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Single-cylinder engine tests were conducted as part of a long-range effort to develop a technology base for coal-fueled stationary modular power plants based on the Cooper-Bessemer LS Series four-stroke diesel engine. These engine test results established the new state of development for this technology as well as setting priorities for the remaining R&D effort on specific components. The current outlook on the overall economics of coal diesel power is presented, indicating that CWS processing cost dominates the question of economic feasibility. A description of the coal-tolerant fuel injection system development is also given. Wear results indicate that nozzle erosion is the critical element in extending the duration of continuous engine operation. Substantial nozzle wear was observed in just two hours of CWS operation. The ash content of the coal was found to affect the wear rate of the ring set as well as the nozzle tip. Combustion results indicate that the natural gas jet cell is a viable ignition aid and that the variable area poppet nozzle, which lends itself to the use of durable coatings, provides satisfactory engine performance.

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Successful operation of the Cooper-Bessemer JS-1 engine on coal–water slurry (CWS) fuel has been achieved at full power output, part load, and part speed conditions with varying degrees of diesel pilot fuel including zero pilot (auto-ignition of CWS). Selected results of the effect of pilot fuel quantity, pilot fuel timing, and manifold air temperature on engine performance are presented. Also, the influence of injector nozzle hole size and CWS mean particle size on engine performance is studied. High injection pressures resulted in good atomization of CWS and in combination with heated combustion air resulted in short ignition delays and very acceptable fuel consumption. Low CO/CO2 ratios in exhaust gas analysis confirmed good combustion efficiency. NOx emissions are compared for CWS and diesel fuel operation of the engine. Effect of injector nozzle hole size and manifold air temperature on NOx emissions is studied.

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