Background: Autonomy Limitation in CNG Trucks
Heavy-duty trucks powered by Compressed Natural Gas (CNG) are a cleaner and more economical alternative to diesel, offering up to 40% fuel savings and reduced emissions. However, they face a critical limitation in driving range due to:
- Lower energy density of CNG compared to diesel.
- Restricted tank capacity.
- Need for more frequent refueling infrastructure.
The 360ES-PEM-H2+O2 system addresses this challenge by enhancing combustion efficiency through controlled hydrogen and oxygen injection, delivering 20-30% increases in efficiency and autonomy, making CNG trucks more competitive against diesel in long-distance transport.
GGE stands for Gasoline Gallon Equivalent. It is the unit used in the United States to compare the energy content of CNG with gasoline.
- 1 GGE = 114,000 BTU ≈ 33.7 MJ ≈ 9.4 kWh of energy.
- 1 gallon of gasoline contains ~33.7 MJ (≈ 9.4 kWh).
- Diesel contains ~128,000 BTU per gallon (≈ 35 MJ ≈ 10.0 kWh).
Executive Summary
This document compares the performance of the Shacman X3000 Golden Version CNG, both in its standard configuration and with the addition of the 360ES-PEM-H2+O2 hydrogen injection system. It integrates scientific references (NASA 1979, Natkin & Sorenson 1979) and modern engineering design to explain why and how efficiency and autonomy increase.
For the Shacman X3000 CNG, its tank capacity of 35 kg of CNG equals ~43 GGE, meaning the same energy as ~400 kWh of gasoline.
Shacman X3000 CNG Base Data
Engine
CNG, 430 HP, 2000 N-m
Displacement
13 liters (brochure) / 11.6 liters (technical specification)
CNG Capacity
35 kg (~43 GGE)
Performance
3-5 miles/GGE
Autonomy
129-215 miles
Average performance: 4 miles/GGE
Autonomy: ~172 miles
Base efficiency: standard CNG combustion
Comparative Analysis
| Feature | Shacman X3000 CNG (Base) | Shacman X3000 CNG (With 360ES-PEM-H2+O2) |
|---|---|---|
| Performance (miles/GGE) | 3-5 | 3.6-6.5 (+20% to +30%) |
| Autonomy (miles) | 129-215 | 155-280 (+20%) / 168-323 (+30%) |
| Engine efficiency | Base | 20-30% improvement |
| CNG consumption | Base | 20-30% less |
Why and How Efficiency and Autonomy Increase
The improvement is explained by fundamental combustion physics validated by NASA and Natkin & Sorenson:
1. Hydrogen as ignition promoter
- ‣High flame speed stabilizes combustion in lean mixtures.
- ‣Small doses of H2 accelerate flame propagation, increasing the fraction of fuel burned.
2. Additional oxygen availability
- ‣Controlled O2 injection improves local oxygen concentration.
- ‣Ensures more complete combustion and faster reaction rates.
3. Microcomputer-controlled dosing (Tuner)
- ‣Reads RPM, MAP, intake temperature, throttle position.
- ‣Adjusts electrolysis and dosing per second.
- ‣Synchronizes spark ignition timing with H2+O2 dosing.
- ‣Prevents knocking and over-injection, maximizing efficiency.
4. Resulting operational benefits
- ‣More complete combustion -> less unburned fuel.
- ‣Higher thermal efficiency -> more usable torque.
- ‣Reduced specific fuel consumption -> extended autonomy.
Energy Production from 1 Liter of Water
The PEM electrolysis cell in the 360ES-PEM-H2+O2 system separates water into hydrogen and oxygen:
- 1 gallon of water = 3.78 liters = 210 moles.
- Electrolysis yields:
- 210 moles of H2 (≈ 4700 liters of hydrogen gas at STP).
- 105 moles of O2 (≈ 2350 liters of oxygen gas at STP).
- Energy content of H2 produced:
- Each mole of H2 = 286 kJ.
- 210 moles = 60 MJ (≈16.7 kWh).
Thus, 1 gallon of water can generate ~16.7 kWh of usable energy in the form of H2, which is used as an additive to optimize combustion, not as a primary fuel.
Benefits of the 360ES-PEM-H2+O2 System
- Extended autonomy: up to 323 miles per CNG load.
- Efficiency increase: more complete combustion with H2+O2 dosing.
- Precise ignition control: microcomputer tuner synchronizes spark timing with additive injection.
- Operational profitability: longer refueling stops, lower CNG consumption.
- Environmental sustainability: reduced CO, HC, and soot emissions.
Conclusion
The 360ES-PEM-H2+O2 system leverages proven scientific principles (NASA, Natkin & Sorenson) and modern adaptive control to deliver measurable efficiency and autonomy gains in CNG spark-ignition engines.
By integrating hydrogen and oxygen dosing, PEM electrolysis, and microcomputer-controlled ignition timing, the system transforms the autonomy limitation of CNG trucks into a competitive advantage, making them more profitable and sustainable for long-haul operations in the U.S. market.
Consumer Field Test
See how the 360ES-PEM system delivered a 55% fuel efficiency improvement on a high-performance Range Rover Sport.
Read Consumer Field TestCommercial Field Test
Explore the 20% fuel efficiency gains and operational benefits validated on a Volvo DD 9800 heavy-duty vehicle.
Read Commercial Field Test