Why Coolant ?

Tim Hayward
Today’s agenda will include an overview of:

 The History of Coolant / Antifreeze.

 The Composition of Formulated Coolant.
 The Functions of Coolant.
 Challenges of the Coolant System.
 Coolant related problems and everyday practices.
 Understanding DCA@ vs. DCA 4 technology.
 Introducing water filters.
 Coolant testing equipment.
 Peripheral product overview.
General Q&A Session
Our objectives for the day include:

 Introduce coolants and why they play such an critical

role in engine longevity.
 Understand how coolant works and how it’s made
up.
 Identify and prevent costly practices.
 Identifying the way you manage coolant.
1. Coolant History.
 Since their inception,
internal combustion
engines have produced
more heat energy than
they could convert into
work energy
 This “waste” heat has to
be removed from the
engine, in order for the
engine to operate
1. Coolant History.
 Although a few engines
use air to remove this
heat, most have used
water to remove and
transport waste heat away
from the engine
 Water is the best
convection heat transfer
fluid for use in radiators
 Water also has some
disadvantages
1. Coolant History.
 Water freezes at 32ºF
(0ºC)
 Unlike many fluids, as
water freezes, its volume
increases by about 9%
 In a closed area, such as
an engine block, this
expansion can exert
tremendous force causing Crack in Block
engine damage
1. Coolant History.
 Water also boils at
relatively low temperatures
(212ºF or 100ºC)
compared to engine
operating conditions
 High temperatures in the
head and block can cause
water to boil, forming
steam
 Steam does not conduct
heat and can cause
engine damage
1. Coolant History.
 Because of this, different
fluids have been mixed
with water over the years
to lower the temperature at
which the solution will
freeze (freeze point)
 Early attempts used wood
alcohols as an “antifreeze”
 These water/alcohol
solutions required constant
monitoring due to
evaporation
1. Coolant History.
 In the early 1920’s,
glycerin based antifreezes
came onto the market as a
“permanent type”
antifreeze due to the fact
they did not require
monitoring for evaporation
 Ethylene glycol was also
used for the same reason,
but was not as popular
due to its 1/3 higher cost
1. Coolant History.
 In 1927, Prestone brand
ethylene glycol coolant
was released
 By the late 1930’s,
ethylene glycol prices had
dropped and glycerin was
forced out of the market
 Ethylene glycol, a
petrochemical product,
presents its own set of
issues
1. Coolant History.
 Ethylene glycol (EG) has a
variety of uses
 As well as antifreeze, EG is a
base material for polyester
fibers and plastic soda bottles
 With the volatility of oil prices
and demand for use in other
products, EG costs can
fluctuate wildly
 EG is also highly toxic,
ingestion of as little as 2
tablespoons (100 ml) can be
fatal
1. Coolant History.

 In order to get around the

toxicity challenge, some
coolants are made using
propylene glycol (PG) as a
base
 PG, like EG, is a
petrochemical product
2. The Composition of Coolant.

By Definition:

“A cooling fluid made from a blend of either ethylene

or propylene glycol (boil point inhibitor) and water
including chemical additives to protect engines
against wear and corrosion.”
2. The Composition of Coolant.

All coolants are made up as follows:

The carrier solution (water)

Freeze inhibitors (either ethylene or propylene
glycol)
Additive packages.
2. The Composition of Coolant.

Ethylene
Water
+glycol = Only Anti -freeze

A
Ethylene
Water
+ glycol + Additives
= Real
Coolant !
2. The Composition of Coolant.

Water quality is critical !!!!!

 Hardness <170 ppm

– Calcium & Magnesium Carbonate
– Causes Deposits on Liners, Heads & Coolers

 Chloride (Cl) <40 ppm

– Causes General Corrosion Cast Iron

 Sulfur (SO4) <100 ppm

– Causes General Corrosion Cast Iron
2. The Composition of Coolant.

What is Glycol?

 Most coolants are based on Glycol.

 Both EG and PG are petrochemical derivatives.
 EG predominantly used over PG, but this is
changing!
 Glycol is used in the manufacture of textiles and
plastic bottles.
 PG is lower in toxicity compared to EG
2. The Composition of Coolant.

 Conventional additives comprised of mainly

inorganic additives such as Nitrate & Silicate.
 Hybrid additives comprised mainly of buffers
such as Borate & Phosphate.
 OAT additives are generally Borate &
Phosphate free.
2. The Composition of Coolant.

Common organic additives:

 Borate- Used to maintain
pH levels in coolant.
 Phosphate- Used to Typical inorganic additives:
maintain pH levels in
coolant.  Tolytriazole- Prevents
copper & brass corrosion.
 Silicate- Used to prevent
Aluminum corrosion.  Benzotiazole- Prevents
copper & brass corrosion.
 Nitrites- For prevention of
liner pitting.
 Nitrates- General
corrosion inhibitor.
3. What does a Coolant do?
 Lowers the specific gravity of water, which in turn
decrease’s the temperature that water freezes at.
 Provides efficient heat exchange.
 Protects metals against corrosion.
 Gives protection to seals, plastic and rubber
components and hoses against elastomer degradation.
 Provides protection against cavitations specifically in
wet liners.
3. What does a Coolant do?
Coolant systems provide engine
protection for combustion temperatures
exceeding 2200 deg C.

•33 % converted to useful

work (crankcase hp)
•37 % lost through exhaust
and general heat loss
•30 % must be removed
through coolant system
3. What does a Coolant do?
Absorbs heat of combustion
from engine components by
circulation of liquid coolant.

Dissipates heat absorbed

by coolant to the atmosphere
through the radiator.

Maintains engine temperature

within safe operating range and
provides thermal stability to the
engine.
3. What does a coolant do?

The consequences of using the wrong

coolant are:
Poor Higher
Poor Coolant
Coolant
Selection + System
Maintenance
= Overall
vehicle
Costs
4. Challenges of the cooling system.

Today’s diesel engines are

producing more horsepower
than ever before, and they are
doing it with less engine size
and weight, with a bigger
diversity of various metals.
Lighter engines mean greater
payloads for trucking and other
related industries. This calls for
a robust coolant formulation!

The modern diesel engine- A raging inferno!

4. Challenges of the cooling system.
This horsepower relates
directly to heat generation,
and the task of controlling
this heat falls to the
cooling system.

40% - 50%
of all engine problems have their
origin in the cooling system!
4. Challenges of the cooling system.

The cooling system is designed to perform 4

main functions in an internal combustion
engine. These are:

 Absorb,
 Circulate, HEAT
 Dissipate
and
 Control
4. Challenges of the cooling system.

All diesel engines with wet

liners are subject to liner
pitting. It is very important for
us to understand what causes
this pitting or cavitation
corrosion, as it is known in the
industry.
4. Challenges of the cooling system.
Typical Cylinder Lining Pitting

1. Bubble 2. Bubble 3. High 4. Metal

formed collapses. pressure jet removed
through of coolant from the
movement hits liner. surface of
of liner. liner
(Magnified).
4. Challenges of the cooling system.

Liner vibration is the direct

cause of liner pitting, and with
proper maintenance practices
and products, liner pitting can
be controlled.

LINER PITTING or Cavitation Corrosion

caused by imploding vapor bubbles will drill
a hole through the liner wall.
Shock wave impact measured at
15,000 to 20,000 PSI
4. Challenges of the cooling system.
In addition to liner pitting there are other concerns
or problems that can occur effecting cooling
system efficiency and engine performance. Of
these, Corrosion is a major factor.
4. Challenges of the cooling system.

This corrosion can lead to

poor performance of the
cooling system itself, and
costly repairs or parts
replacement.
4. Challenges of the cooling system.

Another concern is with poor

quality water and scale
buildup caused by excessive
levels of dissolved calcium or
magnesium salts.
4. Challenges of the cooling system.
Scale will prevent proper heat
dissipation through the liner,
and restrict coolant flow in
radiator or cooler passages.
4. Challenges of the cooling system.
All of these concerns can, and must be
controlled by a quality coolant, and specific
maintenance practices.

Poor coolant and poor

maintenance practices
relate directly to higher
operating costs!
5. Coolant Related Problems.

The root cause of most of these problems

are often traced back to improper cooling
system maintenance.
5. Coolant Related Problems.

 Corroded and  Worn rings

clogged radiators  Scuffed
 Water pump and pistons
thermostat housing  Burnt valves
damage  Corroded
 Perished radiator bearings
hoses
 Overheating
5. Coolant Related Problems.

The coolant system looses coolant not just water, antifreeze or sca’s.

 Causes - Dilution  Field Problems

– Adding Straight A/F – Water Quality
or Water Concerns
– Using High Silicate – Control SCA Levels
A/F – Control Freeze Point
– Not Adding SCA’s – Silicate Gelation
5. Coolant Related Problems.

So what are the solutions?

YOUR OEM SHOULD PROVIDE YOU WITH …

Service engineering support.

Fleet coolant sampling.
Maintenance training.
9. Testing Coolants.
9. Testing Coolants.
9. Testing Coolants.
9. Testing Coolants.
9. Testing Coolants.
9. Testing Coolants.
9. Testing Coolants.
9. Testing Coolants.
9. Testing Coolants.
9. Testing Coolants.
9. Testing Coolants.
9. Testing Coolants.
9. Testing Coolants.
9. Testing Coolants.
9. Testing Coolants.
9. Testing Coolants.
9. Testing Coolants.
Any Questions ?

Thank you for your attendance.

Thank You for your
attendance.

Cummins Confidential