors @ 43.5 psi = 32.5 lbs fuel/hour @ 43.5 psi
We want this flow rate, but we want it at 80% duty cycle, so we will need a larger injector.
To solve simple multiply by 1.25. This takes our needed size and makes it 80% of the product of the calculation.
32.5 lbs/hr * 1.25 = 40.625 lbs/hour.

By now there are two things that stand out.
One is the psi, Honda calls for 50~55 psi.
Two is the unit of measure, Honda uses cc/min, not lbs/hour.

Fuel flow increases almost proportionally to the square root of the difference in pressure increase.

Ok, rated pressure was 43.5psi. We are gonna run 55psi as per Honda. The difference is:
55psi / 43.5psi = 1.2643678160919540229885057471264
and the square root of the difference is:
1.1244411127720090718243445638738


Take the injector rating at 80% and 100% duty cycle and multiply them by this new number from the pressure increase.

80% duty cycle + 32.5 * 1.1244411127720090718243445638738 = 36.54 lbs/hr

100% duty cycle = 40.625lbs/hr * 1.1244411127720090718243445638738 = 45.68 lbs/hr


That means that by increasing the psi at the fuel pressure regulator by 11.5 psi we saw an increase fuel flow of about 12%:up:

Solving for cc/min is easy. The conversion factor for gasoline from pounds per hour to cc per min is 10.5

So, 40.625 lbs/hr multiplied by 10.5 nets 426.56 cc/min
This is our target size for an injector as per the 43.5 psi standard at 100% duty cycle.
This injector will flow 341 cc/min at 80% duty cycle at 43.5 psi and will flow near 382.2 cc/min at 55psi.


Notes:
*1
*2
*3
 
#10 ·
Thanks bro:D
Nice to see something that I am going to school to learn. :up:
I am learning too. I am the first to say I am not a pro, but I want to learn as much as I can. If anyone has info they would like to contribute I am all for it. :up:
 
#11 ·
I start my organics next semester (and thermo's), so I will sit at the back of the classroom and just watch for now LOL

I will say this, the only class I am not looking foward to is p-chem. Those 4k level chem courses look like really high mountains right now. :dance:

Thanx for posting this though. It gives me something to "chew on" for a little while.

The, "How much fuel do I need to meet my power goals?" Section should be stickied. That is very good information. I think many people can benefit from that.
 
#12 ·
The, "How much fuel do I need to meet my power goals?" Section should be stickied. That is very good information. I think many people can benefit from that.
I think so too, gonna post up links to some online calcs and request users post their setups.:up:
 
#13 ·
One thing I would like to point out regarding E85. A lot of people have a misconception that due to its alcohol like qualities and higher octane rating it will make more power on a stock untuned motor than gasoline. This is false. E85 has about 25% less energy content than gasoline. E85 is harder to ignite, making idle in cold weather difficult for some. But, because it is harder to ignite, adjusting ignition may yield some gains on a stock motor, but K-pro or AEM EMS is required. On a boosted motor, or very high horsepower NA build, the knock resistance will allow a higher BMEP, resulting in more power potential. Fuel requirements are at least 30% more for E85 vs 93 oct gasoline.
 
#14 ·
i just read through it really quick and it is alot of good info.

the only disagreement i have is where you talk about injector duty cycle and having fuel puddle on the back of the intake valve, you say that

Having the injector pour fuel into a closed intake port is not good at all.
i have done some experimenting and found that it dosnt matter. i tuned my h22 with stock injectors running upto 85% duty, then put in some 1000 cc injectors. It was a while ago so i dont remember the exact pulsewidth, but suffice it to say it was short enough to get all the fuel in while the intake valve is open. I calculated the injector timing as best i could to get the injector firing only when the intake valve was open.

i got a little better gas mileage with some carefull tuning of the 1000cc injectors ( i used a driver box so i could have good control at low pw) but power was close enough that i considered it the "same"

this was on a stock bottom end h22 with jun3 cams. on something thats pushing the limits there might be a little more difference, but anything over about 50% duty is going to puddle regardless.
 
#16 ·
i just read through it really quick and it is alot of good info.

the only disagreement i have is where you talk about injector duty cycle and having fuel puddle on the back of the intake valve, you say that



i have done some experimenting and found that it dosnt matter. i tuned my h22 with stock injectors running upto 85% duty, then put in some 1000 cc injectors. It was a while ago so i dont remember the exact pulsewidth, but suffice it to say it was short enough to get all the fuel in while the intake valve is open. I calculated the injector timing as best i could to get the injector firing only when the intake valve was open.

i got a little better gas mileage with some carefull tuning of the 1000cc injectors ( i used a driver box so i could have good control at low pw) but power was close enough that i considered it the "same"

this was on a stock bottom end h22 with jun3 cams. on something thats pushing the limits there might be a little more difference, but anything over about 50% duty is going to puddle regardless.
How can you prove it didnt puddle? There will still be vaporized fuel inside the intake tract, it will get back in. Not that fuel can puddle on a hot intake valve anyways, they are pointed at the back of the valves for economy reasons, helps cool the valves and vaporize the fuel on them.
 
#19 ·
Holy Significant Digits Batman (1.2643678160919540229885057471264)!!!

Hey Aaron, this is good information.

Due to a combination of my laziness and your knowledge base, I'd like some more information on the relationship between octane ratings and permissible compression ratios (like 91 is good for 12.5:1; what about 93? 100?).

And I know that the flame front increases in speed with pressure. But does the flame front speed increase with octane? I am under the impression that it doesn't, but I'm just guessing.
 
#20 ·
You can run a 12.5:1 comp motor on 87, the det limit is in the design of the motor as well as the chemical composition of the fuel.
The same can be said about the flame front. Burn rate differences have been documented on fuels of the same obtane from different manufacturers.
 
#21 ·
wow this is some crazy stuff about fuels or what not, and im currently finishing up my k24 build and looking into types of fuel to use and whats better for my 13.7:1 compression more like 14.0:1 somethign like that im going back and forth on possibly trying 91 pump gas, 110,116 and e85 whats better for more power and whats cheaper and more efficient...