Limpiego del gas naturale liquefatto (GNL) nei trasporti stradali.

Normative, standard e tecnologie.

CONFERENZA GNL
Roma, 21 Gennaio 2014

Speaker:
Gabriele Masciali, Sales Manager

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

-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

since 1991

Company Headquarters

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: tomorrows
technology already available today

- 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

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.

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 (*)

d-gid Diesel Dual Fuel Layout

or LNG

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

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

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

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.

- 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

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

Volume Vs. Fuels Energy Content

DIESEL
1 Litre

CNG
5 Litres

NG Compressed at 220 bar

=
DIESEL

GNL/LNG
1,8 Litres

Liquid at -162C

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

First Italian Diesel Dual Fuel LNG Truck Retrofit

DAF FX 460 EURO5

Equipped with d-gid LNG

Diesel Dual Fuel System

Emission test made by

European Joint Research Centre
JRC in Ispra ITALY

Tested Vehicle:
DAF XF 460 EURO5

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 -162C 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 23 bar

LNG Heat
Exchanger

NG pressure
regulator
Input
Output 3 bar
NG press.
23 bar

NG injection

NG injection
NG press.
23 bar

- 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

Reach Stacker KALMAR DRF 450

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:

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.

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.

Cummins QMS11 Retrofit Data Comparison

400
350
300
250
200
150
100
50
0

Oil Temperature

Originale
Dual Fuel

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]

Exhaust Temperature
xhaust Temperature [C]

Oil Temperature [C]

Power [Hp]

Power

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]

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

Dual Fuel

80

Consumo Metno [kg/h]

Natural Gas Consumption (Metano)

Thank You