DOE OSTI2019
Reactivity-Controlled Compression Ignition (RCCI) is a promising new advanced, low temperature combustion mode that offers efficiencies equal to or greater than conventional diesel combustion, but significantly lower soot and NOx emissions. Additionally, RCCI has enhanced controllability over the combustion process compared to some of the other advanced combustion modes. Therefore, RCCI combustion has the potential to be of great benefit to the public by increasing the efficiency and reducing the harmful pollutant emissions from transportation. However, RCCI combustion achieves this favorable level of performance through the use of two distinct fuels (e.g., diesel and gasoline, diesel and natural gas, or diesel and ethanol). In a vehicle application, RCCI therefore requires two different fuel tanks and fuel injection systems, which presents a significant drawback to the commercialization RCCI. This project proposed a new concept to enable RCCI combustion from a single parent fuel stored onboard the vehicle in a single fuel tank. Specifically, the parent fuel would be stored in the fuel tank and one branch of the fuel system would deliver the parent fuel, unaltered, to the cylinder, while a second branch of the fuel system would route the parent fuel through a fuel reformer to chemically react the fuel into a gaseous fuel mixture, called “reformate”, that has different properties from the original parent fuel. In this way, there can be two fuels at the engine that have different properties, but only one parent fuel needs to be stored and refilled in the vehicle. This initial, exploratory investigation into the feasibility of this promising new concept included reacting three potential parent fuels (diesel, gasoline, and natural gas) in a fuel reformer and determining the composition of the gaseous reformate fuel that exited the fuel reformer. There are different types of reformation processes, but since this project was a proof-of-concept investigation into the potential of Single-Fuel RCCI and the combustion process in the cylinder, a catalytic partial oxidation (CPOX) reformation process was selected, which is more straightforward to perform and control, and would potentially be easier to implement in a vehicle application compared to other reformation processes. Once the three parent fuels were reformed to varying degrees and their reformate compositions were determined, their autoignition tendencies were experimentally determined by comparing advanced combustion results of the reformate mixtures with known reference fuels. This showed that diesel fuel and its reformate fuel mixture exhibited the largest reactivity separation, which is necessary to enable RCCI combustion in the cylinder. Using diesel fuel as the parent fuel, experimental testing was conducted to provide a better understanding of the operational considerations, benefits, and drawbacks of Single-Fuel RCCI with onboard fuel reformation. The experimental testing was accompanied by computational fluid dynamics and system-level modeling to help complement the experiments and further expand the understanding. The main conclusions are that Single-Fuel RCCI using diesel fuel as the direct injected, high reactivity fuel and diesel’s gaseous reformate mixture as the premixed, low reactivity fuel is viable. The efficiencies were equal to, or sometimes greater than, RCCI with conventional fuel pairs, and the emissions were comparable as well. A key consideration is that gaseous reformate fuel contains a large amount of diluents in the fuel which displace air entering the cylinder and act as EGR inside the cylinder. Additionally, the reactivity separation between diesel and its reformate fuel mixture is larger than diesel-gasoline, but less than diesel-natural gas, and the combustion process therefore responded in a manner that was between the two conventional fuel pairs. Finally, although achievable in the cylinder, there are practical drawbacks or other disadvantages of Single-Fuel RCCI with onboard fuel reformation. First, this project used a CPOX reformation process which is exothermic, meaning that a portion of the fuel’s energy was released in the reformer where it could not be converted into useful work. This constituted an efficiency penalty of the system of on the order of 10% or 4 percentage points. Future research should therefore focus on alternate reforming processes including steam-methane reforming or autothermal reforming where there might not be any energy released in the reformer, or there could even be an energy gain in the reformer (through an endothermic process with waste heat recovery). Practical drawbacks that exist, but were beyond the scope of this preliminary proof-of-concept research project, are the added cost of the fuel reformer, which is a catalyst made of precious metals, transient response of the system, and the lifetime of the fuel reformer.
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