Conversion of a diesel engine to a spark ignition natural gas engine

摘要

Requirements for alternatives to diesel-fueled vehicles are developing, particularly in urban centers not in compliance with mandated air quality standards. An operator of fleets of diesel- powered vehicles may be forced to either purchase new vehicles or equip some of the existing fleets with engines designed or modified to run on alternative fuels. In converting existing vehicles, the operator can either replace the existing engine or modify it to burn an alternative fuel. Work described in this report addresses the problem of modifying an existing diesel engine to operate on natural gas. Tecogen has developed a technique for converting turbocharged automotive diesel engines to operate as dedicated spark-ignition engines with natural gas fuel. The engine cycle is converted to a more-complete-expansion cycle in which the expansion ratio of the original engine is unchanged while the effective compression ratio is lowered, so that engine detonation is avoided. The converted natural gas engine, with an expansion ratio higher than in conventional spark- ignition natural gas engines, offers thermal efficiency at wide-open- throttle conditions comparable to its diesel counterpart. This allows field conversion of existing engines. Low exhaust emissions can be achieved when the engine is operated with precise control of the fuel air mixture at stoichiometry with a 3-way catalyst. A Navistar DTA- 466 diesel engine with an expansion ratio of 16.5 to 1 was converted in this way, modifying the cam profiles, increasing the turbocharger boost pressure, incorporating an aftercooler if not already present, and adding a spark-ignition system, natural gas fuel management system, throttle body for load control, and an electronic engine control system. The proof-of-concept engine achieved a power level comparable to that of the diesel engine without detonation. A conversion system was developed for the Navistar DT 466 engine. NOx emissions of 1.5 g/bhp-h have been obtained.