HOERBIGER CleenCOM Product Technologies Rich-to-Lean Burn Engine … · 2018. 7. 19. · 0 2 4 6 8...

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


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






Future Work

Next Steps?

Wrap Up / Q & A


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


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


> 1


> 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




Rosemount Flow Meter

Installed on engine before

CleenCOM is installed to

quantify fuel consumption.

Altronic DET-1600


Protection

EZ-Rail

Fuel Rail (>70psi)

Fuel Rail (>70psi)

EZ-Rail

ENGINE

Intake Manifold

Intake Manifold


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


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)




Altronic VariSpark

Ignition Control

Altronic DET-1600


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


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 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)


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






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




Alberta/BC Green House Gas Credits Engine pre/post audit requirements.

Additional required equipment?


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






Future Work

Next Steps?

Wrap Up / Q & A


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



Canadian Emissions Legislation Horizon



Future Work Power Upgrades via Cam and/or Turbo

Next Steps?

Wrap Up / Q & A


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



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



Canadian Emissions Legislation Horizon



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!

HOERBIGER CleenCOM Product Technologies Rich-to-Lean Burn Engine … · 2018. 7. 19. · 0 2 4 6 8...

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Transcript of HOERBIGER CleenCOM Product Technologies Rich-to-Lean Burn Engine … · 2018. 7. 19. · 0 2 4 6 8...