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At least 19 records
All sourcesNASA NTRSDOE OSTI
DOE OSTI2023

Parametric evaluation of ducted fuel injection in an optically accessible mixing-controlled compression-ignition engine with two- and four-duct assemblies

Ducted fuel injection (DFI) is a strategy to improve fuel/charge-gas mixing in direct-injection compression-ignition engines. DFI involves injecting fuel along the axis of a small tube in the combustion chamber, which promotes the formation of locally leaner mixtures in the autoignition zone relative to conventional diesel combustion. Previous work has demonstrated that DFI is effective at curtailing engine-out soot emissions across a wide range of operating conditions. This study extends previous investigations, presenting engine-out emissions and efficiency trends between ducted two-orifice and ducted four-orifice injector tip configurations. For each configuration, parameters investigated include injection pressure, injection duration, intake manifold pressure, intake manifold temperature, start of combustion timing, and intake-oxygen mole fraction. For both configurations and across all parameters, DFI reduced engine-out soot emissions compared to conventional diesel combustion, with little effect on other emissions and engine efficiency. Emissions trends for both configurations were qualitatively the same across the parameters investigated. The four-duct configuration had higher thermal efficiency and indicated-specific engine-out nitrogen oxide emissions but lower indicated-specific engine-out hydrocarbon and carbon monoxide emissions than the two-duct assembly. Both configurations achieved indicated-specific engine-out emissions for both soot and nitrogen oxides that comply with current on- and off-road heavy-duty regulations in the United States without exhaust-gas aftertreatment at an intake-oxygen mole fraction of 12%. High-speed in-cylinder imaging of natural soot luminosity shows that some conditions include a second soot-production phase late in the cycle. The probability of these late-cycle events is sensitive to both the number of ducted sprays and the operating conditions.

Yraguen, Boni Frances↗
DOE OSTI2023

A Computational Investigation of Engine Heat Transfer with Ducted Fuel Injection

Ducted fuel injection (DFI) is an innovative method that curtails or prevents soot formation in direct-injection compression-ignition engines. DFI uses a simple duct, positioned outside each injector hole, facilitating the fuel/charge gas mixing before ignition. This reduces the equivalence ratio below two, in the autoignition zone, which in turn decreases soot formation. But this method also reduces fuel-conversion efficiency. This study investigates the effects of DFI on in-cylinder heat transfer. Experiments with conventional diesel combustion (CDC) and DFI were performed at four different dilution levels. Computational fluid dynamics (CFD) simulations were carried out at conditions matching those of the experiments, and the simulations were validated by the experimental data. The CFD simulations enabled to examine of in-cylinder heat release and temperature distributions. The heat transfer to the piston, head, and cylinder was investigated. The results show that DFI increased the heat transfer to the walls compared to CDC under the same conditions. This could help explain why DFI has been observed to reduce fuel-conversion efficiency by approximately 1% (absolute) relative to CDC under certain conditions. The efficiency loss typically decreases with dilution, such that DFI can improve fuel-conversion efficiencies relative to CDC at higher dilution levels.

Şener, Ramazan↗
DOE OSTI2020

A phenomenological rate of injection model for predicting fuel injection with application to mixture formation in light-duty diesel engines

Fuel injection rate laws are one of the most important pieces of information needed when modeling engine combustion with computational fluid dynamics. In this study, a simple phenomenological model of a common-rail injector was developed and calibrated for the Bosch CRI2.2 platform. The model requires three tunable parameter fits, making it relatively easy to calibrate and suitable for injector modeling when high-fidelity information about the internal injector’s geometry and electrical circuit details are not available. Each injection pulse is modeled as a sequence of up to four stages: an injection needle mechanical opening transient, a full-lift viscous flow inertial transient, a Bernoulli steady-state stage, and a needle descent transient. Parameters for each stage are obtained as polynomial fits from measured injection rate properties. The model enforces total injected mass, and the intermediate stages are only introduced if the injection pulse duration is long enough. Experimental rates of injection from two separate campaigns on the same injector were used to calibrate the model. The model was first validated against measured injection rate laws featuring pilot injections, short partially premixed combustion pulses, and conventional diesel combustion injection strategies. Then, it was employed as an input to engine computational fluid dynamics simulations, which were run to simulate experiments of mixture formation in an optically accessible light-duty diesel engine. It was found that, though simple, this model is capable of predicting both pilot and main injection pulse mass flow rates well: the simulations yielded accurate predictions of in-cylinder equivalence ratio distributions from injection strategies for both partially premixed combustion and pilot injections. Also, once calibrated, the model produced appropriate results for a wide range of injected mass and rail pressure values. Finally, it was observed that usage of such a relatively simple model can be a good choice when high-fidelity injection rate input and highly detailed information of the injector’s geometry and operation are not available, particularly as noticeable discrepancies can be present also among different experimental campaigns on similar hardware.

42 ENGINEERING↗
DOE OSTI2024

Determining tolerance requirements for spray-duct alignment in ducted fuel injection

Several ducted fuel injection (DFI) studies have highlighted the importance of accuracy in aligning the duct axis with that of its corresponding spray for optimal effectiveness, as misalignment adversely impacts the method’s performance. The need for accurate alignment could lead to added manufacturing complexity via tighter tolerances. This study systematically explores cases of horizontal, vertical, and rotational misalignment, analyzing their respective effects on DFI performance. Vertical and horizontal misalignments at the duct inlet plane were varied at magnitudes of 6.25%, 12.5%, and 25.0% of the duct diameter, corresponding to 0.125, 0.25, and 0.5 mm, respectively. Rotational misalignments were set at 1°, 2°, and 4°, corresponding to 3.65%, 7.30%, and 14.6%, respectively, of the duct diameter at its inlet plane. The investigation yields spray-duct alignment tolerance limits and highlights the influence of misalignment direction on emissions due to the interactions with swirl and squish inside the combustion chamber. The results indicate that the tolerance limits for the alignment are within 4° and 0.5 mm relative to the geometrically aligned position. If the misalignment exceeds 4°of rotation or 0.5 mm in the horizontal direction, the beneficial effects on soot reduction using this method are no longer observed. The findings contribute to an understanding that can be used to optimize DFI for cleaner and more efficient combustion in compression-ignition engines.

Şener, Ramazan↗
DOE OSTI2020

Ducted Fuel Injection versus Conventional Diesel Combustion: An Operating-Parameter Sensitivity Study Conducted in an Optical Engine with a Four-Orifice Fuel Injector

Ducted fuel injection (DFI) has been shown to attenuate engine-out soot emissions from diesel engines. The concept is to inject fuel through a small tube within the combustion chamber to enable lower equivalence ratios at the autoignition zone, relative to conventional diesel combustion. Previous experiments have demonstrated that DFI enables significant soot attenuation relative to conventional diesel combustion for a small set of operating conditions at relatively low engine loads. This is the first study to compare DFI to conventional diesel combustion over a wide range of operating conditions and at higher loads (up to 8.5 bar gross indicated mean effective pressure) with a four-orifice fuel injector. This study compares DFI to conventional diesel combustion through sweeps of intakeoxygen mole fraction (XO 2 ), injection duration, intake pressure, start of combustion (SOC) timing, fuel-injection pressure, and intake temperature. DFI is shown to curtail engine-out soot emissions at all tested conditions. Under certain conditions, DFI can attenuate engine-out soot by over a factor of 100. In addition to producing significantly lower engine-out soot emissions, DFI enables the engine to be operated at low-NO x conditions that are not feasible with conventional diesel combustion due to high soot emissions.

42 ENGINEERING↗
DOE OSTI2023

Fuel injection assembly for a turbomachine

Fuel injection assemblies and combustors are provided. A fuel injection assembly includes a fuel injector having a first annular wall that about an axial centerline and extends from a primary inlet disposed at a first end to a primary outlet disposed at a second end. A second annular wall surrounds the first annular wall. A fuel plenum is defined between the first annular wall and the second annular wall. A fuel duct extends from a fuel outlet defined in the second annular wall to a fuel inlet. wherein the fuel duct is in fluid communication with the fuel plenum. The fuel duct includes a polygonal segment and a cylindrical inlet segment. The polygonal segment extends from the fuel outlet to the cylindrical inlet segment.

Griffis, Clay Thomas↗
DOE OSTI2020

Ducted Fuel Injection vs. Conventional Diesel Combustion: Extending the Load Range in an Optical Engine with a Four-Orifice Fuel Injector

Ducted fuel injection (DFI) is a technique to attenuate soot formation in compression ignition engines relative to conventional diesel combustion (CDC). The concept is to inject fuel through a small tube inside the combustion chamber to reduce equivalence ratios in the autoignition zone relative to CDC. DFI has been studied at loads as high as 8.5 bar gross indicated mean effective pressure (IMEP g ) and as low as 2.5 bar IMEP g using a four-orifice fuel injector. Across previous studies, DFI has been shown to attenuate soot emissions, increase NO x emissions (at constant charge dilution), and slightly decrease fuel conversion efficiencies for most tested points. This study expands on the previous work by testing 1.1 bar IMEPg (low-load/idle) conditions and 10 bar IMEPg (higher-load) conditions with the same four-orifice fuel injector, as well as examining potential causes of the degradations in NO x emissions and fuel conversion efficiencies. DFI and CDC are directly compared at each operating point in the study. At the low-load condition, the intake charge dilution was swept to elucidate the soot and NO x performance of DFI. The low-load range is important because it is the target of impending, more-stringent emissions regulations, and DFI is shown to be a potentially effective approach for helping to meet these regulations. The results also indicate that DFI likely has slightly decreased fuel conversion efficiencies relative to CDC. We find that the increase in NO x emissions with DFI is likely due to longer charge gas residence times at higher temperatures, which arise from shorter combustion durations and advanced combustion phasing relative to CDC.

42 ENGINEERING↗
DOE OSTI2022

Fuel injection module for segmented annular combustion system

The present disclosure is directed to a fuel injection module for a segmented annular combustion system. The fuel injection module includes a housing body, a fuel nozzle portion, and at least one fuel injection lance. The fuel nozzle portion is fluidly coupled to a fuel nozzle plenum within the housing body, and the at least one fuel injection lance is fluidly coupled to an injector fuel plenum within the housing body. In some cases, the fuel nozzle portion is a bundled tube fuel nozzle having one or more subsets of tubes. The fuel injection lances are positioned along a radial side of the housing body or circumferentially between two subsets of tubes. Liquid fuel cartridges extend through the fuel nozzle portion, the fuel injection lances, or both.

42 ENGINEERING↗
DOE OSTI2022

Ducted fuel injection with Low-Net-Carbon fuels as a solution for meeting future emissions regulations

Several studies have proven how ducted fuel injection (DFI) reduces soot emissions for compression-ignition engines. Nevertheless, no comprehensive study has investigated how DFI performs over a load range in combination with low-net-carbon fuels. In this study, optical-engine experiments were performed with four different fuels—conventional diesel and three low-net-carbon fuels—at low and moderate load, to measure emissions levels and performance. The 1.7-liter single-cylinder optical engine was equipped with a high-speed camera to capture natural luminosity images of the combustion event. Conventional diesel and DFI combustion were investigated at four different dilution levels (to simulate exhaust-gas recirculation effects), from 14 to 21 mol% oxygen in the intake. At a given dilution level, with commercial diesel fuel, DFI reduced soot by 82% at medium load, and 75% at low load without increasing NO x . The results further show how DFI with dilution reduces soot and NO x without compromising engine performance or other emission types, especially when combined with low-net-carbon fuels. DFI with the oxygenated low-net-carbon blend HEA67 simultaneously reduced soot and NO x by as much as 93 % and 82 %, respectively, relative to conventional diesel combustion with commercial diesel fuel. These soot and NO x reductions occurred while lifecycle CO 2 was reduced by at least 70 % when using low-net-carbon fuels instead of conventional diesel. All emissions changes were compared with future emissions regulations for different vehicle sectors to investigate how DFI can be used to facilitate achievement of the regulations. Finally, the results show how the DFI cases fall below several future emissions regulation levels, rendering less need for aftertreatment systems and giving a possible lower cost of ownership.

33 ADVANCED PROPULSION SYSTEMS↗
DOE OSTI2024

The Case for Reducing Emissions from Heavy-Duty Off-Road Applications via Ducted Fuel Injection

Designers of heavy-duty diesel engines use a variety of techniques to improve efficiency and reduce pollutant emissions. Ducted fuel injection (DFI), high fuel injection pressures, optimized injection orifices, multiple injection sites, and oxygenated fuels are a few techniques used by designers to improve fuel/charge-gas mixtures within the combustion chamber to improve efficiency and emissions results. Ducted fuel injection (DFI) has been proven to substantially reduce soot for low- and mid-load conditions in heavy duty engines, without significantly increasing nitrogen oxides (NO x ). This study investigates the performance of DFI utilizing conventional diesel fuel and the potential the technique has for future research utilizing varieties of test fuels and operating parameter values. Optimization for high engine efficiency and low emissions will help facilitate DFI deployment for substantial environmental benefits in heavy-duty sectors where electrification and/or carbon-free fuels aren’t feasible.

33 ADVANCED PROPULSION SYSTEMS↗
DOE OSTI2023

Analysis of ducted fuel injection at high-pressure transcritical conditions using large-eddy simulations

Ducted fuel injection (DFI) is a proposed fuel injection concept for achieving substantial reductions in emissions. In this concept, the fuel is injected through a coannular duct, resulting in increased fuel-air mixing and minimized formation of soot and other unwanted combustion products. Apart from comprehensive experimental investigations on DFI, so far computational studies have been limited to single-point Reynolds-averaged Navier Stokes simulations. Therefore, the objective of this work is to complement these studies by performing large-eddy simulations using a diffuse-interface method to examine the physical mechanisms and combustion processes of DFI, specifically focusing on the mixing process and the effect of fuel-ducting on combustion and pollutant emissions. To this end, finite-rate chemistry simulations are performed of the DFI configuration corresponding to the Engine Combustion Network Spray A injector at transcritical conditions (n-dodecane fuel, 60 bar pressure and 1000 K temperature chamber conditions). A two-equation soot model is employed for the qualitative analysis of soot emissions. Direct comparisons of averaged and instantaneous flow field results with the Spray A configuration are performed to assess the effect of DFI on the first- and second-stage ignition and soot formation. Compared to the free-spray condition, the results show that the DFI case exhibits a combination of (i) increased mass flow rate and entrained air, (ii) larger pressure drop magnitude and flow velocity, and (iii) a closer-to-stoichiometric mixture composition (both globally and locally), each of which is conjectured to contribute toward reduced soot production.

33 ADVANCED PROPULSION SYSTEMS↗
DOE OSTI2021

Combustor with axially staged fuel injection

A combustor with axially staged fuel injection includes an endcover and a fuel injector that extends axially downstream from the endcover. The fuel injector includes a cylindrical shell formed by an outer wall and an inner wall. A first plurality of outlets is circumferentially spaced across the inner wall. A first plurality of premix channels is defined between the outer wall and the inner wall. Each premix channel of the first plurality of premix channels is in fluid communication with a fuel supply, a compressed air supply and a respective outlet of the first plurality of outlets.

Berry, Jonathan Dwight↗
DOE OSTI2022

Durability Study of a High-Pressure Common Rail Fuel Injection System Using Lubricity Additive-Dosed Gasoline-Like Fuel—Improved Endurance with Upgraded Hardware

Gasoline compression ignition (GCI) is a promising combustion technology that can help the commercial transportation sector achieve operational flexibility and meet upcoming criteria pollutant regulations. However, high-pressure fuel injection systems (>1000 bar) are needed to enable GCI and fully realize its benefits compared to conventional diesel combustion. This work is a continuation of previous durability studies that identified three key technical risks after running gasoline-like fuel through a heavy-duty, common rail injection system: (i) cavitation damage to the inlet check valve of the high-pressure pump, (ii) loss of injector fueling capacity, (iii) cavitation erosion of the injector nozzle holes. Upgraded hardware solutions were tested on a consistent 400- to 800-hour NATO durability cycle with the same gasoline-like fuel as previous studies. The upgraded pump showed no signs of abnormal wear or cavitation damage to the inlet check valve. In contrast to previous studies, there were no signs of pump performance degradation observed after 400 hours of testing. Material selection and design upgrades were also made to the injector which, only showed a 6.5% loss in fueling capacity after 800 hours of durability testing compared to 49.3% previously. Finally, geometric nozzle hole features such as higher inlet radius of curvature and higher K-factor were found to correlate with reduced cavitation erosion. However, mitigation of eccentric radial needle motion (i.e., wobble) is likely needed to further suppress cavitation. In general, the results from this study indicate there are viable hardware-based solutions for improving the endurance of high-pressure systems when running with gasoline-like fuel.

33 ADVANCED PROPULSION SYSTEMS↗
DOE OSTI2023

Ducted fuel injection system alignment device

An alignment device for a ducted fuel injection system comprising a mounting block removably attachable to a duct of the ducted fuel injection system. The mounting block can include a passageway extending therethrough. The passageway can align with the duct when the mounting block is attached to the duct. The alignment device further comprises an imaging device configured to capture an image viewing through the duct toward an outlet of a fuel injector. A portion of the imaging device can extend in the passageway. The alignment device additionally comprises a centering structure configured to align a portion of the imaging device with a central axis of the duct. The image captured by the imaging device can be configured for use aligning a position of an outlet of a fuel injector with respect to a position of the duct.

Nilsen, Christopher William↗
DOE OSTI2021

Adaptive mesh based combustion simulations of direct fuel injection effects in a supersonic cavity flame-holder

Here, we present high-fidelity reacting simulations of a supersonic cavity flame-holder configuration. The focus of this work is on flame stabilization brought about by varying the location of fuel injection in a cavity stabilized supersonic flow of air. Central to our approach is a compressible multi-species reacting flow solver that uses adaptive-mesh-refinement (AMR), enabling the resolution of flame, shock-waves, boundary-layers, and small-scale structures in the computational domain. Our analysis indicates that fuel injection closer to the ramp at the aft end of the cavity allows for greater mixing and lower peak temperatures compared to fuel injection upstream that is closer to the backward facing step of the cavity. This difference is mainly due to greater turbulent fluctuations generated from the shear-layer towards the cavity ramp, thereby enhancing the mixing of fuel and air. A low frequency oscillatory behaviour in heat-release and pressure was also observed for the upstream injection case while a much higher-frequency phenomena was observed in the near-ramp injection case. By identifying the important physical determinants of the combustion processes, this study illustrates a promising pathway to design and optimize direct fuel injection strategies in supersonic cavity flame-holders that can improve flame stability, combustion efficiency, and reduce emissions.

42 ENGINEERING↗
DOE OSTI2020

Combustor with axially staged fuel injection

A combustor with axially staged fuel injection includes a plurality of nozzle segments annularly arranged about a center fuel nozzle. Each nozzle segment includes a fuel plenum partially defined between a forward plate and an aft plate and a plurality of tubes that extends through the fuel plenum and the aft plate. A panel fuel injector extends axially downstream from the aft plate and includes an outer wall, an inner wall, a plurality of outlets defined along at least one of the outer wall and the inner wall and a plurality of premix channels defined between the outer wall and the inner wall. Each premix channel is in fluid communication with a fuel supply, a compressed air supply and a respective outlet of the plurality of outlets.

42 ENGINEERING↗