[Gasification] Integration of Ford fuel injection/Producer-Gas

[Mark Ludlow]

Great report, Andy!

And a great job of integrating existing engine control systems into your
bio-hybrid! Three lb/mile of fuel seems reasonable; what fuel were you
using? Pictures?

Mark

-----Original Message-----
From: gasification-bounces at listserv.repp.org
[mailto:gasification-bounces at listserv.repp.org] On Behalf Of andy schofield
Sent: Wednesday, July 04, 2007 6:50 PM
To: gasification at listserv.repp.org
Subject: [Gasification] Integration of Ford fuel injection/Producer-Gas

Dear members,

   I installed my gas-plant aboard an F-150 shortbox 4x4 pickup. The old GMC

is worn-out. This Ford engine has good wear-condition despite the 195000 
miles it has covered since new.
The engine is an electronic fuel injected 5.0 L. The computer makes 
operation very stable. I found much information here: fordfuelinjection.com 
. Although this engine does not use a Mass Air Flow (MAF) sensor (It 
instead, uses Ford's "speed density" stratagy), current REPP discussion 
covers MAF sensors, They are touched on under the 'Sensors' section in that 
site. Builders may find this component useful for measurement in clean 
gas-streams.

This set-up features improved producer-gas/air mixer, with remote-manual 
air-control. The driver can read engine-exhaust excess-air during 
steady-state cruising. The signal is quite noisy during conditions other 
than steady-state. The signal reads very high when manually inducing draft 
on the gasifier for warm up. The Electronic Control Module (ECM) shares the 
Heated Exhaust Gas Oxygen (HEGO) signal with the new display in the cab.

   Lighting-off and warming up the gasifier is affected using induced-draft 
from the engine fueled by gasoline. One mile in first gear at 2500 RPM 
brings the hearth to gas-making temperature. Opening a switch in the 
electric fuel-pump relay control circut when gasification temperature is 
attained, stops gasoline flow to the (eight) 19Lb/hr injectors. The 
injectors still cycle open and shut. A better system (in the future, nothing

automated exists yet) should  lean-out the gasoline more gradually, when 
transitioning to full woodgas. Then come back in proportionally when the 
machine is climbing a steep grade. Engine-combustion air should increase to 
lean the total mixture in this mode. Doing this manually and very roughly, 
we increased the range of the 15-gallon tank by 65 miles however, I 
raced-back to the shop on gasoline 18 miles with the gasifier "cold iron" 
when I blew a gas-filter during the last gasoline fill-up (when serious 
testing began).

  This simple woodgas set-up does not share the load with gasoline, except 
when heating the hearth. The computer still controls spark-advance (with 
detonation sensing), exhaust gas recirc, senses intake manifold pressure, 
water-jacket temperature, cruise speed PID control, exhaust-catylist air, 
and some valves to control evaporation in the gasoline-storage tank at all 
times.

Wood consumption is around three pounds per mile for this machine on a mix 
of flat and hilly roads, and soft sand trails. I've driven it 60MPH on flat 
terrain. Most power is around 2500 RPM. The (seven) tuyere whistle loudly 
when the throttle-body is wide-open. The exhaust tone is softer, and may 
allow a less flow-restrictive muffler for the same sound-level.

   I welcome suggestions. Happy Independence Day!

Andy Schofield
Great Lakes Renewable Fuel systems

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