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Search indexed NASA NTRS and DOE OSTI research on propulsion, heat transfer, battery materials and energy systems. Follow report and document links to the original sources.

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At least 37 records · Page 2
All sourcesNASA NTRSDOE OSTI
DOE OSTI2021

Solid particulate mass and number from ducted fuel injection in an optically accessible diesel engine in skip-fired operation

Ducted fuel injection (DFI) is a new combustion strategy that has been shown to significantly attenuate soot formation in diesel engines. While previous studies have used optical diagnostics and optical filter smoke number methods to show that DFI reduces in-cylinder soot formation and engine-out soot emissions, respectively, this is the first study to measure solid particle number (PN) emissions in addition to particle mass (PM). Furthermore, this study quantitatively evaluates the use of transient particle instruments for measuring particles from skip-fired operation in an optical single cylinder research engine (SCRE). Engine-out PN was measured using an engine exhaust particle sizer following a catalytic stripper, and PM was measured using a photoacoustic analyzer. The study improves on earlier preliminary emissions studies by clearly showing that DFI reduces overall PM by 76%–79% and PN for particles larger than 23 nm by 77% relative to conventional diesel combustion at a 1200-rpm, 13.3-bar gross indicated mean effective pressure operating condition. The degree of engine-out PM reduction with DFI was similar across both particulate measurement instruments used in the work. Through the use of bimodal distribution fitting, DFI was also shown to reduce the geometric mean diameter of accumulation mode particles by 26%, similar to the effects of increased injection pressure in conventional diesel combustion systems. This work clearly shows the significant solid particulate matter reductions enabled by DFI while also demonstrating that engine-out PN can be accurately measured from an optical SCRE operating in a skip-fired mode. Based on these results, it is believed that DFI has the potential to enable fuel savings when implemented in multi-cylinder engines, both by lowering the required frequency of active diesel particulate filter regeneration, and by reducing the backpressure imposed by exhaust filtration systems.

33 ADVANCED PROPULSION SYSTEMS↗
DOE OSTI2023

A computational parametric study of ducted fuel injection implementation in a heavy-duty diesel engine

Experiments have shown that ducted fuel injection (DFI) effectively reduces soot emissions from direct-injection diesel engines. Although many computational studies have evaluated DFI’s spray development and soot reduction mechanisms in constant volume chambers, only limited computational work on internal combustion engines exists. The DFI duct assembly changes the engine’s in-cylinder flow, spray, and combustion development. Therefore, current production engine designs might not be optimal for achieving the best engine performance with DFI. Here, this work conducted an extensive numerical study to evaluate how parameter changes affect DFI performance. The parameters include swirl ratio, piston geometry, compression ratio (CR), number of injector orifices, split injection strategy, and exhaust gas recirculation (EGR) in a heavy-duty diesel engine utilizing DFI. The combustion and soot emission data from the Sandia compression ignition optical research engine were used for model validation. Simulations showed that an increased swirl ratio resulted in more intense jet flame-piston interaction, slowing down the combustion heat release during the late combustion stage and leading to lower indicated thermal efficiency (ITE) due to higher exhaust losses. A piston-bowl design with a reentrant inner piston edge yielded the highest thermal efficiency, due to the reduced cylinder head heat transfer loss. Additional injector orifices led to higher efficiency owing to a more advanced combustion phasing. Nevertheless, the maximum pressure rise rate (MPRR) and oxides of nitrogen (NO x ) emissions also increased with the number of injector orifices due to more rapid heat release and higher combustion temperature. Implementation of a split injection strategy combined with a higher EGR rate effectively inhibited the excessive MPRR and NO x formation. In general, the study concluded that DFI is not sensitive to most parameter changes but will benefit from future parameter optimization.

33 ADVANCED PROPULSION SYSTEMS↗
DOE OSTI2021

Transforming Energy through Computational Excellence. Exascale Computing: Combustion; Simulating Effects of Fuel Injection Location in Supersonic Jet Engines

Computational tractable simulations using an adaptive-mesh-refinement solverfor compressible reacting flows help researchers understand how variations in fuel injection location within the supersonic flow cavity impacts combustion efficiency. By identifying the important physical determinants of the combustion processes, this study shows a promising pathway to improving flame stability and combustion efficiency, as well as reducing emissions.

adaptive mesh refinement↗
DOE OSTI2023

Development of a High-Pressure Fuel Injection System for Use with Propane-DME

Paper details the design approach and performance of a high-pressure common rail fuel injection system used with Propane-DME mixtures targeting high injection pressures on a light duty 2.2L inline-4 compression ignition engine. The study estimates the bulk modulus of elasticity based on the hardware geometry and operating pressures to assess the compressibility of Propane and DME across a range of pressures typical of the LD engine application. The compressibility factor ranges from 500 to 3000 bar, significantly lower than the theoretical values for the conditions tested. The high-pressure pump performance is optimized via the implementation of an inlet metering valve operated on a crank-angle open/close sequence to control pressure at the common rail. The application of a model-based controller and the use of high-speed sampling of rail pressure indicate that pressure at the rail can be attained with the pump metering valve, and without use of the pressure relieve valve present in the rail. Results show a significant reduction on pumping work parasitics and of fuel heating, on the order of 40°C, at typical working conditions with the proposed approach. Injector rates of injection with Propane-DME are very similar to those of Diesel. Paper compares bench data of rates of injection versus simulation predictions across operating pressures of 200 to 1000bar and from injection commands spanning 0.20 to 2.0ms. Furthermore, the accuracy of the model predictions are attributed in part by to the updated fuel compressibility modulus descriptions attained during the testing.

42 ENGINEERING↗
DOE OSTI2023

Correlating Impacts of Injected Fuels on Carbon Emissions in Blast Furnace with Computational Fluid Dynamics Modeling

A major challenge for steelmaking is the reduction of CO 2 emissions. In this regard, the blast furnace (BF) is critical due to the high associated CO 2 levels. This investigation assesses the impact of tuyere‐injected fuels on BF CO 2 emissions. Specifically, computational fluid dynamics results obtained previously at Purdue University Northwest are analyzed to obtain CO 2 emissions when natural gas (NG), syngas, hydrogen, or hydrogen/NG are injected. CO 2 emissions are compared with those produced when 95 kg of NG/thm is injected. Among these scenarios, the largest CO 2 reduction occurs when 102 kg of syngas/thm (COG feedstock #1) is injected at 973 K, reducing CO 2 by 190.6 kg thm −1 . The largest CO 2 reduction obtained with NG occurs when 130 kg thm −1 is injected at 600 K, reducing emissions by 65 kg thm −1 . H 2 injection also reduces CO 2 , but requires careful adjusting to reach stable operation. For instance, injecting 35 kg of H 2 /thm reduces CO 2 by 52 kg thm −1 . Increasing gaseous injection rates can significantly reduce CO 2 emissions, with fuel preheating providing an addendum, but high injection rates can lead to unstable operation. Furthermore, results show a correlation between CO 2 emissions and average temperature of shaft region for multiple fuels and injection conditions.

Metallurgy & Metallurgical Engineering↗
DOE OSTI2021

Heavy-Duty Mixed-Controlled Compression Ignition: Fuel Effects and Ducted Fuel Injection.

This project is focused on developing advanced combustion strategies for mixing-controlled compression ignition (MCCI, i.e., diesel-cycle) engines that are synergistic with renewable and/or unconventional fuels in a manner that enhances domestic energy security, economic competitiveness, and environmental quality. During this reporting period, the two focus areas were ducted fuel injection (DFI) and surrogate diesel fuels.

33 ADVANCED PROPULSION SYSTEMS↗
DOE OSTI2025

Mapping ammonia-diesel combustion on a single-cylinder 107 mm bore diesel engine retrofitted for ammonia port-fuel injection

Ammonia is garnering significant interest from the international maritime sector as an alternative fuel. It is attractive as a hydrogen carrier and as a fuel because it has a higher volumetric energy density compared with gaseous or liquid hydrogen, making it easier to store and transport without requiring high pressures or cryogenic storage. Ammonia has significant toxicity concerns, but safe handling procedures have already been established because it is one of the most widely produced chemicals worldwide for use as a fertilizer. Barriers to consuming NH 3 as a fuel in engines include (1) less favorable ignition energy and flame speed compared with conventional fuels; (2) emissions challenges, including potentially high NH 3 , NO X , and N 2 O emissions; and (3) fuel delivery and handling challenges. Although NH 3 has been used to fuel compression-ignition marine engines in limited demonstration projects, technical barriers still exist. The use of NH 3 as a fuel in smaller-bore, high-speed auxiliary engines for large vessels and for smaller inland and coastal marine applications remains unaddressed. This work investigates a late-injection diesel pilot ignition dual-fuel NH 3 strategy using a single-cylinder, high-speed Cummins four-stroke diesel engine platform with a 107 mm bore and 1.1 L displacement per cylinder. The engine was modified for port fuel injection of heated gaseous anhydrous NH 3 . The diesel fuel injection system and the combustion geometry were unmodified to represent a retrofit application, which would minimize additional hardware to maximize diesel fuel displacement with NH 3 . Furthermore, the results show the applicability of a late injection diesel pilot strategy to overcome the challenging fuel properties of NH 3 over the engine operating envelope. Mapping results focusing on emissions are presented, and comparisons are made to a conventional diesel combustion baseline.

Ship engines↗
DOE OSTI2023

Ducted Fuel Injection Provides Consistently Lower Soot Emissions in Sweep to Full-Load Conditions

Earlier studies have proven how ducted fuel injection (DFI) substantially reduces soot for low- and mid-load conditions in heavy-duty engines, without significant adverse effects on other emissions. Nevertheless, no comprehensive DFI study exists showing soot reductions at high- and full-load conditions. This study investigated DFI in a single-cylinder, 1.7-L, optical engine from low- to full-load conditions with a low-net-carbon fuel consisting of 80% renewable diesel and 20% biodiesel. Over the tested load range, DFI reduced engine-out soot by 38.1–63.1% compared to conventional diesel combustion (CDC). This soot reduction occurred without significant detrimental effects on other emission types. Thus, DFI reduced the severity of the soot–NO x tradeoff at all tested conditions. While DFI delivered considerable soot reductions in thepresent study, previous DFI studies at low- and mid-load conditions delivered larger soot reductions (>90%) compared to CDC operation at the same conditions. Therefore, the DFI configuration used here has been deemed nonoptimal (in terms of parameters such as the injector-spray and piston geometries), and several improvements are recommended for future studies with high-load DFI. Further, these improvements include employing better spray-duct alignment, a deeper piston bowl with a smaller injector umbrella angle, and a fuel injector that opens and closes faster. The study also suggests future research to make DFI ready for commercialization, such as metal-engine tests to ensure desirable DFI performance over an engine’s complete speed/load map. Overall, this study supports the continued development and commercialization of DFI to meet upcoming emissions regulations for heavy-duty vehicles. Specifically, multicylinder engine experiments and CFD simulations should be utilized to optimize the performance and clarify the full potential of DFI.

33 ADVANCED PROPULSION SYSTEMS↗
DOE OSTI2023

Deep reinforcement learning to discover multi-fuel injection strategies for compression ignition engines

Over the past several decades, regulation of compression ignition engine emissions has become increasingly stringent as concern about the environmental and health implications of these emissions has grown. These changing constraints have led to a series of new, alternative fuel injection strategies that aim to maintain power output while reducing in-cylinder generated emissions by operating in the low-temperature combustion (LTC) regime. These advanced injection strategies are created and retuned for individual combinations of engine geometry, fuel, and emissions constraints. Deep reinforcement learning has been shown to be an effective alternative to traditional optimization approaches for highly combinatorial control problems, such as discovering the optimal injection schedules for compression ignition engines. In this study, we deploy a previously presented deep reinforcement learning framework to iteratively optimize a series of engine geometries over a range of increasingly strict NO x emissions regulations. We then examine the resulting injection schedules. We discuss the potential for using this deep reinforcement learning framework for fuel selection screening and for discovering unique injection strategies for different engine geometries and future emissions standards.

33 ADVANCED PROPULSION SYSTEMS↗
DOE OSTI2024

Ducted Fuel Injection And Cooled Spray Technologies For Particulate Control In Heavy-duty Diesel Engines (Final Report)

Cooled Spray (CS) and Ducted Fuel Injection (DFI) are in-cylinder technologies for diesel engines that can reduce particulate matter and soot emissions and data has been published showing that these technologies can reduce soot emissions by 75-100% for some engines at some operating conditions. However, little is known about scaling the devices for engine size. Additionally, the performance of either technology over the engine duty cycle has not been explored. This project addresses both of these points through single-cylinder engine investigations. The objectives of this project are to provide details about dimensional scaling of these devices and to demonstrate 75% PM reduction over a range of operating conditions on a single-cylinder engine. Two engines were used for this project: a 125mm bore optically accessible engine at Sandia National Laboratories and a 168mm bore metal engine at Southwest Research Institute. The optical engine was used to study the performance of DFI and CS inserts for a large injector orifice diameter injector that is characteristic of a locomotive engine and to perform scaling studies for DFI. The metal engine was used to perform scaling and alignment studies for CS and to evaluate the technology for both EGR and non-EGR engines over the engine operating map. Modifications were required for both engines to accept the prototype inserts being tested. The optical engine required a new fuel injector, cylinder head and piston so that tests could be run at the pressures and engine speeds required. Additionally, a novel rotating stage was designed for the optical engine to simplify alignment of the modules. The metal engine required a modified cylinder head to accept CS inserts and a modified piston to provide additional space around the fuel injector for the CS inserts. Tests on the optical engine showed that DFI reduces PM emissions for both small injector orifices (0.170mm diameter) and large injector orifices (0.290mm). For high load testing, the DFI modules were not as effective as at low load testing, but it was acknowledged that minimal geometric optimization was performed and more improvements may be possible. Comparing DFI to CS and conventional diesel combustion (CDC), DFI performed better than CS or CDC. The CS geometries used in these studies may not be ideal for that engine and additional modifications likely would improve performance. Tests on the metal engine showed PM reductions as high has 80% at some operating conditions with duty-cycle PM reductions of ~50% for EGR and non-EGR configurations. The CS testing on the metal engine showed that chamfering of the fuel passage inlet either through hydro-erosion or mechanical grinding provided significant improvements in the PM reduction capabilities of the insert. Additionally, alignment sensitivities were explored and the data show that the tolerance to misalignment is approximately 0.05 to 0.1mm for the inserts that were studied here. Air-fuel ratio was shown to be important in the effectiveness of the CS inserts. In several tests, it was shown that the CS inserts are more effective at reducing the PM for high-AFR operating conditions compared to low AFR conditions. In summary, multiple designs were evaluated on both engines. It was found that for the conditions and configurations studied here, a fuel passage diameter of ~2.5mm performed best overall. Significant duty-cycle PM reductions are possible using these technologies and sensitivities to AFR, alignment fuel passage diameter and inlet fuel passage shaping were explored and are reported here. More PM reduction may be possible with improved geometric design and attention to alignment practices.

02 PETROLEUM↗
DOE OSTI2024

Ducted Fuel Injection and Cooled Spray Technologies for Particulate Control in Heavy-Duty Diesel Engines

Heavy-duty diesel engine manufacturers are continually seeking simple, low-cost technologies to reduce emissions. Ducted Fuel Injection (DFI) and Cooled Spray (CS) technologies have emerged as promising solutions, offering the potential for nearly sootless operation. These innovations could significantly decrease harmful Particulate Matter (PM) emissions while enabling further optimization to reduce Nitrogen Oxides (NOx) and increase efficiency. While initial experiments across various engine types have shown promise, uncertainties remain regarding the ideal geometry, scaling properties, and effectiveness of these technologies across different operating conditions. This project aims to address these knowledge gaps through experiments in both optical and metal single-cylinder engines.

33 ADVANCED PROPULSION SYSTEMS↗
DOE OSTI2021

Ducted Fuel Injection and Cooled Spray Technologies for Particulate Control in Heavy-Duty Diesel Engines

Heavy-Duty diesel engine manufacturers are continuously in pursuit of simple and low-cost technologies that can reduce emissions. Ducted fuel injection (DFI) and Cooled Spray (CS) technologies are two technologies that continue to show promise for significant particulate emissions reductions. These technologies represent a breakthrough in diesel engine combustion from the potential of nearly sootless diesel combustion. This can provide a significant decrease in harmful PM emissions and may enable further system optimization for reduced NOx emissions and increased efficiency. Combustion vessel experiments and engine demonstrations at Sandia, together with the large bore engine tests performed by Wabtec show that this technology may be applicable to heavy duty diesel engines across a wide range of engine sizes and speeds representing the majority of off-road diesel engines. However, very little is known about the ideal geometry, scaling properties or effectiveness of these technologies over the engine operating map. This project will address those uncertainties through a series of experiments performed in an optical and a metal single-cylinder engine.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗
DOE OSTI2020

Ducted Fuel Injection vs. Free-Spray Injection: A Study of Mixing and Entrainment Effects Using Numerical Modeling

Diesel engines are an important technology for transportation of both people and goods. However, historically they have suffered a significant downside of high soot and nitrogen oxides (NO x ) emissions. Recently, ducted fuel injection (DFI) has been demonstrated to attenuate soot formation in compression-ignition engines and combustion vessels by 50% to 100%. This allows for diesel engines to be run at low-NO x emissions that would have otherwise produced significantly more soot due to the soot/NO x tradeoff. Currently the root causes of this soot attenuation are not well understood. To be able to better optimize DFI for use across a variety of engines and conditions, it is important to understand clearly how it works. This study expands on the current understanding of DFI by using numerical modeling under nonreacting conditions to provide insights about the roles of entrainment and mixing that would have been much more challenging to obtain experimentally. We report this study found that DFI enhances charge gas entrainment upstream of the duct and blocks entrainment inside of the duct. Mixing is enhanced by the duct, which results in lower peak equivalence ratios at the exit of the duct.

42 ENGINEERING↗
DOE OSTI2021

Deep reinforcement learning for dynamic control of fuel injection timing in multi-pulse compression ignition engines

Conventional compression-ignition (CI) engines have long offered high thermal efficiencies and torque across a wide range of loads, but often require extensive exhaust gas treatment that decreases efficiency to meet ever-increasing emissions regulations. One strategy to decrease emissions is to split the fuel injection into a series of smaller injections. In this paper, we explore a new way of discovering optimal control strategies for the next generation of CI engines using deep reinforcement learning (DRL). We outline a DRL procedure to maximize the weighted reward of engine work while minimizing end-of-cycle NO x emissions. Through the procedure outlined in this paper, we show that the DRL agent is able to reduce NO x emissions threefold while only decreasing network by 2%. We demonstrate the use of transfer learning (TL) across hierarchies of physical models to accelerate the learning process, making this approach feasible for a range of control problems within this space. This paper presents a framework and demonstration for using DRL to design control systems in technology areas such as multi-pulse engine control where a hierarchy of models combined with multi-objective rewards are used for optimal operation.

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 OSTI2021

Oxygenated Fuel Blending Effects in a Mixing-Controlled Compression-Ignition Engine Equipped with Ducted Fuel Injection [Slides]

Continued creation of harmful emissions such as NO x and soot from compression-ignition engines utilizing mixing-controlled combustion systems (i.e., diesel engines) remains a problem and is the subject of on-going research. The inherently high efficiency, relatively low cost, and numerous other desirable attributes of such engines, coupled with a widely supported infrastructure, motivates their continued advancement. Recently, a scientifically distinct and mechanically simple technology called ducted fuel injection (DFI) has shown a robust ability to allow such engines to operate with simultaneously low engine-out soot and NO x emissions when it is employed with simulated exhaust-gas recirculation. To better understand the property ranges of sustainable, oxygenated-fuel blending stocks that will most improve engine performance, two oxygenated blendstocks were separately blended with a commercial diesel base fuel and tested within a heavy-duty diesel optical engine equipped with a four-duct DFI configuration. Conventional and crank-angle-resolved optical diagnostics were used to elucidate the effects of fuel ignition quality, oxygenate molecular structure, and overall oxygen content on engine performance.

33 ADVANCED PROPULSION SYSTEMS↗