1. Utilization of Waterless Coolant to Improve Fuel Economy and Increase Engine Durability
Mark V Alexander, Mark J Stone
Evans Cooling Systems, Inc.

2. Topics Covered Why Waterless Coolants Properties Comparison
Advantages of Waterless Coolant
Applications of the Technology
Meeting Industry Standards
Disclosure: Specific properties and test results presented are based on
waterless coolant technologies developed by Evans Cooling Systems, Inc.
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3. Why Waterless Coolant?
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4. Positives of Water In a Coolant
Water has been the choice for cooling engines for decades because:
Water is cheap
Water is available
Water is non-toxic
Water has superior thermal conductivity
- In its liquid state
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5. Negatives of Water In a Coolant
Water supports electrolysis and is
corrosive
Electrical Conductivity (us/cm)
50/50 Coolant/Water 3000
Waterless Coolant 700
Water has a low boiling point
Little margin between coolant operating temperature under load and boiling point of water at the system pressure.
Failure temperature of the system is the boiling point of water – where free vapor is formed
Water retains just 4% of it’s thermal conductivity when it changes to vapor
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6. What is Waterless Coolant
Components: (One example)
Proprietary base blend, additives, and No water
Properties:
Water Content, wt%: <0.5
Specific 20/20C: 1.12
Pour Point, °C/°F: <-40
Viscosity, - 40°C/- 40°F: 2.0
Boiling point, °C/°F: 375/191
Thermal Conductivity, W/m·K 0.27
@ 212°F/100°C
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7. Waterless Coolant vs Ethylene Glycol/Water
Properties Comparison
Waterless Coolant vs Ethylene Glycol/Water
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8. Boiling Point Comparison
Boiling point of water is the failure temperature
of the system, at the system pressure
Waterless Coolant – No pressure
50/50 EG/Water – 1 atmosphere /15 psi gauge
Water – 1 atmosphere / 15 psi gauge
Elevation (Meters)
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9. Boiling Point Safety Margin
Waterless Coolant creates a large separation between its boiling point and the operating temperature of the system
An engine operating temperature of 230°F/110°C is much colder than the boiling point of Waterless Coolant (375°F/191°C)
Cooling system continues to function under load and after shutdown:
Coolant continues safely absorbing heat from the metal
No vapor generation at high temperature/low pressure areas
No after-boil with abrupt shutdown
Can restart the engine at any time
The boiling point of water is no longer the limitation
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10. Liquid and Vapor Phases of 50/50 EG/Water vs. Waterless Coolants
Thermal Conductivity
Liquid and Vapor Phases of
50/50 EG/Water vs. Waterless Coolants
Water: 0.68
EG/Water:50/50 – Liquid
0.43
Waterless Coolant – Liquid
0.27
EG/Water:50/50 - Vapor
0.024
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11. Heat Transfer Failure of Water Vapor
A = Waterless Coolant B = Water-Based Coolant
With Waterless Coolant, Metal Temperatures Are Controlled
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12. Vapor Pressure With Waterless Coolant, System is Not Pressurized
Only 1.4 g of water are needed to produce
enough vapor to open the pressure cap
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13. Advantages of Waterless Coolant
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14. Benefits of Waterless Coolant Technology
Enhances Engine Efficiency
Enables Fuel Savings Strategies
Helps Reduce Emissions
Improves Engine Durability and Reduces Maintenance Costs
Reduces component failures
Minimizes coolant replacement
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15. Fuel Economy Challenges
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16. Enables Fuel Savings Strategies
Large boiling point safety margin enables system to safely run at a higher operating temperature while controlling metal temperatures
Two strategies to capitalize on this:
Reduce fan-on time by raising fan-on temperature
Fans on heavy duty diesel engines draw up to 70 HP
Minimizing fan operation yields significant fuel savings
40-60+% fan-on time reduction in some tests
Combine strategy 1 with a higher temperature
thermostat for better thermal efficiency
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17. Fuel Economy Tests - Waterless Coolant
Company/Test Vehicle
Method
Improvement
Notes
Veolia Waste Collection Truck – 2009 Mack AI 350 ASET 12 L 350 HP
Road Test
- 110 C Fan-On
3.5%
Fuel Economy
Oil Analysis
Veolia Waste Collection Truck – 2011 Mack MP7 11 L 330 HP
4.4 – 8.5%
USA Hauling Waste Collection Truck
Mack E7 350 HP
5.5 – 8.6%
NYC Waste Collection Truck
Mack MP7 11 L 330 HP
Chassis Dyno
110 C Fan-On %
Emissions
UPS Delivery Truck Cummins ISX
96 C T-Stat
>3%
Used Telematics
Perdue Farms Fleet Truck
International Max Force 13 L
-110 C Fan-On
5.5%
Murphy Brown Fleet Truck Mack MP8 13 L 390 HP
On-Road Emiss.
4.0%
Emissions by SEMTECH-DS mobile analyzer
Program for Advanced Vehicle Evaluation (PAVE)
Detroit Diesel 14 L 435 HP Series 60
102 C T-Stat
>3.0%
Run at Auburn University
Fuel Economy by
SAE/J1321 Type II
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18. Tests in NYC Department of Sanitation Truck
2009 MY Mack MP7
Body Type
Refuse
Collection
Weight (ton)
25.8 (net18.5)
No. of Axles 3
Engine Size
10.8 L
Horsepower
330
Fuel Type
Diesel
After Treatment
DPF
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19. Tests in NYC Department of Sanitation Truck
Test Cycles
New York City Garbage Truck Cycle
Central Business District
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20. Tests in NYC Department of Sanitation Truck
Test Results1 ─ 230F/110C Fan-On
Parameter
50/50 EG/Water
Waterless
Change (%)
Fuel Economy (mpg)
1.28
1.34
4.7
BSFC (gal/hp-hr)
0.055
0.050
-9.1
Coolant Temperature (℃)
- Engine Inlet
91.0
98.7
8.5
- Engine Outlet
95.5
103.9
8.8
Engine Oil Temperature (℃)
83.9
85.9
2.3
CO2 (g/hp-hr)
0.560
0.511
-8.6
PM (g/hp-hr)
0.0023
0.0018
-21.7
NOx (g/hp-hr)
2.29
2.53
10.5
1 NYCGTC Test Cycle
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21. Improved Durability/Reduced Maintenance Costs
No water + higher boiling point + low system pressure translates into:
Lower potential for corrosion and electrolysis
Protection against water pump cavitation and cavitation erosion
Minimal wet sleeve cylinder liner cavitation erosion
Significantly reduced potential for EGR cooler failures
Less stress on hoses and gaskets
Minimal coolant loss/makeup
Water-based: New Trucks – 5 gal/yr
Older Trucks – 12 gal/yr
Non-SCA formula avoids potential for
additive deposits or plugged filters
Excessive Additive Buildup
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22. Cylinder Liner Protection
ASTM D7583 Engine Cavitation Test
John Deere Engine Cavitation Test is a real-world predictor of coolant protection to wet sleeve liners
250 Hours
Speed/Load Cycling
Waterless Coolant tested by
Southwest Research Institute
Results were 70% better than
the best water-based coolant tested
Pass = ≤ 200 pits
Best 50/50 Glycol/Water = 70 pits
Waterless Coolant = 21 pits
Waterless Coolant
Poor-Performing
Water-Based Coolant
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23. EGR Cooler Failures Significant Issue in the Industry
E.g., Replacement Every 2 $2000 – 3000 each
Coolers see gas inlet temperature of 1100–1200+F ( C)
Heat load: Must Drop >700 degrees in ~2 feet
More Severe With Natural Gas
Gas is 180F (100C) hotter
Causes 18% higher stress
Failures can happen 2x
faster than with diesel
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24. EGR Cooler Failures Failure mode is tube cracking due to
Thermal cycling/stress
Vibration
Corrosive condensate (gas side)
Thermal stress likely exacerbated
by vapor film on coolant side
Analogous to cylinder head
Fatigue Break Points
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25. EGR Cooler Failures Metro California bus fleet
2800 buses, all natural gas
Chronic EGR cooler failures
Typical rate is every miles
Waterless coolant installed in a problematic bus
“Super-abnormal EGR cooler failures”
Post - conversion: no failures out to miles
No coolant makeup needed vs 1 to 1 ½ gal/month
10 additional buses converted and being monitored
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26. Applications of the Technology
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27. Technology Applications - Land, Air, Marine
Validated in many applications worldwide:
Cars, aircraft, generators, wind turbines, mining, off-road, and heavy duty vehicles
Most installations answer challenging engine cooling problems not solved by conventional coolants
Waterless Coolant technology offers ability to drive operating efficiency and durability
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28. Example: Waterless Coolant Reserve Capacity
Kunlun Mountains of China
At 16,000 ft. the trucks could not carry full loads and required periodic shut-downs for cooling off.
Converted a truck to Waterless Coolant that had not been able to perform well at the high altitude.
Afterward, no boil-over despite full loads and no cool-down times.
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29. Other Technology Applications
Prevents Overheating Of Rotax Engines In Predator UAV
Made Generators In Iraq Reliable At 140oF On The Tarmac
Helped Increase Fuel Economy In Prototype Bullet Truck
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30. Meeting Industry Standards
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31. New Technology, New Standards
Waterless Coolant meets many ASTM standards developed for water-based coolants.
Some standards are not relevant to waterless coolants because they require the addition of water.
New ASTM sub-committee (D15.22) established to develop new standards and specifications appropriate for waterless engine coolants
Standards currently being developed and balloted
New task group formed within TMC1 to develop a Recommended Practice (RP) for waterless coolants
1 Technology & Maintenance Council of the American Trucking Association
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32. Thank you!
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