LPG Co-Injection into
Diesel Generators and Heavy Vehicles
in Fiji
1
1
Presentation Overview
 The Project Outline
 The Technology (Overview, Schematic and History)
 Trial Methodology Overview
 Test Engine Details
 Trial Outcomes Summary
 Independent Trial Outcomes Assessment
 Relative Emissions Benefits
2
2
The Project Outline
 Bluegas identify gas substitution opportunity for large
genset and delivery trucks in Fiji
 1 x FEA CAT3516 1.4MW genset and 2 x Bluegas
delivery trucks fitted with GasMastor system
 Testing program developed with data captured using
PEMS and independent trial audit team from USP
 Trial work completed and outcomes documented
3
3
The Technology
Australian designed, Internationally patented diesel engine
combustible gas injection system…
 Suitable for the majority of Stationary and Mobile diesel engines.
 Engine requires no modification as gas is injected into the air intake stream.
 LPG or any combustible gas can be used.
 Engine can continue to run exclusively on diesel only, if desired.
 Gas and diesel mixture is combusted achieving a cleaner, more complete burn.
 Reduced CO2, NOx and Particulate emissions.
 Longer engine life and maintenance cycles reflected in cleaner lube oil results.
4
4
System Schematic and
Installation Images
5
5
Product Timeline and Milestones
6
6
Trial Methodology Overview
 GasMastor systems fitted and tuned in early 2015
 Trials conducted on 1 x genset and 2 x trucks
 Genset run for minimum period prior to testing to ensure at
normal operating temperature
 Trucks run over standard driving route
 Test runs completed at different gas substitution rates
and system tune settings and also engine loads
 Full data sets recorded using GasMastor PEMS tool
 Independent trial outcomes assessment completed by
USP
7
7
Test Engines
Genset Details
 1.4MW Genset
 Model: CAT3516
 Engine: Caterpillar 30L Capacity
Truck Details – “Small”
 4500kg gvm
 Model: Hino 4cycl (2009 Model)
 Engine: 4L Capacity
Truck Details – “Large”
 25000kg gvm
 Model: Sinotruk 6cyl (Euro 3)
 Engine: 10L Common rail (380hp)
8
8
Genset Trial Summary Data – Run 1
[Higher Gas Substitution Target ; Load: ~1.0MW]
Fuel Metrics
Base
Diesel Usage
Unit
% Variance
269.20
208.45 L/hr
0.00
60.55 L/hr
269.20
0.00
269.00 L/hr
22.49 %
0.08
9675.22
9121.67 MJ/hr
5.72
Gas Usage
Total Fuel Consumption
Calculated Gas Substitution
Fuel Energy Density
Comparison
Full Trial Fuel Flows
22.57
Select Comparison Period Fuel Flows
Diesel Consumption & Gas Supply
Diesel Consumption & Gas Supply
350
80
70
300
350
70
300
60
250
50
200
40
150
30
100
20
50
10
150
30
100
Diesel Consumption (L/hr)
40
Gas Supply (L/hr)
Diesel Consumption (L/hr)
50
200
Gas Supply (L/hr)
60
250
20
50
10
0
-
2.00
4.00
6.00
8.00
10.00
12.00
14.00
0
16.00
0
0
-
0.50
1.00
Test Duration (mins)
Base Diesel Consumption (L/hr)
1.50
2.00
2.50
3.00
3.50
4.00
Test Duration (mins)
Comparison Gas Supply (L/hr)
Base Diesel Consumption (L/hr)
Comparison Diesel Consumption (L/hr)
9
Comparison Gas Supply (L/hr)
9
Genset Trial Summary Data – Run 1
[Higher Gas Substitution Target ; Load: ~1.0MW]
Engine Metrics
Base
RPM
Comparison
Unit
% Variance
4585.36
4591.98 Hz
-0.14
Exhaust Temperature
463.77
465.52 °C
-0.38
Manifold Pressure
116.74
106.96 kPa
8.38
Selected Comparison Period Manifold Pressure
140
120
MAP (kPa)
100
80
60
40
20
0
-
0.50
1.00
1.50
2.00
2.50
3.00
3.50
4.00
Test Duration (mins)
Base Manifold Pressure (kPa)
Comparison Manifold Pressure (kPa)
10
10
Genset Trial Summary Data – Run 1
[Higher Gas Substitution Target ; Load: ~1.0MW]
Emissions Metrics
Base
CO2
71,460.89
70,932.22 ppm
0.74
NOx
1315.57
1522.77 ppm
-15.75
Particulates
Comparison
14.05
Unit
% Variance
6.76 mg/m3
51.88
Calculated CO2 Equivalent
460,869.56
521,671.16 ppm
-13.19
Calculated CO2 Production
718,868.56
660,787.83 g CO2/hr
8.08
Selected Comparison Period NOx
Selected Comparison Period Particulates Concentration
16
1800
14
1600
1400
12
1200
ppm
Particulates (mg/m3)
10
1000
8
800
6
600
4
400
2
200
0
0
-
0.50
1.00
1.50
2.00
2.50
3.00
3.50
4.00
-
0.50
1.00
1.50
Test Duration (mins)
Base Particulates (mg/m3)
2.00
2.50
3.00
3.50
4.00
Test Duration (mins)
Comparison Particulates (mg/m3)
Base Nox (ppm)
Comparison Nox (ppm)
11
11
Genset Trial Summary Data – Run 1
[Higher Gas Substitution Target ; Load: ~1.0MW]
Assumed Cost Benefit Variables
Operating Hours
4000 hrs/yr
Diesel Price
1.00 $/L
Gas Price
0.80 $/L
Effective Comparison Price
0.95 $/L
Cost Benefit Metrics
Base
Total Fuel Cost
Fuel Cost Saving PA
269.20
$
Comparison
Unit
256.89 $/hr
% Variance
4.57
49,261.02 $/PA
12
12
Genset Trial Summary Data – Run 3
[Lower Gas Substitution Target ; Load: ~0.7MW]
Fuel Metrics
Base
Diesel Usage
Fuel Energy Density
Unit
% Variance
196.32
159.31 L/hr
0.00
34.82 L/hr
196.32
0.00
194.14 L/hr
17.74 %
1.11
7055.79
6663.14 MJ/hr
5.56
Gas Usage
Total Fuel Consumption
Calculated Gas Substitution
Comparison
Full Trial Fuel Flows
18.85
Select Comparison Period Fuel Flows
Diesel Consumption & Gas Supply
Diesel Consumption & Gas Supply
300
45
300
45
40
40
250
250
25
150
20
100
15
200
30
25
150
20
100
15
10
50
Gas Supply (L/hr)
30
Diesel Consumption (L/hr)
200
35
Gas Supply (L/hr)
Diesel Consumption (L/hr)
35
10
50
5
0
-
2.00
4.00
6.00
8.00
10.00
12.00
14.00
0
16.00
5
0
0
-
0.50
1.00
Test Duration (mins)
Base Diesel Consumption (L/hr)
1.50
2.00
2.50
3.00
3.50
4.00
Test Duration (mins)
Comparison Gas Supply (L/hr)
Base Diesel Consumption (L/hr)
Comparison Diesel Consumption (L/hr)
Comparison Gas Supply (L/hr)
13
13
Genset Trial Summary Data – Run 3
[Lower Gas Substitution Target ; Load: ~0.7MW]
Engine Metrics
Base
RPM
Exhaust Temperature
Comparison
Unit
% Variance
4590.91
4588.12 Hz
0.06
431.32
430.40 °C
0.21
Manifold Pressure
71.79
67.32 kPa
6.23
Selected Comparison Period Manifold Pressure
90
80
70
MAP (kPa)
60
50
40
30
20
10
0
-
0.50
1.00
1.50
2.00
2.50
3.00
3.50
4.00
Test Duration (mins)
Base Manifold Pressure (kPa)
Comparison Manifold Pressure (kPa)
14
14
Genset Trial Summary Data – Run 3
[Lower Gas Substitution Target ; Load: ~0.7MW]
Emissions Metrics
Base
CO2
64,225.56
63,601.60 ppm
0.97
NOx
1191.14
1201.75 ppm
-0.89
Particulates
Comparison
16.25
Unit
% Variance
10.59 mg/m3
Calculated CO2 Equivalent
416,802.67
419,319.60 ppm
Calculated CO2 Production
524,244.87
485,322.28 g CO2/hr
Selected Comparison Period Particulates Concentration
34.84
-0.60
7.42
Selected Comparison Period NOx
20
1400
18
1200
16
1000
14
ppm
Particulates (mg/m3)
12
10
800
600
8
6
400
4
200
2
0
0
-
0.50
1.00
1.50
2.00
2.50
3.00
3.50
4.00
-
0.50
1.00
1.50
Test Duration (mins)
Base Particulates (mg/m3)
2.00
2.50
3.00
3.50
4.00
Test Duration (mins)
Comparison Particulates (mg/m3)
Base Nox (ppm)
Comparison Nox (ppm)
15
15
Genset Trial Summary Data – Run 3
[Lower Gas Substitution Target ; Load: ~0.7MW]
Assumed Cost Benefit Variables
Operating Hours
4000 hrs/yr
Diesel Price
1.00 $/L
Gas Price
0.80 $/L
Effective Comparison Price
0.96 $/L
Cost Benefit Metrics
Base
Total Fuel Cost
Fuel Cost Saving PA
196.32
$
Comparison
Unit
187.17 $/hr
% Variance
4.66
36,600.10 $/PA
16
16
Small Truck Trial Summary
8.5km Comparison Drive Test Route
Emissions Metrics
Base
Comparison
Unit
% Variance
CO2
51,882.12
44,058.86 ppm
15.08
NOx
322.47
244.87 ppm
24.06
Particulates
20.70
Calculated CO2 Equivalent
147,331.86
Calculated CO2 Production
30,942.68
18.19 mg/m3
12.13
116,540.90 ppm
20.90
25,669.04 g CO2/hr
17.04
Selected Comparison Period NOx
Selected Comparison Period Particulates Concentration
60
700
600
50
500
ppm
Particulates (mg/m3)
40
400
30
300
20
200
10
100
0
0
0
1
2
3
4
5
6
7
Distance Travelled (km)
Base Particulates (mg/m3)
Comparison Particulates (mg/m3)
8
9
0
1
2
3
Base Nox (ppm)
4
5
Distance Travelled (km)
6
7
8
9
Comparison Nox (ppm)
17
17
Large Truck Trial Summary
5.0km Comparison Drive Test Route
Emissions Metrics
Base
Comparison
Unit
% Variance
CO2
56,233.01
47,813.36 ppm
14.97
NOx
696.72
684.99 ppm
1.68
Particulates
9.53
Calculated CO2 Equivalent
262,463.10
Calculated CO2 Production
74,540.56
5.35 mg/m3
43.86
250,570.82 ppm
4.53
65,805.26 g CO2/hr
Selected Comparison Period Particulates Concentration
11.72
Selected Comparison Period NOx
30
1400
1200
25
1000
ppm
Particulates (mg/m3)
20
800
15
600
10
400
5
200
0
0
0
1
2
3
4
5
Distance Travelled (km)
Base Particulates (mg/m3)
Comparison Particulates (mg/m3)
6
0
1
2
Base Nox (ppm)
3
Distance Travelled (km)
4
5
6
Comparison Nox (ppm)
18
18
USP Trial Outcomes Assessment
 The raw emissions data collected by GasMastor’s PEMS compared well to the
Horiba Gas Analyser provided by USP.
 Claims by GasMastor that their diesel substitution system reduces fuel
consumption and increases engine efficiency in diesel engines are valid, and
can be accepted with confidence.
 Claims that their system reduces particulates in the emissions are also true.
 The truck trial report shows that fumigation of the two mobile truck engines
produced reduction in both diesel fuel consumption, as well as particulate and
NOx emissions.
 There was also qualitative evidence, as recorded by the truck drivers (reported
to me verbally) of a better engine performance and reduction in visible
emissions.
19
19
Relative Emissions Benefit
Avg % Reduction /
RELATIVE
EMISSIONS
REDUCTION
Assumptions:
ITEM
UNITS
Installed Unit (1)
(%)
CO2
ppm
6.3
NOx
ppm
21.6
Particulates
mg/m3
56.4
Calculated CO2 Equivalent
ppm
16.4
Calculated CO2 Equivalent (2)
t/yr
11.8
(1) Based on Australian Emission reduction trials
(2) Assumes average of 4000 op hrs per engine per year
 Comparable Fiji trial outcomes to Global testing database
 Large fuel cost savings and environmental benefits upside
20
20
Thanks to Bluegas Fiji for providing the funds
to undertake these trials…
Questions…
21
21