Masciali Gabriele - Responsabile Commerciale - Ecomotive Solutions

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Slides presentate a Roma il 21 gennaio 2014 in occasione del Workshop "L'Impiego del gas naturale liquefatto (GNL) nei trasporti stradali. Normative, Standard e Tecnologie" promosso da @ConferenzaGNL, un progetto a cura di Symposia e WEC Italia - TWITTER #GNL

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Masciali Gabriele - Responsabile Commerciale - Ecomotive Solutions

  1. 1. L’impiego del gas naturale liquefatto (GNL) nei trasporti stradali. Normative, standard e tecnologie. CONFERENZA GNL Roma, 21 Gennaio 2014 Speaker: Gabriele Masciali, Sales Manager
  2. 2. Content -Ecomotive Solutions A short presentation - Retrofitting Process Dual Fuel d-gid Technology - Diesel Dual Fuel & LNG LNG: more green energy in less space - LNG Retrofitting Case in Italy Development, Data and Considerations
  3. 3. -Ecomotive Solutions A short presentation - Retrofitting Process Dual Fuel d-gid Technology - Diesel Dual Fuel & LNG LNG: more green energy in less space - LNG Retrofitting Case in Italy Development, Data and Considerations
  4. 4. since 1991 Company Headquarters
  5. 5. 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”
  6. 6. - Ecomotive Solutions A Short Presentation - Retrofitting Process Dual Fuel d-gid Technology - Diesel Dual Fuel & LNG LNG: more green energy in less space - LNG Retrofitting Case in Italy Development, Data and Considerations
  7. 7. Diesel Fuel Fuel Definition “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 Dual Fuel (DDF) d-gid ECU Natural Gas (Methane) (Engine Control Unit) Diesel Engine d-gid can also manage dual fuel applications using Biogas, Syngas, Hydrogen, DIESEL 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.
  8. 8. d-gid DDF Technology – Diesel & Gas Injection Control Original ECU (Engine Control Unit) Original diesel injection signal d-gid real time gas injection processing CAN-BUS Data Gas injection processed by d-gid Gas injectors controlled by d-gid (*) (*) The gas injection is managed and controlled by “d-gid Man” software “d-gid Man”: management software for the gas injection (*)
  9. 9. d-gid Diesel Dual Fuel Layout or LNG
  10. 10. Complete Four Stoke Diesel Cycle 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 Intake “Dual Fuel Phased Injection” NG Injectors Injected Natural Gas quantity is controlled by d-gid DFF ECU Air Turbo Charger Inlet Manifold Exhaust Manifold
  11. 11. Complete Four Stoke Diesel Cycle Natural Gas NG Injectors Ignition Compression 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. Intake “Dual Fuel Phased Injection” Injected Diesel quantity is controlled by d-gid DDF ECU Air Turbo Charger Inlet Manifold Exhaust Manifold
  12. 12. Complete Four Stoke Diesel Cycle Natural Gas NG Injectors Overlap Exhaust Power Ignition Compression 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. Intake “Dual Fuel Phased Injection” Exhaust gases cleaner thanks to NG Phased Injection Air Air from the intake manifold Turbo Charger Inlet Manifold Exhaust Manifold Exhaust gases Good Very Good
  13. 13. Diesel Fuel Fuel Advantages  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.
  14. 14. - Ecomotive Solutions A Short Presentation - Retrofitting Process Dual Fuel d-gid Technology - Diesel Dual Fuel & LNG LNG: more green energy in less space - LNG Retrofitting Case in Italy Development, Data and Considerations
  15. 15. 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
  16. 16. Volume Vs. Fuels Energy Content DIESEL 1 Litre CNG 5 Litres NG Compressed at 220 bar = DIESEL = GNL/LNG 1,8 Litres Liquid at -162°C
  17. 17. Carbon Footprint Benefits Fuel Emissions 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
  18. 18. First Italian Diesel Dual Fuel LNG Truck Retrofit DAF FX 460 EURO5 Equipped with d-gid LNG Diesel Dual Fuel System
  19. 19. Emission test made by European Joint Research Centre JRC in Ispra ITALY Tested Vehicle: DAF XF 460 EURO5
  20. 20. d-gid Flexible Dual Fuel LNG/CNG System LNG Liquid Natural Gas Cryogenic Tank Storage CNG Compressed Natural Gas Hi-pressure Cylinders Storage Cryogenic Storage Liquid Natural Gas at -162°C 8 bar Hi Pressure Storage Natural Gas Compressed at 220 bar d-gid ECU can easily manage both LNG and CNG according with desired Diesel Dual Fuel strategy NG pressure regulator Input 220 bar Output 2÷3 bar LNG Heat Exchanger NG pressure regulator Input Output 3 bar NG press. 2÷3 bar NG injection NG injection NG press. 2÷3 bar
  21. 21. - Ecomotive Solutions A Short Presentation - Retrofitting Process Dual Fuel d-gid Technology - Diesel Dual Fuel & LNG LNG: more green energy in less space - LNG Retrofitting Case in Italy Development, Data and Considerations
  22. 22. Reach Stacker KALMAR DRF 450
  23. 23. 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. 1674 N.m @1400rpm Torque/Speed: Aspiration T-charged & Intercooled Method: Emission Tier III Standard:
  24. 24. Activities Developed on the Engine Dynamometer Phase 1 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 - 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.
  25. 25. Activities Developed in Field Phase 2 A preliminary activity was to mount back the Cummins engine on Kalmar Reach Stacker. Developed Activities in Field -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.
  26. 26. Cummins QMS11 Retrofit Data Comparison 400 350 300 250 200 150 100 50 0 Oil Temperature Originale Dual Fuel Oil Temperature [°C] Power [Hp] Power 100 98 96 94 92 90 88 86 84 82 Originale Dual Fuel 800 1000 1100 1200 1400 1600 1700 1800 1900 2000 800 1000 1100 1200 1400 1600 1700 1800 1900 2000 Rpm [rpm/min] RPM [rpm/min] xhaust Temperature [°C] Exhaust Temperature 800 700 600 500 Originale 400 300 200 Dual Fuel 100 0 800 1000 1100 1200 1400 1600 1700 1800 1900 2000 Rpm [rpm/min]
  27. 27. Cummins QMS11 Retrofit Data Comparison Consumo Gasolio [lt/h] Diesel Consumption 80,0 70,0 60,0 50,0 Originale 40,0 30,0 20,0 10,0 0,0 Dual Fuel Substitution Rate Peak CH4 70% Peak Diesel 30% 800 1000 1100 1200 1400 1600 1700 1800 1900 2000 Giri [rpm/min] 50% Average 40,00 35,00 30,00 25,00 20,00 15,00 10,00 5,00 0,00 Giri [rpm/min] 00 20 00 19 00 18 00 17 00 16 00 14 00 12 00 00 11 10 0 Dual Fuel 80 Consumo Metno [kg/h] Natural Gas Consumption (Metano)
  28. 28. Thank You

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