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The goal of this project was to demonstrate a low emissions, high efficiency heavy-duty on-highway natural gas engine. The emissions targets for this project are to demonstrate US 2010 emissions standards on the 13-mode steady state test. To meet this goal, a chemically correct combustion (stoichiometric) natural gas engine with exhaust gas recirculation (EGR) and a three way catalyst (TWC) was developed. In addition, a Sturman Industries, Inc. camless Hydraulic Valve Actuation (HVA) system was used to improve efficiency. A Volvo 11 liter diesel engine was converted to operate as a stoichiometric natural gas engine. Operating a natural gas engine with stoichiometric combustion allows for the effective use of a TWC, which can simultaneously oxidize hydrocarbons and carbon monoxide and reduce NOx. High conversion efficiencies are possible through proper control of air-fuel ratio.

The goal of this project was to demonstrate that a Mack E7G engine operating stoichiometric with Exhaust Gas Recirculation (EGR) and a three-way catalyst can meet the 2010 emission standards for heavy-duty on-highway engines. Results using natural gas and gasoline as the fuel are presented. The Mack E7G is currently a lean burn natural gas fueled engine, which was originally derived from the diesel engine. The calibration of the lean burn engine was modified to operate as a stoichiometric engine. An EGR system and a three-way catalyst were added to the engine. One of the lean burn natural gas ratings for this engine is 242 kW at 1950 rpm and 1424 N-m, at 1250 rpm. This rating was also used for the stoichiometric natural gas engine. Transient emissions and 13-mode steady-state emissions tests were conducted on the engine on natural gas. The engine meets the transient emission standards for 2010 for NOx, NMHC, and CO on natural gas.