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HDGAS – Heavy Duty Gas Engines integrated into Vehicles

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EGVIA - ERTRAC 1st European Conference Results from Road Transport Research in H2020 projects
29 November 2017 to 30 November 2017
Brussels

Published in: Automotive
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HDGAS – Heavy Duty Gas Engines integrated into Vehicles

  1. 1. This project has received funding from the [European Union’s Horizon 2020 research and innovation programme under grant agreement No 653391 HDGAS Heavy Duty Gas Engines integrated into Vehicles Gernot Hasenbichler Gernot.hasenbichler@avl.com Project status & results EGVIA conference Brussels, November 30, 2017
  2. 2. This project has received funding from the [European Union’s Horizon 2020 research and innovation programme under grant agreement No 653391 Agenda • Introduction • Objectives and achievements • Outlook and challenges • Final event, impact, publications
  3. 3. This project has received funding from the [European Union’s Horizon 2020 research and innovation programme under grant agreement No 653391
  4. 4. This project has received funding from the [European Union’s Horizon 2020 research and innovation programme under grant agreement No 653391
  5. 5. This project has received funding from the [European Union’s Horizon 2020 research and innovation programme under grant agreement No 653391 Main objectives Engine Fuel system Aftertreatment system
  6. 6. This project has received funding from the [European Union’s Horizon 2020 research and innovation programme under grant agreement No 653391 Project structure
  7. 7. This project has received funding from the [European Union’s Horizon 2020 research and innovation programme under grant agreement No 653391 WP2 OBJECTIVES AT A GLANCE • Development of LNG tank systems for different engine types: - Spark ignited - Dual fuel - Compression ignited • Development and standardization of fueling interface for LNG truck fueling LNG vehicle fuel systems and standardization
  8. 8. This project has received funding from the [European Union’s Horizon 2020 research and innovation programme under grant agreement No 653391 WP2 ACHIEVEMENTS ✓ Tank system layout defined ✓ Prototype tank systems have been developed and have partly being delivered ✓ Low pressure system delivered to MAN ✓ Medium pressure system delivered to Iveco ✓ High pressure pump has been developed and built up. Delivery to OEM according time schedule of OEM ✓ Simulation of the refueling process has been performed containing ✓ Pressure behavior in the tank (vapor collapse) ✓ Spray bar positioning ✓ Standard for LNG refueling interface created and presented to ISO ✓ Prototype fueling nozzles and receptacles have been delivered and being tested LNG vehicle fuel systems and standardization
  9. 9. This project has received funding from the [European Union’s Horizon 2020 research and innovation programme under grant agreement No 653391 WP3 Exhaust after treatment systems and emission control OBJECTIVES AT A GLANCE • To use fundamental studies to develop and deliver aftertreatment systems for natural gas applications:  Stoichiometric  lean NG  Dual fuel  HPGI (carry over form diesel EU VI) • Ageing impact study on methane oxidation catalyst • Calibration of systems to meet Euro VI emissions limits
  10. 10. This project has received funding from the [European Union’s Horizon 2020 research and innovation programme under grant agreement No 653391 WP3 ACHIEVEMENTS ✓ Novel MOC reducing the impact of ageing ✓ SCR catalyst dedicated to NG engine applications for the higher exhaust temperature and mimimized N2O formation ✓ Sulphur removal strategy developed to maintian efficiency of methane oxidation catalyst. ✓ Aftertreatment systems delivered to partners ✓ Calibration of aftertreatment system under development Exhaust after treatment systems and emission control 150 200 250 300 350 400 450 500 550 0,0 0,1 0,2 0,3 0,4 0,5 0,6 0,7 0,8 0,9 1,0 NOconversion Temperature, °C Cu-SCR2 Fe-SCR1 V-SCR1 Fe-SCR1+Cu-SCR2
  11. 11. This project has received funding from the [European Union’s Horizon 2020 research and innovation programme under grant agreement No 653391 WP4 OBJECTIVES AT A GLANCE • Development of two versions (stoichiometric and lean burn) of a new direct positive ignition NG engine capable of:  > 10% fuel efficiency  10% reduced GHG emissions  10% higher performance in comparison with current engines  Vehicle range > 800km Low pressure direct injection spark ignited engine
  12. 12. This project has received funding from the [European Union’s Horizon 2020 research and innovation programme under grant agreement No 653391 WP4 ACHIEVEMENTS ✓ 1D and CFD simulation of stoichiometric and lean burn concept performed ✓ SCE testing finalized, HW for multi-cylinder engine selected ✓ Procurement and construction of prototype engines ✓ Both engine concepts are operating on the test bed and being optimized ✓ Summary of results from engine tests (to date)  Fuel efficiency target reached for stoichiometric engine (BSFC 190g/kWh of G20 in best point)  10% Increased performance feasible  Emission compliance not an issue on stoich concept ✓ Vehicle assembly in progress Low pressure direct injection spark ignited engine
  13. 13. This project has received funding from the [European Union’s Horizon 2020 research and innovation programme under grant agreement No 653391 WP5 OBJECTIVES AT A GLANCE • Development of a low pressure port injected dual fuel engine capable of:  15% diesel substitution increase compared to 2013 state of the art dual-fuel HD engines  10% reduced GHG emissions compared to present diesel vehicle  Exhaust emissions meeting EU VI  Diesel-like performance and driveability  Vehicle range > 800km  Vehicle to operate in pure diesel mode Low pressure port injected dual fuel engine
  14. 14. This project has received funding from the [European Union’s Horizon 2020 research and innovation programme under grant agreement No 653391 WP5 ACHIEVEMENTS Engine: ✓ Simulations carried out, controls developed ✓ Calibration of WHTC is ongoing in order to find the best trade off between Nox and CH4 ✓ Warm up and warm keeping strategies are being worked out in order to reduce emissions in cWHTC and meet composite WHTC limit ✓ First version of Fuel Quality Sensor and LNG Tank installed ✓ Vehicle ready for engine integration ✓ LNG refueling test for WP2 carried out Low pressure port injected dual fuel engine
  15. 15. This project has received funding from the [European Union’s Horizon 2020 research and innovation programme under grant agreement No 653391 WP6 OBJECTIVES AT A GLANCE • To develop and demonstrate a new Heavy Duty Methane Gas engine and vehicle, based on a High Pressure Direct Gas Injection (HPGI) with:  Exhaust emissions meeting EU VI  > 20% reduction of greenhouse gas emissions compared to present diesel engine  Same engine power, torque and drivability as diesel engine  > 90% substitution of diesel in real driving cycle  > 800 km driving range High pressure gas direct injection engine
  16. 16. This project has received funding from the [European Union’s Horizon 2020 research and innovation programme under grant agreement No 653391 WP6 ACHIEVEMENTS ✓ Prototype injector developed and performance proven by tests ✓ Combustion system optimization by CFD ✓ Single cylinder testing completed and hardware for multi cylinder selected ✓ Multi cylinder testing ongoing, fulfilment of project targets verified ✓ Vehicle under development with:  device to mitigate all methane boil-off  low friction LNG pump ✓ Summary of results from engine tests (to date)  Fuel efficiency better than diesel  Soot emissions close to zero  Methane emissions engine-out meeting EU VI  > 90% substitution of diesel High pressure gas direct injection engine
  17. 17. This project has received funding from the [European Union’s Horizon 2020 research and innovation programme under grant agreement No 653391 WP7 OBJECTIVES AT A GLANCE • Independent assessment of the achieved results compared to state of the art from 2013:  GHG and CO2  Driving range  Emission compliance on test bed and on road • Cost assessment HIGHLIGHTS  Testing procedures defined  Baseline testing performed  First target testing planned December 2017 ( dual fuel engine) Independent testing and overall assessment
  18. 18. This project has received funding from the [European Union’s Horizon 2020 research and innovation programme under grant agreement No 653391 WP8 ▪ Publication of results ☑ under ‘latest news’ & ☑ in newsletter -> please subscribe ! ▪ Publishable summaries ☑ under ‘results’ ☑ regular updates Dissemination, communication and preparative exploitation activities progress:
  19. 19. This project has received funding from the [European Union’s Horizon 2020 research and innovation programme under grant agreement No 653391 Outlook and challenges Low pressure port injected dual fuel engine Low pressure direct injection spark ignited EGR engine High pressure gas direct injection diesel pilot ignition engine WP7: Independent testing and overall assessment WP3: Engine aftertreatment system WP2: Advanced LNG vehicle fuel system WP2: Tank and fuel systems have been developed and have been delivered to the vehicle OEMs. Integration of a new partner as supplier for high pressure gas system and reduction of gas pressure from 500 to 300 bar will secure a proper operation in the vehicle WP3: Methane conversion efficiency and catalyst ageing are being considered as main challenge. New catalyst compositions will make a major contribution being emission compliant without major fuel efficiency penalties by applying targeted thermal management WP4: The stoichiometric SI engine is considered as straight forward technology with no concerns in terms of emission compliance. With several new technologies being implemented, major steps reducing fuel consumption will be realized. The goal of 10% reduction on best point has been reached, while reduction of 10% GHG emission remains challenging. The lean burn version should easily reach the targets connected to improved efficiency while compliance with emission level of methane is the main challenge WP5: Dual fuel engines offer great flexibility to its operators while the LNG network still needs improvements in terms of coverage. Reaching the 10% of CO2 reduction has been achieved already. Being emission compliant in all conditions still remains as the main challenge. To achieve this aim the optimization of transient conditions and the maintenance of the MOC catalyst over a range of temperature is crucial. WP6: HPGI offers high CO2 reduction potential (>20%) as well as no major concerns in terms of emission compliance. System complexity and cost are areas to be in focus WP4 WP5 WP6
  20. 20. This project has received funding from the [European Union’s Horizon 2020 research and innovation programme under grant agreement No 653391 Final Event: 11 April 2018 Final Event and Exhibition: ▪ Date & Place: Wednesday April 11, Turin, Italy, CNH Industrial Village ▪ Program: Meeting presentations followed by large-scale exhibition ▪ Presentation of FPT demonstrator truck– outside test rides possible; engines of MAN and VOLVO available too ▪ HDGAS Final Event will be announced via partners’ websites and NGVA
  21. 21. This project has received funding from the [European Union’s Horizon 2020 research and innovation programme under grant agreement No 653391 Publications (1) Title 1st Author Partner Conference/ Journal Year Case study of a modern lean-burn methane combustion catalyst for automotive applications: What are the deactivation and regeneration mechanisms Niko M. Kinnunen University of Eastern Finnland Science direct 2017 The effect of CH4 on NH3-SCR catalysts for lean-burn NG vehicles Roberta Villamaina Politecnico di Milano EuropaCat 2017 2017 The effect of CH4 on NH3-SCR over metal-promoted zeolites and V-based catalysts for lean-burn NG vehicles Roberta Villamaina Politecnico di Milano Durability evaluations and rapid ageing methods in commercial emission catalyst development for diesel, natural gas and gasoline applications Teuvo Maunula Springer 2017 Regeneration of a methane oxidation catalyst: Fundamental understanding of sulfate species decomposition with model catalysts Niko M. Kinnunena
  22. 22. This project has received funding from the [European Union’s Horizon 2020 research and innovation programme under grant agreement No 653391 Publications (2) Title 1st Author Partner Conference/ Journal Year Natural Gas Engines for Long-Haulage Applications: Current Approach and Future Developments Stefano Golini FPT 16th Conference „The Working Process of the Internal Combustion Engine“, Graz 2017 Gas Exchange and Injection Modeling of an Advanced Natural Gas Engine for Heavy Duty Applications Davide Paredi Politecnico di Milano ICE 2017 - 13th International Conference on Engines and Vehicles, Capri 2017 FPT Industrial’s Leadership in Natural Gas Technologies for Industrial Engines P. Krähenbühl FPT 38th Internationales Wiener Motorensymposium, Wien 2017 HD GAS – Heavy Duty Gas Engines integrated into vehicles Johann Weinzierl MAN EGVIA workshop on “European funded project results: Reduction of CO2 emissions from Heavy-Duty Trucks 2017 A High Efficiency Lean Burn Mono Fuel Heavy Duty Natural Gas Engine For Achieving Euro VI Emissions Legislation & Beyond Andrew Auld Ricardo 12th International MTZ Conference on Heavy-Duty, On- and Off-Highway Engines 2017 Conference in Augsburg, Germany on 28th November 2017 2017 A simulation approach to meeting Euro VI emissions legislation with a natural gas lean burn heavy duty engine Andrew Auld Ricardo The IMechE Internal Combustions Engines 2017 Conference in Birmingham, England on 6th December 2017 2017
  23. 23. This project has received funding from the [European Union’s Horizon 2020 research and innovation programme under grant agreement No 653391 Expected or potential impact Technological impact ▪ The main challenges of gas powered HD vehicles are: Vehicle costs, vehicle performance, vehicle/engine availability and infrastructure. Except the last item (infrastructure) all items will be covered and hurdles being lowered in this project. Environmental impact: ▪ Reducing GHG by min. 10% from 2013 state of the art HD engines will contribute to limit global warming ▪ Gas enignes with help to improve air quality due to the fact that they emit significantly less pollutants ▪ Using biogas instead of Natural gas would further reduce the CO2 by over 90% Economical and social impact: ▪ Providing know how in terms of gas engines and LNG vehicles to the EU industry, enables the development and sales of related products - strengthen the industry – securing jobs within the EU
  24. 24. This project has received funding from the [European Union’s Horizon 2020 research and innovation programme under grant agreement No 653391 Achievements - overview Indicator Units used Project reference Project objective Current achievements Types of vehicles CO2 or fuel consumption reduction CO2 [g/km] and [%] Best in class 2013 Min 10% No final result yet available HD vehicles Pollutant emissions reduction (EU VI compliant) [g/kWh] EU VI EU VI in WHTC Preliminary results show compliance of all technologies HD vehicles Demonstrator developed 3 HD trucks with gas enignes and LNG system - HD vehicles Min range of 800km Km - Min 800km Not verified yet HD vehicles
  25. 25. This project has received funding from the [European Union’s Horizon 2020 research and innovation programme under grant agreement No 653391 END of PRESENTATION www.hdgas.eu

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