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State-of-the-Art Technologies for
Stationary Natural Gas Engines
California ARICE Workshop, Sacramento
Research Director
Bryan Willson
July 10, 2001
NOx Emissions from Power
Generation Options
lb NOx / MW-hr
Typical mix of California gas-fired power plants 0.5
New natural gas peaking turbine 0.1 – 0.8
Existing Diesel Standby Generators 25 – 30
Diesel Engine w/ Best Available Control 7
Dual-fuel natural gas IC generator 1.0 -2.5
Current lean-burn natural gas engine 1.25
Advanced natural gas IC generator 0.7
DOE Advanced Natural Gas 0.07
2 Reciprocating Engine targets
CSU-EECL
The Role of Natural Gas
Engines
US: 8,000 slow speed natural gas engines produce over
60 billion kW-hr of power for natural gas transmission
each year
California: 2,5001-15,0003 medium-speed natural gas
engines
California: 2,6001-16,0002 medium-speed diesel engines
– could be converted to natural gas using dual-fuel
technology
1CARB Oct 2000 BACT/RACT proposal reports 2,596 diesel engines & 2,478 natural gas engines
2based on CARB Diesel Risk Reduction Plan, believed to be significantly low
3based on CARB Diesel Risk Plan inventory and April 2001 CARB BACT/RACT determination that there
were roughly equal numbers of stationary diesel and natural gas engines.
3
CSU-EECL
Outline
• Current gas engine research
• Prognosis for dual-fuel diesel / natural gas
engines
Presentation focuses on large bore natural gas
engines since this has been one of the most
active areas of gas engine research over past
decade
Significant application of large-bore work to
medium-speed engines
4
CSU-EECL
Large
Engines
at the
2-stroke lean burn gas engine
Cooper-Bessemer GMV-4 EECL 4-stroke lean burn gas engine
Waukesha 3521
4-stroke diesel engine 4-stroke rich burn gas engine
Caterpillar 3508 - uninstalled Superior 6G-825
US Natural Gas Pipeline
System
6
CSU-EECL
Typical 2-Stroke Gas
Compression Engine
7
CSU-EECL
Large Bore Engine Testbed
Funded by Pipeline Research
Council International & GTI
Research Focus
• Enhanced mixing
• NOx / HAPs research
• Advanced ignition systems
9
CSU-EECL
“Low Pressure”
Gas Admission
• Fuel injected late in
scavenging
/ early in compression
• Fuel injected at low
pressure
• Poor air/fuel mixture,
→ poor combustion
→ increased emissions
• High pressure injection
produces dramatic
reductions in NOx & fuel
10 consumption
CSU-EECL
Performance Comparison of
Low Pressure vs. High Pressure
BSFC (btu/bhp-hr)
Mechanical Low
Pressure Injection
High Pressure
Fuel Injection
B.S. NOx (g/bhp-hr)
Commercialization of High-Pressure
Fuel Injection Technology
Illustrates focus on rapid technology transfer
& commercial implementation
• Enginuity / Woodward Governor
• Hoerbiger / Altronic
• Louisiana Compressor & Maintenance
• Dresser-Rand
12
CSU-EECL
Enginuity / Woodward
HPFi System
Hoerbiger / Altronic HYPERfuel™ System
Solenoid valve
Gas Inlet
Poppet valve
pgas
pi
pcyl
LCM Medium Pressure
Fuel Injection System
Dresser-Rand
OptiJectTM Injector Insert
Current Research on
Enhanced Mixing
• Experimental studies in optical engine (world’s
largest) to study mixing & validate CFD models
• Computational fluid dynamics (CFD) to model
and optimizing mixing from fuel delivery systems
Current studies on large bore engines:
significant application to port-injected & single-
point medium-speed gas engines
17
CSU-EECL
CSU Optical Engine –
“World’s Largest”
Piston.MOV
18
CSU-EECL
Laser Induced Fluorescence:
Basic Test Setup
19
CSU-EECL
Low Pressure Animation
(EGAV)
Low Pressure
20
Animation.ppt
CSU-EECL
CFD Results
with PLIF
Validation
Current Research on
Natural Gas Engines
• Low-NOx combustion
• NO2 formation in low-NOx engines
• Precombustion chamber NOx formation
• Hazardous air pollutants (HAPs)
22
CSU-EECL
NO vs. NO2
10 1
Boost Map
9 SS Ignition, 0.9
EGAV
8 300 rpm, 440 bhp 0.8
NO or NO 2 (g/bhp-hr)
7 NO 0.7
NO2/NO Ratio
6 0.6
NO2/NO
5 0.5
4 0.4
3 0.3
2 0.2
1 NO2 0.1
0 0
5 7 9 11 13 15 17
23 Air Manifold Pressure ("Hg)
CSU-EECL
Prechamber NOx Study
24
CSU-EECL
HAPs Research:
Crank Angle Resolved
Formaldehyde Measurements
180
160 13.5" Hg Boost
Spark
(both cases) 7.5" Hg Boost
140
CH2O (ppm, raw)
120
100
80
60
40
20
0
-100 -50 0 50 100 150 200
25 Crank Angle (degrees relative to TDC)
CSU-EECL
HAPs Research
• Formaldehyde formation mechanisms
• Engine studies
• Mitigation studies
• Legislative support to EPA
• Catalyst studies
26
CSU-EECL
Ignition Studies
• Conventional ignition systems
• Micro-pilot ignition systems
• Advanced ignition systems
27
CSU-EECL
Ignition Studies:
Combustion Near Lean Limit
PV Diagrams IMEP
Stable Combustion Stable Combustion
28 PV Diagrams IMEP
CSU-EECLNear Lean Limit Near Lean Limit
Conventional Ignition Systems
“Great Ignition Shootout”
29
CSU-EECL
Micropilot Ignition for Gas
Pipeline Engines
• $1.7 million project sponsored by:
– DOE Natural Gas Infrastructure
Program
– Pipeline Research Council
International
– Gas Technology Institute
– Woodward Governor Company
• Application of micropilot ignition
to large bore gas engines
• Ignition quantity less than 1%
• Diesel fuel or crankcase oil
30
CSU-EECL
Advanced
Ignition Systems
Working with other groups to
facilitate advanced ignition
technologies:
• Advanced spark / projecting
plasma systems
• Laser ignition systems
Controls / Sensing /
Information Technology
Advanced Neural Network
Models for Predictive Online Engine:
Emissions Monitoring www.engr.colostate.edu/eecl/
California ARICE Program:
Research Needs
• Advanced natural gas engine concepts being
pursued through DOE Advanced Natural Gas
Reciprocating Engine program
• DOE funding university research on ignition &
friction reduction for advanced natural gas engines
• Precompetitive research needed on oxidation
catalysts & selective catalytic reduction (SCR)
systems for natural gas and diesel engines
• Significant research needs on dual-fuel engine
conversions to convert diesel engines to natural gas
operation
33
CSU-EECL
California ARICE Program
Dual-Fuel Emissions
20
Various systems
NOx, g/kW-h
& sources
15
10
5
0 ???
0 20 40 60 80 100
% Natural Gas Substitution
34
CSU-EECL
California ARICE Program:
Dual-Fuel Engines
• Dedicated dual-fuel systems for
new engine installations:
– Clean Air Partners / Caterpillar
– Westport / Cummins
• Retrofit dual-fuel systems for existing engines:
– No widely recognized general conversion systems
• Significant need for:
– Concept development for high quality electronic dual-fuel
systems
– System validation
– Demonstration / field studies
– Certification
Contact Information
Dr. Bryan Willson
Research Director
Engines & Energy Conversion Laboratory
Department of Mechanical Engineering
Colorado State University
Fort Collins, CO 80523-1374
Phone: (970) 490-1418
e-mail: bryan@engr.colostate.edu
Website: www.engr.colostate.edu/eecl/
