EGVIA - ERTRAC 1st European Conference Results from Road Transport Research in H2020 projects 29 November 2017 to 30 November 2017 Brussels

1. This project has received funding from the
[European Union’s Horizon 2020 research and
innovation programme under grant agreement
No 653391
HDGAS
Heavy Duty Gas Engines
integrated into Vehicles
Gernot Hasenbichler
Gernot.hasenbichler@avl.com
Project status & results
EGVIA conference
Brussels, November 30, 2017

2. This project has received funding from the
[European Union’s Horizon 2020 research and
innovation programme under grant agreement
No 653391
Agenda
• Introduction
• Objectives and achievements
• Outlook and challenges
• Final event, impact, publications

3. This project has received funding from the
[European Union’s Horizon 2020 research and
innovation programme under grant agreement
No 653391

4. This project has received funding from the
[European Union’s Horizon 2020 research and
innovation programme under grant agreement
No 653391

5. This project has received funding from the
[European Union’s Horizon 2020 research and
innovation programme under grant agreement
No 653391
Main objectives
Engine
Fuel
system
Aftertreatment
system

6. This project has received funding from the
[European Union’s Horizon 2020 research and
innovation programme under grant agreement
No 653391
Project structure

7. This project has received funding from the
[European Union’s Horizon 2020 research and
innovation programme under grant agreement
No 653391
WP2
OBJECTIVES AT A GLANCE
• Development of LNG tank systems for different
engine types:
- Spark ignited
- Dual fuel
- Compression ignited
• Development and standardization of fueling
interface for LNG truck fueling
LNG vehicle fuel systems and standardization

8. This project has received funding from the
[European Union’s Horizon 2020 research and
innovation programme under grant agreement
No 653391
WP2
ACHIEVEMENTS
✓ Tank system layout defined
✓ Prototype tank systems have been developed and have partly being delivered
✓ Low pressure system delivered to MAN
✓ Medium pressure system delivered to Iveco
✓ High pressure pump has been developed and built up. Delivery to OEM
according time schedule of OEM
✓ Simulation of the refueling process has been performed containing
✓ Pressure behavior in the tank (vapor collapse)
✓ Spray bar positioning
✓ Standard for LNG refueling interface created and presented to ISO
✓ Prototype fueling nozzles and receptacles have been delivered and being tested
LNG vehicle fuel systems and standardization

9. This project has received funding from the
[European Union’s Horizon 2020 research and
innovation programme under grant agreement
No 653391
WP3
Exhaust after treatment systems and emission control
OBJECTIVES AT A GLANCE
• To use fundamental studies to develop and deliver aftertreatment
systems for natural gas applications:
 Stoichiometric
 lean NG
 Dual fuel
 HPGI (carry over form diesel EU VI)
• Ageing impact study on methane oxidation catalyst
• Calibration of systems to meet Euro VI emissions limits

10. This project has received funding from the
[European Union’s Horizon 2020 research and
innovation programme under grant agreement
No 653391
WP3
ACHIEVEMENTS
✓ Novel MOC reducing the impact of ageing
✓ SCR catalyst dedicated to NG engine applications for the higher exhaust
temperature and mimimized N2O formation
✓ Sulphur removal strategy developed to maintian efficiency of methane
oxidation catalyst.
✓ Aftertreatment systems delivered to partners
✓ Calibration of aftertreatment system under development
Exhaust after treatment systems and emission control
150 200 250 300 350 400 450 500 550
0,0
0,1
0,2
0,3
0,4
0,5
0,6
0,7
0,8
0,9
1,0
NOconversion
Temperature, °C
Cu-SCR2
Fe-SCR1
V-SCR1
Fe-SCR1+Cu-SCR2

11. This project has received funding from the
[European Union’s Horizon 2020 research and
innovation programme under grant agreement
No 653391
WP4
OBJECTIVES AT A GLANCE
• Development of two versions (stoichiometric
and lean burn) of a new direct positive
ignition NG engine capable of:
 > 10% fuel efficiency
 10% reduced GHG emissions
 10% higher performance in
comparison with current engines
 Vehicle range > 800km
Low pressure direct injection spark ignited engine

12. This project has received funding from the
[European Union’s Horizon 2020 research and
innovation programme under grant agreement
No 653391
WP4
ACHIEVEMENTS
✓ 1D and CFD simulation of stoichiometric and lean burn concept
performed
✓ SCE testing finalized, HW for multi-cylinder engine selected
✓ Procurement and construction of prototype engines
✓ Both engine concepts are operating on the test bed and being optimized
✓ Summary of results from engine tests (to date)
 Fuel efficiency target reached for stoichiometric engine (BSFC
190g/kWh of G20 in best point)
 10% Increased performance feasible
 Emission compliance not an issue on stoich concept
✓ Vehicle assembly in progress
Low pressure direct injection spark ignited engine

13. This project has received funding from the
[European Union’s Horizon 2020 research and
innovation programme under grant agreement
No 653391
WP5
OBJECTIVES AT A GLANCE
• Development of a low pressure port injected dual
fuel engine capable of:
 15% diesel substitution increase compared
to 2013 state of the art dual-fuel HD
engines
 10% reduced GHG emissions compared to
present diesel vehicle
 Exhaust emissions meeting EU VI
 Diesel-like performance and driveability
 Vehicle range > 800km
 Vehicle to operate in pure diesel mode
Low pressure port injected dual fuel engine

14. This project has received funding from the
[European Union’s Horizon 2020 research and
innovation programme under grant agreement
No 653391
WP5
ACHIEVEMENTS
Engine:
✓ Simulations carried out, controls developed
✓ Calibration of WHTC is ongoing in order to find the best
trade off between Nox and CH4
✓ Warm up and warm keeping strategies are being worked
out in order to reduce emissions in cWHTC and meet
composite WHTC limit
✓ First version of Fuel Quality Sensor and LNG Tank
installed
✓ Vehicle ready for engine integration
✓ LNG refueling test for WP2 carried out
Low pressure port injected dual fuel engine

15. This project has received funding from the
[European Union’s Horizon 2020 research and
innovation programme under grant agreement
No 653391
WP6
OBJECTIVES AT A GLANCE
• To develop and demonstrate a new Heavy Duty Methane
Gas engine and vehicle, based on a High Pressure Direct
Gas Injection (HPGI) with:
 Exhaust emissions meeting EU VI
 > 20% reduction of greenhouse gas emissions
compared to present diesel engine
 Same engine power, torque and drivability as diesel
engine
 > 90% substitution of diesel in real driving cycle
 > 800 km driving range
High pressure gas direct injection engine

16. This project has received funding from the
[European Union’s Horizon 2020 research and
innovation programme under grant agreement
No 653391
WP6
ACHIEVEMENTS
✓ Prototype injector developed and performance proven by tests
✓ Combustion system optimization by CFD
✓ Single cylinder testing completed and hardware for multi cylinder selected
✓ Multi cylinder testing ongoing, fulfilment of project targets verified
✓ Vehicle under development with:
 device to mitigate all methane boil-off
 low friction LNG pump
✓ Summary of results from engine tests (to date)
 Fuel efficiency better than diesel
 Soot emissions close to zero
 Methane emissions engine-out meeting EU VI
 > 90% substitution of diesel
High pressure gas direct injection engine

17. This project has received funding from the
[European Union’s Horizon 2020 research and
innovation programme under grant agreement
No 653391
WP7
OBJECTIVES AT A GLANCE
• Independent assessment of the achieved
results compared to state of the art from
2013:
 GHG and CO2
 Driving range
 Emission compliance on test bed and
on road
• Cost assessment
HIGHLIGHTS
 Testing procedures defined
 Baseline testing performed
 First target testing planned
December 2017 ( dual fuel engine)
Independent testing and overall assessment

18. This project has received funding from the
[European Union’s Horizon 2020 research and
innovation programme under grant agreement
No 653391
WP8
▪ Publication of results
☑ under ‘latest news’ &
☑ in newsletter
-> please subscribe !
▪ Publishable summaries
☑ under ‘results’
☑ regular updates
Dissemination, communication and
preparative exploitation activities
progress:

19. This project has received funding from the
[European Union’s Horizon 2020 research and
innovation programme under grant agreement
No 653391
Outlook and challenges
Low pressure
port injected
dual fuel
engine
Low pressure
direct
injection spark
ignited EGR
engine
High pressure
gas direct
injection diesel
pilot ignition
engine
WP7: Independent testing and overall assessment
WP3: Engine aftertreatment system
WP2: Advanced LNG vehicle fuel system
WP2: Tank and fuel systems have been developed and have
been delivered to the vehicle OEMs. Integration of a new
partner as supplier for high pressure gas system and reduction
of gas pressure from 500 to 300 bar will secure a proper
operation in the vehicle
WP3: Methane conversion efficiency and catalyst ageing are
being considered as main challenge. New catalyst compositions
will make a major contribution being emission compliant
without major fuel efficiency penalties by applying targeted
thermal management
WP4: The stoichiometric SI engine is considered as straight
forward technology with no concerns in terms of emission
compliance. With several new technologies being implemented,
major steps reducing fuel consumption will be realized. The
goal of 10% reduction on best point has been reached, while
reduction of 10% GHG emission remains challenging.
The lean burn version should easily reach the targets connected
to improved efficiency while compliance with emission level of
methane is the main challenge
WP5: Dual fuel engines offer great flexibility to its operators
while the LNG network still needs improvements in terms of
coverage. Reaching the 10% of CO2 reduction has been
achieved already. Being emission compliant in all conditions still
remains as the main challenge. To achieve this aim the
optimization of transient conditions and the maintenance of
the MOC catalyst over a range of temperature is crucial.
WP6: HPGI offers high CO2 reduction potential (>20%) as well
as no major concerns in terms of emission compliance. System
complexity and cost are areas to be in focus
WP4
WP5
WP6

20. This project has received funding from the
[European Union’s Horizon 2020 research and
innovation programme under grant agreement
No 653391
Final Event: 11 April 2018
Final Event and Exhibition:
▪ Date & Place: Wednesday April 11, Turin, Italy, CNH Industrial Village
▪ Program: Meeting presentations followed by large-scale exhibition
▪ Presentation of FPT demonstrator truck– outside test rides possible;
engines of MAN and VOLVO available too
▪ HDGAS Final Event will be announced via partners’ websites and NGVA

21. This project has received funding from the
[European Union’s Horizon 2020 research and
innovation programme under grant agreement
No 653391
Publications (1)
Title 1st Author Partner Conference/ Journal Year
Case study of a modern lean-burn methane
combustion catalyst for automotive applications: What
are the deactivation and regeneration mechanisms
Niko M.
Kinnunen
University
of Eastern
Finnland
Science direct 2017
The effect of CH4 on NH3-SCR catalysts for lean-burn
NG vehicles
Roberta
Villamaina
Politecnico
di Milano
EuropaCat 2017 2017
The effect of CH4 on NH3-SCR over metal-promoted
zeolites and V-based catalysts for lean-burn NG vehicles
Roberta
Villamaina
Politecnico
di Milano
Durability evaluations and rapid ageing methods in
commercial emission catalyst development for diesel,
natural gas and gasoline applications
Teuvo Maunula Springer 2017
Regeneration of a methane oxidation catalyst:
Fundamental understanding of sulfate species
decomposition with model catalysts
Niko M.
Kinnunena

22. This project has received funding from the
[European Union’s Horizon 2020 research and
innovation programme under grant agreement
No 653391
Publications (2)
Title 1st Author Partner Conference/ Journal Year
Natural Gas Engines for Long-Haulage Applications:
Current Approach and Future Developments
Stefano Golini FPT 16th Conference „The Working Process
of the Internal Combustion Engine“,
Graz
2017
Gas Exchange and Injection Modeling of an Advanced
Natural Gas Engine for Heavy Duty Applications
Davide Paredi Politecnico
di Milano
ICE 2017 - 13th International
Conference on Engines and Vehicles,
Capri
2017
FPT Industrial’s Leadership in Natural Gas Technologies
for Industrial Engines
P. Krähenbühl FPT 38th Internationales Wiener
Motorensymposium, Wien
2017
HD GAS – Heavy Duty Gas Engines integrated into
vehicles
Johann
Weinzierl
MAN EGVIA workshop on “European funded
project results: Reduction of CO2
emissions from Heavy-Duty Trucks
2017
A High Efficiency Lean Burn Mono Fuel Heavy Duty
Natural Gas Engine For Achieving Euro VI Emissions
Legislation & Beyond
Andrew Auld Ricardo 12th International MTZ Conference on
Heavy-Duty, On- and Off-Highway
Engines 2017 Conference in Augsburg,
Germany on 28th November 2017
2017
A simulation approach to meeting Euro VI emissions
legislation with a natural gas lean burn heavy duty
engine
Andrew Auld Ricardo The IMechE Internal Combustions
Engines 2017 Conference in
Birmingham, England on 6th December
2017
2017

23. This project has received funding from the
[European Union’s Horizon 2020 research and
innovation programme under grant agreement
No 653391
Expected or potential impact
Technological impact
▪ The main challenges of gas powered HD vehicles are: Vehicle costs, vehicle performance,
vehicle/engine availability and infrastructure. Except the last item (infrastructure) all items
will be covered and hurdles being lowered in this project.
Environmental impact:
▪ Reducing GHG by min. 10% from 2013 state of the art HD engines will contribute to limit
global warming
▪ Gas enignes with help to improve air quality due to the fact that they emit significantly less
pollutants
▪ Using biogas instead of Natural gas would further reduce the CO2 by over 90%
Economical and social impact:
▪ Providing know how in terms of gas engines and LNG vehicles to the EU industry, enables
the development and sales of related products - strengthen the industry – securing jobs
within the EU

24. This project has received funding from the
[European Union’s Horizon 2020 research and
innovation programme under grant agreement
No 653391
Achievements - overview
Indicator Units used Project
reference
Project
objective
Current
achievements
Types of
vehicles
CO2 or fuel consumption
reduction
CO2 [g/km] and [%] Best in class 2013 Min 10% No final result yet
available
HD vehicles
Pollutant emissions
reduction
(EU VI compliant)
[g/kWh] EU VI EU VI in WHTC Preliminary results show
compliance of all
technologies
HD vehicles
Demonstrator developed
3 HD trucks with gas
enignes and LNG system
- HD vehicles
Min range of 800km
Km - Min 800km Not verified yet HD vehicles

25. This project has received funding from the
[European Union’s Horizon 2020 research and
innovation programme under grant agreement
No 653391
END
of
PRESENTATION
www.hdgas.eu