DUAL FUEL CONVERSION SYSTEMS - Huegli Tech

HUEGLITECHSWITZERLAND

DUAL FUEL CONVERSION SYSTEMS

DUAL FUEL CONVERSION FOR HIGH SPEED DIESEL ENGINES

• Gensetsconvertedtouseassociatedgasatoilwells

• Biogasgeneratorsonfarmsturnwasteintoelectricity

• Biofuel/naturalgasCHPapplications(wheretheliquidfuelischeaperbutmaybesubjecttoshortagesuntilthesupplyinfrastructureimproves)

Virtually unlimited Applications e.g

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HUEGLITECHoffersaninnovativeretrofittechnologytocon-verthighspeeddieselenginestooperatereliablyandeffici-entlyindualfuelmode,i.e.typicallywith25%dieselfueland75%naturalgas,orothergaseousfuel.

Nointernalmodificationstothedieselenginearerequired;thestandardcompressionratioandpistonsetc.areretained.

Note:Oursystemdynamicallycontrolsbothfuelssimultane-ously,allowingbetterresponsetoloadchangesthanapuregasengine,whilstmaximisingcostsavings insteady-stateconditions.

HUEGLITECHhasdeveloppedacomprehensiverangeofkeycomponents,allowingeachsystemtobetailoredtomeetin-dividualcustomerrequirements.

Thesystemautomaticallycompensatesforvariationsingasqualityandavailabilityandwillcontinuetofunctionasapuredieselengineifthegassupplyisinterrupted.Thisallowsformaximumutilisationofthemostcost-effectivegaseousfuelsandtarriffs.

This kit is an inexpensive method to get an existing highspeed diesel engine running on dual fuel and significantlyreducingfuelcostswhileretainingthefulloutputpowerandflexibilityoftheoriginalengine.

The larger the engine and the higher the annual runninghours,theshorterthepaybackperiodwillbe.

Return of Investment: Can often be less than 6 Months

The Benefits

• Savemoneywithcheaperfuel

• Simpleconversioniscosteffective

• Lowpressuregascompatible

• 100%powerwithdieselordualfuel

• Fastresponsetime

• Improveddynamicperformance

• Runningcleangascanextendserviceintervals

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TARGET - OPERATING PRINCIPLE

TargetThedevelopmenttargetwastocombinesimplicitywithhightech components to safely operate the engine at an opti-miseddieselfuel/gasratioofatleast25%/75%,andtomain-tainthesamepoweroutputandresponsetoloadchangesastheoriginaldieselengine.

Operating PrincipleTheHT-SG105DualFuelModulesetstheamountofinjecteddieselfuelviathedieselactuator(withpositionalfeedbacksensor) linked to the fuel pump. Simultaneously, the HT-SG100alsoregulatestheamountofgasintothespecialair/gasblenderbymeansofathrottlebody.Theair/gasmixturethen passes through the turbo charger, through the inter-cooler and into the engine. The requested engine speedis controlled by the governor,which measures the enginespeedattheengineringgearviaaspeedsensor.Both,iso-chronousordroopmodearepossible.

Dynamic PerformanceTheHT-SG105andtheHT-SG100controlthefastrespondingelectricactuatorsinsuchawaytooptimiseeconomyinsteadystateanddy-namicperformanceduringloadsteps.

Protection and SafetyThesystemprotectstheengineagainstharmfulsituations.Each cylinder exhaust temperature is monitored individu-ally. If the temperature should exceed the set (safe) limit,theDFC-2000controlreducesthegasportion,andincreasesthedieselfuelportion.All combustion engines are susceptable to harmful kno-cking(Detonation),butgas-fuelledengines,runninghotter,aremorepronethanliquidfuelledones.Westronglyrecom-mendtheuseofananti-knockingcontrolsystem.Multipleknock sensors continually monitor engine vibrations, andthe Antiknock Controller uses these inputs to ensure thattheenginecanberuncloseto,butstillwithintheknockingthreshold.Asanoption,andasanadditionalprotectionagainstover-speed,etc,oneortwosolenoid-operatedairintakeshutoffvalvescanbesupplied.

Cost per hour vs Genset Power

0

20

40

60

80

100

120

140

160

0 150 250 350 450 650 1000 1450

Genset Power (kVA)

Cost/h (USD)

Diesel 100%Dualfuel 70/30%

Costsaving60 USD/hour

Cost per Year(at 14 hours operating a day)

$0

$100'000

$200'000

$300'000

$400'000

$500'000

$600'000

$700'000

$800'000

0 150 250 350 450 650 1000 1450

Genset Power (kVA)

Cost/Year (USD)

Diesel 100%Dualfuel 70/30%

Costsaving300'000USD/Year

! Uninterrupted power supply around the clock save cost for production and investment!

Thebelowcomparisonisbasedonaveragefuelandgascosts.AnautomaticcalculationtableisavailableinExcelwhichallowscalculatingwithanyfuelcost.Pleasecontactussowecanprovidemoreinforma-tiontoyou.

Whilst looking to minimise the conversion costs, no compromise was made regarding quality. All components are of top quality and offer utmost reliability, at an affordable price!

QUALITY

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Fuel EconomyA Dual Fuel conversion is a perfect investment for poweruserswhoarelookingtoupgradetheircurrentsystemtoal-ternativefueltechnology,withoutrevampingtheirentiresys-tem.Asaretrofittechnology,theHT-SG105systemprovidesaneconomicallyattractivealternativetobuyingcostlynewgenerators.Withtheabilitytoutilisebothfuels,theenginewillneverbedownduetoalackofadequategasfuelsupply.Anotherdistinctadvantageofdualfuelisthedecreasedenginewearthatcomeswiththeuseofcleanerfuel.Duetoareductionofcarbonsootbuild-upandcleanerlubeoil,longerintervalsbetweenservicemaintenancecanbeexpected,sometimesdoubled.Thismeansalongereconomiclifefortheengineandabetteroverallreturnonyourinvestment.

SavingsTodetermineapproximatecostsavingsyouwillneedtobeawareofyourpresentfuelcost.Thefuelreplacementper-centageandreplacementcostwithnaturalgasisintheratioofapprox:25/75,butalsocanbelower.Besuretoapplyanylossesofefficiencyandalwaysestimateonthesafeside.AskaHUEGLITECHrepresentativetohelpyouindeterminingyourprojectedannualcostsavingsincludingfuelandmain-tenance.Whenconsideringthecostofnaturalgas,alsobearinmindthatmanysuppliersarewillingtogivebetterratesiftheyareabletointerruptyourfuelsupply.Adualfuelengine,whichcancontinuetorunondieselaloneifthegasisinterrupted,allows theoperator to take full advantageof these tarriffswithoutcompomisingsystemavailability.

The Benefits

Overview Inline Engine 1 Mixer 1 Turbo

Note:

TheDieselActuatorhastobeselectedenginespecificitwillbeeitheranintegralorecternaltype!

TheGasStreethastobeselectedaccordingthegaspressuresuppliedfromthemainlineincomingtothebuilding!

CONFIGURATION EXAMPLES

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Overview V-Engine Single Mixer 2 Turbo

Overview V-Engine 2 Mixer 2 Turbo

Note:

TheDieselActuatorhastobeselectedenginespecificitwillbeeitheranintegralorecternaltype!

TheGasStreethastobeselectedaccordingthegaspressuresuppliedfromthemainlineincomingtothebuilding!

CONFIGURATION EXAMPLES

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HT-SG105,Dual FuelControlmodule takescontrolof theGasactuator in-dependantly.Theunitisfittedwithaloadanticipationfeaturethatsimulta-neouslyadjuststhesupplyoftheGasFueltoreduceloadtransientstoanabsoluteminimum, oftenachievingbetter transient performance than theoriginaldieselengine.

DFC-2000TemperatureControlModulemonitorstheexhausttemperaturesandcontrolstheY-FlapandsignalstotheDFMifdieselfuelneedstobeincreasedtocoolthecombustionchamber.

HT-DST4602AMFandPARALLELgensetcontroller.HT-DST4602isahighlyconfigurablegen-setcontrollerdesignedtohandleabroadrangeofcriticalandcomplexparallelapplications, includingmul-tipleMainsandCHPsystems.Itincludesaninternalloadsharingunitthatallows simple implementation ofMultiple PrimeMover applications. PLCfunctions(includingPIDblocks)areavailableinthisunit.Asplitversionwithaseparatedisplayandbaseboxisalsoavailable.

HT-SG100isanisochronousspeedgovernortailoredtocommunicatewiththeHT-SG105orHT-TPD100.Featuressuchasdualgain, switchableengineconfiguration, start smokelimitationandoverspeedetc.make thisgovernoran idealchoice fordualfuelapplications.

HT-TPD100isadualactuatordriverwithbalancingfunction.Thisunitcanalsobeusedtogetherwithdieselenginesthathavetwofuelpumps,suchastheCumminsQST30orsome8and12cyl.Komatsuengines.

THE INDIVIDUAL COMPONENTS

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DFC-2000

HT-DST4602

Denoxantiknockingcontrol.Eachindividualcylinderismonitoredandprotectedagainstknocking.

Denox antiknocking control

HT-SG100

HT-SG105

HT-TPD100

Y-Flap,auniquedevicethatworkswiththeDFC-2000tocontrolthegasflowtotheindividualcylinderbanks!Thisprovidesaccuratelybalancedcylinderbanktemperatures.

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DF-5isasimplebuteffectiveairgasmixerdesignedspecificallyfordual-fuelsystems.Itcanbeadaptedtofitawiderangeofinductionsystemdia-metersandtheinternalgasinlettubecanbeoptimisedon-site.

DF-5 Air Gas Mixer

ITBseriesactuatorsaredesignedforpreciseefficientmeteringofgasflow.TheactuatorismounteddirectlytotheDF-5mixerandfeaturesaproporti-onal electromagnetically driven throttle plate. Two internal return springsmakethisanormally-closedfail-safedesign.

Y-Flap

ITB Actuator

Actuator Variouse Variouseactuatorsareavailableforthedieselfuelpump.Wealsoofferinte-gralasexternalsolutionsincludingpositionfeedback.

TYPICAL APPLICATION

CustomspecifiedconversiononabrandnewCAT3306withCNG.Fuelratio:20%Diesel80%Gasat100%load.TheenginewasconvertedinourfactoryinSwitzerland.Testconditions:Ambienttemperature:28°C,humidity:40%re-lative,resistiveloadbank.

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Project: CAT 3306

Project: Cummins KTA 38

Project: Volvo 1613G

Project: Cummins KTA 50

Project: CAT 3412

ConversionmadeinIndonesia.DuetoAirtoAircooledsystemitwaspos-siblereducingthedieselfueldownto10%and90%ofnaturalgasat100%load.Finaladjustmentsetto30%diesel70%gas.Ambienttemperature40°C.

ConversionmadeinJakarta.Ratio30%Diesel70%Gas.CylinderTempera-turebalancewithin1 to3degreesC°viaY-Flap.Ambient temperature35-38°Chighhumidity.

ConversionmadeinPakistanthroughR.A.Engineering.FuelRatio30%Diesel70%Gasat100%power.

ConversionmadeinUSA.FuelRatio30%Diesel70%Gas.

CumminsNTA855,KTA19,38and50,allenginesoperatingwith30%Diesel70%Gas.Totalsetsconverted,15pcs.

MAN28401pcs,engineoperatingwithBioGasat18%Diesel,82%Gas.

VolvoTD7106Cylinder,1pcs.30%Diesel70%Gas.

Jinan12Cylinder190,1pcs.Engineisoperatingwith20%Diesel80%Gas.

CAT34061pcs,engineoperatingat28%Diesel,72%Gas.




Application:HydraulicDrillsets,worldwidefirsttime3enginesparalleltohydraulicindualfuelmode.

CAT3406andMitsubishi6Cylinderoperatingat25%Dieseland75%Gas.

KTA-19operatingat30%Diesel70%Gas.

KTA-38operatingat35%Diesel65%Gas.

KTA-38at35%Diesel65%Gas,allnewHT-TECHNOLOGY

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SOME REFERENCES

Pakistan

Germany

Indonesia

China

Egypt

China

China

China

China

USA

Iran

Indonesia

Korea

Local Distributor / Partner: HUEGLITECHareactivedirectlyorthroughagentsin:

EUROPEAUSTRIA,BALTICSTATES,BELGIUM,DENMARK,EIRE,FAEROEISLAND,FINNLAND,FRANCE,GERMANY,GREECE,GREENLAND,ICELAND,ITALY,MOLDAVIA,NETHERLANDS,NORWAY,POLAND,RUMANIA,RUSSIA,SPAIN,SWEDEN,SWITZERLAND,UNITEDKINGDOM,TURKEY.

FAREASTANDAUSTRALIAAUSTRALIA,BANGLADESH,CAMBODIA,CHINA,HONGKONG,INDIA,INDONESIA,JAPAN,KOREA,LAOSMIANMAR,MALAYSIA,NEWZEALAND,PHILIPPINES,SINGAPORE,TAIWAN,THAILAND,VIETNAM.

MIDDLEEASTANDAFRICAALGERIA,EGYPT,IRAN,IRAQ,ISRAEL,LEBANON,SYRIAANDNIGERIA,PAKISTAN,SAUDIARABIA,TUNESIA,UNITEDARABEMIRATES.

NORTHAMERICAUSA,CANADA.

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HUEGLI TECH AG (LTD)Murgenthalstrasse 304900 Langenthal SwitzerlandPhone: +41 62 916 50 30Fax: +41 62 916 50 35


Solution Provider for:• GasManagementSystems• DualFuelConversionSystems• GoverningSystems• AutomationSystems• EngineProtection• StartingSolutions• BatteryCare• OilTreatmentandRecycling• ThermostaticControlValves

DUAL FUEL CONVERSION SYSTEMS - Huegli Tech

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