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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 451 records · Page 25
All sourcesNASA NTRSDOE OSTI
DOE OSTI2016

Application of High Performance Computing for Simulating Cycle-to-Cycle Variation in Dual-Fuel Combustion Engines

Interest in operational cost reduction is driving engine manufacturers to consider lower-cost fuel substitution in heavy-duty diesel engines. These dual-fuel (DF) engines could be operated either in diesel-only mode or operated with premixed natural gas (NG) ignited by a pilot flame of compression-ignited direct-injected diesel fuel. One promising application is that of large-bore, medium-speed engines such as those used in locomotives. With realistic natural gas substitution levels in the fleet of locomotives currently in service, such fuel substitution could result in billions of dollars of savings annually in the US alone. However, under certain conditions, dual-fuel operation can result in increased cycle-to-cycle variability (CCV) during combustion, resulting in variations in cylinder pressure and work extraction. In certain situations, the CCV of dual-fuel operation can be notably higher than that of diesel-only combustion under similar operating conditions. Excessive CCV can limit the NG substitution rate and operating range of a dual-fuel engine by increasing emissions and reducing engine stability, reliability and fuel efficiency via incomplete natural-gas combustion. Running multiple engine cycles in series to simulate CCV can be quite time consuming. Hence innovative modelling techniques and large computing resources are needed to investigate the factors affecting CCV in dual-fuel engines. This paper discusses the use of the High Performance Computing resource Titan, at the Oak Ridge Leadership Computing Facility at Oak Ridge National Laboratory, to investigate cycle-to-cycle combustion variability of a dual-fuel engine. The CONVERGE CFD software was used to simulate multiple, parallel single cycles of dual-fuel combustion with perturbed operating parameters and boundary conditions. These perturbations are imposed according to a sparse grids sampling of the parameter space. The sampling scheme chosen is similar to a design of experiments method but uses functions designed to minimize the number of samples required to achieve a desired degree of accuracy. The perturbed input parameters were connected to engine performance output over a large parameter space. Additionally, the same methodology was used to perform a set of diesel-only simulations at similar operating conditions to assess the numerical capability of capturing relatively low combustion variation. Lastly, this technique is expected to be useful to understand and predict combustion stability limits (knock and misfire) which are important for designing dual-fuel engines with improved operability and reliability.

33 ADVANCED PROPULSION SYSTEMS↗
DOE OSTI2018

Prediction of Cyclic Variability and Knock-Limited Spark Advance (KLSA) in Spark-Ignition (SI) Engine

Engine knock remains one of the major barriers to further improve thermal efficiency of Spark Ignition (SI) engines. Knock can be suppressed by lowering the compression ratio, or retarding the spark ignition timing, however, at an expense of efficiency penalty. SI engine is usually operated at knock-limited spark advance (KLSA) to achieve possibly maximum efficiency with given engine hardware and fuel properties, such as Research Octane Number (RON), Motor Octane Number (MON), and heat of vaporization, etc. Co-optimization of engine design and fuel properties is promising to improve the engine efficiency and predictive CFD models can be used to facilitate this optimization process. However, difficulties exist in predicting KLSA in CFD simulations. First, cyclic variability of SI engine demands that multi-cycle results are required to capture the extreme conditions. Secondly, Mach Courant-Friedrichs-Lewy (CFL) number of 1 is desired to accurately predict the knock intensity (KI), resulting in unaffordable computational cost, especially for multi-cycle simulations. In this study, a new approach to numerically predict KLSA using large Mach CFL number of 50 is proposed. This approach is validated against experimental data for a boosted Direct Injection Spark Ignition (DISI) engine at multiple loads and spark timings. G-equation combustion model coupled with well-mixed chemical kinetic model are used to predict the turbulent flame propagation and end-gas auto-ignition, respectively. Simulations run for 10 consecutive engine cycles at each condition. The results show good agreement between model predictions and experiments in terms of cylinder pressure, combustion phasing and cyclic variation. Engine knock is predicted with early spark ignition timing, indicated by significant pressure wave oscillation and end-gas heat release. Maximum Amplitude of Pressure Oscillation (MAPO) analysis is performed to quantify the KI, and the slope change point in KI extrema is used to indicate the KLSA accurately. Using a smaller Mach CFL number of 5 also results in the same conclusions thus demonstrating that this approach is insensitive to the Mach CFL number. The use of large Mach CFL number allows us to achieve fast turn-around time for multi-cycle engine CFD simulations.

Yue, Zongyu↗
DOE OSTI2018

Sensitivity of Emissions to Uncertainties in Residual Gas Fraction Measurements in Automotive Engines: A Numerical Study

Initial conditions of the working fluid (air-fuel mixture) within an engine cylinder, namely, mixture composition and temperature, greatly affect the combustion characteristics and emissions of an engine. In particular, the percentage of residual gas fraction (RGF) in the engine cylinder can significantly alter the temperature and composition of the working fluid as compared with the air-fuel mixture inducted into the engine, thus affecting engine-out emissions. Accurate measurement of the RGF is cumbersome and expensive, thus making it hard to accurately characterize the initial mixture composition and temperature in any given engine cycle. This uncertainty can lead to challenges in accurately interpreting experimental emissions data and in implementing real-time control strategies. Quantifying the effects of the RGF can have important implications for the diagnostics and control of internal combustion engines. This paper reports on the use of a well-validated, two-zone quasi-dimensional model to compute the engine-out NO and CO emission in a gasoline engine. The effect of varying the RGF on the emissions under lean, near-stoichiometric, and rich engine conditions was investigated. Numerical results show that small uncertainties (~2–4%) in the measured/computed values of the RGF can significantly affect the engine-out NO/CO emissions.

33 ADVANCED PROPULSION SYSTEMS↗
DOE OSTI2016

Modeling Heat Loss through Piston and Effects of Thermal Boundary Coatings in Diesel Engine Simulations using Conjugate Heat Transfer models

Heat loss through wall boundaries play a dominant role in the overall performance and efficiency of internal combustion engines. Typical engine simulations use constant temperature wall boundary conditions. These boundary conditions cannot be estimated accurately from experiments due to the complexities involved with engine combustion. As a result they introduce a large uncertainty in engine simulations and serve as a tuning parameter. Modeling the process of heat transfer through the solid walls in an unsteady engine computational fluid dynamics (CFD) simulation can lead to the development of higher fidelity engine calculations. These models can be used to study the impact of heat loss on engine efficiency and explore new design methodologies that can reduce heat losses. In this work, a single cylinder diesel engine is modeled along with the solid piston coupled to the fluid domain. Conjugate heat transfer (CHT) modeling techniques were implemented to model heat losses for a full cycle of a Navistar diesel engine. This CFD model is then validated against experimental data available from thermocouples embedded inside the piston surface. The overall predictions from the model match closely with the experimental observations. The validated model is further used to explore the benefits of thermal barrier coatings (TBC) on piston bowls. The effect of TBC coatings were modeled as a thermal resistance in the heat transfer models. Full cycle 3D engine simulations provide quantitative insights into heat loss and thus calculate the efficiency gain by the use of TBC coatings. The work establishes a validated modeling framework for CHT modeling in reciprocating engine simulations.

Kundu, Prithwish↗
DOE OSTI2019

Engine-Aftertreatment in Closed-Loop Modeling for Heavy Duty Truck Emissions Control

An engine-aftertreatment computational model was developed to support in-loop performance simulations of tailpipe emissions and fuel consumption associated with a range of heavy-duty (HD) truck drive cycles. For purposes of this study, the engine-out exhaust dynamics were simulated with a combination of steady-state engine maps and dynamic correction factors that accounted for recent engine operating history. The engine correction factors were approximated as dynamic first-order lags associated with the thermal inertia of the major engine components and the rate at which engine-out exhaust temperature and composition vary as combustion heat is absorbed or lost to the surroundings. The aftertreatment model included catalytic monolith components for diesel exhaust oxidation, particulate filtration, and selective catalytic reduction of nitrogen oxides (NOx) with urea. Both the engine and aftertreatment models have been calibrated with dynamometer measurements from a commercial 2010-certificated 15-L Cummins diesel engine. The fuel consumption engine map with the reduced data is attached in the appendix. Simulations with the combined engine and aftertreatment models above appear to reveal important trends among the fuel efficiency, emissions control, power demand for HD trucks under realistic drive cycle conditions. Thus, this type of computational simulation appears to have significant value in choosing among options for HD vehicle design and operation.

Gao, Zhiming↗
DOE OSTI2022

An Investigation into the Effects of Swirl on the Performance and Emissions of an Opposed-Piston Two-Stroke Engine using Large Eddy Simulations

Opposed-piston two-stroke (OP-2S) engines have the potential to achieve higher thermal efficiency than a conventional four-stroke diesel engine. However, the uniflow scavenging process is difficult to control over a wider range of speed and loads due to its sensitivity to pressure dynamics, port timings, and port design. Specifically, the angle of the intake ports can be used to generate swirl which has implications for open and closed cycle effects. This study proposes an analysis of the effects of port angle on the in-cylinder flow distribution and combustion performance of an OP-2S using computational fluid dynamics engine. Large Eddy Simulation (LES) was used to model turbulence given its ability to predict in-cylinder mixing and cyclic variability. A three-cylinder model was validated to experimental data collected by Achates Power and the grid was verified using an LES quality approach from the literature. The model was used to simulate port angles from 12 to 29 degrees at constant pressure and temperature boundary conditions. Results indicated that the higher bulk swirl ratio generated by larger port angles tends to trap more internal residuals. This effect on the scavenging performance, combined with the larger trapped swirl ratio, also has a significant impact on the combustion performance in a two-stroke engine. It was concluded that there exists a tradeoff of efficiency and emissions that must be considered when increasing the port angle in a uniflow two-stroke engine. 1. Introduction Two-stroke engines were developed in the 1800s and are commonly used in practice today for lightweight power applications such as motorcycles or handheld power tools, as well as large-bore low speed engines for stationary power and marine applications. Two-stroke engines provide the distinct advantage of higher torque/power output but present challenges due to its coupled intake and exhaust process. Four-stroke engines have the benefit of using two full piston strokes to induct intake charge and to expel exhaust gases. Controlling the trapped charge composition in a twostroke engine via a scavenging process is crucial for reliable and efficient engine operation.

33 ADVANCED PROPULSION SYSTEMS↗
DOE OSTI2018

"COMBUSTION DEVELOPMENT OF A HIGH EFFICIENCY DIESEL MICRO PILOT NATURAL GAS ENGINE."

Dual fuel engine operation with premixed natural gas as the main fuel and diesel pilot ignition has been gaining interest among research and industry as natural gas is among the most promising existing alternative fuels. The dual fuel engine performance has been shown to equal and sometimes, depending on operating conditions, better the performance and efficiency of the diesel engine. Along with its advantages on the combustion high efficiency, diesel-like performance, and emissions of NOx and particulate matter reduction, some disadvantages are brought by the application of such operation. At light load conditions, there is an increase in CO and HC emissions, low fuel efficiency and combustion stability. While operating at higher loads, the dual fuel engine performance showed to be limited by combustion knock. This effectively reduces the maximum break mean effective pressure (BMEP) the engine can output when compared to a diesel engine. Although combustion knock is well defined in SI and diesel engines, dual fuel knock characterization still needs more investigation. This project centers on developing a fuel system for a diesel engine conversion to dual fuel to deliver high load and high efficiency. The selected engine has been converted to the dual fuel operation and dual fuel combustion has been demonstrated. After achieving the project goal of a high load and high efficiency dual fuel engine, the combustion knock in dual fuel operation will be characterized and a method for detection and intensity calculation will be modeled. The characterization will also be compared to spark ignition (SI) and reactivity-controlled compression ignition (RCCI) operating engines.

03 NATURAL GAS↗
DOE OSTI2021

Development of in-use engine speed/torque heat maps across multiple heavy-duty commercial vehicle vocations

The U.S. Department of Energy (DOE) established the SuperTruck program with the goal of achieving brake thermal efficiency (BTE) greater than or equal to 55% as demonstrated in an operational heavy-duty (HD) diesel engine at a 65-miles-per-hour (mph) cruise point. Beyond the line-haul application, HD engines operate in a wide range of speed and torque conditions that are unlikely to yield the same efficiency under real-world operation. Thereby, the in-use engine heat maps described in this paper are a valuable tool to illustrate whether the engine-efficiency “sweet spot” matches the most frequent operating conditions. In this study, NREL developed engine heat maps to quantify the important operating points for various vocations using our Fleet DNA database of commercial fleet vehicle operations data. These heat maps clearly show that high-frequency operating points vary significantly according to vehicle vocation, while only a few of them match the sweet spot. Beyond the illustration, engine in-use heat maps can also be leveraged to build up reduced-order engine-efficiency models, needed by many rapid powertrain simulations. As case studies, nine reduced-order models – including line-haul truck, transfer truck, transit bus, transit bus with compressed natural gas (CNG) engine, drayage, refuse pickup, local delivery, utility truck, and school bus with CNG engine – using a trust-region reflective algorithm to fit the on-road data extracted based on the engine in-use heat maps.

33 ADVANCED PROPULSION SYSTEMS↗
DOE OSTI2024

Next Gen High Efficiency Boosted Engine Development

This work represents an advanced engineering research project partially funded by the U.S. Department of Energy (DOE). Ford Motor Company, FEV North America, and Oak Ridge National Laboratory collaborated to develop a next generation boosted spark ignited engine concept. The project goals, specified by the DOE, were 23% improved fuel economy and 15% reduced weight relative to a 2015 or newer light-duty vehicle. The fuel economy goal was achieved by designing an engine incorporating high geometric compression ratio, high dilution tolerance, low pumping work, and low friction. The increased tendency for knock with high compression ratio was addressed using early intake valve closing (EIVC), cooled exhaust gas recirculation (EGR), an active pre-chamber ignition system, and careful management of the fresh charge temperature. Engine weight reduction measures were implemented throughout the engine system making use of composite materials, advanced manufacturing techniques, and architectural choices. This report outlines the analytical, design, fabrication, and test work conducted for the duration of the project. The combustion system stability, EGR tolerance, and knock resistance were validated on a single cylinder engine. An inline six-cylinder engine was then designed targeting application in the Ford F150. Multi-cylinder engines were produced and tested achieving the target vehicle fuel economy improvement of 23% assessed using measured engine fuel consumption combined with a vehicle drive cycle simulation. Actions were identified and designs were demonstrated to achieve the 15% weight reduction target. This project included items covering a range of technology readiness levels. Some of the technologies explored are production ready, while others were investigated to understand the limitations for what can be achieved in a stoichiometric, gasoline-fueled, spark-ignited internal combustion engine.

42 ENGINEERING↗
DOE OSTI2024

Catalytic enhancement in the performance of the microscopic two-stroke heat engine

Here we consider a model of heat engine operating in the microscopic regime: the two-stroke engine. It produces work and exchanges heat in two discrete strokes that are separated in time. The working body of the engine consists of two d-level systems initialized in thermal states at two distinct temperatures. Additionally, an auxiliary nonequilibrium system called catalyst may be incorporated with the working body of the engine, provided the state of the catalyst remains unchanged after the completion of a thermodynamic cycle. This ensures that the work produced by the engine arises solely from the temperature difference. Upon establishing the rigorous thermodynamic framework, we characterize twofold improvement stemming from the inclusion of a catalyst. Firstly, we prove that in the noncatalytic scenario, the optimal efficiency of the two-stroke heat engine with a working body composed of two-level systems is given by the Otto efficiency, which can be surpassed by incorporating a catalyst with the working body. Secondly, we show that incorporating a catalyst allows the engine to operate in frequency and temperature regimes that are not accessible for noncatalytic two-stroke engines. We conclude with a general conjecture about the advantage brought by a catalyst: including the catalyst with the working body always allows to improve efficiency over the noncatalytic scenario for any microscopic two-stroke heat engines. We prove this conjecture for two-stroke engines where the working body is composed of two d-level systems initialized in thermal states at two distinct temperatures, as long as the final joint state leading to optimal efficiency in the noncatalytic scenario is not a product state, or at least one of the d-level system is not thermal.

71 CLASSICAL AND QUANTUM MECHANICS, GENERAL PHYSIC↗
DOE OSTI2024

Practical low-temperature gasoline combustion for very high efficiency off-road, medium- and heavy-duty engines

Low-temperature gasoline combustion (LTGC) with additive-mixing fuel injection (AMFI) is a new combustion strategy that has been demonstrated to deliver 9%–25% better brake thermal efficiency than similar-sized market-leading diesel engines over the operating map. Moreover, the LTGC-AMFI engine shows near-zero smoke, and NOx emissions are 4–100 times lower than those of a diesel, sufficiently low that no aftertreatment, or only passive NOx aftertreatment, would be sufficient (diesel exhaust fluid is not required). LTGC-AMFI combustion is based on kinetically controlled compression ignition of a dilute charge with a variable amount of low-to-moderate fuel stratification. Fast combustion control is provided by adding minute amounts of an ignition-enhancing additive into the fuel each engine cycle to control its reactivity. This strategy was used to operate a medium-duty (MD) LTGC-AMFI engine at loads from idle to 16.3 bar BMEP and speeds from 600 to 2400 rpm with regular E10 gasoline, which covers nearly the entire operating map of a typical MD engine. Turbine-out temperatures were sufficient for an oxidation catalyst to control hydrocarbon and CO emissions. Autonomie simulations over the GEM ARB Transient and the GEM 55 mph Cruise driving cycles for class-6 trucks using this technology showed fuel economies of 8.1 and 11.4 mpg-gasoline-equivalent, respectively, corresponding to 18.6% and 13.4% improvements over a similar-size diesel engine. Engine-out NOx emissions were 0.024 and 0.01 g/bhp-h, respectively, well below current U.S. emission standards. These results show that switching from diesel to LTGC-AMFI engines would greatly reduce greenhouse gas (GHG) emissions for off-road, MD and HD applications, which will continue to rely on combustion engines because electrification is not practical in the foreseeable future. Finally, with their reduced fuel consumption, the lower cost of gasoline compared to diesel fuel, and much lower aftertreatment costs, LTGC-AMFI engines also offer a significantly lower total cost of ownership.

33 ADVANCED PROPULSION SYSTEMS↗
DOE OSTI2016

Hige Compression Ratio Turbo Gasoline Engine Operation Using Alcohol Enhancement

The overall objective of this project was to quantify the potential for improving the performance and efficiency of gasoline engine technology by use of alcohols to suppress knock. Knock-free operation is obtained by direct injection of a second “anti-knock” fuel such as ethanol, which suppresses knock when, with gasoline fuel, knock would occur. Suppressing knock enables increased turbocharging, engine downsizing, and use of higher compression ratios throughout the engine’s operating map. This project combined engine testing and simulation to define knock onset conditions, with different mixtures of gasoline and alcohol, and with this information quantify the potential for improving the efficiency of turbocharged gasoline spark-ignition engines, and the on-vehicle fuel consumption reductions that could then be realized. The more focused objectives of this project were therefore to: Determine engine efficiency with aggressive turbocharging and downsizing and high compression ratio (up to a compression ratio of 13.5:1) over the engine’s operating range; Determine the knock limits of a turbocharged and downsized engine as a function of engine speed and load; Determine the amount of the knock-suppressing alcohol fuel consumed, through the use of various alcohol-gasoline and alcohol-water gasoline blends, for different driving cycles, relative to the gasoline consumed; Determine implications of using alcohol-boosted engines, with their higher efficiency operation, in both light-duty and medium-duty vehicle sectors.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗
DOE OSTI2019

Characterization of Low Temperature Reactions in the Standard Cooperative Fuel Research (CFR) Engine

A number of proposals for fuel rating in spark ignition (SI) engine have been suggested till date and still no consensus on this has been reached. The automobile industry is continuing to use RON and MON tests for rating fuels, and still there exists a need to come up with new fuel rating systems. The fuel’s knocking tendency in SI engines is mainly governed by the end-gas autoignition. Another combustion mode, homogeneous charge compression ignition (HCCI), is also driven by autoignition of the complete charge inside the cylinder. Fundamentally, the combustion process in both combustion modes is driven by autoignition, and HCCI combustion mode can be used to understand the knocking behavior in SI engines. The lean combustion environment in HCCI mode provides a good platform to replicate the operating conditions of modern SI engines, which are operating at boosted pressures and low intake temperatures, and understanding of the fuel knocking behavior under such conditions is vital for achieving high-efficient engines. Therefore in this study, HCCI combustion will be used in the standard CFR engine to understand the autoignition behavior of the fuels for SI engines. For this purpose, three fuel blends were selected, which had the research octane number equal to 90. The standard CFR engine was operated with varying intake pressures and temperatures under HCCI combustion mode. The Lund-Chevron HCCI fuel number was used to rate the fuels and this was compared with RON and MON of the blends. It was found that HCCI combustion could be used to rate the fuels with the standard CFR engine with minor modifications to accommodate the boosted conditions without affecting the geometry and the flow inside the CFR engine. Low temperature reactions were observed and were correlated with the Lund-Chevron HCCI fuel numbers.

33 ADVANCED PROPULSION SYSTEMS↗
DOE OSTI2020

Multi-mode advanced combustion engine with supervisory control

An engine system uses data associated with at least one operating condition of an engine to set the engine system to an AI mode when the engine is in an SI mode 1) within first operating condition limits, and 2) when a rate of change of a first operating condition is within rate of change limits, maintain the engine system in the SI mode when the engine is outside of first operating condition limits or when the rate of change of the first operating condition is not within rate of change limits, set the engine system to the SI mode when the engine is in the AI mode outside second operating condition limits, and maintain the engine system in the AI mode when the engine is within second operating condition limits, wherein the second operating condition limits are different from the first operating condition limits.

42 ENGINEERING↗
DOE OSTI2019

3-D Modeling of the CFR Engine for the Investigation of Knock on Natural Gas

Abstract: Engine knock and misfire are barriers to pathways leading to higher efficiency natural gas (NG) engines, where the general tendency to knock is highly dependent on engine operating conditions and the fuel reactivity. The problem is further complicated by low emissions limits and the wide range of chemical reactivity in pipeline quality NG, making the understanding of fuel- engine interactions essential to achieving high efficiencies in spark-ignited NG engines. The present work highlights a three-dimensional computational fluid dynamics (CFD) model of the Cooperative Fuel Research (CFR) engine to investigate knock behavior when running on NG. Using a Converge CFD model of the CFR engine fuel-engine interactions that lead to knock with NG, including effects of fuel reactivity, engine operating parameters, and exhaust gas recirculation, are being investigated. A GT-Power model is used to estimate appropriate initial conditions in the Converge CFD model, including cylinder wall, piston, valves, and port surface temperatures as well as residual gas fraction. In order to validate the model, in-cylinder pressure data taken with a CFR engine is compared to model predictions while varying compression ratio, CA50, and BMEP.

CFR Engine, Converge CFD, knock, Natural Gas↗
DOE OSTI2021

Influence of Fuel Properties on Gasoline Direct Injection Particulate Matter Emissions Over First 200 s of World-Harmonized Light-Duty Test Procedure Using an Engine Dynamometer and Novel “Virtual Drivetrain” Software

Abstract The influence of fuel properties on particulate matter (PM) emissions from a catalytic gasoline particulate filter (GPF) equipped gasoline direct injection (GDI) engine was investigated using novel “virtual drivetrain” software and an engine mated to an engine dynamometer. The virtual drivetrain software was developed in labview to operate the engine on an engine dynamometer as if it were in a vehicle undergoing a driving cycle. The software uses a physics-based approach to determine vehicle acceleration and speed based on engine load and a programed “shift” schedule to control engine speed. The software uses a control algorithm to modulate engine load and braking to match a calculated vehicle speed with the prescribed speed trace of the driving cycle of choice. The first 200 s of the World-harmonized Light-duty Test Procedure (WLTP) driving cycle was tested using six different fuel formulations of varying volatility, aromaticity, and ethanol concentration. The first 200 s of the WLTP was chosen as the test condition because it is the most problematic section of the driving cycle for controlling PM emissions due to the cold start and cold drive off. It was found that there was a strong correlation between aromaticity of the fuel and the engine-out PM emissions, with the highest emitting fuel producing more than double the mass emissions of the low PM production fuel. However, the post-GPF PM emissions depended greatly on the soot loading state of the GPF. The fuel with the highest engine-out PM emissions produced comparable post-GPF emissions to the lowest PM producing fuel over the driving cycle when the GPF was loaded over three cycles with the respective fuels. These results demonstrate the importance of GPF loading state when aftertreatment systems are used for PM reduction. It also shows that GPF control may be more important than fuel properties, and that regulatory compliance for PM can be achieved with proper GPF control calibration irrespective of fuel type.

Energy & Fuels↗
DOE OSTI2019

Diesel Engine Characterization and Performance Scaling Via Brake Specific Fuel Consumption Map Dimensional Analysis

The goal of this work is to develop easily generalized models of heavy duty truck engine maps that allow for approximate comparisons of engine performance, thus enabling fuel efficient matching of engines to a set of corresponding loads and routes. This is achieved by applying dimensional analysis to create a uniformly applicable, dimensionless Brake Specific Fuel Consumption (BSFC) map that fits the behavior of a wide range of diesel engines. Here, a commonality between maps was found to occur when engine data is scaled by specific dimensional parameters that target data consistency among the primary operating points across engines. This common map highlights observable trends in engine performance based on the influence of these same parameters being scaled across engines. The resulting dimensionless engine map fits the minimum BSFC regions of four diesel engines to within 2.5 percent.

33 ADVANCED PROPULSION SYSTEMS↗
DOE OSTI2014

Advanced Natural Gas Reciprocating Engine(s)

The objective of the Cummins ARES program, in partnership with the US Department of Energy (DOE), is to develop advanced natural gas engine technologies that increase engine system efficiency at lower emissions levels while attaining lower cost of ownership. The goals of the project are to demonstrate engine system achieving 50% Brake Thermal Efficiency (BTE) in three phases, 44%, 47% and 50% (starting baseline efficiency at 36% BTE) and 0.1 g/bhp-hr NOx system out emissions (starting baseline NOx emissions at 2 – 4 g/bhp-hr NOx). Primary path towards above goals include high Brake Mean Effective Pressure (BMEP), improved closed cycle efficiency, increased air handling efficiency and optimized engine subsystems. Cummins has successfully demonstrated each of the phases of this program. All targets have been achieved through application of a combined set of advanced base engine technologies and Waste Heat Recovery from Charge Air and Exhaust streams, optimized and validated on the demonstration engine and other large engines. The following architectures were selected for each Phase: Phase 1: Lean Burn Spark Ignited (SI) Key Technologies: High Efficiency Turbocharging, Higher Efficiency Combustion System. In production on the 60/91L engines. Over 500MW of ARES Phase 1 technology has been sold. Phase 2: Lean Burn Technology with Exhaust Waste Heat Recovery (WHR) System Key Technologies: Advanced Ignition System, Combustion Improvement, Integrated Waste Heat Recovery System. Base engine technologies intended for production within 2 to 3 years Phase 3: Lean Burn Technology with Exhaust and Charge Air Waste Heat Recovery System Key Technologies: Lower Friction, New Cylinder Head Designs, Improved Integrated Waste Heat Recovery System. Intended for production within 5 to 6 years Cummins is committed to the launch of next generation of large advanced NG engines based on ARES technology to be commercialized worldwide.

Pike, Edward↗