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CarEcology: New Technological and Ecological Standards in Automotive Engineering Green Fuels The use of the gas fuels CNG, LNG and LPG as alternative automotive fuels Merkouris Gogos Technological Educational Institute of Thessaloniki Department of Vehicles Antwerp, October 2009

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2 Alternative fuels CarEcology: New Technological and Ecological Standards in Automotive Engineering Antwerp, October 2009 The term alternative fuel is used to describe any fuel suggested for use in transportation vehicles other than petrol or Diesel fuel. The EU has set the objective of a 10% substitution of traditional fuels in the road transport sector by alternative fuels before the year 2020. Alternative fuels include biofuels (eg. bioethanol, biogas, biodiesel), natural gas, hydrogen, methanol, liquefied petroleum gas (LPG) and gas-to-liquids (GTL). Not to be confused with renewable sources or biofuels.

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3 Consumption of Solid, Liquid and Gas Fuels CarEcology: New Technological and Ecological Standards in Automotive Engineering Antwerp, October 2009 R.Hefner III Actual and projected consumption of fuels

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4 Gas Fuels CarEcology: New Technological and Ecological Standards in Automotive Engineering Antwerp, October 2009 Three alternative gas fuels will be discussed in this lecture: Compressed Natural Gas (CNG) Liquefied Natural Gas (LNG) Liquefied Petroleum Gas (LPG) Although not green, these fuels are certainly greener than traditional Diesel or petrol.

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5 CarEcology: New Technological and Ecological Standards in Automotive Engineering Antwerp, October 2009 History of Gas fuelled vehicles: The early days World War I A bus powered by coal gas on Waverley Bridge, Edinburgh, during World War I Petrol shortage compelled this war- time improvisation - a 'gas-bag' omnibus with Lothian chassis operated by Scottish Motor Traction Company, 1914-18 www.edinphoto.org.uk

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6 CarEcology: New Technological and Ecological Standards in Automotive Engineering Antwerp, October 2009 Early Natural Gas Vehicles used low pressure natural gas stored in bladders Circa 1930 NREL/CD-540-37146 History of Gas fuelled vehicles: The early days

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7 CarEcology: New Technological and Ecological Standards in Automotive Engineering Antwerp, October 2009 Tempi s.p.a. Top: This Citron bus was the first one modified by the Alberto Laviosa workshop of Piacenza, Italy to run on methane gas. In 1935, it was test-driven on the line Piacenza - Rivergaro. Bottom: in September 1936, this Alfa Romeo 350 bus, fuelled by methane gas, won the Italian National race in five stages Tempi s.p.a. History of Gas fuelled vehicles: The early days

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8 CarEcology: New Technological and Ecological Standards in Automotive Engineering Antwerp, October 2009 Popular Science (April, 1940) blog.modernmechanix.com History of Gas fuelled vehicles: WW II

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9 CarEcology: New Technological and Ecological Standards in Automotive Engineering Antwerp, October 2009 Traction avant Citron fonctionnant au gaz de ville*, Paris, Octobre 1941 *Town Gas: mixture of H 2, CO, CH 4 and impurities (CO 2, N 2 and other) About half the energy content of methane. LAPI / Roger-Violle History of Gas fuelled vehicles: WW II

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10 CarEcology: New Technological and Ecological Standards in Automotive Engineering Antwerp, October 2009 The energy shortages during World War II made NGVs popular in Europe. Advancements in compressor technology allowed the use of higher pressure steel cylinders on the roof of this Citron sedan. History of Gas fuelled vehicles: WW II

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11 CarEcology: New Technological and Ecological Standards in Automotive Engineering Antwerp, October 2009 Le Gazogne

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12 Alternative Gas Fuels CarEcology: New Technological and Ecological Standards in Automotive Engineering Antwerp, October 2009 Today the alternative gas fuelled engines can be modified or retrofitted engines that were originally designed for petrol or Diesel fuelling. They are, therefore not the optimum design for the other fuels. However, various operational requirements for retrofitted engines need to be taken into account: The different combustion characteristics of alternative fuels require a change in the injection and ignition timing. Many alternative fuels, especially those in gaseous form, have low lubrication, causing increased wear of fuel components such as fuel injectors and valves.

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13 Energy consumption in road transportation CarEcology: New Technological and Ecological Standards in Automotive Engineering Antwerp, October 2009 European Communities, 2008 LPG 1.5% CNG 0.2% (2005 shares)

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14 CarEcology: New Technological and Ecological Standards in Automotive Engineering Antwerp, October 2009 Natural Gas Natural gas is found underground where it was formed millions of years ago from organic matter. Tremendous pressure from the overlying rock, combined with the earth's heat, converted the matter into a gaseous fossil fuel trapped under layers of solid rock. It is an organic compound made up of hydrogen and carbon and is usually referred to as a hydrocarbon. It is often produced in association with production of crude oil. However, wells are also drilled for the express purpose of producing natural gas.

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15 Fuel prices in Europe (1/2) CarEcology: New Technological and Ecological Standards in Automotive Engineering Antwerp, October 2009 Gas Vehicles Report, Sep 2009 Data updates Dec 2008 - July 2009 Country Premium Petrol (/litre) Regular Petrol (/litre) Diesel (/litre) CNG (/Nm) CNG price per litre petrol CNG price per litre Diesel Armenia0.790.730.710.270.240.28 Austria1.061.051.040.890.800.91 Belarus0.690.55 0.270.240.28 Belgium1.281.260.990.610.550.63 Bosnia-Herzegovina0.810.640.740.250.220.26 Bulgaria0.920.860.870.550.520.59 Croatia0.840.830.860.330.300.34 Czech Republic1.241.280.640.570.66 Finland1.461.421.200.780.700.80 France1.481.371.150.640.570.66 Germany1.421.221.330.700.540.72 Iceland1.471.391.410.900.810.92 Italy1.481.391.340.680.640.71 Latvia0.790.820.230.210.24 Liechtenstein1.081.011.100.530.460.50

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16 CarEcology: New Technological and Ecological Standards in Automotive Engineering Antwerp, October 2009 Data updates Dec 2008 - July 2009 Country Premium Petrol (/litre) Regular Petrol (/litre) Diesel (/litre) CNG (/Nm) CNG price per litre petrol CNG price per litre Diesel Lithuania1.091.070.970.650.580.67 Luxembourg1.081.060.870.530.470.54 Moldova0.500.430.180.160.18 Netherlands1.351.280.990.530.470.54 Norway1.481.431.320.460.410.47 Poland1.081.150.910.510.460.52 Portugal1.131.071.010.550.490.56 Russia0.800.690.700.220.200.23 Serbia0.940.840.660.590.68 Slovakia1.021.011.060.760.680.78 Spain0.970.870.900.570.440.49 Sweden1.011.021.010.800.90 Switzerland0.950.921.090.860.750.82 Turkey1.701.601.260.780.680.76 United Kingdom1.041.001.160.710.630.73 Fuel prices in Europe (2/2) Gas Vehicles Report, Sep 2009

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17 Transportation of Natural Gas CarEcology: New Technological and Ecological Standards in Automotive Engineering Antwerp, October 2009 Pipelines are convenient and economical for onshore transport of natural gas. Offshore, as the water depth and distance increase, pipeline transport of gas becomes difficult. LNG for offshore transport of gas. LNG is liquid at -162 C and atmospheric pressure, transported in specially designed ships. 40% of the trade movement of natural gas in 2008 was as LNG (BP Statistical Review, 2009).

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18 LNG Tanker CarEcology: New Technological and Ecological Standards in Automotive Engineering Antwerp, October 2009

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19 Projected routes of natural gas pipelines CarEcology: New Technological and Ecological Standards in Automotive Engineering Antwerp, October 2009 NORTH STREAM: Russia - EU (via Baltic sea) Capacity: 55 billion m 3 /year Scheduled for operation: First line:2011 Second line: 2012 SOUTH STREAM: Russia - EU (via Black sea) Capacity: 63 billion m 3 /year Scheduled for operation: End of 2015 NABUCCO: Caspian region - EU Capacity: 31 billion m 3 /year Scheduled for operation: End of 2015 www.energy.eu

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20 Pipeline Natural Gas composition CarEcology: New Technological and Ecological Standards in Automotive Engineering Antwerp, October 2009 Methane 85 - 95% In the ground, natural gas contains a wide range of compounds. During well-head cleaning and processing, gas quality is improved to pipeline standards. Gas in the pipeline has a range of acceptable compositions. Typical pipeline gas would be as shown. NREL/CD-540-37146

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21 Natural Gas Properties CarEcology: New Technological and Ecological Standards in Automotive Engineering Antwerp, October 2009 Main component is methane CH 4 Lighter than air (specific gravity 0.55 to 0.65) Tasteless and odourless. Odorant is added for safety Non-toxic Simple asphyxiant gas (ie. displaces oxygen from the air) Flammable in concentrations of 5% to 15% by volume in air Not a liquid when compressed (it just becomes very dense) Boiling point -162 C. Above this temperature it is gaseous

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22 Advantages of Natural Gas (1/2) CarEcology: New Technological and Ecological Standards in Automotive Engineering Antwerp, October 2009 Nearly zero sulphur level and, thus, negligible sulphate emissions Very low particulate emissions because of low carbon-to- hydrogen ratio Due to its low carbon-to-hydrogen ratio, it produces less carbon dioxide than either gasoline or diesel Low cold start emissions due to its gaseous state Superior anti-knock properties due to its very high Octane number, thus allowing higher compression ratios and operation under turbocharged conditions Very low summer smog potential Negligible evaporative emissions

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23 Advantages of Natural Gas (2/2) CarEcology: New Technological and Ecological Standards in Automotive Engineering Antwerp, October 2009 Lower adiabatic flame temperature than conventional fuels, leading to lower NOx emissions Higher calorific value than petrol on a mass basis Much higher ignition temperature than petrol and diesel, making it more difficult to auto-ignite, thus it is safer Does not contain toxic components Much lighter than air and thus it is safer Methane is not a volatile organic compound (VOC) Engines fuelled with natural gas in heavy-duty vehicles offer more quiet operation than equivalent diesel engines, making them more suitable for use in urban areas Stable combustion at leaner mixtures due to its extended flammability limits

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24 Disadvantages of Natural Gas (1/2) CarEcology: New Technological and Ecological Standards in Automotive Engineering Antwerp, October 2009 Transportation of natural gas on board a vehicle is complicated; it can be stored as compressed gas at 200 bar or as a liquid at -162C and 2-6 bar pressure It requires dedicated catalysts with high loading of active catalytic components to maximise methane oxidation Its composition varies widely between countries and between cities, depending on the gas origin, which affects the stoichiometric air/fuel ratio Limited driving range because its energy content per unit volume is relatively low as a result of its gaseous state The energy required for the compression of natural gas leads to 4% more CO 2 emitted by the car It requires special refuelling stations

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25 Disadvantages of Natural Gas (2/2) CarEcology: New Technological and Ecological Standards in Automotive Engineering Antwerp, October 2009 Longer refuelling time than petrol or diesel Increased consumption due to a heavier fuel tank Lower burning rate compared to petrol due to lower laminar flame speed Injection of natural gas into the port at low pressure and directly into the cylinder at high pressure requires modified and special injectors, respectively Exhaust emissions of methane (GHG) are relatively high Absorbs water vapour which may freeze under certain conditions; thus its maximum water content should be limited Approx. 10% lower power output than equivalent petrol fuelled vehicles

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26 Worldwide NGVs CarEcology: New Technological and Ecological Standards in Automotive Engineering Antwerp, October 2009 TotalCars/LDVs MD/HD Buses MD/HD Trucks Others % of total NGVs in the world 1Pakistan2 191 0002 140 9604050 00020.84% 2Argentina1 786 989 17.00% 3Brazil1 605 041 15.27% 4Iran1 537 7901 532 2685 52214.63% 5India700 000315 20012 000715372.0856.66% 6Italy523 100519 6002 3001 2004.98% 7China400 000231 685112 7551 10054 4603.80% 8Colombia294 615179 33213 8009 66091 8232.80% 9Bangladesh180 000117 2293 2338 35551 1831.71% 10Thailand147 265119 88810.19515 5091 6731.40% 11Ukraine120 0007 00030 50029 50053 0001.14% 12Bolivia116 292 1.11% 91.34% Gas Vehicles Report, Oct 2009 Data updates Dec 2008 - July 2009 ???

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27 Worldwide Natural Gas fuelling stations CarEcology: New Technological and Ecological Standards in Automotive Engineering Antwerp, October 2009 TotalPublicPrivatePlanned % of total fuelling stations in the world 1 Pakistan2 941 18.47% 2 Argentina1 826 11.47% 3 Brazil1 746 10.97% 4 China1 3369204162308.39% 5 Iran928867616385.83% 6 Italy70063070804.40% 7 India5001813193.14% 8 Colombia458 2.88% 9 Bangladesh425 2.67% 10 Thailand33130625722.08% 11 Ukraine224204201.41% 12 Bolivia128 0.80% 72.5% Data updates Dec 2008 - July 2009 Gas Vehicles Report, Oct 2009

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28 CarEcology: New Technological and Ecological Standards in Automotive Engineering Antwerp, October 2009 CNG powered 3-wheelers in India CSE New Delhi, 2001

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29 CarEcology: New Technological and Ecological Standards in Automotive Engineering Antwerp, October 2009 CNG powered 3-wheeler Rozgar 4-Stroke CNG 200 cc Water Cooled Engine from Pakistan

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30 CarEcology: New Technological and Ecological Standards in Automotive Engineering Antwerp, October 2009 The GasHighWay NGVA Europe, 2009 The long-term objective of this EU- project is to promote the realisation of a network of filling stations for biogas and natural gas reaching from the northernmost tip of Europe, Finland, to the south of Italy, in other words: the GasHighWay.

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31 Methane properties CarEcology: New Technological and Ecological Standards in Automotive Engineering Antwerp, October 2009 Bechtold, 1997 Fuel PropertyMethanePetrolDiesel FormulaCH 4 C 4 to C 12 C 8 to C 25 Molecular weight16100-105~200 Composition (% w/w) Carbon7585-8884-87 Hydrogen2512-1513-16 Oxygen00-40 Density (kg/L) (gases at boiling point)0.420.69-0.790.81-0.89 Freezing Point (C)-182-40-40 to -1 Boiling Point (C)-16227-225188-343 Autoignition temperature (C)540~ 257~ 316 Latent Heat of Vaporisation (kJ/kg)510349233 Lower Heating Value (MJ/kg)5041-4342-44 Flammability limits (%v/v)5-151.4-7.61.0-6.0 Stoichiometric Air-Fuel Ratio17.214.7 Octane Number (RON)120 est.88-100- Octane Number (MON)120 est.80-90- Cetane Number--40-55

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32 CarEcology: New Technological and Ecological Standards in Automotive Engineering Antwerp, October 2009 Energy Density: Natural Gas vs. Diesel 1 m 3 1 bar 20 o C 11000 Natural Gas 10 Wh/L Diesel 10 kWh/L

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33 CarEcology: New Technological and Ecological Standards in Automotive Engineering Antwerp, October 2009 CNG Volume vs. Diesel Volume 5 CNG 200 bar Diesel 200 bar 1

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34 CarEcology: New Technological and Ecological Standards in Automotive Engineering Antwerp, October 2009 LNG Volume vs. Diesel Volume12 Diesel = 0.83 kg/L LNG -162 C = 0.35 kg/L

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35 CNG vs. LNG Comparison CarEcology: New Technological and Ecological Standards in Automotive Engineering Antwerp, October 2009 CNGLNG Physical stateGasLiquid Temperature in vehicle tankAmbient-162 C Typical pressures in tank200 or 250 bar5-8 bar Density175 kg/m 3 @200bar435 kg/m 3 Energy content 27% petrol eq. @ 200bar 33% petrol eq. @ 2 50bar 67% petrol eq. Typical usageCars/BussesTrucks

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36 Fuel storage on-board a vehicle CarEcology: New Technological and Ecological Standards in Automotive Engineering Antwerp, October 2009 Fuel storage system Volume (gal) Weight incl. fuel (lb) Energy (10 3 BTU) Tank Cost ($ 1993) Range (mi) Petrol12.487141525332 CNG Steel/Comp 39.633214201545333 CNG Alum/Comp 40.329314351695337 CNG All Comp 39.614314152050332 LNG18.015714351875337 Ingersoll, 1996

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37 Fuel storage: Natural Gas vs. Petrol CarEcology: New Technological and Ecological Standards in Automotive Engineering Antwerp, October 2009 Fuel storage systemVolume Weight incl. fuel Tank Cost Petrol111 CNG Steel/Composite3.23.862 CNG Alum/Composite3.33.468 CNG All Composite3.21.682 LNG1.51.875

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38 Catalyst conversion efficiency vs. temperature CarEcology: New Technological and Ecological Standards in Automotive Engineering Antwerp, October 2009 0 20 40 60 80 100 Conversion Efficiency (%) 100200300400500 Catalyst Temperature ( o C) Methane CH 4 Ethane C 2 H 6 Ethylene C 2 H 4 Propylene C 3 H 6 Propane C 3 H 8 Butane C 4 H 10

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39 Natural Gas Vehicles CarEcology: New Technological and Ecological Standards in Automotive Engineering Antwerp, October 2009 Dedicated vehicles Dedicated vehicles are run on natural gas only. Bi-Fuel vehicles Bi-Fuel vehicles operate on CNG while retaining the ability to use petrol as a reserve fuel. The engine can operate on either fuel but not on both simultaneously. The compression ratio of the engine must remain at a level suitable for petrol. Currently this type of engine is used almost exclusively on vehicles below 3500 kg. Dual Fuel vehicles Dual Fuel engines are derived from diesel engines. A small amount of diesel is retained as a pilot source of ignition. The primary fuel, Natural Gas, is mixed with the incoming air as the bulk fuel. Dual Fuel engines are auto ignited by compression and require no spark plugs.

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40 CarEcology: New Technological and Ecological Standards in Automotive Engineering Antwerp, October 2009 Compressed Natural Gas

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41 Schematic diagram of a 6 Cylinder MPI system CarEcology: New Technological and Ecological Standards in Automotive Engineering Antwerp, October 2009 Gas Injectors Pressure Regulator Injector Supply Manifold (Rail) Electronic Control Unit Coils Spark Plugs Gas supply (200 bar) Lambda Probe Engine Speed Sensor Phase Sensor Water Temp Sensor Air Temp Sensor Air Flow Sensor Throttle Position Sensor

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42 Components for natural-gas operation CarEcology: New Technological and Ecological Standards in Automotive Engineering Antwerp, October 2009 Bosch, 2007

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43 Cylinder Properties CarEcology: New Technological and Ecological Standards in Automotive Engineering Antwerp, October 2009 Four Cylinder Types: Type 1: All metal made of steel with no covering, other than paint. This is the most common type of cylinder. Type 2: Metal cylinder (steel or aluminium) with a partial wrapping made of glass or carbon, contained in an epoxy or polyester resin. Type 3: Cylinder fully wrapped most often with carbon fibre. This type has a metal liner (usually aluminium). Type 4: All-composite (non-metallic). Cylinder is fully wrapped with 100% carbon fibre and a plastic or carbon fibre liner. As a safety factor, all tanks are over-designed in order to withstand a pressure more than 2.5 times the operational pressure.

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44 CarEcology: New Technological and Ecological Standards in Automotive Engineering Antwerp, October 2009 Fiat Panda 1.2 CNG tanks Fiat Marketing, 2007

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45 CarEcology: New Technological and Ecological Standards in Automotive Engineering Antwerp, October 2009 Opel Zafira 1.6 CNG

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46 CarEcology: New Technological and Ecological Standards in Automotive Engineering Antwerp, October 2009 Opel factory www.cng.cz

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47 CNG powered urban busses CarEcology: New Technological and Ecological Standards in Automotive Engineering Antwerp, October 2009

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48 CNG powered urban busses CarEcology: New Technological and Ecological Standards in Automotive Engineering Antwerp, October 2009 City Total number of busses Natural Gas busses % of Natural Gas busses Berlin1700100.60% Paris4000531.30% Rome2383401.70% Madrid1000151.50% Athens203941620.40% New York56753586.30% Los Angeles263879530.10% Toronto15001258.30% Vancouver1006515.10% Sydney39002546.50% Perth850526.10% Beijing10000164016.40% Delhi12000617551.50% Sgourakis, 2008

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49 Natural Gas filling station in Athens CarEcology: New Technological and Ecological Standards in Automotive Engineering Antwerp, October 2009

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50 CarEcology: New Technological and Ecological Standards in Automotive Engineering Antwerp, October 2009 ECE Regulation No.110 (E/ECE/TRANS/505) TNO, 2008 The Economic Commission for Europe (ECE) has introduced Regulation No. 110 to provide uniform provisions concerning: I.Approval of specific components of motor vehicles using CNG in their propulsion system; II.Approval of vehicles with regard to the installation of specific components of an approved type for the use of CNG in their propulsion system. To prevent bursting of a CNG cylinder during accidents involving fires, automotive CNG cylinders have to be equipped with a Pressure Relief Device (PRD). The effectiveness of the specified fire protection system has to be tested in a Bonfire as defined in annex 3 (article 5.3.5 and appendix A.15) of ECE Regulation No. 110 (E/ECE/TRANS/505).

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51 CarEcology: New Technological and Ecological Standards in Automotive Engineering Antwerp, October 2009 Bonfire test CNG automotive cylinder TNO, 2008

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52 Auto Fire with CNG Fuel Tank Explosion (1/6) CarEcology: New Technological and Ecological Standards in Automotive Engineering Antwerp, October 2009 Seattle Fire Department Incident #26564, March 26, 2007 Dispatch 0230 hours for car fire (Engine 10) E10 arrived and requested FIB for multiple vehicles with possible structural exposures (freeway columns and overpasses) 12 vehicles damaged or destroyed Firefighter near miss when CNG vehicle exploded as E10 crew approached with a handline (approximately 15-20 m away) Determined to be arson

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53 Auto Fire with CNG Fuel Tank Explosion (2/6) CarEcology: New Technological and Ecological Standards in Automotive Engineering Antwerp, October 2009 Debris from the explosion was thrown up to 30 m in all directions including on the over-passes above the incident

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54 Auto Fire with CNG Fuel Tank Explosion (3/6) CarEcology: New Technological and Ecological Standards in Automotive Engineering Antwerp, October 2009 Roof is blown completely off vehicle and doors blown open

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55 Auto Fire with CNG Fuel Tank Explosion (4/6) CarEcology: New Technological and Ecological Standards in Automotive Engineering Antwerp, October 2009 ++ ++ ++ ++ Backhoe Fuel tank Trunk lid Bumper frame Roof debris 30 m

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56 Auto Fire with CNG Fuel Tank Explosion (5/6) CarEcology: New Technological and Ecological Standards in Automotive Engineering Antwerp, October 2009

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57 Auto Fire with CNG Fuel Tank Explosion (6/6) CarEcology: New Technological and Ecological Standards in Automotive Engineering Antwerp, October 2009 Evidence indicates that the fuel tank may have ricocheted off the underside of a freeway overpass

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58 CNG Filling CarEcology: New Technological and Ecological Standards in Automotive Engineering Antwerp, October 2009 Two categories: Fast fill (3-5 min) In a fast fill station pressurized fuel is stored in tanks that are continually refilled by compressors. Multiple tanks may be configured in a cascading arrangement, in which tanks come into service as needed. Slow fill (overnight) In a slow fill facility vehicles are filled directly from the compressor. Such equipment, which includes compressors but no storage tanks, typically serves small fleets.

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59 CNG Fast Fill CarEcology: New Technological and Ecological Standards in Automotive Engineering Antwerp, October 2009 1. Gas grid 2. Gas dryer 3. Gas compressor 4. Priority panel 5. Storage cylinders (cascade) 6. Dispenser 1 2 3 456

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60 Fast Fill cascade installation CarEcology: New Technological and Ecological Standards in Automotive Engineering Antwerp, October 2009

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61 Fast Fill Nozzles (1/2) CarEcology: New Technological and Ecological Standards in Automotive Engineering Antwerp, October 2009 OFF When the handle is rotated 180 to the on position, an arrow visible from the top, points toward vehicle ON

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62 Fast Fill Nozzles (2/2) CarEcology: New Technological and Ecological Standards in Automotive Engineering Antwerp, October 2009 OFF ON OFF ON

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63 CNG Slow Fill (Fleet filling) CarEcology: New Technological and Ecological Standards in Automotive Engineering Antwerp, October 2009 1 2 54 3 1. Gas grid 2. Compressor station 3. Buffer 4. Dispensing posts 5. Connectors

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64 CNG Slow Fill (Fleet filling) CarEcology: New Technological and Ecological Standards in Automotive Engineering Antwerp, October 2009

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65 CarEcology: New Technological and Ecological Standards in Automotive Engineering Antwerp, October 2009 Slow Fill Nozzles

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66 CNG Slow Fill (Home filling) CarEcology: New Technological and Ecological Standards in Automotive Engineering Antwerp, October 2009 1 234 1. Gas grid 2. Gas metre 3. Home refuelling appliance 4. Connector

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67 CNG Residential Refuelling CarEcology: New Technological and Ecological Standards in Automotive Engineering Antwerp, October 2009

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68 CarEcology: New Technological and Ecological Standards in Automotive Engineering Antwerp, October 2009 Liquefied Natural Gas

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69 CarEcology: New Technological and Ecological Standards in Automotive Engineering Antwerp, October 2009 LNG Although natural gas is a gas at normal temperatures and pressures, it becomes a liquid when it is cooled to -162C (LNG cannot be converted to a liquid by pressure alone), at which point the gas condenses into a liquid. Liquefaction removes oxygen, carbon dioxide, sulphur compounds, and water. By liquefying natural gas, it is possible to reduce the bulk or volume of the gas by about a factor of 600 which facilitates its transport by ship and tanker lorries. It can be turned back into a gas and delivered into domestic gas pipelines.

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70 CarEcology: New Technological and Ecological Standards in Automotive Engineering Antwerp, October 2009 LNG on board storage The LNG fuel tank is a cryogenic container that is designed as two separate pressure vessels, one inside the other. The inner vessel stores the cold LNG in its liquid form and is wrapped with multiple layers of non-combustible insulation and reflective foil. It is then sealed within the outer vessel. The space between the inner and outer vessels is then evacuated to produce a superior insulation system.

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71 CarEcology: New Technological and Ecological Standards in Automotive Engineering Antwerp, October 2009 LNG: Safety first A LNG vehicle parked indoors and unmoved for a week or more will vent a flammable gas mixture that could catch fire in the vicinity of an ignition source. To address this safety issue, LNG use should be restricted to frequently driven fleet vehicles or to vehicles stored outdoors. Only trained personnel should service the vehicles. EPA420-F-00-038, March 2002, www.epa.gov

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72 Dual-Fuel Fundamentals CarEcology: New Technological and Ecological Standards in Automotive Engineering Antwerp, October 2009 A Dual-Fuel engine is a diesel engine no basic change Dual-Fuel uses a diesel pilot injection to ignite a lean, homogeneous mixture of natural gas and air Retains diesel-cycle performance & efficiency with up to 90% gas substitution Can use LNG or CNG Delivers lower regulated & carbon emissions than diesel Returns to 100% diesel operation automatically and instantaneously when gas supply is terminated

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73 LNG Trucks CarEcology: New Technological and Ecological Standards in Automotive Engineering Antwerp, October 2009 Clean Air Power, 2008

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74 LNG Tanks CarEcology: New Technological and Ecological Standards in Automotive Engineering Antwerp, October 2009 Clean Air Power, 2008

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75 LNG Filling station CarEcology: New Technological and Ecological Standards in Automotive Engineering Antwerp, October 2009 Offload Connectors Vaporiser Storage Vessel 5.5 - 7 bar LNG Cryogenic pump LNG Dispenser NexGen Fuelling

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76 LNG/LCNG filling station CarEcology: New Technological and Ecological Standards in Automotive Engineering Antwerp, October 2009 Worlds largest LNG/LCNG station built by Chart-NexGen in California. 460.000 litres storage capacity, 6 LNG dispensers and 3 LCNG dispensers. Serving 200 refuse vehicles (www.chart-ferox.com)

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77 LCNG Filling station CarEcology: New Technological and Ecological Standards in Automotive Engineering Antwerp, October 2009 Offload Connectors Ambient Vaporiser Storage vessel LCNG Cryogenic pump CNG Dispenser Odouriser CNG storage Cascade system NexGen Fuelling

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78 CarEcology: New Technological and Ecological Standards in Automotive Engineering Antwerp, October 2009 Liquefied Petroleum Gas

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79 Liquefied Petroleum Gas CarEcology: New Technological and Ecological Standards in Automotive Engineering Antwerp, October 2009 LPG consists mainly of propane (C 3 H 8 ) with some butane (C 4 H 10 ). The ratio of carbon to hydrogen is important; the smaller the ratio of C to H, the better for the environment. It follows that methane is a better gas in this respect, but only if is fully burnt! It has been used as a vehicle fuel for at least the past 70 years. Nearly all LPG vehicles are conversions of petrol vehicles.

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80 Production of LPG CarEcology: New Technological and Ecological Standards in Automotive Engineering Antwerp, October 2009 About half of LPG is produced in association with production of natural gas and the other half is produced in association with crude oil refining. Natural gas must be free of those gases that would liquefy under the modest pressures used in natural gas pipelines. Such gases are the LP gases propane and butane.

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81 Use of LPG CarEcology: New Technological and Ecological Standards in Automotive Engineering Antwerp, October 2009 The major use of LPG is for heating. It is also an important feedstock for petrochemicals. It can be used to power cars, buses and trucks, however, it is not really suitable for vehicles above 3.5 t gvw, as it does not provide the required performance. For various reasons, one of which being the fact that alternative fuels are available, LPG is best suited to light vehicles such as cars and small vans which normally run on petrol.

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82 LPG Storage CarEcology: New Technological and Ecological Standards in Automotive Engineering Antwerp, October 2009 LPG is liquefied by moderate compression at normal temperatures (less than 20 bar) and is stored in appropriate tanks and cylinders. The liquefaction is necessary to provide a reduction in volume and produce acceptable energy densities. The main application discussed here is as a fuel for motor vehicles.

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83 Propane properties CarEcology: New Technological and Ecological Standards in Automotive Engineering Antwerp, October 2009 Bechtold, 1997 Fuel PropertyPropanePetrolDiesel FormulaC3H8C3H8 C 4 to C 12 C 8 to C 25 Molecular weight44.09100-105~200 Composition (% w/w) Carbon8285-8884-87 Hydrogen1812-1513-16 Oxygen00-40 Density (kg/L) (gases at boiling point)0.580.69-0.790.81-0.89 Freezing Point (C)-187-40-40 to -1 Boiling Point (C)-4227-225188-343 Autoignition temperature (C)457~ 257~ 316 Latent Heat of Vaporisation (kJ/kg)426349233 Lower Heating Value (MJ/kg)4641-4342-44 Flammability limits (%v/v)2.1-9.51.4-7.61.0-6.0 Stoichiometric Air-Fuel Ratio15.714.7 Octane Number (RON)11288-100- Octane Number (MON)9780-90- Cetane Number--40-55

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84 Benefits of using LPG CarEcology: New Technological and Ecological Standards in Automotive Engineering Antwerp, October 2009 The cost per litre is halved compared to petrol. LPG vehicles are eligible for grants (amongst other low exhaust-polluters). e.g. LPG vehicles can qualify for 100% exemption from the London Congestion charge. Burning LPG results in less sulphur deposits on the engine, while at the exhaust end fewer HC and less CO are emitted.

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85 Disadvantages of LPG CarEcology: New Technological and Ecological Standards in Automotive Engineering Antwerp, October 2009 The extra volume taken up by the gas tank will reduce the available load space. The vehicle manufacturers original guarantee may be invalidated. The insurance premiums may be increased. Low number of fuel stations. About 5% less power than petrol

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86 Schematic diagram of an LPG system CarEcology: New Technological and Ecological Standards in Automotive Engineering Antwerp, October 2009 Bosch, 2007 1.Gas shut-off valve 2.Evaporator pressure regulator 3.Throttle device 4.Intake manifold pressure sensor 5.Injector 6.Ignition coil with spark plug 7.Lambda sensor 8.Control unit 9.Speed sensor 10.Temperature sensor 11.Primary catalytic converter 12.Lambda sensor 13.CAN interface 14.Diagnosis lamp 15.Diagnosis interface 16.Ventilation line 17.LPG tank 18.Housing with tank fittings 19.External filler valve 20.Main catalytic converter

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87 LPG Sequential Injection Kit CarEcology: New Technological and Ecological Standards in Automotive Engineering Antwerp, October 2009 LPG tank Multivalve Switch Electronic Control Unit Pressure sensor Injection Rail LPG filter LPG regulator Emmegas BRC

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88 LPG dispenser on a wharf at Constance lake CarEcology: New Technological and Ecological Standards in Automotive Engineering Antwerp, October 2009 Emission values for new mid-sized vehicle registrations in the EU in 2002

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89 CNG and LNG incentives in Italy (2009) CarEcology: New Technological and Ecological Standards in Automotive Engineering Antwerp, October 2009

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90 Price List 2008/09 CarEcology: New Technological and Ecological Standards in Automotive Engineering Antwerp, October 2009 For all engine transformations to LPG or CNG, a price list for the public has been adopted by all workshops, thereby guaranteeing a maximum amount which cannot be overridden.

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91 LPG/CNG ECU Features CarEcology: New Technological and Ecological Standards in Automotive Engineering Antwerp, October 2009 Fully Functional OBDII Keeps the original equipment manufacturer OBDII system completely functional when operating on Petrol and also when operating on LPG or Natural Gas. Does not intervene the OEM OBD trouble codes or malfunction indication lights. The calibration of the Alternative Fuel system must be done and verified using an OBD scanner. Automatic Change Over Fuels Petrol to CNG/LPG or CNG/LPG to Petrol automatic change over. The installer can define and adjust change parameters based on multiple conditions considering fuel temperature, fuel pressure, RPM, etc. Calibration The ECU can be calibrated manually at different engine loads during the calibration process to achieve emission levels equal to the OEM. Real Engine Mapping The ECU can capture real engine mapping while the engine run at different power load on the road or on a dynamometer.

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92 CarEcology: New Technological and Ecological Standards in Automotive Engineering Antwerp, October 2009 Emissions

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93 Pollutant emissions: CO CarEcology: New Technological and Ecological Standards in Automotive Engineering Antwerp, October 2009 Emission values for new mid-sized vehicle registrations in the EU in 2002

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94 Pollutant emissions: NMHC CarEcology: New Technological and Ecological Standards in Automotive Engineering Antwerp, October 2009 Emission values for new mid-sized vehicle registrations in the EU in 2002

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95 Pollutant emissions: NOx CarEcology: New Technological and Ecological Standards in Automotive Engineering Antwerp, October 2009 Emission values for new mid-sized vehicle registrations in the EU in 2002

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96 Pollutant emissions: Particulates CarEcology: New Technological and Ecological Standards in Automotive Engineering Antwerp, October 2009 Emission values for new mid-sized vehicle registrations in the EU in 2002

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97 CarEcology: New Technological and Ecological Standards in Automotive Engineering Antwerp, October 2009 Athens under photochemical smog Pollutant effects: Summer smog

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98 CarEcology: New Technological and Ecological Standards in Automotive Engineering Antwerp, October 2009 Belgium, December 2007 Pollutant effects: Winter smog

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99 Pollutant effects: Acid Formation CarEcology: New Technological and Ecological Standards in Automotive Engineering Antwerp, October 2009 Emission values for new mid-sized vehicle registrations in the EU in 2002

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100 Pollutant effects: Acid Rain CarEcology: New Technological and Ecological Standards in Automotive Engineering Antwerp, October 2009 Great Smoky Mountains National ParkSacr-Cur Gargoyle

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101 Pollutant effects: Greenhouse gas CarEcology: New Technological and Ecological Standards in Automotive Engineering Antwerp, October 2009 Emission values for new mid-sized vehicle registrations in the EU in 2002

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102 BioGAS (BioMethane) CarEcology: New Technological and Ecological Standards in Automotive Engineering Antwerp, October 2009 Biomethane is a renewable resource and does not compete with food production. Methanisation is used for producing biogas from organic matter of plant or animal origin. Biogas is rich in methane, which is also found in natural gas. Biogas can be collected directly in landfill waste disposal centres or produced with the aid of digesters. All kinds of organic matter can be converted into biogas. Effluents can be methanised in waste treatment plants. Liquid manure, agricultural waste and energy crops can be methanised in small biogas units on farms or in co-digestion units. Solid household waste and green waste can also be converted into biogas in large plants for methanisation of solid waste.

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103 Hythane = Hydrogen + Methane CarEcology: New Technological and Ecological Standards in Automotive Engineering Antwerp, October 2009 Hythane is a mixture of natural gas and hydrogen 5-7% by energy. Benefits include: Extended lean flammability limits, increased flame speed, easier ignition and more efficient catalysis.

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104 Thanks for your attention! CarEcology: New Technological and Ecological Standards in Automotive Engineering Antwerp, October 2009