Fuel Additives Senior Design

Overview

As part of their sustainability goal to reduce carbon emission by 30%, Newmont Corporation is looking to reduce particulate emissions from their diesel equipment. This is especially important for underground mining since the particulate emissions reduce air quality and require heavy ventilation of the mine tunnels. This project aims to find a cost-effective solution to reducing diesel emissions for Newmont Corporation. The work of a previous team identified diesel fuel additives as a potential solution to this problem, along with biodiesel blends. For this semester, our project team designed and worked on a test procedure for comparing different brands of fuel additives on an actual heavy-duty diesel engine. After comparing several options, the team selected a Caterpillar C15 engine as the best choice for testing, due to its use in the mining industry. Wagner CAT generously donated the engine to the project at no charge. The remainder of the semester was spent preparing for the test, where the engine will be connected to a generator and emissions sampled after running on several different additives.  Virtual Energy provided us the use of their facilities and valuable input on the test procedure. As part of the Newmont Corporation Senior Design studio format, we also prepared our project for continuation next semester with execution of the generator tests and a possible field test.

This is a non-traditional project as part of the Newmont Corporation Design Studio. The team inherited the project from a previous team that graduated in Fall 2020. Over two semesters, the previous team did introductory work on the feasibility of using biodiesel or diesel fuel additives at mine sites to reduce emissions. After sending some fuel additive samples to a lab for testing, they selected 3 fuel additives as candidates for further testing. 

The challenge for the team this semester was to determine a method of testing the fuel additives in a more realistic setting. Newmont Corporation desired a full-scale engine test before running any costly fuel additive studies in the field. The first major step was to obtain an engine that could be used for testing. The team compared a number of options shown in the decision matrix below, ranging from small scale single cylinder engines to full scale engines from heavy-duty industrial equipment. In order to best replicate mine equipment, the team chose a Cat C15 diesel engine for the testing. This is a 15.0 liter, heavy-duty engine that is commonly used in semi-trucks, excavators, and other large industrial equipment. Although it would be the most challenging for the team to work on, the results would be the most accurate from the C15. The engine was generously donated to the team by Wagner CAT, a roughly $10,000 value.

With the engine selected, the team focused on conducting testing. In order to test the fuel additives, the team needed to connect the engine to a generator as well as a load cell to dissipate the power. This allows the engine to be run on a load to simulate operating conditions. The team also needed access to an emissions testing bench to sample the emissions and determine the operating impacts of the fuel additives. The team got into contact with Virtual Energy in Colorado Springs, who generously offered the use of their facilities and expertise to help out with the project. The tests involve running fuel lines to separate containers with the 3 fuel additives, a biodiesel blend, and a control sample of ULSD diesel and running the engine to sample the exhaust and determine emissions levels.