Post on 29-Aug-2021
HOERBIGER CleenCOM Product Technologies
Rich-to-Lean Burn Engine Conversions
December 3, 2014
Agenda
CleenCOM Technology Overview
What is “Rich” and “Lean” burn combustion?
What is HOERBIGER CleenCOM?
Canadian Emissions Legislation
Alberta/BC Green House Gas Credits
HOERBIGER CleenCOM ROI
Future Work
Next Steps?
Wrap Up / Q & A
Product Technology Path to Efficiency & Performance
Time
Factory
Rich-to-
Lean Burn
Conversion
(RTL)
Factory
Rich
Burn
CleenCOM
Level 1
RTL
+
Electronic
Pre-Chamber
Combustion
Control
(ePCC)
CleenCOM
Level 2
RTL +
ePCC
+
Varispark1
1
2 3
4 5
CleenCOM Level 4
RTL + ePCC + PFI +
Varispark +
Engine Tuning
1-Varispark with CPU-95EVS
2-PFI: Port Fuel Injector
CleenCOM
Level 3
RTL + ePCC
+ Varispark
+ PFI2
Product Technology Path to Efficiency & Performance
Time
Factory
Rich-to-
Lean Burn
Conversion
(RTL)
Factory
Rich
Burn
1
Rich Burn vs Lean Burn Combustion Technology
Rich Burn Main chamber has excess fuel
No pre-combustion chamber
No gas admission valve
Fuel mixture in main chamber is easier
to ignite
More emissions are released including
NOx, CO2 and. CxHx.
Has high exhaust temperature
Requires an after treatment to keep
emissions low (eg. Catalytic converter)
spark
plug
main chamber (excess fuel)
< 1
= Air/Fuel Ratio
Rich Burn vs Lean Burn Combustion Technology
main chamber (excess air)
> 1
spark
plug
pre-combustion
chamber
admission
valve
= Air/Fuel Ratio
Lean Burn Main chamber has excess air
Pre-combustion chamber
Admission valve
The spark plug ignites the rich
fuel mixture in the pre-chamber
to produce a flame that ignites
the lean mixture in the main
chamber
Has lower emissions, exhaust
temperature and doesn’t require
any after treatment
0
2
4
6
8
10
12
0.5 1 1.5 2 3 3.5 4 4.5 5 11
Infr
are
d A
bso
rban
ce/c
m
% O2 in Exhaust
Rate of Nitration
Lean Burn Engine Benefits
Lean-burn engines have lower exhaust gas temperatures (200-250°C lower) and
a leaner air/fuel ratio than equivalent rich-burn engines:
Lower peak combustion temps result in lower NOX emissions
Lower combustion temp’s lead to longer life cycle for power cylinder components (head,
pistons, valves, seats)
Lower the rate of oil nitration which increase the life of the oil (reduces oil change
frequencies) Mobile Technical Topic 2009
Nitration of Lubricating Oil in NG Engines
VHP GL 9.8%
(< 0.5 IA/cm) VHP GSI 1.35%
(Best Economy)
Rich-to-Lean Cooling System Requirements
Component Coolant
Loop
Waukesha
L7042 GSI
Waukesha
L7042 GL Increase
GSI-GL
Increase
Engine Main 1,022 825 -197.0 -197.0
Oil Cooler Auxiliary 102 126 +24.0
+117.0 Intercooler Auxiliary 66 159 +93.0
Compressor
Cooler Auxiliary 16.4 16.4 0.0
Total 1,206.4 1,126.4 -80.0 -80.0
Cooling Loads (kW) at Engine Rated Conditions
The cooling requirement for the auxiliary loop will increase. Additional cooling capacity
may need to be added.
The cooling for the main coolant line will decrease and there will be more cooling
capacity which would be beneficial during hot days.
Fuel Gas
Fuel gas must be free of any particles and liquids including
coolant, water and hydrocarbons
Dew point of fuel gas to be 11°C below gas inlet temperature
The fuel gas must be treated to remove any liquid and any gas that will
condense in the engine due to pressure and temperature changes.
Coalescing filters and scrubbers are required as addition insurance to
remove any liquids in the fuel gas after the fuel gas treatment.
Particle filters are also required for the fuel gas.
Agenda
What is “Rich” and “Lean” burn combustion?
What is HOERBIGER CleenCOM?
Canadian Emissions Legislation
Alberta/BC Green House Gas Credits
HOERBIGER CleenCOM ROI
Future Work
Next Steps?
Wrap Up / Q & A
Product Technology Path to Efficiency & Performance
Time
Factory
Rich-to-
Lean Burn
Conversion
(RTL)
Factory
Rich
Burn
CleenCOM
Level 1
RTL
+
Electronic
Pre-Chamber
Combustion
Control
(ePCC)
1
2
1-PFI with GV50
2-Varispark with CPU-95EVS
CleenCOM Lean Burn
Factory vs HOERBIGER Pre-Chamber Technology
Factory Lean Burn
fuel
electronic
admission
valve
pre-combustion
chamber
spark
plug
spark
plug fuel
mechanical
admission
valve
main chamber (excess air)
> 1
main chamber (excess air)
> 1,
= Relative Air/Fuel Ratio
HOERBIGER CleenCOM
Lean Burn Combustion Stability!
Unstable Lean Combustion Stable Lean Combustion CleenCOM ePCC
Cycle-to-cycle variations In firing
pressure due to mechanical valve!
Consistent firing pressure every
engine cycle is achieved with
precise pre-chamber fueling!
150 psi 25 psi
225 psi
HOERBIGER CleenCOM
Lean Burn Combustion Stability
More consisting firing pressure result in:
Increase power
Reduced opportunity for damage of power cylinder
components from misfires or detonations
Longer service/oil change intervals
Extended life of power cylinder components
Reduced NOx emissions
DET-1600 – Detonation & Misfire Protection
It protects natural gas fueled engines from
destructive knock and detonation.
Vibration sensors are mounted onto the engine
to monitor for misfire and detonation.
It will automatically reduce the load to reduce
misfire and detonation.
It can also adjust the ignition timing if combined
with a digital ignition system.
If the adjustments don’t work then as a last
resort it will shutdown the engine.
HOERBIGER CleenCOM
Electronic Pre-Combustion Control (ePCC)
ePCC Valve Electronically
Controlled
Admission
Valve (1 per cylinder)
Solenoid Driver Module (SDM)
ePCC Valve Driver for
Pre-Chamber Fuelling Control (1 SDM for up to 20 cylinders)
EZ-Rail
Fuel Rail (>70psi)
Fuel Rail (>70psi)
EZ-Rail
ENGINE
Intake Manifold
Intake Manifold Altronic DET-1600
Detonation & Misfire
Protection
HOERBIGER CleenCOM
Solenoid Driver Module (SDM)
ePCC Valve Driver for
Pre-Chamber Fuelling Control (1 SDM for up to 12 cylinders)
Rosemount Flow Meter
Installed on engine before
CleenCOM is installed to
quantify fuel consumption.
Altronic DET-1600
Detonation & Misfire
Protection
EZ-Rail
Fuel Rail (>70psi)
Fuel Rail (>70psi)
EZ-Rail
ENGINE
Intake Manifold
Intake Manifold
Product Technology Path to Efficiency & Performance
Time
Factory
Rich-to-
Lean Burn
Conversion
(RTL)
Factory
Rich
Burn
CleenCOM
Level 1
RTL+
Electronic
Pre-Chamber
Combustion
Control
(ePCC)
CleenCOM
Level 2
RTL +
ePCC
+
Varispark1
1
2 3
4 5
1-Varispark with CPU-95EVS
CPU95-EVS – Digital Ignition Systems
Electronically controls the ignition.
6 spark energy profiles to select from.
Set it to maximize engine performance and improve
combustion stability.
Ignite lean mixture for emission reduction.
Improve starting and loading characteristics.
Profiles can be changed while the engine is running.
It can independently control each spark’s intensity
and duration. The energy are often order of
magnitude higher then other ignition technology.
Assure combustion of leaner mixture, operate at
higher efficiency and extend service intervals.
HOERBIGER CleenCOM Plus
Altronic Ignition Control &Detonation/Misfire Protection
ePCC Valve Electronically
Controlled
Admission
Valve (1 per cylinder)
Solenoid Driver Module (SDM)
ePCC Valve Driver for
Pre-Chamber Fuelling Control (1 SDM for up to 20 cylinders)
Altronic VariSpark
Ignition Control
Altronic DET-1600
Detonation & Misfire
Protection
EZ-Rail
Fuel Rail (>70psi)
Fuel Rail (>70psi)
EZ-Rail
ENGINE
Intake Manifold
Intake Manifold
SDM
Waukesha L7042GL + CleenCOM Plus INJECTOR LEAD RAIL (EZ-Rail) & CleenCOM Panel
SDM
DE3000
CleenCOM Panel
VariSpark
DET-1600 Ignition J-box
ePCC
Pulse Width
EZ-Rail
Product Technology Path to Efficiency & Performance
Time
Factory
Rich-to-
Lean Burn
Conversion
(RTL)
Factory
Rich
Burn
CleenCOM
Level 1
RTL
+
Electronic
Pre-Chamber
Combustion
Control
(ePCC)
CleenCOM
Level 2
RTL +
ePCC
+
Varispark1
1
2 3
4 5
1-Varispark with CPU-95EVS
2-PFI: Port Fuel Injector
CleenCOM
Level 3
RTL + ePCC
+ Varispark
+ PFI2
HOERBIGER CleenCOM PFI
Injects fuel based on an electric signal into the air
stream from the intake manifold before it enters the
main chamber.
Eliminate the carburetor, hydraulic governor and
mechanical admission valves.
Fast response speed governing.
Precise control of fuel injection at start-up and load
changes.
Improves combustion stability with firing cylinders at
“full load” fueling.
HOERBIGER GV50/70/90
Port Fuel Injectors
HOERBIGER CleenCOM
Electronic Pre-Combustion Control (ePCC)
PFI Port Fuel
Injector (1 per cylinder)
Solenoid Driver Module (SDM)
PFI Driver for
Fuelling Control (1 SDM for up to 20 cylinders)
EZ-Rail
Fuel Rail
Fuel Rail
EZ-Rail
ENGINE
Intake Manifold
Intake Manifold
Agenda
What is “Rich” and “Lean” burn combustion?
What is HOERBIGER CleenCOM?
Canadian Emissions Legislation
Alberta/BC Green House Gas Credits
HOERBIGER CleenCOM ROI
Future Work
Next Steps?
Wrap Up / Q & A
Emissions Regulations: Current
Stationary Non-Emergency SI Natural Gas Engines: Brake Specific Output
Legislating
District
NOX CO VOC
(g/hp-hr)
NOTES
(g/hp-hr) (g/kW-hr) (g/hp-hr) (g/kW-hr)
Alberta1 4.5 6.0* None None None
Engines commissioned after May 1988
of more than 600kW.
*Emissions limits based on Best
Available Developed Technology (BADT).
BC2 2.0 2.7** None None None **NOX is NO2 equivalent (NO+NO2).
Drivers more than 200 hours per year.
Sources
1-Informational Letter 88-5 (IL88-5)
2-BC Reg. 254/2005 Environmental Management Act: Oil and Gas Waste Regulations
3-US Federal Register CFR 40 Parts 60, 63, et al.
Canada has no current regulations on CO or VOC’s!
Stationary Non-Emergency SI Natural Gas Engines: Brake Specific Output
Legislating
District Timeline
Engine Type
NOX CO NOTES
(g/hp-
hr) (g/kW-
hr) (g/hp-hr) (g/kW-hr)
Environment
Canada1
2015 Modern 2.0 2.7 None None Regular Use >75kW
Low Use >100kW
2021 Original 3.0 4.0 None None
50% total engine fleet
power compliant or 8
g/kW-hr yearly fleet
average
2026 Original 3.0 4.0 None None 100% total engine fleet
power compliant.
Note
Modern Engine – Manufactured after January 1, 2015
Original Engine – Manufactured before January 1, 2015, >250kW
Sources
1 – Multi-Sector Air Pollutants Regulations (MSAPR) – June 2014
Emissions Regulations (Proposed): January 1, 2015
Agenda
What is “Rich” and “Lean” burn combustion?
What is HOERBIGER CleenCOM?
Canadian Emissions Legislation
Alberta/BC Green House Gas Credits Engine pre/post audit requirements.
Additional required equipment?
HOERBIGER CleenCOM ROI
Future Work
Next Steps?
Wrap Up / Q & A
Green House Gas (GHG) Credits via
HOERBIGER’s Partnership with Cap-Op Energy
GHG is measured in units of tonnes of equivalent CO2 (CO2e).
Each emission species are assigned a Global Warming Potential (GWP) factor based
on how harmful it is to the environment.
For example for CO2 it is 1, CH4 is 25 etc…
CO2e is calculated by multiplying the tonnes of the specie by the GWP.
Credit will be give based on the difference in CO2e before and after the engine
upgrades.
Credits are awarded based on actual engine running conditions.
Requires a minimum of (3) pre/post engine audits.
Audits must include engine RPM, IMP/T, AFR, emissions AND fuel flow!
Continuous tracking of the data is required throughout the year
Credits given for improvements not required by law or for “business as usual” (i.e. not part of
a scheduled maintenance)
Green House Gas (GHG) Credits via
HOERBIGER’s Partnership with Cap-Op Energy
GHG reductions must be verified by an independent third party qualified by Alberta
Environment’s (AENV) GHG reduction program.
HOERBIGER is a Level 1 Manufacturer Member with Cap-Op Energy, a qualified GHG
quantifier for Alberta. We work with Cap-Op Energy to have them verify the GHG reductions
for you.
We currently aren’t working with any verifiers for BC at the moment.
A recommended minimum of 5 engines with GHG reduction upgrades is suggested before
pursuing GSG credit for it to be financially feasible due to the amount of work involved.
Credits can be received for up to 8 years with verification (post audits) required every year
with daily operating data.
Agenda
What is “Rich” and “Lean” burn combustion?
What is HOERBIGER CleenCOM?
Canadian Emissions Legislation
Alberta/BC Green House Gas Credits
HOERBIGER CleenCOM ROI
Future Work
Next Steps?
Wrap Up / Q & A
HOERBIGER CleenCOM ROI
Lower exhaust gas temperature (200-250°C lower) and more stable
combustion
Reduced opportunity for damage of power cylinder components from abnormal
combustion events such as misfires or detonations
Longer life cycle for power cylinder components (head, pistons, valves, seats)
Extending the time it take to replace them from 4 months to 1 year
Lower rate of oil nitration, longer spark plug, piston ring and oil filter life. This
leads to longer service/oil change intervals
Extending the service/oil change interval from every 3 months to 6 months
Extending the life of the admission valve
From 6 months (mechanical admission valve) to over a year (ePCC)
Increases fuel savings
Reduced NOx emissions
3,388
3,151
0
500
1000
1500
2000
2500
3000
3500
4000
L7042GSI L7042GL
Fu
el C
on
su
mp
tio
n
(kW
)
Waukesha Rated Power Fuel Consumption
HOERBIGER CleenCOM: Fuel Consumption Reduction
-237
(7.0%)
Rich-to-Lean (R2L)
(Factory rich) (Factory lean)
HOERBIGER CleenCOM: NOx Reductions
22
1.5
0.40
5
10
15
20
25
L7042GSI L7042GL L7042GL
NOx(g/bhp-hr)
Waukesha Rated Power NOx EmissionsStandard Carb Setting (Best Economy) and 9.8% Exhaust O2
(Factory rich) (Factory lean) (CleenCOM ePCC)
Proposed Limit
3.0 g/bhp-hr (4.0 g/kW-hr)
Total ROI with HOERBIGER Technology and
Partnership with Cap-Op for GHG Credits
Parameter
Waukesha
L7042GSI2
(rich burn)
Waukesha
L7042GL2
CleenCOM
Reduction
Unit Savings/C
redits3 ($1000/yr) D D%
Fuel
Consumption 3388 2855 237 7.0% kW
$39000 ($21.5K-
56.5K)
GHG 7600 6407 1193 15.7% CO2E
tonnes/yr
$14000
($10-18K)
Service Events 4 2 2
50% events / yr
$2600 Downtime4,6 12 6 6 hrs / yr
Power
Cylinder
Events 3 1 2 67%
heads / yr
$17600 Downtime5,6 30 10 20 hrs / yr
1-Estimated according to CAPP Guide 2003 using $15-credit/tonne
2-OEM Waukesha L7042GSI performance ratings & L7042GL CleenCOM dyno data
3-Estimate from at-the-well-head price of $4.97 per Mcf (1000 ft3)
4-Estimated downtime of 3 hours per 2500 hr service
5-Estimated downtime of 10 hours per head/piston/liner swing.
6-Estimated with compressor output of 500 dam3/day (17.657 MMcf/day)
TOTAL $73200
Agenda
What is “Rich” and “Lean” burn combustion?
What is HOERBIGER CleenCOM?
Canadian Emissions Legislation Horizon
Alberta/BC Green House Gas Credits
HOERBIGER CleenCOM ROI
Future Work Power Upgrades via Cam and/or Turbo
Next Steps?
Wrap Up / Q & A
Product Technology Path to Efficiency & Performance
Time
Factory
Rich-to-
Lean Burn
Conversion
(RTL)
Factory
Rich
Burn
CleenCOM
Level 1
RTL
+
Electronic
Pre-Chamber
Combustion
Control
(ePCC)
CleenCOM
Level 2
RTL +
ePCC
+
Varispark1
1
2 3
4 5
CleenCOM Level 4
RTL + ePCC + PFI +
Varispark +
Engine Tuning
1-Varispark with CPU-95EVS
2-PFI: Port Fuel Injector
CleenCOM
Level 3
RTL + ePCC
+ Varispark
+ PFI2
HOERBIGER Engine R&D: Future Work
Power upgrade of L7042GL
L7042GL rated power is 1480hp
Target is to achieve 1700hp
Hoerbiger alternative to Waukesha L7044GSI Series 4
Involves a custom camshaft and turbo modification to reach higher horsepower
Increase power delivery per stroke.
Power cam needs to achieve 220hp (15%) increase.
Will also achieve regulated emissions (4.0 g/kW-hr)!
Agenda
What is “Rich” and “Lean” burn combustion?
What is HOERBIGER CleenCOM?
Canadian Emissions Legislation Horizon
Alberta/BC Green House Gas Credits
HOERBIGER CleenCOM ROI
Next Steps?
Wrap Up / Q & A
HOERBIGER’S CleenCOM Solution: Next Steps
Questions:
1. Any bad actor engines with frequent servicing and maintenance?
2. Do you know where your fleet emissions level is at? Any engines not NOx
compliant?
3. Any engines delivering the power that you need?
Questions?
Thank You!