natural gas engine research at colorado state university vgf (f18gld) • knock (detonation) limits...
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Natural Gas Engine Research at Colorado State University
Electrical Generating Systems Association (EGSA) EGSA Fall Conference, September 14th, 2015
Daniel B. Olsen, Associate ProfessorMechanical Engineering Department
Colorado State UniversityFort Collins, Colorado, USA
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Energy Institute at Colorado State University
Research
EnterpriseEducation & Outreach
Create innovative energy solutions through cross-disciplinary and entrepreneurial approaches
Mission
• Provide opportunities and support to faculty members and students
• Foster linkages across University
• Provide a portal for external partnersto connect with CSU expertise
• Facilitate large scale application of energy ideas and innovation
Key Strategies
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Energy Centers and Programs
Energy Centers ProgramsResearch
Technology to Market
Education and Outreach
Strategic Partnerships
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The Powerhouse Energy Campus
• A facility of the Energy Institute at CSU
• 100,000 sq. ft. of project, office, and classroom space
• Facility includes Engines and Energy Conversion Laboratory, Electric Power Systems Laboratory, and Laser Sensing and Diagnostics Laboratory
• Fourth floor incubator, start-up, office space
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The Engines and Energy Conversion Laboratory at the Powerhouse Energy Campus
• More than 2 decades of delivering solutions to meet the global energy challenges and opportunities of the 21st Century.
• Focus on market-driven solutions for industry: Engines, Fuels, Energy Conversion, Energy Distribution
• 24,000 sq.ft. world class facility: large-bore engine lab; diesel lab; grid-based renewable energy lab
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• 25regularfaculty• 6specialfaculty• 18researchstaff• 5administrativestaff
• 859 ME undergraduates• 157 Dual-degree ME/Biomed• 1016 Total undergraduates• 58 MS, 47 PHD• 30 ME (Master of Engineering)• 135 Total Graduate Students
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•
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* Track III will be changing names in the fall 2015 to IDP+ (Integrated Degree Programs Plus).
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•••••
http://www.engr.colostate.edu/me/
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• 9GraduateStudents 1PhD,8MS– ChrisVanRoekel,JenniferVaughn,ArunachalamLakshminarayanan,BenjaminNeuner,ChrisPage,JohnLadd,PreranaGhotge,RobbieMitchel,TroyNygren
• 5UndergraduateStudents 2sophomores,1junior,2seniors– MaryStevens,DevinLink,JohnFinke,BrigidMcCreery,MaxBeard
• 1visitingscholar GermanAmadorDiaz:UniversidaddelNorte,Columbia
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• Largeindustrialnaturalgasinternalcombustionengines
• Pollutantemissionsreductiontechnologies– highenergyignitionsystems,fuelinjectionsystems,exhaustaftertreatment,controlsystems
• Gaseousbiofuelsandfuelvariability–combustioncharacterization,emissionsimpacts;producergas,digestergas,shalegas
• Liquidbiofuels– combustioncharacterization,emissionsimpacts,durabilitytesting
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1314 September 201513
Large Engines
at the EECL
Cooper-Bessemer GMV
Waukesha VGFCaterpillar 3516C
Caterpillar 3508Cummins QSK19
Superior 6G-825
Waukesha VHP
Cummins QSK19G
Cummins QSK19
Cummins QSK50
Engines outlined in blue are currently installed (Sept 2015).
Caterpillar 3412
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14
5-Gas Analyzer
Rack
Nicolet 6700 FTIR
Some Key Measurement CapabilitiesPartial Dilution Tunnel
ECM AF Recorder
Varian CP-4900 MicroGCHP 5890
Series II GC
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• InvestigationofDualFuelandItsEffectsonLubricantPerformance,ChevronOronite.
• InvestigationofaGasFuelConditioningSystemforAlternativeGasFuels,CumminsInc.
• EvaluationofEthanolSubstitutioninDieselEngines,ColoradoCorn.• FieldEvaluationofTimedPowerCylinderLubeOilInjection,
PipelineResearchCouncilInternational.• VariableFuelCompositionAirFuelRatioControlofLeanBurn
Engines,PipelineResearchCouncilInternational.• NSCRCatalystTestinginSupportofKSUModelingEffort,PRCI.• FieldEvaluationofOxidationCatalystDegradationona2‐Stroke
Lean‐BurnNGEngine,PipelineResearchCouncilInternational.• ImpactofH2‐NGBlendingonLambdaSensorNSCRControland
LeanBurnEmissions,SouthernCaliforniaGas.
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Major Natural Gas Compressor Stations,2008, Interstate + Intrastate
http://205.254.135.7/pub/oil_gas/natural_gas/analysis_publications/ngpipeline/images/compressorMap.gif
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12 Cylinder Cooper GMV
8 Cylinder Cooper V-275
Click for animation,Clark TLA-6
35 -56 cm bore
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NSPS Quad J, Federal Register/Vol. 73, No. 13, Jan 2008/Rules and Regulations.
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20Natural Gas Fuel for Drilling & Completions Symposium, American Exploration & Production Council (AXPC), Houston, Texas, Nov. 4-5, 2013.
High engine-out NOx and CO emissions. 3-way catalyst required.
Highest efficiency, BMEP. Low emissions without catalyst. Engine must be controlled
between detonation and misfire limits.
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Efficiency Trends
21Heywood, J. B., “Internal Combustion Engine Fundamentals”, McGraw-Hill, Inc., 1988.
34%
35%
36%
37%
38%
39%
40%
41%
42%
100 150 200 250 300 350 400
bmep (psi)
Increasing boost & power at constant A/F
• Higher power density (bmep) results in higher efficiency
• Higher compression ratio yields higher efficiency
Waukesha VGF (F18GLD)
• Knock (detonation) limits compression ratio and bmep of engine
• Fuel quality determines knock limit
Fuel A Knock Limit
Fuel B Knock Limit
Efficiency
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22
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PV Diagrams Stable Combustion
PV Diagrams Near Lean Limit
IMEP Stable Combustion
IMEP Near Lean Limit
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•••
2
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PRECOMBUSTION CHAMBERS
25
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Precombustion Chamber (PCC) CharacterizationInstrumentationPort
Fuel Supply
Checkvalve
PCC Nozzle
Cooper – Bessemer GMV-4TF
Diesel Supply Co. Screw-in-
Prechamber
Justin M. Lisowski, Daniel B. Olsen, and Azer P. Yalin, “Visible Flame Imaging of Prechamber Initiated Combustion in a Large Bore Natural Gas Engine”, GMRC Gas Machinery Conference, Oklahoma City, OK, October 2006.
PCCs extend the lean limit and accelerate and stabilize combustion.
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• Precombustionchamber PCC ignitionstabilizescombustionandreducesvariability
• Extendsleanlimitbyallowingoperationathigherboostatconstantload
27
300 rpm, 440 bhp, LPP 18 deg ATDC
30
40
50
60
70
80
90
100
0 5 10 15 20 25
Boost (inches Hg)
SDPP
(psi
)
HP Check Valve PCC
Spark HP Fuel Injection
Daniel B. Olsen, Jessica L. Adair, and Bryan D. Willson, “Precombustion Chamber Design and Performance Studies for a Large Bore Natural Gas Engine”, ASME Internal Combustion Engine Division 2005 Spring Technical Conference, Paper # ICES2005-1057, April 5-7, 2005,Chicago, IL.
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Fused silica window
High speed photography equipment
Optical access in head in bored out air start port
Camera view angle
Precombustion Chamber Jet Visualization
Justin M. Lisowski, Daniel B. Olsen, and Azer P. Yalin, “Visible Flame Imaging of Prechamber Initiated Combustion in a Large Bore Natural Gas Engine”, GMRC Gas Machinery Conference, Oklahoma City, OK, October 2006.
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Optimal PCC Fueling (≈20psi, 8SLPM)
Point 1
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Optimal PCC Fueling (≈20psi, 8SLPM)
Point 2
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Optimal PCC Fueling (≈20psi, 8SLPM)
Point 3
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Optimal PCC Fueling (≈20psi, 8SLPM)
Point 4
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Optimal PCC Fueling (≈20psi, 8SLPM)
Point 5
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Optimal PCC Fueling (≈20psi, 8SLPM)
Point 6
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Optimal PCC Fueling (≈20psi, 8SLPM)
Point 7
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Optimal PCC Fueling (≈20psi, 8SLPM)
Point 8
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Optimal PCC Fueling (≈20psi, 8SLPM)
Point 9
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Optimal PCC Fueling (≈20psi, 8SLPM)
Point 10
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Optimal PCC Fueling (≈20psi, 8SLPM)
Point 11
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Optimal PCC Fueling (≈20psi, 8SLPM)
Point 12
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Optimal PCC Fueling (≈20psi, 8SLPM)
Point 13
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Optimal PCC Fueling (≈20psi, 8SLPM)
Point 14
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Optimal PCC Fueling (≈20psi, 8SLPM)
Point 15
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Optimal PCC Fueling (≈20psi, 8SLPM)
Point 16
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Estimating jet penetration
35.0°
Enables quantification of flame development
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PCC Design Study
Simpson, D. and Olsen, D.B., “Precombustion Chamber Design for Low NOx Emissions from Large Bore NG Engines” Journal of Engineering for Gas Turbines and Power, Vol. 132, No. 12, August 2010.
Note: 54 cc = 1.6% of Clearance Vol.; 8.6 cc = 0.25% of Clearance Vol.
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Results: NOx vs. CO
0
20
40
60
80
100
120
140
160
180
200
0 50 100 150 200 250
NO
x pp
m @
15%
O2
CO ppm @ 15% O2Baseline Multiple Nozzle Fueled Micro ePCC
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4848
Checkvalve
PCC Volume
PCC Nozzle
Sparkplug
Sparkplug
PCC Volume
PCC Nozzles
Checkvalve
Baseline DesignNew Design – Fueled Micro PCC
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HIGH PRESSURE FUEL INJECTION
49
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“Low Pressure” Gas Admission
Richregion
Leanregion
Fueldisplaces
air
richlean
richrich
rich rich
stoich
stoich
stoich
stoich
stoich
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Fuel Injection
• At time of spark (end of simulation), fuel and air and not fully mixed
• Improved fuel injection technique is needed
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Dresser-Rand / WoodwardHPFi System
Also commercialized by Hoerbiger Corp.
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High Pressure Fuel Injection
Performance Benefits
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GASEOUS FUEL CHARACTERIZATION
54
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CFR Engine – MN Measurement
55
62.4
30.0
61.570.2 66.3
23.9
139.1 139.6
0
20
40
60
80
100
120
140
160
1, ReformedNatural Gas
2, Coal Gas 3, Wood Gas 4, Wood Gas 5, DigesterGas
6, Landfill Gas 7, ReformedNatural Gas
8, Coal Gas
Met
hane
Num
ber
Typical Natural Gas
# Test Gas %CH4 %H2 %N2 %CO %CO2
1 Reformed Natural Gas 39.7 46.7 0.8 0.9 11.9
2 Coal Gas * 24.8 16.3 58 1 3 Wood Gas 10 40 3 24 23 4 Wood Gas 1 31 35 18 15 5 Digester Gas 60 * 2 * 38 6 Landfill Gas 60 * * * 40
7 Reformed Natural Gas 1.2 30.8 49.0 15.6 3.4
8 Coal Gas 7 44 * 43 6
• Current work with Caterpillar• Measure MN for syngas blends• Examine other metrics
o Boost requirementso De-ratingo Critical compression
ratioo Combustion statisticso Knock statistics
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MN Measurement for Producer Gas Blends
56
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ENGINE CONTROL WITH NOX SENSORS
57
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5814 September 2015
Broad perspective and Overall Project Goals:• Smaller (1500 hp and lower) natural gas engines used for power generation, water
pumping, and gas compression are often stoichiometric engines.
• These engines have high utilization factors, often running 24/7 through most of the year.
• They use a 3-way, or NSCR, catalyst similar to what is used in most US automobiles.
• The objectives of this work are:
Determine the feasibility of using a minimization algorithm with a NOx sensor to control Non-Selective Catalytic Reduction (NSCR) catalyst systems
Demonstrate that that we can achieve strict CARB 2007 fossil fuel emissions levels.
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Engine Configuration
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Continental NOx Sensor Behavior
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NOx Sensor Feedback AFR Control
NOx sensor closed loop operation turned on at
rich starting point
NOx sensor closed loop operation turned on at
lean starting point
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DUAL FUEL ENGINE RESEARCH
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6414 September 2015
DualFuelEngineSetup:JohnDeer6.8literT2
9/14/2015
Natural gas metered into air intake between air filter and turbocharger compressor inlet.
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6514 September 2015
Natural Gas Substitution
% , x 100
0
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0 50 100 150 200
NaturalGasSubstitution(%
)
Power(kW)
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6614 September 2015
CO, NOx Comparison
0
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0 50 100 150 200
BrakeSpecificEm
isions[g/bkW
‐hr]
Power[kW]
DieselCODualFuelCODieselNOxDualFuelNOx
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6714 September 2015
ISO Weighted Emissions
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6814 September 2015
ISO Weighted EmissionsRegulated Emissions
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Optimized %NG Substitution
69
0
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90
12% 25% 50% 75% 100%
NG Sub
stitu
tion (%
)
Load
Baseline
Optomized
0% NGSubstitution
Optimized
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Oxidation Catalysts: NGEngine Testing
Approximate Diesel Engine Exhaust TemperatureRange 400-1200
Daniel B. Olsen, Benjamin Neuner, Koushik Badrinarayanan, and Gregg Arney, “Performance Characteristics of Oxidation Catalysts for Lean-Burn Natural Gas Engines”, 2013 Gas Machinery Conference, October 6-9, 2013.
To meet T2 CO limit, 70% CO reduction is required.
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Oxidation Catalysts: NGEngine Testing
Approximate Diesel Engine Exhaust TemperatureRange 400-1200
To meet T2 (NOx+NMHC) limit, 75% NMHC reduction is required.
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72
Contact: Daniel B. OlsenAssociate ProfessorMechanical Engineering Department(970) [email protected]://www.energy.colostate.edu/p/powerhouse-energy-campus