Modular 9.0L and 4.5L Non-Road Spark-Ignited Engines for Power Generation

Following the successful commercial use of a 9.0L, V-8 automotive-derivative engine for stationary power generation, a new 4.5L, four-cylinder engine has been developed utilizing a modular family design approach. Substantial commonality of power cylinder components has been achieved including the complete power cylinder and cylinder head. This paper describes the design and development approach to the engine family. These spark-ignited engines are typically used for standby emergency power and demand response applications utilizing commercial grade natural gas or propane. Driving a synchronous electrical generator operating at 60 HZ or 50Hz, engine speeds are either 1800 rpm/3600 rpm or 1500 rpm/3000 rpm respectively, depending upon selection of either a 2-pole or 4-pole alternating current generator. Designed for stoichiometric combustion, the engine configurations can include naturally-aspirated, turbocharged or turbocharged and after-cooled versions. Depending upon end-use applications, exhaust emissions technology and regulatory compliance can be met solely through engine calibration or inclusion of a 3-way catalyst with active air-fuel ratio control. Since the 9.0L engine version was successfully introduced in 2012, significant efforts have been undertaken to achieve commonality of desired features between the existing veeengine and the future in-line versions, including optimization of performance characteristics in consideration of future power rating structures. Starting from 9.0L commercial introduction, the content herein specifically describes the development of the new 4.5L engine with regard to design and analysis.