gaseous fuel systems for on-road diesel engines-13 corp. powerpoint presensation.… · or common...

Gaseous Fuel System forOn-Road Diesel Engines

Technology Overview

Co-firing of diesel fuel and natural gas 50% ~ 75% natural gas use

No engine modifications required Compression ignition –no spark plugs No power loss / equivalent efficiencies Retrofit kit Easy to install

Technology Overview Continued…

Designed for severe on-road service Fail-safe design; system automatically defaults to

100% diesel mode Automatic switching of fuel modes Electronic monitoring of critical parameters Compatible with turbocharged and normally

aspirated diesel engines

Gaseous Fuel Advantages

Reduced operating costs Fuel flexibility

Vehicle can operate on 100% diesel fuel if required

Lower cost vs. spark-ignited gas engines Compatible with compressed natural gas (CNG)

or liquefied natural gas (LNG) fuel storagesystems

Compatible Diesel Engines

4-cycle Turbocharged Normally aspirated Mechanically fuel injected using in-line pump

or common fuel rail some rotary / distributor-type pumps not

compatible limited compatibility with electronic engines new kit under development that will be compatible

with most electronic diesel engines

Typical Applications

Buses Refuse haulers Delivery trucks Dump trucks Short-haul cargo

carriers (CNG) Long-haul cargo

carriers (LNG)

GFS Kit –Safe by Design

All high pressure gas components UL listedand/or CSA approved

Gas supplied to engine at atmospheric pressurereducing possibility of over-fueling

Gas concentration in engine combustion air isless than 3% by volumemixture is non-explosive / non-flammable until

compressed in the combustion chamber

CNG / LNG on-board fuel systems haveexcellent safety history worldwide

Natural Gas Overview

Pipeline quality natural gas composed primarily ofmethane (C1)

Odorless, colorless, formless gas Lower explosive limit (LEL) 5% by volume Upper explosive limit (UEL) 15% by volume Approximately 1000 Btu per cubic foot Approximately 37 MJ per cubic meter

Low energy density compared to diesel fuel

Comparison of Natural Gas andDiesel Fuel

1 gallon no. 2 diesel equivalent to 130 standardcubic feet of natural gas

1 liter of no. 2 diesel equivalent to 1 cubic meterof natural gas

1 gallon of liquid natural gas (LNG) equivalent to0.60 gallon no. 2 diesel

1 liter of liquid natural gas (LNG) equivalent to0.60 liter no. 2 diesel

Gas Ratio vs. Duty Cycle

Urban duty cycletypically yields 50%to 65% gas ratio

On-highway dutycycle typically yields65% to 75% gasratio

Mixed duty cycle willresult in variable gasratio

Estimating Gas StorageRequirements

Typical diesel fuelconsumption per dayor route

Estimated maximumgas substitution forduty cycle

Refuelingopportunities?

Gas Storage Calculation

Urban bus using 170 liters of diesel / day Fueled at yard –1 x day Estimated gas ratio of 60% 40% diesel = 68 liters / day (170 x .40) 60% natural gas = 102 cubic meters

CNG storage = 102 cubic meters LNG storage = 143 liters (102 liters x 1.4)

Fuel Cost Savings

Based on cost differential between CNG or LNGand diesel fuel

Large cost differential between diesel and CNGor LNG results in rapid ROI

High fuel consumption applications result inlarger savings Light-duty diesels may not generate

adequate savings due to low fuelconsumption

Calculating Fuel Cost Savings

Cost of diesel / unit Cost of CNG or LNG / equivalent energy unit Average daily diesel consumption before

conversion Average daily diesel consumption + average daily

CNG or LNG consumption after conversion Savings / day x operating days / year = savings

per year

Sample Saving Analysis

Assumptions:Urban bus duty cycleNormal daily diesel consumption of 170 litersDiesel cost of $1.00 / literCNG cost of $0.45 / cubic meter60% average gas substitution260 operating days / year

Savings Calculation

Average daily diesel fuel consumption of 170liters = $170 / day fuel cost

Average daily diesel fuel consumption afterconversion is 68 liters = $68.00 / day diesel cost based on 40% diesel use

Average daily CNG consumption after conversionis 102 cubic meters x 0.45 = $45.90 / day CNGcost based on 60% gas use

Daily savings = $170 –($68 + $45.90) = $56.10 Annual savings = $56.10 x 260 days = $14,586

GFS Kit ComponentsOn-Road CNG / LNG

Applications

GFS Conversion Kit

Kit Contents

Gas Train Diesel Fuel Controller Air-Gas Mixer Electronic Controller Wiring Harnesses Optional CNG Level Display System Status Indicators Installation Manual

Items not included

CNG Cylinder(s) LNG Tank(s) Mounting Brackets CNG / LNG Fill Valve Manual Isolation Valve High Pressure Tubing Mechanical Pressure Gauge

GFS Air-Gas Mixer

High efficiency design Integral gas power

valve Aerospace quality

materials andconstruction

No moving parts Mil-spec anodized

finish for long servicelife

Mixer Installation

Installed upstream ofturbo compressor inlet

Mixer kit includes humphoses and clamps

Air flow directionindicated on mixerbody

Available in 3”, 4”, 5”and 6”diameters(76.2mm, 101.6mm,127mm and 152.4mm)

Air-Gas Mixer with Hump HoseAdaptors

Air-Gas Mixer Markings

GFS Gas Train

High Pressure Regulator

UL Listed 38N5 Rated for 3600 psi /

24,840 KPa Pressure relief device Factory-set outlet

pressure Water jacket heated

to prevent ice crystalformation

Long service life

Gas Solenoid Valve

CSA Approved Rated for 3,600 psi /

24,840 KPa 2-way normally closed

design is fail-safe Weather-proof

electrical connection 12 Volt DC operation

Low Pressure Regulator

UL Listed 792G Rated for 312 psi /

2153 KPa inletpressure

Gas delivered atatmospheric pressure

Long service life Easily rebuilt in-field

Gas Train Installation

Installed adjacent toair-gas mixer

Flexible fuel hoseconnection to mixer

6mm compressionfitting included

Safely secured usingfour mounting lugs

Diesel Fuel Control Devices

Diesel Fuel Control Valve

Controls fuel pressureto injection pump orengine fuel rail

Fail-safe, 3-way valvedesign; 100% dieselflow when de-energized

DIN rated electricalconnection / 12 Volt DC

Inlet and outlet portsSAE spec for leak-tightinstallation

Installation of Diesel Fuel ControlValve

Installed upstream ofinjection pump / fuelrail inlet

Leak-tight tubefittings and banjoadaptors included inkit

Fuel hose assemblyrated for 250 psi /1725 KPa

Installed off-engineon chassis rail orbulkhead

Aneroid Control Valve

Used with aneroid-controlled injectionpumps

Controls engine boostpressure to injectionpump aneroid device

Fail-safe 3-way valvedesign

DIN rated electricalconnection / 12 Volt DC

Installation of Aneroid ControlValve

Installed upstream ofinjection pumpaneroid device

Leak-tight tubefittings and adaptorsincluded in kit

Tube assembly ratedfor 100 psi / 690 KPa

Installed off-engine onchassis rail orbulkhead

Electronic Control Unit

Electronic Control UnitComponents

Controller Gas Pressure

Transducer Exhaust temperature

thermocouple Wiring Harnesses Indicator Lamps Optional CNG level

indicator

Controller Functions

Engine exhaust gastemperaturemonitoring

CNG / LNG pressuremonitoring

System statusindicators

Display of CNG level Automatically switches

engine to diesel modeif fault detected

Installation of Electronic ControlUnit and Accessories

Control unit mountedinside cab / undervehicle dash

Gas pressuretransducer installed ingas train

Status lamps andoptional CNG levelindicator installed invehicle dash

12 Volt DC powered

Installation Requirements

8 to 10 man hours No special tools

required Some fabrication of

brackets may berequired

Commissioning can bedone on-road or usingchassis dynamometer

Off-Road Applications

Locomotives Earth Moving

Equipment Mobile Cranes Construction

Equipment Yard Tugs

Conversion Systems for Large DieselEngines

400 h.p. to >3,000 h.p. CNG / LNG compatible Sophisticated engine protection systems 50% ~ 80% natural gas use depending on engine

model and gas quality Technology proven on over 900 MW of power

generation applications

1317 Shotgun RoadWeston, Florida 33326

++(1) 954.693.9657 (ph)++(1) 954.472.1447 (fax)

www.gfs-corp.net