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

2. 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

3. 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

4. -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

5. since 1991
Company Headquarters

6. 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”

7. - 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

8. 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.

9. 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 (*)

10. d-gid Diesel Dual Fuel Layout
or LNG

11. 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

12. 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

13. 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

14. 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.

15. - 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

16. 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

17. 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

18. 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

19. First Italian Diesel Dual Fuel LNG Truck Retrofit
DAF FX 460 EURO5
Equipped with d-gid LNG
Diesel Dual Fuel System

20. Emission test made by
European Joint Research Centre
JRC in Ispra ITALY
Tested Vehicle:
DAF XF 460 EURO5

21. 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

22. - 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

23. Reach Stacker KALMAR DRF 450

24. 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:

25. 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.

26. 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.

27. 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]

28. 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)

29. Thank You