Engineering Papers⌕ Search

SEARCH · Engineering Papers

Results for “EGR”

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.

Quote a phrase for an exact phrase match. Source license links do not imply unrestricted reuse.

At least 109 records · Page 6
All sourcesNASA NTRSDOE OSTI
DOE OSTI2016

Extending Lean and Exhaust Gas Recirculation-Dilute Operating Limits of a Modern Gasoline Direct-Injection Engine Using a Low-Energy Transient Plasma Ignition System

The efficiency improvement and emissions reduction potential of lean and exhaust gas recirculation (EGR)-dilute operation of spark-ignition gasoline engines is well understood and documented. However, dilute operation is generally limited by deteriorating combustion stability with increasing inert gas levels. The combustion stability decreases due to reduced mixture flame speeds resulting in significantly increased combustion initiation periods and burn durations. A study was designed and executed to evaluate the potential to extend lean and EGR-dilute limits using a low-energy transient plasma ignition system. The low-energy transient plasma was generated by nanosecond pulses and its performance compared to a conventional transistorized coil ignition (TCI) system operated on an automotive, gasoline direct-injection (GDI) single-cylinder research engine. The experimental assessment was focused on steady-state experiments at the part load condition of 1500 rpm 5.6 bar indicated mean effective pressure (IMEP), where dilution tolerance is particularly critical to improving efficiency and emission performance. Experimental results suggest that the energy delivery process of the low-energy transient plasma ignition system significantly improves part load dilution tolerance by reducing the early flame development period. Statistical analysis of relevant combustion metrics was performed in order to further investigate the effects of the advanced ignition system on combustion stability. Results confirm that at select operating conditions EGR tolerance and lean limit could be improved by as much as 20% (from 22.7 to 27.1% EGR) and nearly 10% (from λ = 1.55 to 1.7) with the low-energy transient plasma ignition system.

33 ADVANCED PROPULSION SYSTEMS↗
DOE OSTI2018

Influence of charge motion and compression ratio on the performance of a combustion concept employing in-cylinder gasoline and natural gas

The present paper represents a small piece of an extensive experimental effort investigating the dual-fuel operation of a light-duty spark ignited engine. Natural gas (NG) was directly injected into the cylinder and gasoline was injected into the intake-port. Direct injection (DI) of NG was used in order to overcome the power density loss usually experienced with NG port-fuel injection (PFI) as it allows an injection after intake valve closing. Having two separate fuel systems allows for a continuum of in-cylinder blend levels from pure gasoline to pure NG operation. The huge benefit of gasoline is its availability and energy density, whereas NG allows efficient operation at high load due to improved combustion phasing enabled by its higher knock resistance. Furthermore, using NG allowed a reduction of carbon dioxide emissions across the entire engine map due to the higher hydrogen-to-carbon ratio. Exhaust gas recirculation (EGR) was used to (a) increase efficiency at low and part-load operation and (b) reduce the propensity of knock at higher compression ratios (CRs) thereby enabling blend levels with greater amount of gasoline across a wider operating range. Two integral engine parameters, CR and in cylinder turbulence levels, were varied in order to study their influence on efficiency, emissions, and performance over a specific speed and load range. Increasing the CR from 10.5 to 14.5 allowed an absolute increase in indicated thermal efficiency of snore than 3% for 7.5% NG (2.5% gasoline) operation at 8 bar net indicated mean effective pressure (IMEP) and 2500 rpm. However, as anticipated, the achievable peak load at CR 14.5 with 100% gasoline was greatly reduced due to its lower knock resistance. The in cylinder turbulence level was varied by means of tumble plates (TPs) as well as an insert for the NG injector that guides the injection "spray" to augment the tumble motion. The usage of TPs showed a significant increase in EGR dilution tolerance for pure gasoline operation, however, no such impact was found for blended operation of gasoline and NG.

Sevik, James↗
DOE OSTI2021

Performance of direct injected propane and gasoline in a high stroke-to-bore ratio SI engine: Pathways to diesel efficiency parity with ultra low soot

This work explores pathways to achieve diesel-like, high-efficiency combustion with stoichiometric 3-way catalyst compatible combustion in a single-cylinder spark ignition (SI) research engine. A unique high stroke-to-bore engine design (1.5:1) with cooled exhaust gas recirculation (EGR) and high compression ratio ( r c ) was used to improve engine efficiency by up to 30% compared with a production turbocharged gasoline direct injection spark ignition engine. Engine experiments were conducted with both 91 RON E10 gasoline and liquified petroleum gas (LPG) (i.e. autogas) and were compared to legacy gasoline data on the production engine. Geometric compression ratio ( r c ) of 13.3:1 was used for both fuels with additional experiments at 16.8:1 for LPG only. Measurements of exhaust soot particle size and number concentrations were made with both fuels. Significant reduction in soot particles across the whole particle size range were achieved with LPG due to the elimination of in-cylinder liquid films. The effects of EGR, late intake valve closing (IVC) and fuel characteristics were investigated through their effects on efficiency, combustion stability and soot production. Results of 47% gross thermal efficiency, and 45% net thermal efficiency at stoichiometric engine operation, at up to 17 bar IMEP and 2000 r/min with 16.8:1 r c were achieved with LPG. Estimated brake efficiency values were compared to a contemporary medium duty diesel engine illustrating the benefits of the chosen path for achieving diesel efficiency parity.

33 ADVANCED PROPULSION SYSTEMS↗
DOE OSTI2021

Cycle-to-cycle variability in spark-assisted compression ignition engines near optimal mean combustion phasing

Stoichiometric spark-assisted compression ignition (SACI) combustion with exhaust gas recirculation (EGR) dilution has demonstrated higher part-load thermal efficiencies compared to spark-ignited engines, while maintaining ultra-low tailpipe emissions. However, SACI is often characterized by high cyclic variability in heat release or torque output, which poses a challenge to its implementation in light-duty vehicles. This paper presents an experimental investigation of cyclic variability in stoichiometric SACI combustion under EGR-dilute conditions, while maintaining mean combustion phasing (θ 50 ) near optimal timing for thermal efficiency. The present work focuses on SACI conditions where the flame-based heat release fraction is between approximately 10% and 40% of the overall heat release, and therefore contributes significantly to the combustion process. For the SACI conditions examined, the variability in θ 50 was driven by variability in autoignition timing, which in turn correlated with the start of measurable heat release (θ 02 ). High variability in θ 50 caused unstable work output due to very late combustion with poor or no end-gas autoignition. The use of a high ignition energy dual-coil offset ignition system had negligible impact in reducing θ 50 variability. Analysis of experimental data from close to 1000 operating conditions showed that the magnitude of θ 50 variability correlates with the flame-based heat release fraction ([Formula: see text]), for a large range of intake pressures, spark timings and exhaust gas recirculation levels. For the SACI conditions examined, combustion phasing variability was largely determined by flame-based combustion and particularly the initial flame formation (θ IGN-02 ), and minimally by the end-gas autoignition heat release. The analysis also demonstrated that θ 50 variability is amplified as the contribution of the flame to the overall heat release increases.

Engineering↗
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 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↗
NASA NTRS1998

Central Renin Injections: Effects on Drinking and Expression of Immediate Early Genes

This study investigated the drinking response and the expression of Fos- and Egr-1-immunoreactivity (Fos-ir, Egr-1-ir) in the brain induced by endogenous angiotensin generated by intracerebroventricular (i.c.v.) injection of renin. Renin induced Fos-ir in the subformical organ (SFO), median preoptic (MnPO), supraoptic and paraventricular nuclei (SON and PVN), area postrema (AP), nuclei of the solitary tract (NTS) and lateral parabrachial nuclei (LPBN). Renin-induced Egr-1-ir exhibited a similar pattern of distribution as that observed for Fos-ir. The dose of i.c.v. renin that induced expression of immediate early gene (IEG) product immunoreactivity also produced vigorous drinking. When renin-injected rats were pretreated with captopril, an angiotensin converting enzyme inhibitor, drinking was blocked. With the same captopril pretreatment, both Fos- and Egr-1-ir in the SFO, MnPO, SON, PVN, AP and LPBN were also significantly reduced.

Xu, Zhice↗
DOE OSTI2011

Use of exhaust gas recirculation as a control approach for thermoacoustic instabilities

Investigation into exhaust gas recirculation (EGR) as a method for reducing costs of postcombustion carbon capture in gas turbine systems reveals that EGR offers potential applications as a control strategy for thermoacoustic instabilities. Introduction of EGR allows semi-independent variation of the operating parameter of flame temperature and characteristic flame length scales, known to play a primary role in the phase of the thermoacoustic coupling mechanism. Measurements were made showing the ability of EGR to reduce the amplitude of thermoacoustic oscillations over a range of operating conditions in a laboratory scale, swirled dump combustor, without affecting the flame temperature. Theoretical analysis was also performed to investigate the limitations on the ability of this approach to influence dynamics.

29 ENERGY PLANNING, POLICY, AND ECONOMY↗
DOE OSTI2012

Fuel Effects on Combustion and Emissions of a Direct-Inection Diesel Engine Operating at Moderate to High Engine Speed and Load

It is advantageous to increase the specific power output of diesel engines and to operate them at higher load for a greater portion of a driving cycle to achieve better thermal efficiency and thus reduce vehicle fuel consumption. Such operation is limited by excessive smoke formation at retarded injection timing and high rates of cylinder pressure rise at more advanced timing. Given this window of operation, it is desired to understand the influence of fuel properties such that optimum combustion performance and emissions can be retained over the range of fuels commonly available in the marketplace. It has been shown in previous studies that varying cetane number (CN) of diesel fuel has little effect on ignition delay at high engine load due to the domination of high cylinder temperature on ignition kinetics. The work here experimentally confirms that finding but also shows that emissions and combustion performance vary according to fuel reactivity. Data are examined from a direct-injection single cylinder research engine for eight common diesel fuels including soy-based biodiesel blends at two high load operating points with no exhaust gas recirculation (EGR) and at a moderate load with four levels of EGR. It is shown in the work that at high engine load where combustion is controlled by mixing processes, CN and other fuel properties have little effect on engine performance, although lower CN fuels produce a small increase in noise, smoke and CO emissions. Biodiesel blends increase NOX emissions and decreases CO and smoke emissions at high load, but otherwise have little effect on performance. At moderate load, higher CN fuels are more tolerant to EGR due to their better chemical reactivity at retarded injection timing, but all fuels produce comparable thermal efficiency at advanced combustion phasing regardless of EGR. In contrast to the high load conditions, there was no increase in NOX emissions for biodiesel at the moderate load condition. It is concluded that although higher CN does not significantly alter ignition delay at moderate to high loads it has a dominant influence on the acceptable injection timing range. Apart from CN effects, fuel oxygen content plays an independent role in reducing some emissions. It is therefore recommended that compensation for fuel ignitability and oxygen content be included in combustion control strategies to optimize emissions and performance of future diesel engines.

33 ADVANCED PROPULSION SYSTEMS↗
DOE OSTI2014

Gasoline-like Fuel Effects on High-load, Boosted HCCI Combustion Employing Negative Valve Overlap Strategy

In recent years a number of studies have demonstrated that boosted operation combined with external EGR is a path forward for expanding the high load limit of homogeneous charge compression ignition (HCCI) operation with the negative valve overlap (NVO) valve strategy. However, the effects of fuel composition with this strategy have not been fully explored. In this study boosted HCCI combustion is investigated in a single-cylinder research engine equipped with direct injection (DI) fueling, cooled external exhaust gas recirculation (EGR), laboratory pressurized intake air, and a fully-variable hydraulic valve actuation (HVA) valve train. Three fuels with significant compositional differences are investigated: regular grade gasoline (RON = 90.2), 30% ethanol-gasoline blend (E30, RON = 100.3), and 24% iso-butanol-gasoline blend (IB24, RON = 96.6). Results include engine loads from 350 to 800 kPa IMEPg for all fuels at three engine speeds 1600, 2000, and 2500 rpm. All operating conditions achieved thermal efficiency (gross indicated efficiency) between 38 and 47%, low NOX emissions ( 0.1 g/kWh), and high combustion efficiency ( 96.5%). Detailed sweeps of intake manifold pressure (atmospheric to 250 kPaa), EGR (0 25% EGR), and injection timing are conducted to identify fuel-specific effects. The major finding of this study is that while significant fuel compositional differences exist, in boosted HCCI operation only minor changes in operational conditions are required to achieve comparable operation for all fuels. In boosted HCCI operation all fuels were able to achieve matched load-speed operation, whereas in conventional SI operation the fuel-specific knock differences resulted in significant differences in the operable load-speed space. Although all fuels were operable in boosted HCCI, the respective air handling requirements are also discussed, including an analysis of the demanded turbocharger efficiency.

efficiency↗
DOE OSTI2016

Demonstration of improved dilution tolerance using a production-intent compact nanosecond pulse ignition system

Transient plasma ignition using nanosecond pulses has demonstrated the potential to enable improved fuel economy and reduced emissions by enabling lean and EGR limit extension in dilute burn engines. Existing spark ignition technology is not adequate because the energy transfer mechanisms between the spark and the fuel-air mixture are not efficient enough to guarantee stable ignition for dilute mixtures at high-load conditions. Additionally, long duration sparks and other advanced ignition solutions that require increased energy delivered accelerate spark plug electrode wear. To date, non-thermal plasma ignition with nanosecond pulses have demonstrated a lean ignition limit beyond an air/fuel ratio of 24 [1], demonstrated high-pressure ignition at densities equivalent to over 100 bar at the time of ignition [2], and demonstrated stable (COV <3 %) ignition at EGR dilution levels >20 % [3]. While low-energy nanosecond pulses have demonstrated strong performance compared to existing solutions, they currently only exist on the market in laboratory systems, rather than a production ready system in a single rugged, weather-proof, under-the-hood enclosure. Transient Plasma Systems (TPS) has recently demonstrated the potential for a retroffitable solution similar to coil-on-plug architecture that allows a direct replacement of existing ignition technology without any engine modification. The system was run on a gasoline direct injection engine at Argonne National Laboratory and demonstrated the same trends as previously observed with research grade systems, including lean and EGR limit extension and more stable ignition across a range of loads. The system was capable of delivering 30 kV pulses in bursts of up to 20 pulses at 30 kHz, and demonstrated stable combustion at an air/fuel ratio of 23.5, exhaust gas recirculation of 23 %, and ignition at 19.2 bar with COV <3 % using only 20 kV pulses.

nanosecond pulsed power↗
DOE OSTI2022

Next-Cycle Optimal Dilute Combustion Control via Online Learning of Cycle-to-Cycle Variability Using Kernel Density Estimators

Dilute combustion using exhaust gas recirculation (EGR) presents a cost-effective method for increasing the efficiency of spark-ignition (SI) engines. However, the maximum amount of EGR that can be used at a given condition is limited by a rapid increment of cycle-to-cycle variability (CCV). This study describes a methodology to design a model-based stochastic optimal controller to adjust the cycle-to-cycle fuel injection quantity in order to reduce CCV and further extend the dilute limit. Given the complexity and chaotic nature of combustion events, the controller was enhanced with online learning in order to identify the statistical properties of combustion efficiency, which are needed to generate predictions for next-cycle events. This study showed that a kernel density estimator (KDE) can be used to learn the combustion properties in real time and can be incorporated into the feedback policy in order to calculate the optimal control command. Experimental results suggested that the dilute limit can be extended from 18.5% to 21% EGR fraction at an operating condition relevant for highway cruising. Additionally, the proposed controller can achieve a large CCV reduction with less fuel enrichment compared to previous methods, overall contributing to an increase in 0.2% indicated fuel conversion efficiency.

33 ADVANCED PROPULSION SYSTEMS↗
DOE OSTI2018

EFFECTS OF PORT FUEL AND DIRECT INJECTION STRATEGIES AND INTAKE CONDITIONS ON GASOLINE COMPRESSION IGNITION OPERATION

GGasoline compression ignition (GCI) using a single gasoline-type fuel for port fuel and direct injection has been shown as a method to achieve low-temperature combustion with low engine-out NOx and soot emissions and high indicated thermal efficiency. However, key technical barriers to achieving low temperature combustion on multi-cylinder engines include the air handling system (limited amount of exhaust gas recirculation (EGR)) as well as mechanical engine limitations (e.g. peak pressure rise rate). In light of these limitations, high temperature combustion with reduced amounts of EGR appears more practical. Furthermore, for high temperature GCI, an effective aftertreatment system allows high thermal efficiency with low tailpipe-out emissions. In this work, experimental testing was conducted on a 12.4 L multi-cylinder heavy-duty diesel engine operating with high temperature GCI combustion using EEE gasoline. Engine testing was conducted at an engine speed of 1038 rpm and brake mean effective pressure (BMEP) of 14 bar. Port fuel and direct injection strategies were utilized to increase the premixed combustion fraction. The impact on engine performance and emissions with respect to varying the injection and intake operating parameters was quantified within this study. A combined effect of reducing heat transfer and increasing exhaust loss resulted in a flat trend of brake thermal efficiency (BTE) when retarding direct injection timing, while increased port fuel mass improved BTE due to advanced combustion phasing and reduced heat transfer loss. Overall, varying intake valve close timing, EGR, intake pressure and temperature with the current pressure rise rate and soot emissions constraint was not effective in improving BTE, as the benefit of low heat transfer loss was always offset by increased exhaust loss.

Wang, Buyu↗
DOE OSTI2020

CHARACTERISTICS OF CYCLE-TO-CYCLE COMBUSTION VARIABILITY AT PARTIAL-BURN LIMITED AND MISFIRE LIMITED SPARK TIMING UNDER HIGHLY DILUTED CONDITIONS

Diluted combustion with exhaust gas recirculation (EGR) has been widely employed to improve the fuel economy of spark ignition engines. The combustion kinetics, however, are affected and the flame propagation speed is decreased. In order to compensate for this adverse effect, the spark timing needs to be recalibrated to achieve maximum brake torque (MBT). At high levels of EGR dilution, the spark timing is constrained by two ignition limits: 1) the partial-bum limit where the spark timing is retarded from MBT and 2) the misfire limit where the spark timing is too advanced. This work uses a probabilistic framework to capture the differences between both ignition limits. In particular, it introduces the concept of a nominal indicated mean effective pressure (IMEP) distribution based on the stochastic properties of the cycle-to-cycle variability (CCV) at nominal stable conditions. By defining a nominal band where fully burned cycles occur with high probability, we introduce a cycle classification method that can be used to 1) determine the level of randomness of misfire and partial-burn events, and 2) measure CCV. The new CCV metric based on the density of the nominal band is compared with the traditional coefficient of variation of IMEP (CoVIMEP). It is shown that the nominal band concept, together with the CoVIMEP, can help to discern between partial-burn limited and misfire limited conditions. Furthermore, the Kullback-Leibler divergence is used to demonstrate that the IMEP distribution is significantly different between nominal and partial-burn/misfire limited conditions. Experiments are carried at various EGR levels and spark timings while recoding in-cylinder pressure at steady state. Although the emphasis of this work is to characterize the differences of both ignition limits from a probabilistic point of view, similarities between partial-burn cycles at either limiting conditions are also discussed.

Maldonado, Bryan↗
DOE OSTI2024

Development of prechamber enabled mixing-controlled combustion strategy for ultra-low methane emissions from lean burn natural gas engines

This numerical study explores the optimization of Prechamber Enabled Mixing-Controlled Combustion (PC-MCC) using natural gas in heavy-duty engines, aiming to enhance combustion efficiency to minimize methane slip and NOx emissions. The approach involves a prechamber ignition system, distinct from conventional spark ignition (SI) systems, to initiate combustion of direct injected natural gas. By leveraging the robust ignition characteristics of the prechamber, the PC-MCC method demonstrates significant potential in achieving efficient combustion akin to diesel engines but with lower greenhouse gas emissions. The research evaluates the effects of various geometric and operational parameters on the combustion process and emissions, including prechamber volume, nozzle diameter, direct injector (DI) geometry, and engine operating strategies. Computational Fluid Dynamics (CFD) simulations are utilized, focusing on a heavy-duty, single-cylinder engine modeled after the Caterpillar C9.3B engine. Key findings indicate that a prechamber volume of 3 cc, coupled with a nozzle diameter of 2.75 mm for two prechamber holes, strikes an optimal balance between combustion efficiency and emissions reduction. This configuration ensures robust combustion across a range of operating conditions while maintaining methane slip within targeted limits. Further investigation into DI geometry shows the significance of the injector umbrella angle and nozzle diameter in shaping the fuel-air mixing and combustion dynamics. An umbrella angle of 130° and a nozzle diameter of 300 microns are identified as optimal, promoting rapid and efficient combustion with minimized methane and NOx emissions. The study also investigates the impact of injection timing and pressure, highlighting their roles in controlling combustion timing and influencing emissions levels. Advanced injection timing is found to be crucial in achieving the desired low methane slip, whereas retarded injection timing assists to reduce NOx emissions while having a slight increase in methane emissions. Operating strategies incorporating various levels of Exhaust Gas Recirculation (EGR) are assessed for their effectiveness in further reducing emissions. The research demonstrates that a judicious combination of internal hot EGR and careful calibration of DI pressure and SOI timing can achieve significant reductions in NOx emissions while keeping methane slip under control. Specifically, an internal EGR level of 15%–25%, combined with DI pressures of 200–300 bar and injection timings at or after top dead center, is recommended. These findings contribute valuable insights into the development of advanced combustion techniques for natural gas engines, offering a viable pathway to reduce methane slip without compromising engine efficiency or performance. The PC-MCC system presents a promising solution for the future of heavy-duty natural gas engine technology to reduce methane emissions.

Nsaif, Osama↗
DOE OSTI2010

Low Temperature Combustion Demonstrator for High Efficiency Clean Combustion

The project which extended from November 2005 to May of 2010 demonstrated the application of Low Temperature Combustion (LTC) with engine out NOx levels of 0.2 g/bhp-hr throughout the program target load of 12.6bar BMEP. The project showed that the range of loads could be extended to 16.5bar BMEP, therefore matching the reference lug line of the base 2007 MY Navistar 6.4L V8 engine. Results showed that the application of LTC provided a dramatic improvement over engine out emissions when compared to the base engine. Furthermore LTC improved thermal efficiency by over 5% from the base production engine when using the steady state 13 mode composite test as a benchmark. The key enablers included improvements in the air, fuel injection, and cooling systems made in Phases I and II. The outcome was the product of a careful integration of each component under an intelligent control system. The engine hardware provided the conditions to support LTC and the controller provided the necessary robustness for a stable combustion. Phase III provided a detailed account on the injection strategy used to meet the high load requirements. During this phase, the control strategy was implemented in a production automotive grade ECU to perform cycle-by-cycle combustion feedback on each of the engine cylinders. The control interacted on a cycle base with the injection system and with the Turbo-EGR systems according to their respective time constants. The result was a unique system that could, first, help optimize the combustion system and maintain high efficiency, and secondly, extend the steady state results to the transient mode of operation. The engine was upgraded in Phase IV with a Variable Valve Actuation system and a hybrid EGR loop. The impact of the more versatile EGR loop did not provide significant advantages, however the application of VVA proved to be an enabler to further extend the operation of LTC and gain considerable benefits in fuel economy and soot reduction. Finally, the transient demonstration was performed in Phase IV. The project demonstrated the achievement of meeting US10 emissions without NOx aftertreatment. The successful execution of the project has served to highlight the effectiveness of closely matched combustion predictive tools to engine testing. It has further served to highlight the importance of key technologies and future areas of research and development. In this regard, recommendations are made towards further improvements in the areas of engine hardware, fuel injection systems, controls and fuels.

33 ADVANCED PROPULSION SYSTEMS↗
DOE OSTI2011

The Use of Exhaust Gas Recirculation to Optimize Fuel Economy and Minimize Emission in Engines Operating on E85 Fuel

This report summarizes activities conducted for the project “The Use of Exhaust Gas Recirculation to Optimized Fuel Economy and Minimize Emissions in Engines Operating on E85 Fuel” under COOPERATIVE AGREEMENT NUMBER DE-FC26-07NT43271, which are as outlined in the STATEMENT OF PROJECT OBJECTIVES (SOPO) dated March 2007 and in the supplemental SOPO dated October 2010. The project objective was to develop and demonstrate an internal combustion engine that is optimized for E85 (85% ethanol and 15% gasoline) fuel operation to achieve substantially improved fuel economy while operating with E85 fuel and that is also production viable in the near- to medium-term. The key engine technology selected for research and development was turbocharging, which is known to improve fuel economy thru downsizing and is in particular capable of exploiting ethanol fuel’s characteristics of high octane number and high latent heat of vaporization. The engine further integrated synergistic efficiency improving technologies of cooled exhaust gas recirculation (EGR), direct fuel injection and dual continuously variable intake and exhaust cam phasers. On the vehicle level, fuel economy was furthered thru powertrain system optimization by mating a state-of-the-art six-speed automatic transmission to the engine. In order to achieve the project’s objective of near- to medium-term production viability, it was essential to develop the engine to be flex-fuel capable of operating with fuels ranging from E0 (0% ethanol and 100% gasoline) to E85 and to use three-way type of catalyst technology for exhaust aftertreatment. Within these scopes, various technologies were developed through systems approach to focus on ways to help accelerate catalyst light-off. Significant amount of development took place during the course of the project within General Motors, LLC. Many prototype flex-fuel engines were designed, built and developed with various hardware configurations selected to achieve the project goals. Several flex-fuel demonstration vehicles were designed and built for carrying out calibration development and final testing to quantify the technology merits. Based on the extensive test results collected from dynamometer and vehicle testing, the fuel economy benefits of cooled EGR from the intended level of turbocharger technology were quantified. When combined with turbo downsizing, the FE benefits are considered large enough for E0 fuel as well as for E85 fuel to warrant further development of the technology beyond the current proof-of-concept level to a level that can meet production driveability quality and durability requirements in order to meet customers’ expectations. Cold-start cart test results from the emissions segment of the project were positive, confirming the assumption of faster thermal response of turbo exhaust system for emissions reductions for both E0 and E85 fuels. Vehicle emissions test results directionally correlated to the cold-start cart findings. The limited number of test runs did demonstrate the potentials of meeting stringent emission standards, however, they did not comprehend the factors such as hardware variability and long-term durability, 3 which are essential for mass production to satisfy customers’ expectations. It is therefore recommended, moving forward, durability concerns over turbocharger, EGR system and aftertreatment system, which would likely impact production viability, should be addressed. The data moreover suggested that further FE increase is likely with turbocharger technology advancement.

Wu, Ko-Jen↗
DOE OSTI2018

Final Scientific / Technical Report: Enabling Technologies for Heavy-Duty Vehicles – Cummins 55BTE

The Cummins 55% BTE (55BTE) program has completed the planned technical work on the project. This work includes the planned engine system demonstration in pursuit of the goal of demonstrating a peak system brake thermal efficiency (BTE) of 55%. The engine system included a high efficiency diesel engine integrated with a state-of-the-art waste heat recovery (WHR) system and an advanced aftertreatment system capable of meeting the current emissions standards. While the ultimate program goal of 55% BTE was not fully achieved due to hardware issues during the final testing phase, the program demonstrated a significant increase in reported engine system BTE for a heavy duty sized engine. The previous demonstrations in the Department of Energy funded SuperTruck 1 programs ranged between 50% - 51% BTE. The Cummins 55% BTE program demonstrated 54% BTE. Additionally, the program established a revised path-to-target showing how the system could be improved to reach the ultimate program goal of 55% BTE with some minor modification to the engine system. The changes in the revised path-to-target were unable to be completed during the course of this program due to time and money constraints placed on the program. The program’s goals were challenging in both scope and timing. Although the program’s goal can be simply stated in terms of demonstrating a system efficiency of 55%, the achievement of a heavy-duty diesel engine capable of full torque curve operation, adequate transient performance, low emissions and high brake thermal efficiency (>51% BTE) had not been previously demonstrated in a heavy-duty engine. The closest efforts to date included the SuperTruck 1 programs referenced earlier. The program made several advancements in all system areas. The combustion system was re-designed for a shorter combustion duration and lower in-cylinder heat loss. This was achieved through optimization of the fuel injection rate shape, number of spray holes, piston bowl shape, compression ratio, piston oil cooling, heat flow through the piston and in-cylinder charge motion. The air handling system was re-designed to provide cooled EGR at virtually no pumping penalty. This was achieved through implementation of a dual loop EGR system, reduction of EGR system pressure drop, and implementation of advanced turbocharger efficiency technologies. The engine friction and parasitic signature was dramatically reduced by the program through adoption of variable flow pumps, advanced rings and coatings, rollerized valvetrain, adoption of low viscosity lubricants and reduction in cylinder line bore distortion. The aftertreatment system was optimized through use of low dP substrates and an ammonia gas injection system. The WHR system development included the use of a dual-entry turbine and a mixed charger cooler. Finding and implementing these solutions in a short two-year program at the budgeted funding provided the greatest challenge for the program.

33 ADVANCED PROPULSION SYSTEMS↗