Sunday, April 24, 2011

Mantika: A Chronicle of a Vegetable Oil Conversion

Nature or nurture argument lingers. One may dispute that nature has the most influence, but another may claim otherwise. It is anything but relative. Furthermore, it is contingent upon the subject matter, such as personality traits, appearance, etc. In my case, for example, my character is mostly predisposed by the people that impacted me especially in my rearing years. Among others, they are the individuals that I was directly in contact with or someone I read about or watched on television, like Superman. Many of you may say that even with these exposures, still, I am less than perfect. That is beside the point, however.

My point: What if I apply the same theory in this vegetable oil conversion? Like the nurture rebuttal, let the project be influenced by its environment, any related media or sources of information. Even then, the final product can still be less than flawless. This time, however, I have better control of the process to produce a desirable outcome. Unlike the nurture case, I can be more proactive in the selection process; I can scrutinize every option available and produce the most robust system. This undertaking has two phases: a) research and development (r&d) b) implementation.



RESEARCH & DEVELOPMENT

In this phase, I research waste vegetable oil (wvo) forums, consult with experts by exchanging e-mail correspondence, namely, Craig Reese the Plant Drive owner, read trade publications, and seek advice from Ed Garcia. A “Jack of all trades,” Garcia is an engineer/electrician/fabricator/mechanic. A good friend of mine, he is a meister of the aforementioned. Therefore, he is enlisted for the task.

There are a number of conversion models available on the market, but Plant Drive’s system is far more superior to others. With the permission of Reese, Garcia and I adopted the Plant Drive’s “3 3-way plumbing” design (Figure 1). It comprises of three three-port valves that directs diesel and wvo from supply tanks (diesel and wvo) to the engine, a switch (Figure 2) to energize and de-energize the valves, an auxiliary fuel tank for wvo, and Vormax, a coolant heated device that warms wvo.

Basically, the switch has three modes: 1)diesel 2)wvo 3)purge. Each of them has to be well orchestrated in order for the system to work effectively. It is analogous in a band. That is, if a drummer cannot coordinate with the cadence of other members, the result is cacophony.

Notwithstanding, in diesel position, one electronic valve would energize for diesel to flow into the engine. This is done before the engine is turned-off for long periods like when parking overnight. Therefore, at initial or cold engine start-ups, a less viscous diesel will be fed through the fuel lines freely and ignite quickly vis-a-vis wvo that has higher viscosity, thus less ignition properties. This is the main reason that there is an extra tank for wvo. At the same time, this method eliminates cross-contamination.

Notwithstanding, with wvo switch activated, another electronic valve would open for wvo to feed through the fuel lines and into the engine. This manual switchover is prompted when the engine has warmed-up, 150 degrees, and wvo has been coolant-heated to at least 90 degrees.

Notwithstanding, on purge mode, the other valve would divert leftover wvo in the fuel lines to the auxillary tank. At the same time, supplies diesel into the lines. This final mode is critical as it serve as scrubber. Not only that it clears wvo, prone to polymerization and solidification, but also makes cold-engine starting easier. After 30 seconds in this position, it must be toggled back to diesel.

In sum, at initial start-ups, the switch is on default: diesel. When the desired temperature is reached, simply turn on wvo. Drive to a destination leaving a clean footprint behind versus a stifling one. Then, before the vehicle is parked longterm, click on purge momentarily. Thereafter, activate back to default before the engine is turned off.

As obtained from my due diligence, there are two more tools needed. They are inline wvo temperature and auxiliary tank sending units. Both of them have gauges in the dash (Figure 2).


IMPLEMENTATION

After countless hours of research and consultation, it is time to apply the information gathered. Of course, subject vehicle and component procurement, must precede all of this.

In 2007, I purchased a wvo-equipped 1979 Mercedes Benz 300SD. It served as a “guinea pig.” Issues such as premature fuel filter clogs were frequent. During the few months of ownership, I learned to perform fuel system maintenance and proper wvo purification. The latter was achieved by allowing time for sediments to settle via solar heat for at least two days. Then, sifting wvo through a one micron bag filter.

I also experimented with different wvo sources. In due time, I learned that Japanese and Indian restaurants are the best source. It is mainly because their oils are non-hydrogenated and animal fat free. Consequently, I established a clientele of four local restaurant sources called accounts. All of them use soybean oil. The supply turned out to be sustainable even with 300 to 500 weekly mileage.

Fortunately, my accounts produce some of the cleanest wvo. In fact, Japanese chefs only cook tempura while Indian chefs solely fry onions. When these oils are mixed together, the result is Asian fusion in culinary proportions. Combust in the diesel engine, the by-product out of the tail pipe is a sultry aroma with hints of curry and onions. Hmmmm scrumptious! This proves that Indian cuisine is overpowering.

A recent acquisition is a 1998 Dodge Ram 2500 (Figure 3), the subject for the conversion, with 12 valve Cummins. Based on feedback from wvo users alike, this is one of the most reliable vegetable oil conversion candidate.

Now, between April (lovely spouse) and I, we have a fleet of diesels. She drives a 2010 Jetta wagon TDI. Dubbed as the clean diesel and equipped with 2nd generation diesel, its emission is cleaner than gas fueled cars. She loves it more than her other car, 2002 BMW X5, mainly because of its fuel efficiency and compact stature. At one point, she was the primary skeptic of my wvo endeavors, but later learned to appreciate them as soon as we begin to reap its benefits.

Most of the components mentioned earlier are procured from Craigslist.org. Others like rubber hoses, brass fittings, electrical wires, nuts and bolts were bought from hardware store and automobile parts retailer.

Alas! We are ready to install. Here is the sequence:
1) Bolt auxillary tank in the truck bed. (Figure 4) (Cesar)
2) Mount Vormax on the auxillary tank. (Figure 5) (Cesar)
3) Plumb coolant and vwo. Then, connect them accordingly. (Both)
4) Incorporate the three three-port valves in the fuel system. (Ed)
5) Crimp electrical wires from the valves and sending units with their
respective gauges, relays, power source, ground post or switch. (Ed)
6) Bleed the coolant and fuel system. (Cesar)
7) Do a system check. (Both)
8) Run the engine w/ diesel and vwo. (Cesar)

One may dismiss this chronology easy, but it is not. Not only that it is time consuming, but also labor intensive and mind boggling. Ed and I employed our brain storming as well as critical thinking skills to make this possible. Two heads are better than one!

Nevertheless, we ran into a system glitch. When swo is on, the engine sputters and shuts off abruptly. “Let’s start from the basics; diagnose the electrical then the fuel lines,” Ed suggests. It took two separate occasions to solve this. In our first meeting, we check the electrical connection for accuracy, but no problem there. In our second meeting, we spot for hose leaks, and not a single trickle found. I begin to worry.

“Your Cummins might not be a good candidate after all,” exclaims Ed. I ponder:
This could not be. A number of these conversions are applied on Dodge Cummins. Some logged more than 100,000 trouble-free miles with this alternative fuel. I did my research.

A light bulb lit and I assert, “How about replacing the primary fuel filter?” I did just that. When finished, I insert the key, crank the engine and toggle to swo. Momentarily, that familiar scrumptious aura is eminent. I am elated. In celebration, I invite Ed for lunch at a Japanese restaurant.


PURPOSE

The funds, time and effort invested in this venture has a purpose beyond its material realm. It is not one to boast arrogance. It is not one to threat the oil companies (they may not even feel a pinch). It is not one to make a demeaning statement. But is it to satisfy a sense of accomplishment. It is to campaign an eco-friendly lifestyle. Most of all, it is to benefit my loved ones and their future ones.





Figure 1


Figure 2


Figure 3


Figure 4




Figure 5




Miscellaneous

Sight Glass


Switch/Oil Temp/WVO Tank Gauge


Pod:Transmission Temp/Pyrometer/Turbo Boost


Cummins

       
             

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