Projects

Retrofit DI-LNG fuel system with negligible methane emission

EngineAlternative initiated this project and founded a Dutch consortium to carry out the required R&D. Main target is to maintain the original marine engine CI engine efficiency when using LNG, combined with negligible methane emission (< 0.5 g/kWh).

By doing so, the CO2 benefit of using LNG will be maximized to approx. 23%; when using biogas the use of LNG can be fully sustainable. Current dual-fuel engines (both OEM as retrofit) struggle to effectuate the CO2 reducing potential of LNG due to methane slippage. In in many cases the methane emission when running on LNG even results in a CO2 penalty! Note that this is the case when the methane emission is > 6 g/kWh.

The DI-LNG concept out-performs even mono-fuel gas engines regarding efficiency and methane emission.

IC-engine related consulting activities

EngineAlternative was hired by the Dutch court as independent expert witness regarding a liability conflict regarding gen-set failure. An other activity comprised a in depth feasibility study regarding the use of 'pyrolysis gas' form a specific kind of waste (confidential) for Caterpillar G3520 gen-set application.

Multiple engine test facility

For a leading Japanese OEM supplier, EngineAlternative carried out the project management as well as the concept development and design of a multiple (10) engine test facility for starter motor endurance testing.

Project was finalized well before SoP dead-line and within -15% of the project budget.

Retrofit MPFI (pre mixed) dual-fuel system, maritime applications

Improvement of duel-fuel combustion regarding (methane) emission, engine efficiency and diesel replacement ratio. Fundamental combustion research carried out on a one-cylinder (Ø170x190) research engine. R&D activities lead by EngineAlternative, included duel-fuel diesel injector design and CPBC (cylinder pressure based control).

EngineAlternative supported the development of an engine management system based on combustion pressure analysis, for (dual-fuel) LNG applications. Both fundamental as practical technical support. Furthermore EngineAlternative carried out the testbed design and supported this R&D project with in-house exhaust gas emission measuring facilities.

New concept for marine propulsion enabling the use of low quality (low MN) LNG

Today's LNG is traded on LHW and Wobbe index; the methane number (MN) is not part of the LNG specification. Gas engines need a minimum MN (often >80) and most LNG does not comply with this specification. Furthermore there is no agreement on a MN calculation standard between engine manufacturers and fuel suppliers.

EngineAlternative developed a concept, that enables the use of low quality LNG in combination with highly efficient gas engines. A cost efficient LNG marine propulsion concept is proposed; a quick patent search showed that this concept is "new". Together with parties in the industry this concept will be further developed and produced.

Support retro-fit LNG dual-fuel marine engine conversion project

EngineAlternative supported a Dutch shipping company on a LNG retro-fit project for a 2000 kW marine engine. The original diesel engine will be converted to a dual-fuel engine. This project includes detailed system specification, knowledge transfer and technical support during the prototype development including support during (prototype) engine tests.

LESAS Rotterdam project, subtask: LNG specification for small scale applications

LNG stakeholders of the "LNG LESAS Rotterdam project" (lead by TNO, DNV, NEN) worked on the "legal and safety assessment for a small-scale LNG supply chain development". This study should reveal all hurdles like legislation, safety etc. when using LNG in small scale applications like inland shipping, short-sea transport and road transport (trucks) or railway.

The objective of the LESAS project is to develop a road map towards an optimal small scale LNG supply chain for the Rotterdam area from a safety, commercial, technical and legal point of view based on the long term vision of relevant stakeholders.

One of the LESAS work packages of TNO addressed the issue of LNG specifications, for the above mentioned small scale applications. EngineAlternative carried out a study on LNG specifications, including the most important potential "show stopper" being the "methane number" (MN). The resulting report proved was positively accepted by the LESAS stakeholders, and proved to be valuable for today's and future discussions and actions on e.g. the MN specification of LNG.

Introduction engine simulations (GT-Power) at the HAN Automotive University

Calculations based on mathematical models of mechanical systems are becoming common practice in today's R&D activities. One of the biggest suppliers of simulation tools for internal combustion engines and complete powertrains is Gamma Technology. The HAN University decided to integrate GT-Power in it's program, in order to comply with the current industry standards.

EngineAlternative carried out the introduction of GT-Power at the HAN University, including the training of professors and staff involved with IC engines. Furthermore GTP-related exercises for students in the engine laboratory compiled. On top of that a GT-Power training course was prepared and a group of 40 students were trained how to use this simulation tool.

Development minor 'engine testing' and minor 'engine calibration' at the HAN Automotive University

Engine Alternative's theoretical knowledge and practical experience was used to compile the syllabi's for two so called "minors" of the HAN.

Compilation of syllabus's for Fontys Automotive University

The Automotive University is a relatively young Fontys branch, which automatically means that a number of syllabi have to be prepared. EngineAlternative supported this task, by compiling the "Advanced Air Management" (turbo charging) syllabus as well as a module comprising "Powertrain Control". Furthermore an extensive practical training regarding turbo charger matching was prepared.

Development railway damper monitoring and control system

Certain high speed trains encountering durability problems in the area of the yaw damper brackets. EngineAlternative supported a railway damper manufacturer with the investigation of the origin of the problem as well as the presentation of a number of solutions. The result was a feasibility study, product definition and concept development of yaw damper monitoring and control system.

One of the solutions was the replacement of the redundant dampers by a electronically controlled damper including a damper monitoring system. This project included safety issues, concept development and communication with customers, manufacturer and subcontractors.

SafiSana business case support

The SafiSana organization applied for Dutch governmental support (ORIO) for it's project comprising a healthy and durable sanitation solution for African countries. This project aims to demonstrate the economic feasibility of a concept where the waste of sanitation facilities will be used to produce biogas. This biogas can be used in the industry or by local citizens.

EngineAlternative's contribution was to support this business case, by developing an economic model by which the different biogas applications can be compared.

Study of possible techniques to reduce engine-out NOx emission

In order to cope with new "2010" NOx emission legislation in The Netherlands (BEMS) a number of known and partial new NOx lowering techniques were evaluated. As a result of this study a new gas engine control algorithm was developed. The new concept also enables cost reduction because of the reduced dimension of the SCR system and the AdBlue consumption.

A patent study showed that the new control algorithm was still "free" to register. Preferably this project needs to be continued in cooperation with a gas engine manufacturer.

Patents

DE4305865 (A1) "mixture controller for gas powered engine with catalytic converter"

http://www.freepatentsonline.com/result.html?query_txt=DE4305865+%28A1%29&sort=relevance&srch=top&patents=on