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DOE OSTI2020

A control-oriented combustion model framework for compression ignition engines operating on low-reactivity fuel

This work focuses on zero-dimensional modeling of the heat release rate in a compression ignition engine operating on gasoline-like fuels. Due to the properties of gasoline, such as high volatility and longer ignition delay than diesel, the injection strategies can vary significantly from the operation with conventional diesel fuel. Different injection strategies are commonly used to achieve varying degrees of in-cylinder stratification in order to shape the combustion event and maximize efficiency. The proposed zero-dimensional combustion model was developed to account for the different stages in combustion caused by the fuel stratification. As the ignition delay model is an integral part of the entire combustion process and significantly affects the prediction accuracy, special attention has been paid to local phenomena influencing ignition delay. A one-dimensional spray model by Musculus and Kattke was employed in conjunction with a Lagrangian tracking approach in order to estimate the local air–fuel ratio within the spray tip, as a proxy for reactivity. The local air–fuel ratio, in-cylinder temperature and pressure were used in an integral fashion to estimate the ignition delay. Heat release rates were modeled using first-order non-linear differential equations. The proposed combustion model was validated against experimental data of a heavy-duty compression ignition engine with up to three injection events at mostly 1038 r/min and 14 bar brake mean effective pressure. Further validation of the model was carried out at other engine loads and speeds. Model prediction errors in CA50 of less than 1 °CA across all conditions were found. Modeling results of other combustion metrics such as combustion duration and indicated mean effective pressure are also highly satisfactory. In addition, the model has been shown to be capable of estimating the ringing intensity for most conditions.

Pamminger, Michael↗

DOE OSTI2021

Mapping the combustion modes of a dual-fuel compression ignition engine

Compression-ignition (CI) engines can produce higher thermal efficiency (TE) and thus lower carbon dioxide (CO 2 ) emissions than spark-ignition (SI) engines. Unfortunately, the overall fuel economy of CI engine vehicles is limited by their emissions of nitrogen oxides (NO x ) and soot, which must be mitigated with costly, resource- and energy-intensive aftertreatment. NO x and soot could also be mitigated by adding premixed gasoline to complement the conventional, non-premixed direct injection (DI) of diesel fuel in CI engines. Several such “dual-fuel” combustion modes have been introduced in recent years, but these modes are usually studied individually at discrete conditions. This paper introduces a mapping system for dual-fuel CI modes that links together several previously studied modes across a continuous two-dimensional diagram. This system includes the conventional diesel combustion (CDC) and conventional dual-fuel (CDF) modes; the well-explored advanced combustion modes of HCCI, RCCI, PCCI, and PPCI; and a previously discovered but relatively unexplored combustion mode that is herein titled “Piston-split Dual-Fuel Combustion” or PDFC. Tests show that dual-fuel CI engines can simultaneously increase TE and lower NO x and/or soot emissions at high loads through the use of Partial HCCI (PHCCI). At low loads, PHCCI is not possible, but either PDFC or RCCI can be used to further improve NO x and/or soot emissions, albeit at slightly lower TE. These results lead to a “partial dual-fuel” multi-mode strategy of PHCCI at high loads and CDC at low loads, linked together by PDFC. Drive cycle simulations show that this strategy, when tuned to balance NO x and soot reductions, can reduce engine-out CO 2 emissions by about 1% while reducing NO x and soot by about 20% each with respect to CDC. This increases emissions of unburnt hydrocarbons (UHC), still in a treatable range (2.0 g/kWh) but five times as high as CDC, requiring changes in aftertreatment strategy.

Engineering↗

DOE OSTI2022

Investigations into EGR dilution tolerance in a pre-chamber ignited GDI engine

EGR is a useful means to improve fuel economy in spark-ignited gasoline engines, especially under part-load conditions by means of reducing throttling losses. There is also a significant reduction in NOx emissions due to the reduced peak cylinder temperatures. However, the ability of conventional spark ignition systems to reliably ignite dilute mixtures limits the dilution tolerance due to the onset of combustion instability. In this study, an active pre-chamber system was evaluated at part load condition with various EGR rates using a regular grade full boiling range gasoline. A premixed air-fuel mixture was supplied to the pre-chamber, which assists in scavenging the residual mass fractions to enable reliable ignition of EGR dilute mixtures in the main combustion chamber. A range of pre-chamber injection, air-fuel mixture formulation, and ignition timing strategies were evaluated during the EGR sweeps. In addition, 0-D and 1-D simulations were conducted in GT-Power to assess the thermodynamic state and composition in the pre-chamber, as well as estimate the jet momentum at the various dilution rates. The active pre-chamber extended the EGR dilution limit from 20% for conventional SI to above 30%, with a higher pre-chamber flow rate (more scavenging) resulting in increased combustion stability. A tradeoff between the jet momentum and spark timing was observed when analyzing the GT-Power simulations and the pre-chamber jet momentum was found to decrease with increasing EGR rate. At unstable high EGR operation, no relation could be found between the pre-chamber indicated data and main chamber combustion stability.

33 ADVANCED PROPULSION SYSTEMS↗

DOE OSTI2023

Additive-Mixing Fuel Injection (AMFI): A device for robust control and improved performance of high-efficiency LTGC engines

Low-temperature gasoline combustion (LTGC) engines can provide high efficiencies with very low NOx and particulate emissions. Despite these major advantages, methods for controlling LTGC combustion timing, achieving robust autoignition, and good low-load performance have challenged the development of practical LTGC engines. A key reason is that the ideal reactivity of the fuel varies with operating conditions, with low-reactivity fuels working well at high loads and higher-reactivity fuels working better at low loads. This article introduces a new technique called Additive Mixing Fuel Injection (AMFI) that adjusts the reactivity of the gasoline to obtain good performance over the operating map. Moreover, AMFI can provide robust combustion-timing control because it precisely meters very small amounts (0.01–0.6 mm 3 ) of an ignition-enhancing additive into the fuel each engine cycle. The additive used was 2-ethylhexyl nitrate (EHN), a common, inexpensive diesel-fuel ignition improver, but other additives could be used. Because additive amounts are so small, a 2-gal reservoir would be sufficient for medium-duty applications with refilling only at service intervals of about 8000 mi. The AMFI system has been installed on a single-cylinder LTGC research engine and demonstrated to provide robust combustion-timing control over wide ranges of combustion phasing, fueling rate, intake boost, engine speed, and intake temperature. AMFI also increases the fuel’s reactivity sufficiently to greatly reduce or eliminate the need for charge heating, simplifying engine design and significantly increasing thermal efficiency and the maximum load at low-boost conditions. The nitrogen in the EHN produced a modest increase in NOx, but it was mitigated by lower intake temperatures, and NOx emissions remained very low. Finally, the additive increases the sensitivity of autoignition reactions to variations in the local fuel/air mixture within the charge. This allows the use of controlled fuel stratification for improved LTGC-engine performance, and its potential to improve low-load operation was demonstrated.

Dec, John E.↗

DOE OSTI2020

Supply Chain Sustainability Analysis of Renewable Hydrocarbon Fuels via Indirect Liquefaction, Ex Situ Catalytic Fast Pyrolysis, Hydrothermal Liquefaction, Combined Algal Processing, and Biochemical Conversion: Update of the 2019 State-of-Technology Cases

This technical report describes the supply chain sustainability analysis (SCSAs) for the production of renewable hydrocarbon transportation fuels via a range of conversion technologies: (1) renewable high octane gasoline (HOG) via indirect liquefaction (IDL) of woody lignocellulosic biomass (note that the IDL pathway in this SCSA represents the syngas conversion design in the 2019 SOT); (2) renewable gasoline (RG) and diesel (RD) blendstocks via ex situ catalytic fast pyrolysis of woody lignocellulosic biomass; (3) RD via hydrothermal liquefaction (HTL) of wet sludge from a wastewater treatment plant; (4) renewable hydrocarbon fuels via biochemical conversion of herbaceous lignocellulosic biomass; (5) renewable diesel via HTL of a blend of algae and woody biomass; and (6) renewable diesel via combined algae processing (CAP). This technical report focuses on the environmental performance of these six biofuel production pathways in their 2019 SOT cases. The results of these renewable hydrocarbon fuel pathways in these SCSA analyses update those for the respective 2018 SOT cases. They also provide an opportunity to examine the impact of technology improvements in both biomass feedstock production and biofuel production that have been achieved in 2019 SOTs on the sustainability performance of these renewable transportation fuels, and they reflect updates to Argonne National Laboratory’s Greenhouse gases, Regulated Emissions, and Energy use in Transportation (GREET®) model, which was released in October 2019. These GREET updates include the production of natural gas, electricity, and petroleum-based fuels that can influence biofuels’ supply chain greenhouse gas (GHG) (CO₂, CH₄, and N₂O) emissions, water consumption, and air pollutant emissions. GHG emissions, water consumption, and nitrogen oxides (NO x ) emissions are the main sustainability metrics assessed in this analysis. In this analysis, we define water consumption as the amount of water withdrawn from a freshwater source that is not returned (or returnable) to a freshwater source at the same level of quality. Life-cycle fossil energy consumption and net energy balance, which is the life-cycle fossil energy consumption deducted from the renewable biofuel energy produced, are also assessed.

09 BIOMASS FUELS↗

DOE OSTI2020

Assessment of Light-Duty Plug-in Electric Vehicles in the United States, 2010 – 2019

This report examines properties of plug-in electric vehicles (PEVs) sold in the United States from 2010 to 2019, exploring vehicle sales, miles driven, electricity consumption, petroleum reduction, vehicle manufacturing, and battery production, among other factors. Over 1.4 million PEVs have been sold, driving over 37 billion miles on electricity since 2010, thereby reducing national gasoline consumption by 0.34% in 2019 and 1.4 billion gallons cumulatively through 2019. In 2019, PEVs used 4.1 terawatt-hours of electricity to drive 12.7 billion miles, offsetting 470 million gallons of gasoline. Since 2010, 69% all PEVs have been assembled in the United States, and over 60 gigawatt-hours of lithium-ion batteries have been installed in vehicles to date.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗

DOE OSTI2020

Assessment of Light-Duty Plug-in Electric Vehicles in the United States, 2010 – 2019

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗

DOE OSTI2021

Assessment of Light-Duty Plug-in Electric Vehicles in the United States (2010 - 2020)

This report examines properties of plug-in electric vehicles (PEVs) sold in the United States from 2010 to 2020, exploring vehicle sales, miles driven, electricity consumption, petroleum reduction, vehicle manufacturing, and battery production, among other factors. Over 1.7 million PEVs have been sold, driving 52 billion miles on electricity since 2010, thereby reducing national gasoline consumption by 0.42% in 2020 and 1.9 billion gallons cumulatively through 2020. In 2020, PEVs used 4.4 terawatt-hours of electricity to drive 13.7 billion miles, offsetting 500 million gallons of gasoline. Since 2010, 68% of PEVs sold in the United States have been assembled domestically, and 77 gigawatt-hours of lithium-ion batteries have been installed in vehicles to date.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗

DOE OSTI2021

Supply Chain Sustainability Analysis of Renewable Hydrocarbon Fuels via Indirect Liquefaction, Ex Situ Catalytic Fast Pyrolysis, Hydrothermal Liquefaction, Combined Algal Processing, and Biochemical Conversion: Update of the 2020 State-of-Technology Cases

This technical report describes the SCSAs for the production of renewable hydrocarbon transportation fuels via a range of conversion technologies in the 2020 SOTs: (1) renewable high octane gasoline (HOG) via indirect liquefaction (IDL) of woody lignocellulosic biomass (note that the IDL pathway in this SCSA represents the syngas conversion design); (2) renewable gasoline (RG) and diesel (RD) blendstocks via ex situ catalytic fast pyrolysis of woody lignocellulosic biomass; (3) RD via hydrothermal liquefaction (HTL) of wet sludge from a wastewater treatment plant; (4) renewable hydrocarbon fuels via biochemical conversion of herbaceous lignocellulosic biomass; (5) renewable diesel via HTL of a blend of algae and woody biomass; and (6) renewable diesel via combined algae processing (CAP). This technical report focuses on the environmental performance of these six biofuel production pathways in their 2020 SOT cases. The results of these renewable hydrocarbon fuel pathways in these SCSA analyses update those for the respective 2019 SOT cases. They also provide an opportunity to examine the impact of technology improvements in both biomass feedstock production and biofuel production that have been achieved in 2020 SOTs on the sustainability performance of these renewable transportation fuels. The SCSA results also reflect updates to Argonne National Laboratory’s Greenhouse gases, Regulated Emissions, and Energy use in Technologies (GREET ® ) model, which was released in October 2020. These GREET updates include the production of natural gas, electricity, and petroleum-based fuels that can influence biofuels’ supply chain greenhouse gas (GHG) (CO 2 , CH 4 , and N 2 O) emissions, water consumption, and air pollutant emissions. GHG emissions, water consumption, and nitrogen oxides (NO x ) emissions are the main sustainability metrics assessed in this analysis. In this analysis, we define water consumption as the amount of water withdrawn from a freshwater source that is not returned (or returnable) to a freshwater source at the same level of quality. Life-cycle fossil energy consumption and net energy balance, which is the life-cycle fossil energy consumption deducted from the renewable biofuel energy produced, are also assessed.

09 BIOMASS FUELS↗

DOE OSTI2021

Supply Chain Sustainability Analysis of Renewable Hydrocarbon Fuels via Indirect Liquefaction, Ex Situ Catalytic Fast Pyrolysis, Hydrothermal Liquefaction, Combined Algal Processing, and Biochemical Conversion: Update of the 2020 State-of-Technology Cases

The Department of Energy’s (DOE) Bioenergy Technologies Office (BETO) aims to develop and deploy technologies to transform renewable biomass resources into commercially viable, high-performance biofuels, bioproducts, and biopower through public and private partnerships (U.S. Department of Energy, 2016). BETO and its national laboratory teams conduct in-depth techno-economic assessments (TEA) of biomass feedstock supply and logistics and conversion technologies to produce biofuels. There are two general types of TEAs: A design case outlines a target case (future projection) for a particular biofuel pathway. It enables identification of data gaps and research and development needs and provides goals and benchmarks against which technology progress is assessed. A state of technology (SOT) analysis assesses progress within and across relevant technology areas based on actual results at current experimental scales relative to technical targets and cost goals from design cases, and includes technical, economic, and environmental criteria as available. In addition to developing a TEA for a pathway of interest, BETO also performs a supply chain sustainability analysis (SCSA). The SCSA takes the life-cycle analysis approach that BETO has been supporting for about 20 years. It enables BETO to identify energy consumption, environmental, and sustainability issues that may be associated with biofuel production. Approaches to mitigate these issues can then be developed. Additionally, the SCSA allows for comparison of energy and environmental impacts across biofuel pathways in BETO’s research and development portfolio. This technical report describes the SCSAs for the production of renewable hydrocarbon transportation fuels via a range of conversion technologies in the 2020 SOTs: (1) renewable high octane gasoline (HOG) via indirect liquefaction (IDL) of woody lignocellulosic biomass (note that the IDL pathway in this SCSA represents the syngas conversion design [Harris et al. 2021]); (2) renewable gasoline (RG) and diesel (RD) blendstocks via ex situ catalytic fast pyrolysis of woody lignocellulosic biomass [Abhijit et al. 2021]; (3) RD via hydrothermal liquefaction (HTL) of wet sludge from a wastewater treatment plant; (4) renewable hydrocarbon fuels via biochemical conversion of herbaceous lignocellulosic biomass (Davis et al. 2021; Lin et al. 2021); (5) renewable diesel via HTL of a blend of algae (Davis and Klein, 2021) and woody biomass (Hartley et al. 2020); and (6) renewable diesel via combined algae processing (CAP) (Wiatrowski and Davis, 2021). This technical report focuses on the environmental performance of these six biofuel production pathways in their 2020 SOT cases. The results of these renewable hydrocarbon fuel pathways in these SCSA analyses update those for the respective 2019 SOT cases (Cai et al. 2020). They also provide an opportunity to examine the impact of technology improvements in both biomass feedstock production and biofuel production that have been achieved in 2020 SOTs on the sustainability performance of these renewable transportation fuels. The SCSA results also reflect updates to Argonne National Laboratory’s Greenhouse gases, Regulated Emissions, and Energy use in Technologies (GREET®) model, which was released in October 2020 (Wang et al. 2020). These GREET updates include the production of natural gas, electricity, and petroleum-based fuels that can influence biofuels’ supply chain greenhouse gas (GHG) (CO 2 , CH 4 , and N 2 O) emissions, water consumption, and air pollutant emissions. GHG emissions, water consumption, and nitrogen oxides (NO x ) emissions are the main sustainability metrics assessed in this analysis. In this analysis, we define water consumption as the amount of water withdrawn from a freshwater source that is not returned (or returnable) to a freshwater source at the same level of quality. Life-cycle fossil energy consumption and net energy balance, which is the life-cycle fossil energy consumption deducted from the renewable biofuel energy produced, are also assessed.

09 BIOMASS FUELS↗

DOE OSTI2022

Report on General Hydrogen Safety

Hydrogen is an important resource for many different industries throughout the world, including refining, manufacturing, and as a direct energy source. Hydrogen production, through methods such as steam methane reforming, has been developed over several decades. There is a large global demand for hydrogen from these industries and safe production and distribution are paramount for hydrogen systems. Codes and standards have been developed to reduce the risk associated with hydrogen accidents to the public. These codes and standards are similar to those in other industries in which there is inherent risk to the public, such as gasoline and natural gas production and distribution. Although there will always be a risk to the public in these types of fuels, the codes and standards are developed to reduce the likelihood of an accident occurring and reduce the severity of impact, should one occur. This report reviews the current state of hydrogen in the United States and outlines the codes and standards that ensure safe operation of hydrogen systems. The total hydrogen demand and use in different industries is identified. Additionally, the current landscape of hydrogen production and fueling stations in the United States is outlined. The safety of hydrogen systems is discussed through an overview of the purpose, methods, and content included in codes and standards. As outlined in this safety overview, the risk to the public in operation of hydrogen generation facilities and fueling stations is reduced through implementation of appropriate measures. Codes, such as NFPA 2, ensure that the risk associated with a hydrogen system is no greater than the risk presented by gasoline refueling stations.

08 HYDROGEN↗

DOE OSTI2022

Determination of Biogenic Content by 14 C in fuels using Liquid Scintillation Analysis Laboratory Analytical Procedure (Laboratory Analytical Procedure)

This procedure covers the determination of the percent 14 C in biogenic gasoline, jet fuel, and diesel range hydrocarbons prepared from distillation of hydrotreated pyrolysis oils and blended with fossil derived hydrocarbons (e.g. fossil diesel, gasoline, jet, or toluene). Either an internal 14C standard or a color quench curve is used to correct for potential signal quenching effects. Recent publications provide some background of direct LSC methods used for determination of biogenic fuel content.

02 PETROLEUM↗

DOE OSTI2023

Catalytic Upgrading of Ethanol into Diesel-Fuel Range C10+ Ethers

Historically, ethanol has been blended into light-duty fuels, mainly in gasoline. However, with the technological advancements in batteries, there is a projected decline in the demand of light-duty fuels in the next 20 years. This is attributed to the rise of electric vehicles, lowering the demand of gasoline. At the same time, there is a projected increase in the demand for transportation fuels such as rail, aviation, marine and heavy duty. The biggest market of transportation fuels is heavy-duty, and in this presentation, we will focus on how we can shift the use of ethanol from light-duty fuel technology, to heavy-fuel duty technology for the development of diesel #2.

Canales, Emmanuel↗

DOE OSTI2024

Adoption of Plug-in Electric Vehicles: Local Fuel Use and Greenhouse Gas Emissions Reductions Across the U.S.

The dependence on gasoline-powered light-duty automobiles has made U.S. households vulnerable to the burden of fuel costs. Tailpipe emissions from these vehicles constitute 58% of greenhouse gas (GHG) emissions in the U.S., which are damaging to the environment (EPA, 2023). The adoption of plug-in electric vehicles (PEVs) has been shown to effectively reduce fuel costs and GHG emissions. However, local effects on these benefits are not well understood by American consumers, potentially limiting adoption and therefore the realization of PEV benefits at scale (MacInnis & Krosnick, 2020; EY Americas, 2023). To fill this research gap, this study estimates the fuel cost savings and GHG emission reductions at the state and ZIP code levels by considering local fuel prices, vehicle class preference, average vehicle model year, fuel efficiencies, and driving intensities. The study's findings reveal that the adoption of PEVs can yield substantial benefits in terms of fuel cost savings and GHG emission reductions nationwide. Specifically, driving a battery electric vehicle (BEV) is estimated to result in annual savings of up to $\$2,200$, while driving a plug-in hybrid electric vehicle (PHEV) can lead to savings up to $\$1,500$, when compared to an internal combustion engine vehicle (ICEV) of equivalent size. Moreover, using population-weighted averages by ZIP code, BEVs and PHEVs show the potential to save 400 and 200 grams of carbon dioxide equivalent per mile, respectively, compared to a representative ICEV of the same class. The magnitude of fuel cost savings and emissions reduction vary by region due to various factors. Generally, regions with high gasoline prices, low electricity prices, preferences for larger vehicles, and high driving intensities tend to see relatively large fuel savings. The emissions reductions are more pronounced in areas with clean grids where consumer preferences lie with large vehicles. This regional variability underscores the importance of considering local contextual factors when assessing the potential benefits of PEV adoption. In more than 99% of U.S. ZIP codes, PEVs result in overall savings in fuel use (and subsequent costs) and GHG emissions. While not a central focus of this analysis, reductions in GHG tailpipe emissions from PEV adoption would also come with reductions in criteria pollutant emissions, contributing to improved local air quality depending on the PEV penetration, population density, and electricity generation infrastructure in the locality.

33 ADVANCED PROPULSION SYSTEMS↗

DOE OSTI2024

Slashing Platinum Group Metals (PGM) in Catalytic Converters: An Atoms-to-Autos Approach

Platinum group metals (PGMs) are used in three-way catalysts (TWCs) for stoichiometric gasoline engine vehicles to simultaneously convert carbon monoxide, hydrocarbons, and nitrogen oxides into nitrogen, carbon dioxide and water. For US light duty gasoline vehicles, about 3-8 grams of PGMs are used in each catalytic converter system and the PGM loading is expected to increase for future vehicles, driven by increasingly stringent emissions standards, potentially lower engine exhaust temperatures, and higher emission control system durability requirements. The technical necessity for the current high PGM loadings is largely driven by: 1) poor atomic efficiency (or metal dispersion) of PGMs on catalyst supports with the current synthesis approaches, and 2) severe deactivation of unstable PGM nanoparticles in high temperature engine exhaust. Therefore, the project team will develop catalyst technologies that not only maximize the PGM atom efficiency and intrinsic activity in the fresh state, but also maintain the benefits during aging with extended exposure in engine exhaust.

36 MATERIALS SCIENCE↗

DOE OSTI2025

Direct Air Capture and Electromicrobial Production (DAC-EMP) (Final Technical Report for ARPA-E Project)

The collaborative effort of UC Berkeley and GE Vernova (formerly GE Research) aimed to develop an integrated, three-step process to directly capture and convert carbon dioxide (CO 2 ) from ambient air into butanol, a platform molecule for diesel and jet fuels. This new process is intended to address the unmet need for carbon-neutral drop-in substitutes for fossil gasoline, which would substantially reduce the carbon footprint of the transportation sector without requiring significant changes to the nation’s transportation infrastructure. The U.S. alone consumes ~120 billion gallons of gasoline per year, and the use of fossil fuels in transportation accounts for ~30% of U.S. greenhouse gas emissions, a major contribution to the ongoing climate crisis. A successful replacement fuel must therefore be produced in a process that has low carbon emissions over its life cycle while demonstrating both scalability and economic competitiveness. The proposed system is tailorable to a wide range of applications and can establish a viable approach for direct capture and conversion of CO 2 to value-added products with much lower land use compared to a biotechnological process relying on corn-derived glucose.

09 BIOMASS FUELS↗

DOE OSTI2025

Develop a Simulation Framework for Understanding Physico-Chemical Processes and Optimization of CHZ' Plastic Thermolyze Technology (CRADA Final Report)

Thermolyzer(TM) technology is a third-generation, multi-reactor, oxygen-free, low pressure, slow pyrolysis process. It has proven to be remarkably versatile in successfully processing all types of hydrocarbon waste. These include all seven types of plastics, tires, auto shredder residue, carpet, electronic waste, and composites. Working with the IACMI, Thermolyzer(TM) technology has recovered the glass and carbon fibers from wind turbine blades for reuse into new applications. Its primary output is a synthesis gas that is rich in H 2 , CH 4 , and small amounts of C 2-4 aliphatic hydrocarbons. Other components are CO and CO 2 . Three unique features set Thermolyzer(TM) apart from other pyrolysis systems: the syngas is clean enough to run in Siemens or Solar gas turbines or IC engines without fouling, clean, salable, byproducts are produced, and CO 2 emissions are lower than natural gas power plants. Research results have been obtained from an operating 7 ton/day facility. A 44 ton/day plant has successfully operated as noted above. The process works because it makes use of the recoverable embodied energy in the feedstock. Surprisingly, a pound of some plastics has the same recoverable energy content as a pound of gasoline. Thus, it is imperative to develop a process that economically converts scrap plastics (including ocean plastics) into energy and thereby conserve the non-renewable fossil fuels for future generations. The Thermolyzer(TM) technology can also be used to create liquid fuels like gasoline and diesel from hydrocarbon wastes. Because of the high hydrogen content of the synthesis gas, hydrogen can be recovered more inexpensively than the current solar or wind energy being used to electrolyze water. That hydrogen can be used for fuel cell powered vehicles or converted into ammonia for agriculture or as a hydrogen storage medium. Extension of this technology to other wastes such as tires, auto shredder residue or wood wastes would expand the circular economy.

36 MATERIALS SCIENCE↗

DOE OSTI2021

EGR Dilution and Fuel Property Effects on High-Efficiency Spark-Ignition Flames

Modern spark ignition internal combustion engines rely on fast combustion rates and high dilution to achieve high brake thermal efficiencies. To accomplish this, new engine designs have moved towards increased tumble ratios and stroke-to-bore ratios. Increased tumble ratios correlate positively with increases in turbulent kinetic energy and improved fuel and residual gas mixing, all of which favor faster and more efficient combustion. Longer stroke-to-bore ratios allow higher geometric compression ratios and use of late intake valve closing to control peak compression pressures and temperatures. The addition of dilution to improve efficiency is limited by the resulting increase in combustion instabilities manifested by cycle-to-cycle variability. A number of effects - preferential diffusion, turbulence-combustion interactions, stochastic flow patterns, laminar-turbulent flame kernel transitions, and relative length and velocity scales between flame and turbulence - are believed to be responsible for the increase in cycle-to-cycle variations, where their contributions are likely interlinked. Several studies have shown the influence of stochastic flow characteristics on the nature of combustion instabilities, such as velocity patterns on flame kernel formation and cycle-to-cycle variations in residual gas. However, few have focused on the specific effects of fuel properties. The objective of this work is to contrast the effects of dilution on propane stoichiometric combustion against gasoline. Dilution tolerance experiments were conducted in a purpose-built high stroke-to-bore ratio single cylinder engine with both gasoline and LPG. Three-dimensional full cycle computational fluid dynamics (CFD) simulations employing a level-set combustion approach and Reynolds averaged Navier-Stokes (RANS) turbulence modeling was used to qualitatively assess the changes in length and velocity scales for turbulence and the flame. The experimental results showed that LPG can tolerate higher exhaust gas recirculation (EGR) dilution under a variety of conditions. Analysis of CFD simulations showed that propane flames are likely less sensitive to influences from the flow field due to less thickening of the flame and higher effective flame speeds.

33 ADVANCED PROPULSION SYSTEMS↗