The Optimization Design for Energy Saving of the LPG Dual Fuel Diesel (DDF/LPG) Engine of a Heavy Du

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Advances in Energy Engineering (AEE) Volume 2, 2014 www.seipub.org/aee

The Optimization Design for Energy Saving of the LPG Dual Fuel Diesel (DDF/LPG) Engine of a Heavy Duty Truck Yang‐Tai Thomas Lin *1, Horng‐Shing Chiou 2, Li‐Shin Lu3 New Environment Foundation

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236, Sec. 2, Fuxing S. Rd., 106 Taipei, Taiwan, R.O.C. Department of Electrical Engineering, Taipei Chengshih University of Science and Technology

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No.2, Xueyuan Rd., 112 Taipei, Taiwan, R.O.C. Department of Mechanical Engineering, Taipei Chengshih University of Science and Technology

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No.2, Xueyuan Rd., 112 Taipei, Taiwan, R.O.C. *1

yttlin36@ms48.hinet.net; 2hschiou@tpcu.edu.tw; 3lslu@tpcu.edu.tw

Abstract Introducing LPG gas into the combustion air intake of a diesel engine acts as an accelerant , promoting the even burning of the diesel fuel , and more complete combustion, resulting in more power being produced and fuel cost savings up to 20% is being achieved through some expensive, modern and sophistical electronic control technology in these few years in Australia,New Zealand,Europe,U.S,Japan and Korea. A much more economical technology by upgrading the early technology of dual‐fuel LPG engines based on a mechanical fumigation system to realized a significant increase in power and fuel cost savings has being developed and presented. The power map and the boost pressure for different loads through 500~3000 engine rpm for both diesel engine and DDF/LPG engine of a Mitsubishi 7545 c.c., 6 cyl. Engine are tested. The results show that the power increase percentage is in proportional to the boost pressure increase rate between the DDF/ LPG engine and the original diesel engine. Since both power and boost pressure are functions of the engine rpm , the fuel consumption of diesel fuel that is proportional to the power is in a function of boost pressure. Therefore , the optimal amount of LPG injection into each cylinder of diesel engine is in a function of boost pressure of the DDF/LPG engine. The boost pressure oriented DDF/ LPG injection controller have been developed and installed on two 11‐ton and 15‐ton refuse trucks and a 35‐ton sandstone trailer respectively. All the three heavy duty DDF/ LPG trucks have run with better performance and 18% fuel cost saving for six months. The cost of the DDF/LPG system of this research is only 5,000 U.S. dollars that is only 1/3 of those of the other modern DDF/LPG Systems. Keywords DDF/LPG; Combustion; Boost Pressure; Oriented Controller; Optimal Injection of LPG; Low Cost Energy Saving System

Introduction Every diesel combustion burns approximately 75% of the diesel in the chamber; by adding a shot LPG into the combustion chamber it is up to 95%. 30% LPG substitution for a Dutch trucking company resulted in 15% saving on fuel cost per vehicle with an overall return on investment of 1.5 years. There are 7 companies produce LPG dual‐fuel systems and another 6 are developing or produce LPG dual‐fuel conversion systems in the world. Two automotive research institutes, in India and China, are engaged in dual‐fuel engine developments (Seisler, 2010). Mixing a shot of LPG with the air through the turbocharger improves the brake specific fuel consumption (BSFC) or the thermal efficiency of the diesel engine. And cost saving up to 20% is been achieved through revamping a DDF/LPG system with ECU and LPG injections near the air intake port of each cylinder of the engine for most heavy duty diesel engines of Euro III and Euro IV emission levels, besides 9~25% CO2 reduction and smoke and particulate emissions decrease significantly; to 40% to 60% by some claims. Four DDF/CNG systems from Japan, USA and New Zealand have been revamped on the diesel buses to conduct the engine performance tests through chassis dynamometer and the off‐road tests on the high way and in sown town Taipei City, Taiwan, R.O.C. for several research projects since 1998 (Lin and Liang, 1998; Lin and Huang, 1998; Lin, 1999; Hsu et al., 2001). The DDF/CNG Bus Project was terminated due to refuelling station safety issues in districts in highly populated metropolitan city. However, 60 LPG

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