OptiBlend Advantages
Operation &
Installation
Major
Components
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Installation & Operating
The OptiBlend System is easy to install, and it requires no changes to the injection timing, valve timing, compression ratio, or any other OEM components. No internal engine modifications are required
The OptiBlend System can be retrofitted in the field, as all of the components are mounted externally on the engine. This can be done in 1-2 days while the engine is operating, with only an hour of downtime needed for changeover. The system requires 1-5 PSI of available natural gas pressure, with approximately 9 SCFH/kW of supply capacity. Hythane Company offers turnkey installation, including coordinating necessary civil work when required.
Once the OptiBlend System is installed and there is adequate fuel supplied to the engine, a Hythane Engineer will perform final tuning of the system. The commissioning procedure includes the verification of all engine protection systems and optimization of fuel cost savings across the entire load range.
The OptiBlend System includes the electronic control and engine protection system, gas delivery system, gas/air mixer and smart gas control valve components.
Theory of Operation
Diesel fuel CI engines retrofitted with the OptiBlend dual fuel kit subsequently use natural gas as the primary fuel. The advantages are both economical and environmental. Typically 50% to 70% of the diesel fuel can be safely displaced with natural gas. This greatly reduces the NOx formation due to lower combustion temperature than diesel fuel; NOx emissions reductions of 60% or more are typical. In addition, due to the lower carbon content of natural gas, less CO2 is generated. An optional diesel oxidation catalyst can also be added to the engine conversion, which will nearly eliminate HC and CO emissions. The OptiBlend system is designed to allow for fuel switching during full or part load conditions, without interruption of engine speed or power. The natural gas is fumigated to the engine cylinders using the stock air intake system. When the diesel fuel is injected into the combustion chamber, it acts as a pilot ignition source for the air-gas mixture. The gas control valve adjusts the fuel flow to the engine based on the generator load (kW).
The OptiBlend gas fuel control is a rugged industrial PLC. If the following parameters are exceeded, the PLC will reduce the flow command to the gas control valve:
- Exhaust gas temperature too high
- Knock detected
- Vibration too high
- Frequency out of range
- Diesel Fuel too low
- High or low engine load
The PLC will disable the gas flow by de-energizing the gas lock-off solenoid under the following conditions:
- Emergency Stop switch is open
- Dual Fuel Enable switch is open
- Gas Control Valve OK relay is open
- Knock Detection OK relay is open
- Low or High load limit exceeded