Waukesha Engine, in cooperation with the Department of Energy, has designed a new high efficiency natural gas engine designed specifically for the power generation market. The APG1000 (Advance Power Generation) engine is capable of achieving 1 MW output at 42% thermal efficiency and less than 1 g/bhp-hr Nox. A design method using modern tools such as 3-D modeling, rapid prototyping and computer simulation have, in a large part, contributed to the success of this engine. This paper discusses the methodology and tools used in the design of the APG engine.

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