Engineering Papers⌕ Search

SEARCH · Engineering Papers

Results for “Fuel Performance Modeling”

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 1,747 records · Page 97
All sourcesNASA NTRSDOE OSTI
NASA NTRS2004

Crash Simulation of a Vertical Drop Test of a Commuter-Class Aircraft

A finite element model of an ATR42-300 commuter-class aircraft was developed and a crash simulation was executed. Analytical predictions were correlated with data obtained from a 30-ft/s (9.14-m/s) vertical drop test of the aircraft. The purpose of the test was to evaluate the structural response of the aircraft when subjected to a severe, but survivable, impact. The aircraft was configured with seats, dummies, luggage, and other ballast. The wings were filled with 8,700 lb. (3,946 kg) of water to represent the fuel. The finite element model, which consisted of 57,643 nodes and 62,979 elements, was developed from direct measurements of the airframe geometry. The seats, dummies, luggage, fuel, and other ballast were represented using concentrated masses. The model was executed in LS-DYNA, a commercial code for performing explicit transient dynamic simulations. Predictions of structural deformation and selected time-history responses were generated. The simulation was successfully validated through extensive test-analysis correlation.

Jackson, Karen E.↗
DOE OSTI2016

Improved Few-group Homogenized Cross-section Sensitivity Analysis for Lattice Physics Calculation

In the conventional reactor physics 'two-step' calculation scheme, lattice-physics calculation is followed by core calculation using neutron diffusion theory. The few-group spatially homogenized cross-sections are the outputs of the lattice-physics calculation as well as the inputs of the core calculation. The uncertainties of fundamental nuclear data will be propagated to the core calculation results through few-group spatially homogenized cross-sections. Consequently, assessing the sensitivity and uncertainty of few-group homogenized cross-sections is necessary for the core-calculation sensitivity and uncertainty analysis. Conventional method for sensitivity analysis is usually performed with respect to effective self-shielding cross sections but not continuous-energy cross sections by neglecting resonance self-shielding effects. The purpose of this work is to improve the sensitivity analysis of few-group cross sections and assess the effects introduced by resonance calculation with the subgroup method being used for resonance calculation. This paper is organized as follows: Firstly, theoretical models of this work are described. Secondly, validation and analysis are performed based on a boiling-water reactor (BWR) fuel-pin cell under hot zero power (HZP) condition. Finally, summaries and conclusions are given. (authors)

21 SPECIFIC NUCLEAR REACTORS AND ASSOCIATED PLANTS↗
DOE OSTI2023

Development and application of sorption mass transfer models for fission product transport in TRISO fuel systems using BISON

Fission product mass transfer within and between TRISO particle and compact layers is an important phenomenon. It directly impacts fission product release predictions, which are used as source terms for safety and licensing calculations. Modeling fission product transport within layers and across bonded interfaces is relatively straightforward under the assumptions of isotropic Fickian diffusion, concentration continuity, and flux continuity. Modeling fission product transport across gaps and debonded layers is more difficult. Gaps are known to form between the buffer and inner PyC (IPyC), and debonding may occur between the IPyC and silicon carbide (SiC). A new mass transfer model was developed to provide a more accurate and robust fission product release calculation by accounting for interlayer sorptivity. One importance of the new model is to account for temperature and material changes across the gap based on sorption isotherm. This work presents the development of the sorption behavioral model and a fission product trapping model, and analyses the subsequent fission product diffusion behavior, specifically cesium, through TRISO particles and compact materials using the BISON fuel performance code.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗
NASA NTRS1984

Fuel property effects on USN gas turbine combustors

For several years the Department of Defense has been sponsoring fuel accommodation investigations with gas turbine engine manufacturers and supporting organizations to quantify the effect of changes in fuel properties and characteristics on the operation and performance of military engine components and systems. Inasmuch as there are many differences in hardware between the operational engines in the military inventories, due to differences in design philosophy and requirements, efforts were initially expended to acquire fuel effects data from rigs simulating the hot sections of these different engines. Correlations were then sought using the data acquired to produce more general, generic relationships that could be applied to all military gas turbine engines regardless of their origin. Finally, models could be developed from these correlations that could predict the effect of fuel property changes on current and future engines. This presentation describes some of the work performed by Pratt and Whitney Aircraft, under Naval Air Propulsion Center sponsorship, to determine the effect of fuel properties on the hot section and fuel system of the Navy's TF30-P-414 gas turbine engine.

Masters, A. I.↗
DOE OSTI2015

The role of Aspo Hard Rock laboratory for the Swedish nuclear fuel and waste management's research, developing and demonstration programme for a final repository of spent nuclear fuel - 15378

The Aspo Hard Rock Laboratory (HRL), located in the Simpevarp area in the municipality of Oskarshamn in Sweden, Figure 1, constitutes an important part of the Swedish Nuclear Fuel and Waste Management (SKB) work with design and construction of a deep geological repository for final disposal of spent nuclear fuel. One of the fundamental reasons behind SKB's decision to construct an underground laboratory was to create an opportunity for research, development and demonstration in a realistic and undisturbed rock environment down to repository depth. Most of the research has concerned with processes of importance for the long-term safety of a future final repository and the capability to model the processes taking place at repository depth. Demonstration addresses the performance of the engineered barriers and practical means of constructing a repository and emplacing the canisters containing spent fuel. SKB will in the coming years more focus on using the Aspo HRL for demonstrating technology for and function of important parts of the repository system before constructing and operate the spent nuclear fuel repository in Forsmark. Aspo HRL includes both a research village with office space for 100 persons and different laboratories, e.g. Chemistry and Material Science Laboratory and Bentonite Laboratory, and an underground research laboratory to a depth of 460 m. The Aspo HRL is also open for other organisations to be used for their own projects and experiments not only related to nuclear waste management research. (authors)

12 MANAGEMENT OF RADIOACTIVE AND NON-RADIOACTIVE W↗
DOE OSTI2018

A novel chemical looping partial oxidation process for thermochemical conversion of biomass to syngas

The Biomass-to-Syngas (BTS) chemical looping process is an advanced thermochemical biomass conversion process for the production of sustainable fuels and chemicals. The BTS process is novel in that it converts biomass feedstock to high purity syngas with adjustable H 2 :CO molar ratio without needing an air separation unit (ASU), a tar reformer, a steam reformer, or a water-gas-shift (WGS) reactor. In the BTS process, biomass feedstock is partially oxidized to produce syngas by oxygen carriers in a reducer that is operated in a co-current gas-solid moving bed contact mode. The reduced oxygen carriers are regenerated in a fluidized bed combustor via the oxidation reaction with air. The BTS process uses the iron-titanium composite metal oxide (ITCMO) material as the oxygen carrier, which is capable of cracking the volatiles produced in biomass pyrolysis as well as regulating the syngas composition. The co-current moving bed reducer eliminates back-mixing, channeling, or bypassing of solid and gas reactants, resulting in a syngas composition that is close to the thermodynamic equilibrium. In this paper, the rationale of a successful BTS process is discussed along with the thermodynamic characteristics of the ITCMO oxygen carrier, that can effectively react with a woody biomass feedstock, analyzed based on an ASPEN Plus model. Bench scale moving bed reducer experiments are presented, indicating the conversion of wood pellets to syngas with a H 2 :CO ratio of 2, which is suitable for methanol or liquid fuel synthesis. The gas and solid composition produced in the bench scale reducer matches the prediction from the ASPEN Plus thermodynamic model. Furthermore, this model is further used to analyze the performance of the BTS process under autothermal conditions for methanol production, with a comparison with a baseline indirectly heated gasification process.

09 BIOMASS FUELS↗
DOE OSTI2020

Advanced Anode for Internal Reforming and Thermal Management in Solid Oxide Fuel Cells

Solid oxide fuel cell (SOFC) is an efficient and clean electrical power generation system compared to conventional combustion based technologies with energy efficiency reaching as high as 85-90% in co-generation mode (electricity and heat). Other advantages of SOFCs are hybridization, modularity of construction, small CO 2 foot print per kWh of generated electricity and fuel flexibility. Hydrocarbons present in the gaseous fuel is utilized in SOFCs by internal or external reforming. There are two different internal reforming concepts: Direct Internal Reforming (DIR) and Indirect Internal Reforming (IIR). For DIR operation, the endothermic reforming reaction and the exothermic reaction from the oxidation reaction are operated together in the single unit eliminating the requirement for a separate fuel reformer. This configuration also simplifies the overall system design, making SOFC more attractive and efficient means of producing electrical power. The main advantage of the DIR type of operation is that the H 2 or CO consumption by the electrochemical reaction could directly promote the conversion of methane at the anode side of the fuel cell resulting in high conversion and high efficiency. The DIR operation, however, requires an anode material that has desired dual catalytic (hetero and electro) properties for reforming reaction and electrochemical reactions. The anode materials also need to remain resistant to carbon formation at the operating temperature and atmosphere with stable cell performance. Another requirement is to match the reforming reactions and electrochemical reactions to avoid local cooling or overheating, which can result in mechanical failure due to thermally induced stresses. Direct internal reforming (DIR) of hydrocarbon fuels simplifies the overall SOFC system design making it more attractive and efficient for producing electrical power. Low cost alloy anodes for distributed internal reforming of methane and other hydrocarbon fuels offer increased fuel-flexibility, reliability, and long term performance stability of solid oxide fuel cells (SOFC). The research program examined modification of the chemical compositions and microstructure of high entropy alloy (HEA) anode materials using thermochemical calculations and process simulation and modeling to achieve distributed reforming over the entire anode to eliminate hot zones. Cell fabrication and testing of the HEA anodes using button cell configuration has been performed to demonstrate the advantages of new anode over traditional Ni-YSZ anodes for distributed reforming and carbon free operation. Technical accomplishments include identification and synthesis of HEA carbon-resistant anode, demonstration of reduction in reforming rate confirmed by GC and modelling data validating effectiveness for thermal management in cell/stacks, electrochemical testing of HEA anode in single cell (HEA-GDC||YSZ||LSM-YSZ) and Characterization of pretest and posttest anode materials by TEM and SEM-EDS confirming carbon-free operation.

30 DIRECT ENERGY CONVERSION↗
DOE OSTI2025

Design of a High-Pressure Fuel System for Use with Dimethyl Ether

The paper documents the modeling and experimental work on a common rail fuel injection system for Dimethyl Ether, a potential diesel substitute with a low carbon intensity signature. The DME fuel system is deployed on a light duty 2.2L compression ignition engine. The paper describes the injector optimization to shift to higher flows to account for the lower heating value and density of the DME when compared to diesel. The type of the injection system used for the DME application is an advanced rendering of the Common rail noted for a one-piece piston-needle injector construction and a solenoid driven spill valve featuring a pressure balanced poppet. A dedicated high-pressure fuel pump designed to pressurize DME is used. The design results in a fast acting open and close injection event, reduced leakage, with reduced cavitation in the fuel injector volume. Design parameters for system optimization included fill and spill orifices, needle lift, bias spring, and injector hole size. The design model provides good correlation of the instantaneous rates of injection with experiments across a wide range of pressure and injection timings. Proposed performance milestones for the design included similar DME injection duration to the diesel counterpart for same fuel energy injected into the cylinder to retain high engine cycle efficiency. Here, the dedicated DME design provided reduced hydraulic delays of 50%. Tests demonstrated sustained operation at pressures of 1000 bar, with capability to reach 1500bar. Durability tests showed no cavitation-deterioration over a 200-hour test cycle by means of spray imaging and hardware inspection.

De Ojeda, William [WM International Engineering, L↗
DOE OSTI2020

Preliminary Study on TRISO Fuel Cross Section Generation

Cross section self-shielding methodologies for TRISO fuel were assessed to provide accurate multigroup cross sections for a high-fidelity reactor physics code so that the code is able to accurately model and simulate advanced reactors with TRISO fuel. Initially, the two existing methodologies (the SCALE method and the Sanchez-Pomraning method) were studied and implemented to MC2-3 for detailed performance tests. Additionally, a new spatial self-shielding method, named the iterative local spatial self-shielding (ILSS) method, for particulate fuels was developed based on the disadvantage factor and implemented to MC2-3 as well. The new method approximately accounts for the effect of randomly distributed particles on the particle shadowing effect using a homogenized compact region surrounding a particle of interest at the center. The self-shielded cross sections of the particle at the center are determined iteratively since the cross sections of the homogenized compact region are calculated using them. For the energy range above 100 keV where the fuel-to-moderator ratio is more important than the random distribution of particles, a single particle unit-cell model is used by preserving the average amount of moderator per fuel particle in the system. The three self-shielding methods implemented in MC2-3 were tested using numerical benchmark problems made based on fuel compact problems of a prismatic-type very high temperature reactor. Test results indicated that the ILSS method produced slightly better results than the SCALE and Sanchez-Pomraning methods, compared to the Serpent-2 Monte Carlo results obtained with 25 independent random particle configurations. The SCALE and Sanchez-Pomraning methods tend to underestimate the heterogeneity effect by 150 and 100 pcm, respectively, while the new ILSS method overestimates the heterogeneity effect by 70 pcm. In future, the new self-shielding method will be extended to perform pebble calculations and compare results with those from the SCALE and Sanchez-Pomraning methods. Furthermore, the new method will be optimized for practical applications to on-the-fly resonance treatment for lattice or whole-core calculations for advanced reactors.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗
DOE OSTI2012

Advanced High-Temperature Reactor Dynamic System Model Development: April 2012 Status

The Advanced High-Temperature Reactor (AHTR) is a large-output fluoride-salt-cooled high-temperature reactor (FHR). An early-phase preconceptual design of a 1500 MW(e) power plant was developed in 2011 [Refs. 1 and 2]. An updated version of this plant is shown as Fig. 1. FHRs feature low-pressure liquid fluoride salt cooling, coated-particle fuel, a high-temperature power cycle, and fully passive decay heat rejection. The AHTR is designed to be a “walk away” reactor that requires no action to prevent large off-site releases following even severe reactor accidents. This report describes the development of dynamic system models used to further the AHTR design toward that goal. These models predict system response during warmup, startup, normal operation, and limited off-normal operating conditions. Severe accidents that include a loss-of-fluid inventory are not currently modeled. The scope of the models is limited to the plant power system, including the reactor, the primary and intermediate heat transport systems, the power conversion system, and safety-related or auxiliary heat removal systems. The primary coolant system, the intermediate heat transport system and the reactor building structure surrounding them are shown in Fig. 2. These systems are modeled in the most detail because the passive interaction of the primary system with the surrounding structure and heat removal systems, and ultimately the environment, protects the reactor fuel and the vessel from damage during severe reactor transients. The reactor silo also plays an important role during system warmup. The dynamic system modeling tools predict system performance and response. The goal is to accurately predict temperatures and pressures within the primary, intermediate, and power conversion systems and to study the impacts of design changes on those responses. The models are design tools and are not intended to be used in reactor qualification. The important details to capture in the primary system relate to flows within the reactor vessel during severe events and the resulting temperature profiles (temperature and duration) for major components. Critical components include the fuel, reactor vessel, primary piping, and the primary-to-intermediate heat exchangers (P-IHXs). The major AHTR power system loops are shown in Fig. 3. The intermediate heat transfer system is a group of three pumped salt loops that transports the energy produced in the primary system to the power conversion system. Two dynamic system models are used to analyze the AHTR. A Matlab/Simulink-based model initiated in 2011 has been updated to reflect the evolving design parameters related to the heat flows associated with the reactor vessel. The Matlab model utilizes simplified flow assumptions within the vessel and incorporates an empirical representation of the Direct Reactor Auxiliary Cooling System (DRACS). A Dymola/Modelica model incorporates a more sophisticated representation of primary coolant flow and a physics-based representation of the three-loop DRACS thermal hydraulics. This model is not currently operating in a fully integrated mode. The Matlab model serves as a prototype and provides verification for the Dymola model, and its use will be phased out as the Dymola model nears completion. The heat exchangers in the system are sized using spreadsheet-based, steady-state calculations. The detail features of the heat exchangers are programmed into the dynamic models, and the overall dimensions are used to generate realistic plant designs. For the modeling cases where the emphasis is on understanding responses within the intermediate and primary systems, the power conversion system may be modeled as a simple boundary condition at the intermediate-to-power conversion system heat exchangers.

22 GENERAL STUDIES OF NUCLEAR REACTORS↗
DOE OSTI2021

Fuel Fabrication and Single Stage Aqueous Process Modeling

The Material Protection, Accounting, and Control Technologies program utilizes modeling and simulation to assess Material Control and Accountability (MC&A) concerns for a variety of nuclear facilities. Single analyst tools allow for rapid design and evaluation of advanced approaches for new and existing nuclear facilities. A low enriched uranium (LEU) fuel conversion and fabrication facility simulator is developed to assist with MC&A for existing facilities. Measurements are added to the model (consistent with current best practices). Material balance calculations and statistical tests are also added to the model. In addition, scoping work is performed for developing a single stage aqueous reprocessing model. Preliminary results are presented and discussed, and next steps outlined.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗
DOE OSTI2010

Verifiable Fuel Cycle Simulation Model (VISION): A Tool for Analyzing Nuclear Fuel Cycle Futures

The nuclear fuel cycle consists of a set of complex components that are intended to work together. To support the nuclear renaissance, it is necessary to understand the impacts of changes and timing of events in any part of the fuel cycle system such as how the system would respond to each technological change, a series of which moves the fuel cycle from where it is to a postulated future state. The system analysis working group of the United States research program on advanced fuel cycles (formerly called the Advanced Fuel Cycle Initiative) is developing a dynamic simulation model, VISION, to capture the relationships, timing, and changes in and among the fuel cycle components to help develop an understanding of how the overall fuel cycle works. This paper is an overview of the philosophy and development strategy behind VISION. The paper includes some descriptions of the model components and some examples of how to use VISION. For example, VISION users can now change yearly the selection of separation or reactor technologies, the performance characteristics of those technologies, and/or the routing of material among separation and reactor types - with the model still operating on a PC in <5 min.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗
DOE OSTI2022

Geologic Disposal Safety Assessment (GDSA) Biosphere Model Development

The Spent Fuel and Waste Science and Technology Campaign of the U.S. Department of Energy Office of Nuclear Energy, Office of Spent Fuel and Waste Disposition is conducting research and development on geologic disposal of spent nuclear fuel and high-level nuclear waste. This work includes the Geologic Disposal Safety Assessment (GDSA) program which is charged with development of generic deep geologic repository concepts and system performance assessment models. One part of the GDSA framework is the development of a biosphere model capable of assessing doses to potential receptors exposed to radionuclides released from geologic disposal sites. As part of the GDSA framework, a biosphere model compatible with the PFLOTRAN massively parallel subsurface flow and reactive transport code is under development. The PFLOTRAN model provides the radionuclide source term for the biosphere model. The GDSA Biosphere model then assesses the potential movement of radionuclides through the surface biosphere and the subsequent exposure to a human receptor living in the biosphere. The biosphere model includes pathways originating from the groundwater as well as pathways originating from surface water bodies that have a water exchange with a contaminated groundwater body. The pathways for human exposure include consumption of drinking water, irrigated crops, meat animals, aquatic vegetation, and animals, etc.; external exposure from irrigated ground surfaces, surface water bodies, recreational activities, etc.; and inadvertent exposures such as ingestion of contaminated soils or shower water, etc. The GDSA Biosphere model was designed to be flexible and generic in order to accommodate a variety of different sites and climate states. This presentation will present the on the purpose, design, and development progress of the GDSA Biosphere Model.

GDSA, biosphere, repository↗
DOE OSTI2016

Evaluation of used fuel disposition in clay-bearing rock

The R&D program from the DOE Used Fuel Disposition Campaign (UFDC) has documented key advances in coupled Thermal-Hydrological-Mechanical-Chemical (THMC) modeling of clay to simulate its complex dynamic behavior in response to thermal and hydrochemical feedbacks. These efforts have been harnessed to assess the isolation performance of heat-generating nuclear waste in a deep geological repository in clay/shale/argillaceous rock formations. This report describes the ongoing disposal R&D efforts on the advancement and refinement of coupled THMC process models, hydrothermal experiments on barrier clay interactions, used fuel and canister material degradation, thermodynamic database development, and reactive transport modeling of the near-field under non-isothermal conditions. These play an important role to the evaluation of sacrificial zones as part of the EBS exposure to thermally-driven chemical and transport processes. Thermal inducement of chemical interactions at EBS domains enhances mineral dissolution/precipitation but also generates mineralogical changes that result in mineral H2O uptake/removal (hydration/dehydration reactions). These processes can result in volume changes that can affect the interface / bulk phase porosities and the mechanical (stress) state of the bentonite barrier. Characterization studies on bentonite barrier samples from the FEBEX-DP international activity have provided important insight on clay barrier microstructures (e.g., microcracks) and interactions at EBS interfaces. Enhancements to the used fuel degradation model outlines the need to include the effects of canister corrosion due the strong influence of H2 generation on the source term.

12 MANAGEMENT OF RADIOACTIVE AND NON-RADIOACTIVE W↗
DOE OSTI2017

Advancement of Functional Expansion Tallies Capabilities in Serpent 2

The need for accident tolerant fuels (ATFs) became self-evident after the series of unfortunate nuclear events at Fukushima Daiichi in 2011. Restarting the Transient Reactor Test Facility (TREAT) at INL is one component in this concerted effort to establish the ATF development and testing program under the United States Department of Energy. Prior to the closure of TREAT in 1994, each experiment required multiple low-power calibration tests before and after each run. Since then, computing advancements have set computer-based modeling and simulation (M and S) as the preferred calibration method. The anticipated savings are both temporal and monetary. MAMMOTH, a collection of M and S tools built from the finite element-based MOOSE Framework, has been established to support the designed experiments intended for TREAT. This collection of tools includes: 1) Rattlesnake, a striking diffusion-based neutronics code, 2) BISON, an advanced materials and fuels performance code, and 3) RELAP-7, a powerful thermal-hydraulics solver. Each is capable of independently performing its function accurately and effectively; unified, they create a powerful multiphysics reactor core M and S application. One unfortunate weakness in this configuration lies in the unique geometry and design of TREAT's core. Although simple to model, this poses a challenge to the diffusion solver in Rattlesnake. One alternative is to replace Rattlesnake with Serpent, a fully-fledged Monte Carlo (MC) neutronics code. Coincidentally, Rattlesnake calculations are frequently validated against Serpent simulations.

11 NUCLEAR FUEL CYCLE AND FUEL MATERIALS↗
DOE OSTI2022

Multiscale modeling of hydrogenolysis of ethane and propane on Ru(0001): Implications for plastics recycling

Plastic waste presents an environmental threat. Chemical recycling via hydrogenolysis can convert plastic waste into waxes, lubricants, and fuels. Among catalysts, Ru stands out for its superior activity and selectivity. The chemistry of light alkane hydrogenolysis can help understanding plastics deconstruction. Here, we perform first-principles calculations, develop descriptor-based relations, and conduct microkinetic modeling and analysis on ethane and propane. Predictions are in excellent agreement with experimental data. We identify a similar cracking pattern for both hydrocarbons entailing a deeply dehydrogenated species with the removal of four hydrogen atoms: CHCH*+* → 2CH* for ethane and CH 3 CCH*+2* → CH 3 C* + CH* for propane. We find that the rate-determining step is the C-C cracking for ethane and the first dehydrogenation from the terminal carbon (CH 3 CH 2 CH 3 *+* → CH 3 CH 2 CH 2 *+H*) for propane. The vinyl species CH 2 CH* produced from propane cracking is responsible for whether a single or multiple cracking events occur and effectively controls the selectivity. Specifically, ethane formation in propane hydrogenolysis is suppressed at elevated temperatures due to over-cracking via multiple (two here) cracking events being preferred over hydrogenation and desorption of ethane from the catalyst. Our workflow and models provide a baseline for future studies on heavier hydrocarbons. Insights into recent experimental studies of polyethylene over Ru-based catalysts are discussed.

37 INORGANIC, ORGANIC, PHYSICAL, AND ANALYTICAL CH↗
DOE OSTI2023

Design optimization of an ethanol heavy-duty engine using design of experiments and bayesian optimization

Diesel-fueled engines still hold a large market share in the medium and heavy-duty transportation sector. However, the increase in fossil fuel prices and the strict emission regulations are leading engine manufacturers to seek cleaner alternatives without a compromise in performance. Alcohol-based fuels, such as ethanol, offer a promising alternative to diesel fuel in meeting regulatory demands. Ethanol provides cleaner combustion and lower levels of soot due to its chemical properties, in particular its lower level of carbon content. In addition, the stoichiometric operating conditions of alcohol fueled engines enable the mitigation of NOx emissions in aftertreatment stage. With the promise of retrofitting diesel engines to run on ethanol to reduce emissions, the thermal efficiency of these engines remains the primary optimization target. In order to find the optimal ethanol-fueled engine design that maximizes the thermal efficiency, a large design space needs to be investigated using engineering tools. In this study, previous research by the authors on optimizing the design of a single-cylinder ethanol-fueled engine was extended to explore the design space for a heavy-duty multi-cylinder engine configuration. A heavy-duty engine setup with multiple operating conditions at different engine speeds and loads were considered. A design optimization analysis was performed to identify the potential designs that maximize the indicated thermal efficiency in an ethanol-fueled compression ignition engine. First, a computational fluid dynamics (CFD) model of the engine was validated using experimental data for four drive cycle points. Using a design of experiments (DoE) approach and a parameterized piston bowl geometry, the model was then exercised to explore the relationship among geometric features of the piston bowl and spray targeting angle and indicated thermal efficiency across all tested operating conditions. After evaluating 165~candidate designs, a piston bowl geometry was identified that yielded an increase between 1.3 to 2.2 percentage points in indicated thermal efficiency for all tested conditions, while satisfying the operational design constraints for peak pressure and maximum pressure rise rate. The increased performance was attributed to enhanced mixing that led to the formation of a more homogeneous distribution of in-cylinder temperature and equivalence ratio, higher combustion temperatures, and shorter combustion duration. Finally, a Bayesian optimization (BOpt) analysis was employed to find the optimal piston bowl geometry with a fixed spray injector angle for one of the operating conditions. Using BOpt, a piston candidate was identified that resulted in a 1.9~percentage point increase in thermal efficiency from the baseline design, yet only required 65\% of the design samples investigated using the DoE approach.

Tekgul, Bulut↗