Modern Diesel Engine Conversion (MDEC) Technology for JP-8 Operability

Navy Expeditionary Forces must be able to reliably operate acquired vehicles andequipment on JP-8, a standardized fuel mandated by the U.S. Department of Defense (DoD).JP-8 is a prescribed blend of hydrocarbons that exhibit different properties than Ultra Low SulfurDiesel (ULSD) and other modern standardized diesel fuels. Due to these differences, the Navymust use only Tier 3 certified engines (2010 and earlier) in its operations. Tier 4 dieselequipment fueled on JP-8 become unreliable and, in some cases, inoperable due to a severalfactors including sulfur poisoning of the aftertreatment catalysts. Further, it is known that JP-8,when used in factory calibrated Tier 4 engines results in lower overall power output due to thefuelĺs lower viscosity and heating value compared to ULSD. In this Phase I project, Exergi willdevelop it Modern Diesel Engine Conversion (MDEC) technology solution to this problem bykeeping much of the existing technology on Tier 4 engines with exception to the aftertreatmentand use custom software to reprogram the engine control unit (ECU). The solution will result inequal or better performance than the Tier 4 engine when operating on ULSD while meeting Tier3 (pre-2010) emissions standards.Exergi brings a team of diesel engine experts together with extensive experience in design,software calibration, testing, and fabrication. The MDEC innovation to solve the Navyĺs problemto fuel commercial off the shelf (COTS) Tier 4 diesel engines with JP-8 is to replace the Tier 4aftertreatment train (DOC, DPF, and SCR) with a conventional muffler and configurable exhaustducting by providing a newly programmed ECU that uses the remainder of the COTS enginecomponents. The solution retains most of the other componentry of the engine including theEGR system, which can be tuned to operate at lower levels for JP-8 operation while stillresulting in rated torque. The primary innovation to be implemented in the solution will be theengine re-calibration effort, which relies on the extensive diesel engine development experienceof the Exergi team and its consultants. The MDEC solution represents the best possibleoutcome for reliable diesel engines of all power ranges for Navyĺs operations in the U.S. andabroad.