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DOE OSTI2018

Influence of Microbial Membranes on Biofilm Formation, Scaling Reactions, and Production Chemistry in Engineered Energy Systems (Final Report)

Humans are engineering the deep subsurface for the purposes of energy-capture, energy-storage, and environmental mitigation. Despite the potential for microbial communities to significantly alter the effectiveness of these technologies, we have historically lacked a clear understanding of how microbial cells interact in a fractured shale system. Existing knowledge has been heavily based on genomic information, lacking studies on in situ physiologies, kinetic rates, and attachment mechanisms governing biogeochemical reactions in the system. The overarching goal of this research was to advance understanding of engineered hydrocarbon extraction systems as they evolve from newly developed environments to mature use. Plasma membranes protect microbial cells, mediate many critical functions, and respond to intracellular cues and ecological perturbations through physicochemical modifications. The project objectives were to 1) characterize variables influencing growth and membrane features of shale taxa, 2) characterize the interactions between shale matrices and microorganisms and 3) elucidate engineered and environmental processes driving biogeochemical signatures at the field scale. Objectives were realized through laboratory experiments involving growth of pure cultures and enrichments in continuous culture and biofilms; access to samples from two DOE-NETL funded energy-capture sites: Marcellus Shale Energy and Environmental Laboratory (MSEEL and MSEEL II); and through collaborations with scientists and engineers at the Environmental Molecular Science Laboratory (EMSL) and National Energy Technology Laboratory (NETL). Key findings showed (a) Halanaerobium congolense WG10 makes its membrane more fluid and thicker through increasing its polyunsaturated fatty acid (PUFA) composition under non-optimal salinities (7% and 20%) compared to the optimum (13% NaCl); (b) anionic phospholipids within the plasma membrane are important for high salinity tolerance in H. congolense WG10 while zwitterionic species modulate biofilm physiologies in both isolate and mixed cultures, and (c) tyrosine accumulation with overexpression of Na+/H+ antiporters are essential for osmoprotection in H. congolense WG10 under high salinity while upregulation of aromatic amino acid synthesis and cell envelope maintenance underpin biofilm formation. It is clear from these results that microbial persistence in fractured shale reservoirs under environmental and engineered perturbations requires strategic plasma membrane lipid chemistry adjustments and metabolic restructuring, with implications for improved shale microbiology management and more efficient hydrocarbon extraction approaches targeting microorganisms.

03 NATURAL GAS↗

DOE OSTI2024

Wide Bandgap Generation (WBGen): Developing the Future Wide Bandgap Power Electronics Engineering Workforce

This Final Technical Report (FTR) summarizes the work conducted at the Center for Power Electronics Systems (CPES) under the Wide-Bandgap Generation (WBGen) fellowship and traineeship program established by the Advanced Manufacturing and Technologies Office (AMMTO) of the U.S. Department of Energy Office of Energy Efficiency and Renewable Energy (EERE) at Virginia Tech, which had as main objective to train the next generation of U.S. citizen power engineers with wide-bandgap (WBG) power semiconductor expertise, with the intent to aid in fulfilling the future workforce needs in this field. The latter was deemed of strategic importance given the fast-paced growth observed—and predicted—in the demand of this technical expertise, whose practitioners have become the enablers and executioners of the electrification transformation process that not just the U.S., but the whole world, is currently undergoing as it seeks for more effective and efficient ways to use energy. As such, the WBGen program set forth to achieve its educational goals, which in addition sought to broaden the range of WBG-based power electronics by conducting research and development on high-efficiency grid apparatus and high-efficiency electrical power systems, and to also enhance the power engineering curriculum by formalizing WBG-oriented design procedures replacing existent yet now obsolete design procedures developed for Silicon (Si) based power electronics. This effort led CPES to spearhead the development of a new major within The Bradley Electrical and Computer Engineering (ECE) Department at Virginia Tech, namely Electronic Power and Energy Systems (EPES), which coalesced power electronics and power systems courses to provide undergraduate students with a strong formation in the power engineering field, while creating a pipeline of graduate students that could pursue the WBG-based curriculum and conduct research at CPES. In all, in what is considered a true success, eight of the twenty WBGen fellows that graduated program were recruited from the ECE department undergraduate cohort. The traineeship emphasized as well, from its beginning, the partnership with industry and national laboratories, which took advantage of the successful industry consortium at CPES that has historically been formed by 80–90 power and energy companies working in close collaboration with the center. This gave WBGen fellows the accessibility and possibility to conduct internships at partner facilities during the summer months, focused solely on the evaluation, testing, and adoption of WBG devices, which were many times tightly related to their respective research work and plans. In addition, WBGen fellows conducted their main research work within the confines of research programs at CPES conducted with these industry partners, providing them with a unique opportunity to develop not just their technical expertise—while advancing their knowledge, but to also learn and practice a slew of skills needed for their professional growth. As such, the fellows tackled a variety of WBG-related research topics, from device reliability and capability aspects as well as packaging and integration, encompassing the use of advanced materials and new structures, current sharing challenges, and insulation systems, to advanced gate-drivers with integrated sensors and protection mechanisms and active current- and voltage-based control, to optimized layouts seeking to maximize the switching and power processing performance of these devices, to power processing solutions adopting Gallium-Nitride (GaN) and Silicon-Carbide (SiC) power semiconductors for a variety of applications; including radiation-hardened converters for space dc distribution systems, direct three-phase ac-to-ac power converters for aerospace systems, dc-ac inverters for automotive traction drives, high-frequency isolated dc-dc battery chargers also for heavy transportation systems, and medium-voltage dc-dc and dc-ac converters for distribution systems and future power grids. The WBGen program ultimately graduated a total of 20 power engineers, all experts on WBG-based power electronics, awarding 18 M.S. and 2 PhD degrees in the process. These fellows, all U.S. citizens, allowed CPES to increase the number of citizens students to 33 % at the peak of the program, as the traineeship made possible the recruitment of talent with more attractive graduate research assistantship (GRA) contracts. Unfortunately, the present U.S. citizen enrollment at CPES has declined back to historic levels—approximately 10 %, as the regular GRA rates are not competitive enough when compared with entry-level industry jobs. In all, WBGen fellows published a total of 7 peer-reviewed journal articles, 44 papers at international technical conferences, made 42 presentations at international technical conferences, and filed 4 invention disclosures and patent applications, which have since then been granted by the U.S. Patent and Trademark Office (USPTO). Their contribution to CPES, Virginia Tech, the United States, and the world, has been significant, and continues to yield results thanks to the exemplary career that the fellows have initiated at many of the partners of the program, which include Wolfspeed, Raytheon Technologies, Infineon, Lockheed Martin, Dominion Energy, Northrop Grumman, Rivian, Aerospace Corporation, Sandia National Laboratory, National Renewable Energy Laboratory, John Hopkins University, and Virginia Tech.

14 SOLAR ENERGY↗

DOE OSTI2024

RANGERS: Methodology Report on Design and Performance Assessment of Engineered Barrier Systems in a Salt Repository for HLW/SNF

Salt formations are one of the potential host rocks for the final disposal of high-level radioactive waste (HLW) in deep geological repositories, both in Germany and the United States. The safe isolation of radioactive waste in these repositories relies on a multi-barrier system, combining engineered and natural barriers. The natural barrier is provided by the salt rock itself, known for its self-sealing properties and long-term stability. The engineered barrier, on the other hand, comprises sealing components strategically placed within the repository to enhance its containment capabilities. In both Germany and the United States, long-term safety assessments require demonstrating the integrity of the natural barrier for a period of up to 1 million years. Concurrently, the engineered barrier system (EBS) must maintain its structural and functional integrity until the long-term sealing, such as the granular salt backfill material, has re-consolidated to its final low porosity and permeability. Based on extensive expertise and experience with engineered barriers in salt formations, BGE TECHNOLOGY GmbH and Sandia National Laboratories have partnered to develop a robust methodology for the integrity and performance assessment of EBS in HLW repositories through the RANGERS project. This collaborative effort aims to establish a unified approach to geotechnical engineering, repository design, integrity and performance evaluation of EBS in salt repositories.

12 MANAGEMENT OF RADIOACTIVE AND NON-RADIOACTIVE W↗

DOE OSTI2026

AOI 5 Improved Efficiency of Medium- and Heavy-Duty Natural Gas and Propane (LPG) Engines

Spark-ignited heavy-duty (HD) natural gas engines typically experience efficiency losses at part-load operation due to throttling requirements needed to maintain stoichiometric combustion. A substantial portion of medium- and heavy-duty engine operation occurs in this low-load region, resulting in increased brake-specific carbon dioxide emissions and reduced overall efficiency. This project designed, developed and demonstrated cylinder deactivation (CDA) technology on an HD natural gas engine to mitigate these losses. CDA enables selective deactivation of cylinders, reducing pumping losses while maintaining required torque output and meeting vehicle noise, vibration, and harshness (NVH) targets. The project objectives were successfully achieved, demonstrating up to 12% improvement in fuel consumption over the next generation HD NG engine on key low loaded HD cycles and maintained compliance with 0.02 g/hp-hr NO x emissions with comparable or better vibrations to current product. These results confirm that CDA technology can substantially improve the fuel efficiency and environmental performance of heavy-duty natural gas engines, reinforcing their potential as a low-carbon bridge solution in the transition toward zero-emission transportation technologies.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗

DOE OSTI2025

Development of Hydrogen Burner for FT4000® Aeroderivative Engine - Final Report

This report details an effort to develop a retrofittable fuel/air injector for the FT4000® aeroderivative gas turbine that enables use of hydrogen as a carbon-free fuel for efficient power generation. The FT4000 engine’s low-NOx combustor was developed by Pratt & Whitney and RTX Technology Research Center with core technology from the Pratt & Whitney PW4000 turbofan aircraft engine. The current FT4000 production engine operates on either natural gas or No. 2 fuel oil with water injection to achieve high thermal efficiency and low emissions. This engine is fielded by Mitsubishi Power Aero and delivers 70 MW of power with a simple-cycle efficiency of over 41% when operating with wet compression. The work reported here advances the technology readiness level of the FT4000 combustor for operation with hydrogen, starting with an experimental assessment of the current production hardware with increasing hydrogen content mixed with natural gas and ending with improved nozzle concepts for fully robust operation with 100% hydrogen. High-pressure single-sector combustor rig tests have been completed, demonstrating the ability for the dual fuel nozzle to operate an FT4000 combustor on 100% hydrogen with low nitrogen oxide (NOx) emissions. Metal temperature measurements and video images of the flame structure from zero to 100% hydrogen highlight opportunities to improve the fuel nozzle robustness for high hydrogen conditions. The design of new fuel/air mixer concepts to improve durability and operability with high hydrogen levels was also completed. A total of eleven new concepts were developed and analyzed, ranging from modifications to the bill-of-materials nozzle to fully clean sheet designs. The concepts were evaluated with non-reacting and reacting flow evaluations to assess the performance of the new hardware designs. Non-reacting tests included Phase Doppler Particle Analysis (PDPA) for droplet size and velocity, mechanical patternation for liquid water flux, and planar laser induced fluorescence (PLIF) with acetone-seeding for gaseous fuel/air mixing characterization. Five scaled candidate fuel nozzle designs, in addition to a scaled bill-of-materials nozzle, were then successfully evaluated in an atmospheric pressure burner rig. The nozzles were evaluated for performance with natural gas, hydrogen/natural gas blends, and pure hydrogen. For 100% hydrogen, the nozzles were evaluated with and without water injection. Optical and infrared imaging of the flame and fuel nozzle was captured. NOx emissions were sampled from fixed emissions probes. The results show measurable differences between the various designs, and the data was used to down-select the two most promising designs to advance to future full pressure rig testing. Results from this study have cleared the current production FT4000 engines with dual fuel nozzles to operate at baseload power on blends of hydrogen mixed with natural gas and water. Two promising nozzle designs have been developed to enable fully robust operation with up to 100% hydrogen. These nozzles require validation at full baseload operating conditions before they can be introduced to the field.

03 NATURAL GAS↗

DOE OSTI2019

Performance Characterization of a Natural Gas-Air Rotating Detonation Engine at Elevated Pressure

Performance of a rotating detonation engine was studied to understand the challenges of achieving and quantifying a net pressure gain at engine-relevant conditions. The combustor under study was designed for operation with natural gas and air at elevated chamber pressures and air preheat temperatures representative of land based power generation gas turbine engines. The thrust produced by the combustor was measured to characterize its performance while high-frequency pressure transducers and high speed imaging of broadband combustion chemiluminescence provided information about the wave structure and dynamics. The rotating detonation engine was tested with two injector configurations to explore the effect of injector design and combustor operating mode on device performance. Analysis using multiple metrics showed nearly identical performance between similar operating conditions that alternately produced a single detonation wave or two counter-propagating waves in the combustion chamber. Across the range of tested conditions, a maximum pressure gain of -42% was measured. Several tests were observed to produce up to 10% more thrust than an ideal, constant pressure combustor, though this comparison ignores injection losses. Comparison of measured pressure gain with idealized simulations showed that the net pressure gain of a rotating detonation engine is closely tied to the area ratio between the inlet and outlet of the combustor.

20 FOSSIL-FUELED POWER PLANTS↗

DOE OSTI2020

Experimental Measurements of NOx Emissions in a Rotating Detonation Engine

An experimental study of NOx emissions in a rotating detonation engine is presented in this paper. Rotating detonation engines produce a pressure gain in the combustion process which leads to increased efficiency compared to conventional constant pressure, deflagration based combustion. However, in order for rotating detonation engines to become a viable alternative to conventional combustion, they must meet NOx emissions regulations. Emissions from rotating detonation engines are not currently well understood. A parametric study was performed to determine time averaged NOx emissions in a rotating detonation engine over a range of operating conditions. The effects of inlet pre-heat, equivalence ratio, flow rate, and fuel composition are investigated.

Ferguson, Donald↗

DOE OSTI2023

Advances in S. cerevisiae Engineering for Xylose Fermentation and Biofuel Production: Balancing Growth, Metabolism, and Defense

Genetically engineering microorganisms to produce chemicals has changed the industrialized world. The budding yeast Saccharomyces cerevisiae is frequently used in industry due to its genetic tractability and unique metabolic capabilities. S. cerevisiae has been engineered to produce novel compounds from diverse sugars found in lignocellulosic biomass, including pentose sugars, like xylose, not recognized by the organism. Engineering high flux toward novel compounds has proved to be more challenging than anticipated since simply introducing pathway components is often not enough. Several studies show that the rewiring of upstream signaling is required to direct products toward pathways of interest, but doing so can diminish stress tolerance, which is important in industrial conditions. As an example of these challenges, we reviewed S. cerevisiae engineering efforts, enabling anaerobic xylose fermentation as a model system and showcasing the regulatory interplay’s controlling growth, metabolism, and stress defense. Enabling xylose fermentation in S. cerevisiae requires the introduction of several key metabolic enzymes but also regulatory rewiring of three signaling pathways at the intersection of the growth and stress defense responses: the RAS/PKA, Snf1, and high osmolarity glycerol (HOG) pathways. The current studies reviewed here suggest the modulation of global signaling pathways should be adopted into biorefinery microbial engineering pipelines to increase efficient product yields.

59 BASIC BIOLOGICAL SCIENCES↗

DOE OSTI2018

Opportunities and Challenges with Polyalkylene Glycol for Engine Oil Application

Base oil plays an important role in engine oil formulation in delivering overall performance attributes in addition to additives. Non-traditional base oil like polyalkylene glycol (PAG) did not get much attention in the past for formulating automotive engine oil. This investigation explored PAGs for enhancing engine oil performance primarily for fuel economy benefit over traditional mineral oil-based formulations. This paper highlights key findings from an extensive investigation, parts of which were published in detail elsewhere, and identifying opportunities and challenges. Several PAG chemistries were investigated depending on their feedstock material. Friction performance was evaluated by several methods starting with laboratory bench tests to engine components to chassis roll dynamometer tests. Durability was also evaluated from laboratory bench tests to engine components to ASTM sequence tests. The investigation revealed that significant friction reduction or fuel economy gain can be achieved with PAG oil but wear protection capability, piston deposit, and varnish require much improvement requiring identification/development of additive components. A few alternative routes for performance improvement are suggested.

Gangopadhyay, Arup↗

DOE OSTI2015

Experimental investigation of a DISI production engine fuelled with methanol, ethanol, butanol, and iso-stoichiometric alcohol blends

Stricter CO2 and emissions regulations are pushing spark ignition engines more and more towards downsizing, enabled through direct injection and turbocharging. The advantages which come with direct injection, such as increased charge density and an elevated knock resistance, are even more pronounced when using low carbon number alcohols instead of gasoline. This is mainly due to the higher heat of vaporization and the lower air-to-fuel ratio of light alcohols such as methanol, ethanol and butanol. These alcohols are also attractive alternatives to gasoline because they can be produced from renewable resources. Because they are liquid, they can be easily stored in a vehicle. In this respect, the performance and engine-out emissions (NOx, CO, HC and PM) of methanol, ethanol and butanol were examined on a 4 cylinder 2.4 DI production engine and are compared with those on neat gasoline. Additionally, measurements were done for E85 and a methanol-gasoline blend with the same air-to-fuel ratio as E85 because this ‘iso-stoichiometric’ methanol-gasoline blend shows very few differences in physical properties to E85 and has the potential to be used as ‘drop-in’ fuel for flex-fuel vehicles. It is shown that the brake thermal efficiency when running on alcohol fuels is significantly better than with gasoline while emitting fewer emissions. In a knock limited case for gasoline, the brake thermal efficiency on methanol was more than 5 percentage points better than on gasoline. The engine test results also confirm that, from an engine control point of view, the ‘iso-stoichiometric’ methanol-gasoline blend can indeed be used as a ‘drop-in’ fuel for E85.

Sileghem, Louis↗

DOE OSTI2015

Impact of Effective Compression Ratio on Gasoline-Diesel Dual-Fuel Combustion in a Heavy-Duty Engine Using Variable Valve Actuation

Dual-fuel combustion using port-injected gasoline with a direct diesel injection has been shown to achieve low-temperature combustion with moderate peak pressure rise rates, low engine-out soot and NOx emissions, and high indicated thermal efficiency. A key requirement for extending high-load operation is moderating the reactivity of the premixed charge prior to the diesel injection. Reducing compression ratio, in conjunction with a higher expansion ratio using alternative valve timings, decreases compressed charge reactivity while maintain a high expansion ratio for maximum work extraction. Experimental testing was conducted on a 13L multi-cylinder heavy-duty diesel engine modified to operate dual-fuel combustion with port gasoline injection to supplement the direct diesel injection. The engine employs intake variable valve actuation (VVA) for early (EIVC) or late (LIVC) intake valve closing to yield reduced effective compression ratio. Testing was conducted at a mid-load operating condition using a gasoline-diesel dual-fuel operating strategy. The impact on dual-fuel engine performance and emissions with respect to varying effective compression ratio is quantified within this study. As effective compression ratio is reduced, overall massflow through the engine decreases, yielding both higher gas exchange efficiencies and increased heat transfer losses. With constant combustion phasing gasoline/diesel fueling fraction, and NOx emissions held constant, overall brake thermal efficiency remains relatively constant across effective compression ratios.

Ickes, Andrew↗

DOE OSTI2015

Effects of Ignition and Injection Perturbation under Lean and Dilute GDI Engine Operation

Turbocharged gasoline direct injection (GDI) engines are quickly becoming more prominent in light-duty automotive applications because of their potential improvements in efficiency and fuel economy. While EGR dilute and lean operation serve as potential pathways to further improve efficiencies and emissions in GDI engines, they also pose challenges for stable engine operation. Tests were performed on a single-cylinder research engine that is representative of current automotive-style GDI engines. Baseline cases were performed under steady-state operating conditions where combustion phasing and dilution were varied to determine the effects on indicated efficiency and combustion stability. Sensitivity studies were then carried out by introducing binary low-high perturbation of spark timing and injection duration on a cycle-by-cycle basis under EGR dilute and lean operation to determine dominant feedback mechanisms. Ignition perturbation was phased early/late of MBT timing, and injection perturbation was set fuel rich/lean of the given air-fuel ratio. COVIMEP was used to define acceptable operation limits when comparing different perturbation cases. Overall results suggests that combustion phasing is very important for dilute operation while the impact of perturbation is reduced due to increased burn duration compared to the stoichiometric baseline without EGR. Lean operation was found to be very sensitive to injection perturbation, with the effect of perturbations amplified by next-cycle feedback. Due to the longer timescale EGR operation was shown to be less sensitive to next-cycle changes in fueling.

Wallner, Thomas↗

DOE OSTI2017

Influence of Compression Ratio on High Load Performance and Knock Behavior for Gasoline Port-Fuel Injection, Natural Gas Direct Injection and Blended Operation in a Spark Ignition Engine

Natural Gas (NG) is an alternative fuel which has attracted a lot of attention recently, in particular in the US due to shale gas availability. The higher hydrogen-to-carbon (H/C) ratio, compared to gasoline, allows for decreasing carbon dioxide emissions throughout the entire engine map. Furthermore, the high knock resistance of NG allows increasing the efficiency at high engine loads compared to fuels with lower knock resistance. NG direct injection (DI) allows for fuel to be added after intake valve closing (IVC) resulting in an increase in power density compared to an injection before IVC. Steady-state engine tests were performed on a single-cylinder research engine equipped with gasoline (E10) port-fuel injection (PFI) and NG DI to allow for in-cylinder blending of both fuels. Knock investigations were performed at two discrete compression ratios (CR), 10.5 and 12.5. Operating conditions span mid-load, wide-open-throttle and boosted conditions, depending on the knock response of the fuel blend. Blended operation was performed using E10 gasoline and NG. An additional gasoline type fuel (E85) with higher knock resistance than E10 was used as a high-octane reference fuel, since the octane rating of E10-NG fuel blends is unknown. Spark timing was varied at different loads under stoichiometric conditions in order to study the knock response as well as the effects on performance and efficiency. As anticipated, results suggest that the knock resistance can be increased significantly by increasing the NG amount. Comparing the engine operation with the least knock resistant fuel, E10 PFI, and the fuel blend with the highest knock resistance, 75% NG DI, shows an increase in indicated mean effective pressure of about 9 bar at CR 12.5. The usage of reference fuels with known knock characteristics allowed an assessment of knock characteristic of intermediate E10-NG blend levels. Mathematical correlations were developed allowing characterizing the occurrence of knocking combustion by using the Livengood-Wu knock integral. For most of the fueling strategies and operating conditions, the mathematical correlations show good agreement when compared to experimental data.

combustion↗

DOE OSTI2018

Large-eddy Simulations of Spray Variability Effects on Flow Variability in a Direct-injection Spark-ignition Engine Under Non-combusting Operating Conditions

Large-eddy Simulations (LES) have been carried out to investigate spray variability and its effect on cycle-to-cycle flow variability in a direct-injection spark-ignition (DISI) engine under non-reacting conditions. Initial simulations were performed of an injector in a constant volume spray chamber to validate the simulation spray set-up. Comparisons showed good agreement in global spray measures such as the penetration. Local mixing data and shot-to-shot variability were also compared using Rayleigh-scattering images and probability contours. The simulations were found to reasonably match the local mixing data and shot-to-shot variability using a random-seed perturbation methodology. After validation, the same spray set-up with only minor changes was used to simulate the same injector in an optically accessible DISI engine. Particle Image Velocimetry (PIV) measurements were used to quantify the flow velocity in a horizontal plane intersecting the spark plug gap. The engine was operated in a skip-fired operating mode and comparisons focused on cycles that included fuel injection, but no spark event and therefore no combustion. 105 total LES engine cycles were simulated using a parallel cycle simulation approach and 3 different perturbation methods in an attempt to isolate the effects of shot-to-shot spray variability and the initial turbulent flow field as well as their interaction effects on overall engine CCVs. The experimental mean and standard deviations were reasonably well matched by the simulations, though quantitative comparisons near the injection event during the intake stroke were difficult due to the high uncertainty in the PIV measurements at these crank angles. The 3 simulation perturbation methods resulted in very similar results, though further analysis found the current parallel cycle approach may be limiting the ability of the simulations to isolate the spray and flow effects.

Cycle-to-cycle Variability↗

DOE OSTI2018

Effects of NOX Storage Component on Ammonia Formation in TWC for Passive SCR NOX Control in Lean Gasoline Engines

A prototype three-way catalyst (TWC) with NOX storage component was evaluated for ammonia (NH3) generation on a 2.0-liter BMW lean burn gasoline direct injection engine as a component in a passive ammonia selective catalytic reduction (SCR) system. The passive NH3 SCR system is a potential approach for controlling nitrogen oxides (NOX) emissions from lean burn gasoline engines. In this system, NH3 is generated over a close-coupled TWC during periodic slightly-rich engine operation and subsequently stored on an underfloor SCR catalyst. Upon switching to lean, NOX passes through the TWC and is reduced by the stored NH3 on the SCR catalyst. Adding a NOX storage component to a TWC provides two benefits in the context of a passive SCR system: (1) enabling longer lean operation by storing NOX upstream and preserving NH3 inventory on the downstream SCR catalyst; and (2) increasing the quantity and rate of NH3 production during rich operation. Since the fuel penalty associated with passive SCR NOX control depends on the fraction of time that the engine is running rich rather than lean, both benefits (longer lean times and shorter rich times achieved via improved NH3 production) will decrease the passive SCR fuel penalty. However, these benefits are primarily realized at low to moderate temperatures (300-500 °C), where the NOX storage component is able to store NOX, with little to no benefit at higher temperatures (>500 °C), where NOX storage is no longer effective. This study discusses engine parameters and control strategies affecting the NH3 generation over a TWC with NOX storage component.

Prikhodko, Vitaly↗

DOE OSTI2020

Design and Development of a High-Efficiency Single Cylinder Natural Gas-Fueled Jet Ignition Engine

The current energy climate has created a push toward reducing consumption of fossil fuels and lowering emissions output in power generation applications. Combined with the desire for a more distributed energy grid, there is currently a need for small displacement, high efficiency engines for use in stationary power generation. An enabling technology for achieving high efficiencies with spark ignited engines for such applications is the use of jet ignition which enables ultra-lean (λ > ~1.6) combustion via air dilution.This paper provides a comprehensive review of the development of a 390cc, high efficiency single cylinder natural gas-fueled jet ignition engine operating ultra-lean. The engine was developed as part of the Department of Energy’s Advanced Research Projects Agency–Energy (DOE ARPA-E) GENSETS program. Design choices for minimizing friction are highlighted as well as test results showing further friction reduction through downspeeding. Extensive hardware optimization of the combustion system has been performed and results are presented for air-flow path optimization and the jet igniter. The efficiency benefits related to enleanment and downspeeding are analyzed using an efficiency loss breakdown based on the First Law of Thermodynamics. Through optimization efforts a peak brake thermal efficiency in excess of 34% was achieved, representing an increase of greater than 20% over the current state-of-the-industry for comparably sized CNG engines.

Peters, Nathan↗

DOE OSTI2023

Performance, Combustion and Emissions Evaluation of Liquid Phase Port-Injected LPG on a Single Cylinder Heavy-Duty Spark Ignited Engine

Liquefied petroleum gas (LPG), like many other alternative fuels, has witnessed increased adoption in the last decade, and its use is projected to rise as stricter emissions regulations continue to be applied. However, much of its use is limited to dual fuel applications, gaseous phase injection, light-duty passenger vehicle applications, or scenarios that require conversion from gasoline engines. Therefore, to address these limitations and discover the most efficient means of harnessing its full potential, more research is required in the development of optimized fuel injection equipment for liquid port and direct injection, along with the implementation of advanced combustion strategies that will improve its thermal efficiency to the levels of conventional fuels. This paper focuses on the development of a liquid phase port-injection system for LPG, the design of a reference piston, and the baseline evaluation of the performance, combustion, and emissions characteristics of a single cylinder research engine to establish a benchmark comparable to existing LPG engines. A sweep of start of injection (SOI) timing is performed by injecting liquid LPG at several closed and open intake valve timings, which demonstrates no significant variation in engine performance, but accounts for a 10% reduction in bsCO with the optimal SOI timing. Spark timing sweep demonstrates the 50% burn crank angle location related to maximum brake torque (MBT) point with a brake thermal efficiency (BTE) of ~34% for the tested load case. The effect of equivalence ratio is also presented with optimal SOI timing at MBT condition. The engine starts exhibiting knocking combustion at 140kPa intake manifold air pressure (IMAP) with a peak torque of 253Nm and a 5% reduction in brake specific fuel consumption compared to the naturally aspirated scenario.

Fosudo, Toluwalase↗

DOE OSTI2013

A Perspective on the Future of High Efficiency Engines

New fuel economy standards and emissions regulations are accelerating the development of new engine technologies, sensors, and on-board computing. These developments will enable unprecedented engine control, which will in turn enable real-world implementations of low temperature combustion, high-speed controls, and other high efficiency engine technologies. With this expanded flexibility in engine design and control, the challenge will now be the exponential increase in the design and calibration space and the need for the development of new simulations, optimization methods, and self-learning control methodologies. This manuscript provides historical and future perspectives on the opportunities and challenges of this unparalleled technology growth on the next generation of high efficiency engines.

Wagner, Robert M↗