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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HUEGLITECHSWITZERLAND
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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HUEGLITECHSWITZERLAND
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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HUEGLITECHSWITZERLAND
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.
Jinan12Cylinder190,10pcs.Engineisoperatingwith20%Diesel80%Gas.
Jinan12Cylinder3012,3pcs.Engineisoperatingwith20%Diesel80%Gas.
Jinan12Cylinder190,100pcs.Engineisoperatingwith20%Diesel80%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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HUEGLITECHSWITZERLAND
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HUEGLI TECH AG (LTD)Murgenthalstrasse 304900 Langenthal SwitzerlandPhone: +41 62 916 50 30Fax: +41 62 916 50 35
HUEGLITECHSWITZERLAND
Solution Provider for:• GasManagementSystems• DualFuelConversionSystems• GoverningSystems• AutomationSystems• EngineProtection• StartingSolutions• BatteryCare• OilTreatmentandRecycling• ThermostaticControlValves