Lessons From the Conversion of a Heavy-Duty Compression Ignition Engine to Natural Gas Spark Ignition Operation

Partial conversion of the large inventory of compression-ignition engines to natural-gas (NG) spark-ignition lean-burn operation can reduce U.S. dependence on imported petroleum and enhance national energy security. This paper describes some of the observations made during such an engine conversion and proposes some solutions to alleviate some of the potential issues. The engine conversion in this study consisted from replacing the diesel injector with a spark plug and adding a port fuel injection system for NG delivery. The results indicated that the retrofitted engine performed reliably at lean-burn conditions, despite the different combustion characteristics compared to conventional SI engines. However, the squish region will trap an important fuel fraction (∼30%) and experience less-optimal burning conditions, hence a slower burning rate. This affected the engine efficiency and increased the unburned hydrocarbon and carbon monoxide emissions. From a combustion point of view, the operation of such converted engines can be optimized by increasing the bowl-to-squish volume ratio, optimizing the piston shape (e.g., by removing the central protrusion and avoiding 90-degree edges inside the bowl). The original compression ratio may also need to be reduced to avoid knocking. Moreover, direct gas injection and/or intake charging will increase the volumetric efficiency, which will benefit engine efficiency and emissions.