Post on 18-Jan-2015
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CONFERENZA GNLRoma, 21 Gennaio 2014
Speaker:Gabriele Masciali, Sales Manager
L’impiego del gas naturale liquefatto (GNL) nei trasporti stradali.Normative, standard e tecnologie.
Content
-Ecomotive Solutions A short presentation
- Retrofitting Process Dual Fuel d-gid Technology
- Diesel Dual Fuel & LNGLNG: more green energy in less space
- LNG Retrofitting Case in ItalyDevelopment, Data and Considerations
-Ecomotive Solutions A short presentation
- Retrofitting Process Dual Fuel d-gid Technology
- Diesel Dual Fuel & LNGLNG: more green energy in less space
- LNG Retrofitting Case in ItalyDevelopment, Data and Considerations
Company Headquarters
since 1991
Ecomotive Solutions is a company of the HOLDIM group, which includes several enterprises specialized in the development of electronic platforms in automotive.
“Since 1991 a global, innovative approach to support the creation of a new generation of products for the market: tomorrow’s technology already available today”
- Ecomotive SolutionsA Short Presentation
- Retrofitting Process Dual Fuel d-gid Technology
- Diesel Dual Fuel & LNGLNG: more green energy in less space
- LNG Retrofitting Case in ItalyDevelopment, Data and Considerations
Diesel Fuel Fuel Definition
In a “Diesel Dual Fuel” system, the engine can still run on 100% diesel fuel.DDF technology does not involve irreversible changes to the basic engine which still works just like a diesel engine where a high percentage of cleaner fuel is burnt.
“Diesel Dual Fuel” (DDF) refers to an engine working with
Diesel and Natural Gas simultaneously.A small pilot injection of diesel oil ignites the Air + Natural Gas mixture, that is controlled and injected into the intake manifold.
DIESEL
Diesel Engine
Diesel Dual Fuel (DDF) d-gid ECU
(Engine Control Unit)Natural Gas(Methane)
d-gid can also manage dual fuelapplications using Biogas, Syngas,Hydrogen,
(*) The gas injection is managed and controlled by “d-gid Man” software
d-gid DDF Technology – Diesel & Gas Injection Control
Original diesel injection signal
Gas injection processed by d-gid
“d-gid Man”: management software for the gas injection (*)
(*)
CAN-BUS Data
d-gid real time gas injection processing
Original ECU (Engine Control Unit)
Gas injectors controlledby d-gid
d-gid Diesel Dual Fuel Layout
or LNG
Complete Four Stoke Diesel Cycle
Inta
ke
ExhaustManifold
Turbo Charger
InletManifold
Air
“Dual Fuel Phased Injection”The gas is injected into the intake manifold, close to the intake valve, phased with the engine cycle. The mixture of air + gas enters the cylinder while the inlet valve is open (Intake Stroke). The injection of natural gas ends before the intake valve closes.
Injected Natural Gasquantity is controlled by d-gid DFF ECU
Natural Gas NG Injectors
Inta
ke
Co
mp
ressio
n
Ign
itio
n
InletManifold
ExhaustManifold
Turbo Charger
Injected Diesel quantity is controlled by d-gid DDF ECU
Air
“Dual Fuel Phased Injection”The gas is injected into the intake manifold, close to the intake valve, phased with the engine cycle. The mixture of air + gas enters the cylinder while the inlet valve is open (Intake Stroke). The injection of natural gas ends before the intake valve closes.
Natural Gas NG Injectors
Complete Four Stoke
Diesel Cycle
Very Good
Inta
ke
Co
mp
ressio
n
Ign
itio
n
Po
we
r
Exh
au
st
Ove
rla
p
InletManifold
ExhaustManifold
Natural Gas NG Injectors
Turbo Charger
ExhaustManifold
Exhaust gasescleaner thanks to
NG Phased Injection
Air from the intake manifold
Air
Exhaust gases
Good
“Dual Fuel Phased Injection”The gas is injected into the intake manifold, close to the intake valve, phased with the engine cycle. The mixture of air + gas enters the cylinder while the inlet valve is open (Intake Stroke). The injection of natural gas ends before the intake valve closes.
Complete Four Stoke
Diesel Cycle
Low impact on the architecture of the engine, which remain a standard Diesel cycle engine: 100% fullback Diesel at any time. No irreversible modification achieved.
Possibility to switch between Diesel/Gas mixture and 100% Diesel mode simply by pressing an on/off selector.
Automatic set to 100% diesel when the natural gas tank is empty or in case of trouble detection.
The engine does not decrease performance and efficiency in DDF mode: torque and power outcomes remain practically unvaried.
Emission levels improved.
Carbon footprint/emission reduced.
Improved engine oil quality determined by high reductions of carbon emission.
Engine noise reduced up to 5db thanks to natural gas smoother combustion.
Significant reductions of operating costs thanks to Diesel-Gas substitution.
Diesel Fuel Fuel Advantages
- Ecomotive SolutionsA Short Presentation
- Retrofitting Process Dual Fuel d-gid Technology
- Diesel Dual Fuel & LNGLNG: more green energy in less space
- LNG Retrofitting Case in ItalyDevelopment, Data and Considerations
Liquefied Natural Gas (LNG)
Liquefied natural gas or LNG is natural gas(predominantly methane, CH4) that has been converted to liquid form for ease of storage or transport.
Liquefied natural gas takes up about 1/600th the volume of natural gas in the gaseous state.
It is odorless, colorless, non-toxic and non-corrosive.
The liquefaction process involves removal of certain components, such as dust, acid gases, helium, water, and heavy hydrocarbons, which could cause difficulty downstream. The natural gas is then condensed into a liquid at close to atmospheric pressure (maximum transport pressure set at around 25 kPa (4 psi)) by cooling it to approximately −162 °C
GNL/LNG1,8 Litres
Liquid at -162°C
CNG5 Litres
NG Compressed at 220 bar
DIESEL1 Litre
Volume Vs. Fuels Energy Content
=DIESEL
=
FuelEmissions
kgCO2/kWh
Wood 0.39
Peat 0.38
Lignite 0.36
Hard coal 0.34
Fuel oil 0.28
Diesel 0.27
Crude oil 0.26
Kerosene 0.26
Gasoline 0.25
Refinery gas 0.24
LPG 0.23
Natural gas 0.20
Carbon Footprint Benefits
DAF FX 460 EURO5Equipped with d-gid LNGDiesel Dual Fuel System
First Italian Diesel Dual Fuel LNG Truck Retrofit
Emission test made by
European Joint Research Centre JRC in Ispra ITALY
Tested Vehicle:
DAF XF 460 EURO5
Hi Pressure StorageNatural GasCompressed at 220 bar
Cryogenic StorageLiquid Natural Gas
at -162°C 8 bar
LNG Heat Exchanger
NG pressureregulatorInput 220 barOutput 2÷3 bar
d-gid ECU can easily manage both LNG and CNG according with desired Diesel Dual Fuel strategy
NG injection NG injection
LNGLiquid Natural Gas
Cryogenic Tank Storage
CNGCompressed Natural Gas
Hi-pressure Cylinders Storage
d-gid Flexible Dual Fuel LNG/CNG System
NG press.
2÷3 bar
NG press.
2÷3 bar
NG pressureregulatorInput Output 3 bar
- Ecomotive SolutionsA Short Presentation
- Retrofitting Process Dual Fuel d-gid Technology
- Diesel Dual Fuel & LNGLNG: more green energy in less space
- LNG Retrofitting Case in ItalyDevelopment, Data and Considerations
Reach Stacker KALMAR DRF 450
Cummins QSM11 355
Engine Model: QSM11-335
Engine Type: 6 Cylinders, in Line
Displacement: 10.8 L
Rated Speed: 2100 rpm
Rated Power: 250 kW(335 HP)
Max.
Torque/Speed:1674 N.m @1400rpm
Aspiration
Method:T-charged & Intercooled
Emission
Standard:Tier III
- d-gid Dual Fuel system platform development on Cummins QSM11 engine.- Engine dedicated Dual Fuel d-gid ECU firmware development. - Engine safety parameters acquisitions for engine reliability purpose (temperatures, pressures, etc.) - Engine operative loads Dyno simulation. - Dual Fuel mapping with target on keeping original torque/power point to point referring to operative engine specifications.
Activities Developed on the Engine Dynamometer
A preliminary activity was to dismantle the original Cummins engine from Kalmar Reach Stacker and transfer it on an engine dynamometer.
Developed Activities on Dyno
Ph
ase 1
-DRF450 on board installation of d-gid dual fuel system. - QSM11 Engine work validation after reassembling on vehicle. (static phase)- DRF450 Reach Stacker validation test in field. (active work phase)
- Original Diesel Test- Dual Fuel LNG Test
- Data acquisition and comparison.
Activities Developed in Field
A preliminary activity was to mount back the Cummins engine on Kalmar Reach Stacker.
Developed Activities in Field
Ph
ase 2
Exhaust Temperature
0
100
200
300
400
500
600
700
800
800 1000 1100 1200 1400 1600 1700 1800 1900 2000
Rpm [rpm/min]
xh
au
st
Te
mp
era
ture
[°C
]
Originale
Dual Fuel
Cummins QMS11 Retrofit Data Comparison
Oil Temperature
82
84
86
88
90
92
94
96
98
100
800 1000 1100 1200 1400 1600 1700 1800 1900 2000
RPM [rpm/min]
Oil
Te
mp
era
ture
[°C
]
Originale
Dual Fuel
Power
0
50
100
150
200
250
300
350
400
800 1000 1100 1200 1400 1600 1700 1800 1900 2000
Rpm [rpm/min]
Po
we
r [H
p]
Originale
Dual Fuel
Diesel Consumption
0,0
10,0
20,0
30,0
40,0
50,0
60,0
70,0
80,0
800 1000 1100 1200 1400 1600 1700 1800 1900 2000
Giri [rpm/min]
Co
ns
um
o G
as
oli
o [
lt/h
]
Originale
Dual Fuel
Natural Gas Consumption (Metano)
0,00
5,00
10,00
15,00
20,00
25,00
30,00
35,00
40,00
800
1000
1100
1200
1400
1600
1700
1800
1900
2000
Giri [rpm/min]
Co
ns
um
o M
etn
o [
kg
/h]
Dual Fuel
Cummins QMS11 Retrofit Data Comparison
30%
Peak DieselPeak CH4
50%Average
70%
Substitution Rate
Thank You