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8/2/2019 Maintaining Engines
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Engines
Maintaining the Life of Your Engine byOperating in a Waterless CapacityMike Tourville
O ,a waterlesscOOlant can leadtO significantfuel saving andmaintenance, oo o o . th ohook o.
EnginE manufacturErs havE bEEn contEnding
with heat transer issues or more than 100 years with a
multitude o modications: powerul ans, larger radiators
and applying engine perormance limitations. The struggle
to gain eciency and meet tighter emissions standards
while controlling costs is an ongoing challenge. Despite
the advances in engine cooling technologies, one aspect has
remained relatively unchanged or more than 50 years: the
basic ormula or coolant is still a 50/50 mix o ethylene
glycol and water. Additives have improved and longer
lie coolants have evolved, but water has been a constant
element. Water is a good thermal conductor, but it has its
drawbacks and limitations: corrosion and a low boiling
point, to be more specic. Cooling systems are designed
to work within the limitations o water, and a lot o energy
is consumed to keep the coolant rom reaching its boiling
point. A simple answer to consider has been developed to
address these issues: to eliminate the problems associated
with water, remove the water. The absence o water in awaterless heavy-duty coolant (HDC) prevents corrosion
and avoids electrolysis. Perhaps the most important aspect
is the high boiling point o 375 F, which translates into a
large separation o the coolant operating temperature and
the boiling point o the coolant.
What is good about water is its cheap and has
superior thermal conductivityas long as it remains
a liquid. Water retains only 4 percent o its thermal
conductivity when it changes into vapor. On the other
hand, water is a poor choice because its boiling point
is too low, and there is very little separation between
the operating temperature o the coolant and the boilingpoint o water. I the coolant boils over, vapor pockets
create an insulating barrier between the metal and the
coolant. The low boiling point o water becomes the
ailure temperature o traditional cooling systems. With
its high boiling point o 375F, a waterless HDC has
the capacity to saely operate at higher temperatures
without overheating, resulting in less downtime.
Maintenance SavingsBecause this type o heavy duty coolant does notcontain water, electrolysis and corrosion are eliminated.
This shows what happens when the additive buildup collects in a coolant flter. This is avoided witha waterless coolant. Images courtesy o Evans CoolingSystems.
20 WasteAdvantage Magazine March 2012
As Seen In
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m e Le Y Ee y ope Wele
Water is the root cause o corrosion in engine
cooling systems, and even the latest inhibitor
technology oten ails to prevent componentailure. The most expensive corrosion problem is
cavitation o cylinder liners. Cavitation erosion
is caused by collapsing bubbles that cause
erosion over the surace o the exterior o the
cylinder liners. The resulting erosion eventually
penetrates the wall o the cylinder and permits
coolant to fow into the cylinder.
The large separation between the operating
temperature and the boiling point o waterlessHDC stops cavitation erosion o cylinder liners.
In a pressurized system, the water-based
coolant must be maintained at a temperature
below the boiling point o water to keep the
system unctional. The absence o water means
that vapor will not be ormed, which can cause pressure in the
system. Typically, cooling systems have up to a 15 lb. pressure
cap to raise the boiling point. Each pound o pressure raises
the boiling point by about three degrees, which means a 15
lb. cap would raise the boiling point to about 257F. This is still
dangerously close to the operating temperature o the coolant
in an engine, especially under hot and dusty environments. The
waterless HDC ormula operates under a much lower pressure,
decreasing stress on hoses and gaskets, reducing the likelihood
o leaks. Additionally, a lower pressure brings an added saety
element to the operator. Opening the cap on a hot radiator can
result in injury to anyone within close proximity o the radiator.
The endurance o the engine is improved by maintaining
control o engine metal temperatures at all times. The absence
o cavitation erosion extends the lie o cylinder liners and
SAE TypE II
FuEl TESTThe SAE Type II
Fuel testing using the
waterless coolant and
215 thermostats and
eliminating the an time
variable, still produced a
3 percent improvement
in uel eciency. Recent
emissions testing showed
a reduction o 3.6 percent
in CO2emissions and a
4 percent uel economy
improvement in a test
perormed by Emisstar
in August 2011. Emisstar
provides independent
third party testing services
or the development o
sustainable transportationtechnology strategies.
Boiling points or the waterless HDC, 50/50 EGW and water.
22 WasteAdvantage Magazine March 2012
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coolant pumps. Pump seals last longer because there are no abrasive additive
deposits on the seals. Water also contributes to pump and cylinder liner
cavitation and corrosion, as well as hot spots that can damage engines.
A waterless coolant can last orever, as long as it doesnt become contaminatedwith water. With a waterless HDC, periodic coolant replacement and disposal
is not necessary and supplemental coolant additives (SCAs) are not required.
HDC additives remain stable and in solution during storage and use resulting
in no abrasive additive deposits. The coolant will not evaporate which means
the occasional topping o can be greatly reduced.
Fuel EconomyMost people wouldnt associate coolants with uel economy. The energy that
it takes to maintain coolant temperatures below the boiling point o water is a
huge waste o uel. The huge separation between the operating temperature o the
coolant and the boiling point allows an extra cooling capacity that your system
already has. When the coolant temperature can be saely raised, the result is a
more ecient heat transer rom radiator to the ambient air. This allows an engine
to run continuously under harsh conditions using less an power and saving uel.
Independent evaluations and feet testing have consistently demonstrated ueleconomy improvements between 3 to 9 percent.
Due to the severe perormance requirements reuse vehicles encounter daily, such
as constant starts and stops, heavy loads and the lack o ram air to cool the engines,
uel savings is adversely aected. A waterless coolant allows a reduction o an-on
time by up to 40 to 50 percent. The ans on heavy-duty diesels draw considerable
horsepower, thereore minimizing an operation leads directly to signicant uel
savings.
Along with reducing uel consumption, decreasing emissions, maintenance
savings are also achievable with a waterless HDC. The waterless ormula
does cost more per gallon than a traditional 50/50 ethylene glycol and water
mixture. However, once in use, the uel saving and maintenance benets have
John DEErE
CAvITATIon TEST
In a recognized test (the John Deere Engine Cavitation Test) perormed in April 2009 by a third party
laboratory, the results showed that waterless coolants provided superior protection against cylinder liner
cavitation erosion. The waterless coolant perormed more than 70 percent better than any other coolant
tested in preventing cavitation erosion. It is now approved as an ASTM standard test method.
Cylinder Liner cavitation erosion can be virtually eliminated with waterless Heavy Duty Coolant.
WasteAdvantage Magazine March 2012 23
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m e Le Y Ee y ope Wele cpy
demonstrated an ROI o 6 months or less, not to mention reduced down time. Thats a considerably shortpayback period, and an investment well worth looking into. | WA
Mike Tourville is Sales and Marketing Director for Evans Cooling Systems, Inc. (Sharon, CT). He can be reached
at (860) 668-1114 or via e-mail at [email protected].
CASE STuDy:
vEolIA EnvIronmEnTAl SAvES FuEl
Veolia Environmental Services in Florida was
trying to reduce uel consumption. They did a year-
long evaluation using Evans Cooling Systems
heavy-duty waterless coolant beginning in October
2009 and ound that waste vehicles in Sheboygan,
WI saved in the range o 4.4 percent uel. Furthertesting in Apopka, FL demonstrated savings in
excess o 9 percent due to reduced an time when
an temperature is raised to 230 F. The coolant
has paid or itsel within a ew months and no
overheating issues were reported. Harold Graves,
Regional Maintenance Manager, East North America
says, Were very happy with the way Evans has
presented their product and services. They are data
purists, and the results are indisputable. Veolia is
beginning to schedule the rest o the regional feet
and plans to continue to expand the conversions to
other areas. Were looking at converting o-highway
equipment in the northeast, not only or uel saving
purposes, but to also improve perormance and
productivity.
Skip Webber, Area Maintenance Manager, Solid
Waste, North America, agrees, The waterless
coolant is a great product and were seeing
signicant uel economy improvement. We havent
had a problem with any o the converted trucks,
including overheating or maintenance issues.
Thermal conductivity o the liquid and vapor phases o a water-based coolant versus a waterless HDC.
2012 Waste Advantage Magazine, All Rights Reserved.Reprinted rom Waste Advantage Magazine.
Contents cannot be reprinted without permission rom the publisher.
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