The effect of Exhaust Gas Recirculation (EGR) on the ...
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The effect of Exhaust Gas Recirculation (EGR) on the emission from a lean-burner gas engine
Projektrapport
March, 1998
Dansk Gasteknisk Center a/s • D r. Neergaards Vej SB • 2970 Hørsholm • Tlf. 2016 9600 • Fax 4516 1199 • www.dgc.dk • [email protected]
The effect of Exhaust Gas Recirculation (EGR) on the emission from a lean-bum gas engine
Per Pedersen
Danish Gas Technology Centre a/s Hørsholm 1998
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The effect o f Exhaust Gas Recirculation (EGR) o n the emission from a lean-bum gas en gine
Project Report
Per Pedersen
March 1998
Danish Gas Technology Centre a/s
717.65; H:\ 717\65\rapport\EGR report.doc
Experimental methods for reduction of emission from gas engines
87-7795-130-1
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This English translation is providedfor convenience only and in case of discrepancy the Danish wording shall be
applicable.
July 1997
DGC-report 1
Table of Contents Page
l Introduetion .... .............................. .............. ... ..... ... ........................ ......... ........................... ....... .... 2
2 Summary .. ... .... ... .... ..................... ..... .. ......................................... .......... ..................... ... .. ... .. ... ..... 3
3 En gine, generator and contro l unit ............................................... .... .. ........ ..... ............................. 5
3.1 Engine ...................................... ... ...... ....... .... ............................... ....... .. ............................. ..... 5
3.2 Generator ................................. ..... ... ...... .. ...... .......................... ... ............ ......... ...... ..... .... ... .... 6
3.3 Control unit .............................. ........................................................ .. ......... ... .. ........ ... ........... 6
3.4 Operation ......................................................... ............. ... ................ ..................... ... .............. 7
4 Meters, analysers and data acquisition .... ... .. ..... ........................................................................... 8
4.1 Uncertainty ....................................... ............................................................................ ......... 8
5 Planning the experiments . . .. .. . .. . .. .. .. .. .. . .. .. .. .. .. .. .. . .. .. .. . .. .. . .. .. .. .. .. . .. .. .. . .. . .. .. .. . .. .. .. . .. .. .. . . . . . . . .. .. .. . .. .. l O
5 .l Range o f parameters .. .. .. .. .. .. .. . .. .. .. .. . .. .. .. .. .. .. .. . .. .. .. . .. .. .. .. .. . . .. . .. .. .. . .. . . . .. .. . .. . . . . .. . .. . .. . .. .. .. .. . . .. . .. l O
5.2 Succession of measurements ....................................... ................................. .............. .. ....... lO
6 Measurements ........................................................ .. .... ...... ..... ... .... .. ...... ...... .............. ....... ....... .. 12
6.1 Ignition timing and air/fuel ratio without EGR .................................................................. . 12
6.2 Measurements with EGR ....... ... ....................................................................................... .... 15
7 Closing remarks ..... ..................................... .... .................. ... ...... .. ...... ........ ... ..... ............ .......... .. 18
Appendix ....... ... ........ ... .. ..... ............ .... .......... .. ............. ...... ........... ....... .......... .............................. .. 19
Analysers .... ................ .................. ... ..... .. .. ..... ... ... ......... ........... ......... ...... ....... ................... ............. 19
Oz ............ ............................ ...... .. ....... ........... .................................................................... ........ . 19
NOx········· ·························· ············ ················· ····· ······ ············································ ············ ···· ····· 19 co ........ .................................. .. ..... .............................................. .. ........ ..................................... I9
THC .... ....... ........... ... .... .......... .. ............................................................................. ............. ........ 20
COz .... .......... ... ......... ..... ..... .. .... .. .. ..................... .............. .. ........ ... ...... .... .... ...... ... ... .............. ..... . 20
Literature .......... .. ....... ...... ............. .............. .......................................................... ..... .......... .... ...... 21
DGC-report 2
1 Introduetion
In recent years, attention has been focused on the emission of unbumed hy
drocarbons in the exhaust gases from natura} gas engines. The stationary gas
engines instaHed in Denmarkare almost exclusively operatedasparts of co
generation plants. The composition of unburned hydrocarbons is dominated
by methane, which is a greenhouse gas.
Emission of total unbumed hydrocarbons (THC) can be caused by many
factors, such as crevice volumes in the combustion chamber and overlapping
valves. Another factor is the mixture completeness. Running an engine on a
Iean mixture is an effective way of reducing nitric oxides in the exhaust
gases. The combustion temperature becomes lower leading to lower forma
tion of nitric oxides (Zeldovich). Unfortunately, running anengine on a Iean
mixture has often an adverse effect on the emission of unburned hydrocar
bons.
Several solutions such as catalysts and improved combustion are presently
being investigated. This project investigates the effect of using exhaust gas
recirculated to the air intake as replacement for air excess.
The work has been sponsored by the Danish gas companies and carried out
at the labaratory at Danish Gas Technology Centre a/s (DGC). Q/A on this
report was done by Brian Schmidt, DGC.
Hørsholm, March 1998
h J~' f Per Pedersen
Project Manager
Dept. of Gas Utilization
Bjarne Spiegelhauer
Viee-President
Dept. of Gas Utilization
DGC-report 3
Purpose
Results
2 Summary
Exhaust gas recirculation (EGR) is a well known method of centrolling
emission of nitric oxides from engines. It w as used on petrol engines befare
introduetion of the three-way catalyst. Recently, it has been re-introduced in
cernbination with the three way catalysts.
On automotive petrol engines smaller rates of EGR are utilised.
When larger rates of EGR are applied, it is known from various sources in
the literature - e.g. /2/ and /3/- that the THC content in exhaust gases in
creases, and, eventually, severe misfires occur at about 30% EGR. In this
project, only smaller EGR-rates were investigated.
The project should demoostrate an indirect effect of EGR on the conten t of
total unburned hydrocarbons (THC) in the exhaust gases from a lean-bum
natura! gas engine.
When running a specific engine on lower air excess (without EGR), it is
known that the THC content in the exhaust gases is aften lower compared to
the THC content when running the engine on higher air excess. On the other
hand, nitric oxides will increase rapidly at decreased air excess. The forma
tion of nitric oxides can be suppressed by the use of EG R.
A small rate of EGR has littie effect on the emission of THC according to
the literature. The indirect effect of replacing air excess with EGR should
thus be a reduction of the emission of THC.
The tests showed that a small amount of about l% (EGR) reduces the nitric
oxides signifieand y, with n o detectable undesired effect on fuel consump
ti an or THC emission. This is the case for gas engines running moderately
lean (max. 50% air excess), and EGR can thus be recommended for these
engines. It lowers the conten t of nitric oxides, or the engine can be operated
on a richer mixture leading to reduced THC emission.
On engines running on ultra lean mixtures, EGR has littie effect, mostly
disadvantages.
The experiments reported here were carried out on a supercharged natura!
gas lean-bum engine instaBed in the labaratory at DGC. The engine has
been built into a mini co-generation unit comprising control unit, asynchro
nous generator and heat exchanger. Emission characteristics have been re
ported in an earlier project repart Il/.
DGC-report
Results without
EGR
Results with
EGR
4
The engine has since then been modified. Forthis reason, the emission char
acteristics were re-investigated prior to the EGR experiments.
The emission of both NOx and unburned hydrocarbons is much lower com
pared to the earlier engine layout. On the other hand, the emission of carbon
monoxide has increased and an oxidation catalyst is required in order to
fulfil the Danish legislation for CO 15/.
From samples of exhaust gases taken just after the exhaust manifold and
samples taken after the turbocharger, it was noted, that unburned bydroear
bons were oxidised in the exhaust system. The effect is pronounced at low
air excess (A~ 1.5) and retarded ignition timing. With increased air excess,
the effect becomes negligible.
Hydrocarbonsis decomposed into carbon monoxide which oxidises further
to C02, but the last step takes place at a slower rate. Thus more CO is ob
served in the exhaust gases after passage of the hottest part of the exhaust
system.
A small amount of cooled and dried exhaust gasses was feed back to the
induction system, after the carburettor at the suction side of the turbo
charger. The amount was measured to be in the range of l% of the volume
of air consumed. This yielded almost 20% reduction in nitric oxides.
The results are similar to other EGR experiments on lean-bum engines re
ported in the literature, but here the results are based on larger EGR rates.
See e.g. 121 and /3/.
DGC-report 5
3 Engine, generator and control unit
The complete unit comprising engine, generator and control unit has been
designed as part of a masters thesis by two students at the Copenhagen
Technical College. The work was done in co-operation with a company
manufacturing small co-generation units. The work was sponsored by the
Danish gas companies, and DGC carried out measurements of emission and
efficiency.
After the masters thesis, the unit was moved to DGC and installed.
3.1 Engine
The engine is a former Ford diesel engine converted by Power Torque for
natural gas operation under the designation SI4. It is a four-cylinder, four
litre dispiacement engine.
The engine was not built for lean-bum operation, therefore some modifica
tion has been made. In order to secure ignition and to maintain high power
output at a lean mixture, the ignition system has been changed and a turbo
charger has been added.
The gas is mixed with air in an Impco gas carburettor. Mixture adjustment
c an be carried out manually, w hil e the engine is running. The throttle is op
erated by a servo motor and a position sensor for remote control. After the
carburettor, the mixture is compressedin the turbocharger. After compres
sion the mixture is cool ed in an intercooler (Mermaid type 4) to about 30-
400C.
The turbocharger is a Garret type T2 with waste-gate. The waste-gate allows
for manual adjustments of charge pressure, which makes it possible to
maintain the same power output at higher air excess.
Between the exhaust manifold and the turbocharger a reactor has been
added. It consists o f a l o o conical expansion from the manifolds, Ø 50 inter
nal diameter on the flange up to 0129. Tubes of this diameter extends for
c a. l, 17 m through two rounded bendings, directing i t to the turbocharger.
Anether l o o con e contracts the diameter to match the turbochargers turbine
inlets. All pipes, cones and flanges are made of stainless steel.
DGC-report 6
The reactor was added as part of another project investigating the effect of
adding a strong oxidising agent to the exhaust gases. Both the manifold and
the reactor are insulated in order topreserve a high temperature in the ex
haust gases and to avoid radiant heat. It soon turned out, that the reactor was
active by itself, oxidising more or less unburned hydrocarbon.
The original ignition system has been replaced by a Motortech IQ250 ca
pacitive discharge ignition system. The ignition timing varies with engine
RPM after a linear relation. The setting can be manually adjusted or re
motely controlled (not used). The selected spark plugs were Champion R.L.
85.G recommended by Power Torque.
The progress of combustion was briefly monitored by means of a Kistier
spark plug with pressure transducer. No signs of knock were ever detected,
regardless of operating conditions.
3.2 Generator
The engine is coupled to an asynchronous generator with a nominalload of
37 kW. The electricity generatedis disposed off by feeding it into the main
electricity supply.
3.3 Control unit
The engine and the generator is controlled by a PLC which takes care of
important operation and monitering tasks, such as starting the engine (using
the original starter motor), running the engine at idle for a few minutes be
fore increasing the speed slowly to slightly above 1500 RPM. When the en
gine has reached this speed, the generator is coupled online. Then the power
is increased slowly until output power reaches 37 kW. The PLC program
then maintains this load, while monitering coolant temperature and lubrica
tion oil pressure during operation. If certain limits are reached, shut-down is
automatically initiated. At normal shut-down procedure, the load is slowly
reduced to O kW, then the generator is de-coupled and the enginespeed is
slowly reduced to idle speed, at which the engine is kept running for five
minutes in order to cool the turbocharger before stopping. Other conditions
will cause emergency shut-down.
DGC-report 7
The engine and the generator are encJosed in a noise-insulation housing. A
door at one end o f tbe hou ing provides access to the en gine. At the opposite
side of the housing, the control unit is placed. The conu·oJ unit has two
witches, a knob and an emergency stop button. A small display indicates
the engineload at normaJ operation. At error conditions, the display indi
eates the error, e.g. missing oiJ pressure.
3.4 Operation
When normal engine load has been reached, the operator can manually over
ride the part of the PLC-program centrolling the engine load, by turning a
switch into the MANUAL position and then, by turning a knob, either de
crease or increase load until full throttle. Befare shutting down the engine,
the switch must be turned back into the AUTO position. Then the first
switch can be turned into the STOP position, and the shut-down procedure
starts. An emergency stop button is placed in the centre of the front panel.
All experiments were carried out in the MANUAL position, and the power
output was adjusted to 35 kW in every measurement.
DGC-report 8
4 Meters, analysers and data acquisition
During installation in the labaratory at DGC, the engine has been equipped
with a number of sensors and meters connected to a data acquisition system.
The sensors and meters are shown in Pigure l.
A number of measured values are instantly processed and shown on the dis
play. This is the case for actual 0 2 and C02 in the exhaust gases and emis
sion of NOx (NO and N02), CO and THC. Purther values shown are fuel
consumption, power and heat produetion and the efficiency of electricity
production. The acquisition system scans all chanoels at an interval of two
seconds. Measured and calculated values are stored in files.
Values of ignition timing must be read using a stroboscope and noted manu
ally.
Intet manifold- pressure and temperature
Spark plug No l replaced by a Kistier spark plu whh pressure transducer
lntercooler
Temperature ol lubrtcation oll
Fuel - pressure and temperature Volume flow olluel
Temperature ol exhaust gases belore and alter turbocharger
Generator
F i g ure l: Location of the various meters and sensors
4.1 Uncertainty
The various meters and analysers contribute to the overall uncertainty on the
resulting values o f emission and efficiency. The foliowing tab le lists the
tolerance of the meters.
DGC-report 9
Min. Max. Values during Tolerance
experiments
Gas meter 1 m"/h 16 m~/h 10 m"/h ±1%.
Flow meter 0,05 m"/h 2,5 m"/h O, 1 m"/h ±3%. coolant flow
Electricity O kW 50 kW 35 kW ±0,5%
Pressure O bar 1 bar 0,3 bar ±0,6 hPa
manifold and gas
Barometer O bar 2 bar 1013 hPa ±0,5 hPa at 1 bar
Temperature 100°C 1100°C 680°C (exhaust) ±3,?DC at soooc NiCr/Ni Al
Temperature ooc 400°C 20°C (gas) ±0,3°C Pt 100 35°C (intake
manifold)
The gas analysers (Appendix l) were calibrated each day using test gases of
±2% relative uncertainty on the concentration. Prior to each measurement,
the analysers' ranges were c hanged if necessary, and se al e factors in the data
acquisition program were c hanged accordingly.
Analyser Measure d Relative uncertainty [%]
02 5,5 vol% ±4,7
co2 8vol% ±2,7
CO 1000 ppm ±3,5
NO x 700 ppm ±4,0
THC 150 ppm ±2,7
DGC-report 1 O
5 Planning the experiments
Previously, many measurements on stationary engineshave been carried out
maintaining certain conditions and then varied e.g. load, air excess, speed or
EG R.
In the literature these conditions are abbreviated as e.g.
WOT Wide Open Throttle
BPSA Best Performance Spark Advance
MBT Minimum advance for Best Torque
W e decided to carry out the measurements at a fixed load of 35 kW at vari
ous values of ignition timing and air excess. First, we measured without
EGR in a wide range of air excess and a more confined range of ignition
timing. The EGR w as applied and som e measurements (at lo w air excess)
were repeated.
5.1 Range of parameters
According to the manual, the SI4 engine should be running at an ignition
timing at of 17° BTDC, when running on rich mixture. A lean mixture bums
at a slower rate, so higher ignition timings were considered to be of interest.
The various experimental set points were selected as 18, 20, 22 and some at
24°BTDC.
From earlier measurements it was found that a compromise between NOx
and CO was found at 50% air excess, A= 1,5. A range of A from 1,3 to 1,8
was selected.
Measurements with EGR were only carried out at the lowest air excess ra
tios.
5.2 Succession of measurements
Ideally, the measurements should be situated equidistantly within a matrix.
For elimination of systematic errors, the succession should be in random
order.
DGC-report
In practice, it is rather time consuming to ad just air/fueJ ratio and subse
quently engine power. Therefore, some rneasurements were carried out in
systematic succession. At fixed air/fuel ratio, the ignition timing, wbich is
much easier to handle, and subsequently engine power, were adjusted.
11
DGC-report 12
6 Measurements
Bach measurement takes approx. an hour. First, the engine is adjusted. Then
after a while, the engine has settled and the analysers read out more or Jess
constant values. Final adjustments of power output and air/fuel ratio must
then be carried out. After a while, the engine has settled again. Then the
actual measurements can take place. This willlast about 10 minutes. The
acquisition system scans all channels at a two-second interval, until 500
rows of data have been collected, then the program stops.
At constant load, a large amount of measurements w as carried out within in
a matrix of air/fuel ratio and ignition timing as deseribed in section 5.1.
Measurements were carried out at both the manifold and in the stack.
6.1 lgnition timing and air/fuel ratio without EGR
The ignition timing compensates for the burning velocity: if the engine runs
slowly, the charge maybeable to bum completely at a given ignition setting.
When the enginespeed is increased, the ignition must be advanced in arder
to allow the charge to be burned befare the exhaust stroke starts. Further
more, the burning velacity is dependant on the air/fuel ratio. Atleaner mix
tures, the charge bums at a slower rate. Finally, the flame paths and com
bustion rates vary with the combustion chamber design and dimensions.
lgnition timing (the time when the spark is fired) is defined as degrees of
crank angle befare top dead centre (0 BTDC).
DG C-repart
ppm
21
lgnition timing [0 BTDC]
18 5
ppm
02 [vol %]
Pigure 2: CO measuredin samples taken in the exhaust manifold
ppm
lgnition timing [ 0 BTDC] 02 [vol %]
18 5
ppm
Pigure 3: NOx measuredin samples taken in the exhaust manifold
13
DGC-report
THC [ppm]
. . ~. . . . - ~
• • - l . . ·,
lgnition ["BTDC]
THC [ppm]
Oxygen [val%]
18 5
Pigure 4: THC measured in samples taken in both the exhaust manifold and in the stack
14
By looking at Figure 3 and Figure 4 it can be seen that when running at low
air excess, the engine produces unacceptable high levels of nitric oxides,
while the level of unburned is very low, especially in the stack. If nitric ex
ides could be reduced without affecting the level of THC, the engine could
be run at lower air excess. This would yield an indirect effect of reducing
THC.
The particular engine used for the experiments hereis scrnewhat special, as
it has a large highly insulated volume just after the exhaust manifold - the
"reactor". The volume is about four times the swept v o l urne of the engine. It
is known from literature /4/, that hydrocarbon can be burned in the exhaust
at temperatures above 650°C and at relatively long residence time. As the
exhaust temperature from the engine used for this project reaches 680°C,
when the reactor is effective, some of the hydrocarbon will be oxidised,
which appears from the measurements shown in Figure 4. There may be
more complex reactions and this is being studied in anether project at DGC.
For commercial engines, a level of THC corresponding to the level marked
"Manifold" in Figure 4, or slightly lower, can be expected.
DGC-report 15
The level of carbon monoxides (see Pigure 2) is high, and as mentianed ear
lier, there iseven more when measuredin the stack, due to the reactor. This
is no problem, as oxidation catalysts are effective in removing carbon mon
oxide.
6.2 Measurements with EGR
If Pigure 4 is viewed from the right side, it willlook as follows:
10000
1000 e c.
.E!; 100 o :t:
• ; .. ~ ~ 1-
10 • 5 6
... .. ~ ... ~
....
7 8
0 2 [vol%]
, •
9 10 11
• THC without EGA
Figure 5: THC versus 0 2 in exhaust gases. As many different ignition timings are represented, the data is sarnewhat scattered.
It is seen that a significant increase in THC eecurs at increased air excess.
It was decided to apply EGR at air excess corresponding to 5.5% 0 2.
Exhaust gas was lead though a coil providing cooling to at bottle calleeting
condensed water. The dry gas was measuredin a flowmeter with a full scale
of 65 litre/minute.
Measurements were then carried out at several ignition timings, and the rate
of recirculated gas w as kept constant at l% based on valurnes at normal
condition.
DGC-report
1000
900
e Q. 800 B d 700 z
600
500
>.
5.50 5.52 5.54 5.56 5.58 5.60
Figure 6: 18° BTDC
1000
900
'[ 800 ~ d 700 z
600
500
• o
0 2 [vol%]
• .....
+ NOx w ithout EGA
o NOx w ith EGA
• NOx w ithout EGA.
o NOx with EGA
5.40 5.45 5.50 5.55 5.60 5.65 5.70
0 2 [volo/o]
Pigure 7: 20° BTDC
16
DGC-report
1300 1250 • 1200
E 1150
c. 1100 ~ 1050 & 1000 z 950
900 850 800
5.45
Figure 8: 22° BTDC
1400
1300
E c. S: 1200 )(
o z 1100
1000 5.45
Figure 9: 24° BTDC
6 ...,
5.50
0 2 [vol%]
~ •
o
5.50
0 2 [vel%]
5.55 5.60
5.55 5.60
• NOx w ~hout EGA
<> NOx w ~h EGA
+ NOx without EGA
<> NOx wilh EGA
The figures show reductions in the range of 15 to 20% of nitric oxides.
17
No direct effect of EGR on THC was seen. No detectable difference in fuel
consumption or electrical efficiency between load with or without EGR w as
observed. It is assumed, however, that the electrical efficiency will decrease
at increased EGR and maintained 0 2 content in the exhaust gas.
DGC-report 18
7 Closing remarks
During the experiments, it became clear that the rate of EGR should be de
termined by other means than a flowmeter. When using flowmeters, the ex
haust gases should by dried. Otherwise, the flowmeter becomes fouled by
condensate. A better way is to measure C02 both in exhaust gases and in
combustion air after mixing.
W e did not achieve levels of nitric oxides fulfilling the Danish legisla-
tion /5/. To do so requires higher rates of EGR and slightly higher air excess.
Our best guess is to run the particular engine at 6% 02 and to increase the
EGR rate to 5-7%. Unfortunately, there was no time to verify this.
More literature on EGR has been published since this project was initiated.
It is well documented in the literature, that a reduction of nitric oxides of
50% can be achieved by using EGR rate of about 7%. There is reported no
significant increase in THC emission at this level /2/. EGR has littie effect
on engines running on very lean mixtures, due to smaller contents of water
vapour and C02•
Finally, attention should be paid to cerrosion and wear problems w hen es
tablishing EGR on commercial natural gas engines. Water vapours condense
in the pipe leading exhaust gases to the inlet. Droplets could damage the
turbo charger and if materiais such as copper are used for EGR pipes, corro
sion could present a problem to the engine.
DGC-report 19
Appendix
Analysers
The sample of flue gas was cooled, filtered and dried in an air conditioner
before being fed into the analysers.
The instruments arelabelled (DGC No.) and a log is kept for each instru
ment.
The analysers w e re calibrated every da y using test gases o f ±2 o/o relative
uncertainty. The test gases used were the following. The bottles oftest gases
are replaced minimum each year.
Manufacture
Type
Range
Accuracy
DGC-no.
Manufacture
Type
Range
Reproducibility
Lineari ty
DGC-no.
CO
Manufacture
Type
Range
Reproducibility
Servemax
572 - paramagnetic
O- 25 vol. o/o
± 0.1 vol. o/o
201
Thermo Environmental Instruments Ine.
lOA/R
from O- 2.5 to to O- 10.000 ppm
l o/o of full scale
±l%
302
Hartmann & Braun AG
Uras 3 G
from O- 200 to O- 2.000 ppm
~ 0.5% of full scale
DGC-report
l Linearily
DGC-no.
THC
Man u faeture
Type
Range
Accuracy
DGC-no.
Man uf aeture
Type
Range
Reproducibility
Lineari ty
DGC-no.
20
±l %1 402
Analysis Automation Ltd.
523
from O- 2.5 ppm to O- 10.000 ppm
± l vol. % o f range
601
Hartmann & Braun AG
Uras 3K
O - l O and O - 20 vol. %
::::; 0.5% of full scale
::::;±1%
501
DGC-report
Uterature
Pedersen P.: Measurements of emission from a lean-burn gas engine. Hørsholm: Danisb Gastechnology Centre, 1997.
2 Raine, R.,R.; Zhang, G.; Pflug A.: Comparison of Emissions from Natural Gas and Gasoline Fuelled Engines. SAE paper 970743, 1997.
21
3 Johansen, Bengt; Docekal, Daniel: Effekt av A., EGR ocb tandvinkel på emissioner och virkningsgrad i en konverterad naturgasmotor. Lund: Lunds Tekniske Højskole, 1995.
4 J., B., Heywood: lnternal Combustion Engine Fundamentals. McGrawHill International, 1988.
5 Miljøstyrelsen: "Bekendtgørelse om kvælstofilteforurening mv. fra gasmotorer og -turbiner", bekendtgørelse nr. 688 af 15/10-1990