KAMAT High-Pressure Pump Unit optimises Methanol Injection Test Bench

High-precision high-pressure technology for research into efficient methanol injection systems

The use of methanol as an alternative marine fuel requires extensive modifications to the fuel injection systems of marine engines. In addition to chemical and physical properties, injection pressure, droplet size and combustion processes are critical to efficiency.

The Research Centre for Internal Combustion Engines and Thermodynamics Rostock (FVTR GmbH) operates a state-of-the-art methanol injection test bench to analyse these factors. For a stable high-pressure supply, FVTR GmbH relies on the KAMAT high-pressure system – a tailor-made solution with high-pressure stability and variable flow rate.

You can find out more about our high-pressure systems here: KAMAT high-pressure systems.

Challenges in developing methanol injection systems

Methanol is very different from conventional fuels. The main challenges are:

• Low viscosity and density: This affects the flow behaviour in the injection system and can lead to leakage losses or cavitation.
• High evaporation enthalpy: efficient mixture formation requires optimised injection strategies for uniform atomisation.
• Aggressive corrosion behaviour: materials and sealing systems must be designed to withstand long-term exposure to methanol.

FVTR GmbH’s methanol injection test bench therefore focuses on investigating these parameters under realistic operating conditions in order to maximise the efficiency and service life of modern injection systems.

KAMAT high-pressure technology for methanol injection test bench

To ensure reproducible results under different operating conditions, the test bench requires a flexible high-pressure supply that can respond quickly and accurately to varying load conditions.

The high-pressure system supplied by KAMAT offers the following technical features:

• Variable flow rate: from less than 2 l/min to 20 l/min at a constant 1000 bar
• High control accuracy: constant pressure supply for precise injection conditions
• ATEX certification for zone 1: safe use in explosive environments
• TA-Luft compliant sealing system with sensor: leak detection and prevention
• External oil pressure supply for highly variable methanol delivery rates (<10%): adaptation to different test requirements

In addition, the system has a hermetically sealed magnetic coupling on the booster pump to ensure a contamination-free and sealed system. A suction line with filter and stabilisation section ensures laminar flow conditions and optimum injection characteristics.

The KAMAT pump unit thus provides a continuously stable pressure supply, which is essential for scientifically usable test bench results.

Methanol injection research at FVTR GmbH

The FVTR GmbH uses the methanol injection test bench to optimise the injection technology and fuel processing. The main research topics are:

• Optimisation of the injection process for various load ranges
• Analysis of the spray and atomisation behaviour of methanol
• Investigation of the injection pressure, nozzle geometry and injection angle
• Material tests for long-term resistance to methanol
• Compatibility with existing high-pressure systems

These findings are crucial for the development of efficient and low-emission methanol engines that meet future environmental requirements.

Why KAMAT for high pressure systems in methanol injection test benches?

The demands on high-pressure supply in injection test benches are particularly high: Precision, reproducibility and robustness are crucial for usable results. KAMAT supplies a tailor-made high-pressure solution that is specially optimised for research applications.

Benefits at a glance:

• Stable pressure control: high precision for reproducible test stand results
• High-quality materials: components designed for long-term use with methanol
• Flexibility: variable delivery rates for different injection strategies
• Reliability : low-maintenance design for smooth continuous operation

The development of efficient methanol injection systems is a decisive step towards the decarbonisation of shipping. KAMAT’s high-pressure pump unit provides FVTR GmbH with a powerful and reliable pressure supply for its methanol injection test bench.

Are you planning a high-pressure system for alternative fuels? Contact us – we will develop a solution to meet your needs.