4. Heavy duty long haulage bio-methane engine with mild electric powertrain

Lead partner: FPT Industrial

Objectives:

  1. Assess the specific advantages of a new combustion concept, with a target of thermal efficiency up to 50%;
  2. Demonstrate a minimum reduction of 30% gaseous emissions (NOx, CO, NMHC and CH4) and PN compared to Euro VI limits at test bench on WHTC with bio-methane. Target for NOx is 0.1g/kWh;
  3. Demonstrate effective emissions levels with bio-methane on a demonstrator vehicle running in real driving conditions with CF=1;
  4. Demonstrate 10% fuel efficiency compared to state-of-the-art 2018 stoichiometric natural gas vehicles in real driving conditions, complementing vehicle results with energy recovery systems results from test bench.


1. Thermodynamic analysis and 1D simulations [AVL – Dec 2020]
Thermodynamic cycle simulation (1D) of stoichiometric spark ignited gas engine, specification of basic engine parameters such as compression ratio, EGR- and charging concept, heat release characteristic, peak cylinder pressure, knock behaviour.

2. CFD simulations and single-cylinder test bench activity [IFPEN – Aug 2022]
Report on the development activity of the combustion system by 3D CFD calculation, analysis of the engine tests results and optimized configuration with its efficiency and pollutants potential for a HD gas engine.

3. Engine integration with new sub-systems [FPT – Aug 2022]
A report which will describe the experimental work performed regarding ‘engine installation at test bench and integration with energy recovery sub-systems‘. The base engine will be installed and will be measured to determine the baseline. Following that, it will be upgraded with eTurbo, WHR and a specific cranktrain, all aimed at reducing fuel consumption. After each step, measurements will be carried out to accurately determine the benefits on fuel consumption.

4. Output from multi-cylinder test bench activity with bio-methane [FPT – Jun 2023]
A report which will describe the experimental work performed regarding ‘testing and evaluation of engine performance and selected aftertreatment system with bio-methane‘. Testing activity will be aimed at the optimization of the engine‚Äôs efficiency in stationary and transient conditions. Target is to improve by 10% the fuel efficiency over the ACEA cycle. Emissions level will be also addressed and assessed on combined WHTCs using the ATS developed in 2. Future powertrains for heavy duty vehicles.

5. Vehicle testing results [IVECO – Jun 2023]
Final report including the results of independent functional vehicle performance testing.

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