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At least 163 records · Page 9

Aqueous Bromide Discharges from U.S. Coal-Fired Power Plants: Points of Origin, Concentration Ranges, and Effluent Treatment Costs

Bromide discharges from coal-fired power plants have received increased attention from regulatory bodies due to their contribution to the formation of disinfection byproducts (DBPs) in downstream drinking water treatment plants. Here, this paper characterizes the relative contributions of bromide from coal feedstocks and bromine-based mercury control processes, estimates the distribution of bromide concentrations at 85 active coal-fired power plants across the United States (U.S.) with wet flue gas desulfurization units, and estimates the cost of bromide removal from wastewater discharge using year 2020 data. Bromide discharges are estimated at the plant level using a combination of the reported coal rank and composition combusted, estimates of bromide addition in mercury control techniques under multiple halogen addition scenarios, and the estimated flue gas desulfurization (FGD) wastewater flow rate. The median, simulated plant-level estimation of total FGD wastewater flow is 18.3 gallons/min at a bromide concentration of 319 mg/L, equivalent to ~11.6 tonnes/year of bromide discharges to the environment. Next, we evaluated the expected cost of employing the best available technology (BAT) to control bromide discharges in FGD wastewater to prevent contributions to DBP formation. Treatment would need to remove more than 99.8% of bromide to reach the 0.2 mg/L voluntary incentive program (VIP) limit. The total cost of treatment depends on whether disposal is on- or off-site; the average costs for all plants combined come to an average of $110 million ($95.2/kgal) in 2021 U.S. dollars for on-site disposal, or $134 million ($115/kgal) for off-site disposal.

01 COAL, LIGNITE, AND PEAT↗

Advanced Engine and Fuel Technologies 2021 Annual Progress Report

This report highlights progress achieved by the Advanced Engine and Fuel Technologies Program during fiscal year 2021. The nature, current focus, and recent progress of the Program are described together with summaries of National Laboratory, industry, and university projects that provide an overview of the exciting work being conducted to address critical technical barriers and challenges to commercializing higher-efficiency engine, emissions control, and fuel technologies for passenger and commercial vehicles.

33 ADVANCED PROPULSION SYSTEMS↗

Spray Combustion and Soot Formation

Mitigating particulate matter (PM) emissions while simultaneously controlling nitrogen oxide and hydrocarbon emissions is critical for both gasoline and diesel engines. The problem is especially critical during cold-start cycles where aftertreatment devices are less effective. Understanding how liquid sprays and films form PM and designing to change the outcome requires advanced combustion concepts developed through joint experimental and computational efforts. However, existing spray and soot computational models are oversimplified and non-physical, and are therefore unable to reliably capture quantitative or even qualitative trends over a wide range of engine operating conditions. This task involves the development and application of advanced optical diagnostics and high-pressure gas and particle sampling/analysis in unique high-temperature, high-pressure vessels to investigate spray dynamics and soot formation with the objective of providing fundamental understanding about soot processes under relevant engine conditions to aid the development of improved soot models for commercial CFD codes

02 PETROLEUM↗

DME-Propane Blends Ignition Experiments and Modeling for Heavy-Duty Mixing Controlled Compression Engines

A blend of dimethyl ether (DME) and propane (C3H8) is being studied in a shock tube at heavy-duty engine conditions at 110 bar. Due to its intrinsic combustion properties, DME/propane blend can potentially replace diesel in mixing controlled compression ignition engines. A blend of DME/propane can reduce emissions in mixing controlled compression ignition in heavy-duty engines through modifications, which require simulations using a high-fidelity chemical kinetics model that can accurately predict the chemistry of the blend. An essential aspect of testing the chemical kinetics model is doing baseline fundamental chemistry studies on neat DME and propane, which include ignition delay time measurements. In this work, using a high-pressure shock tube, ignition delay times were gathered for DME/Propane blends at 110 bar diluted with AR to test chemical kinetic models published in the literature. These models include Aramco 3.0, NUIG V1.1, C3mech V3.3, and Dames et al. Comparisons with the experimental IDTs and models were conducted, and general agreement was observed. A sensitivity analysis was conducted, and important reactions were outlined.

Mohammed, Zuhayr Pasha [University of Central Flor↗

Influence of NOx chemistry on the prediction of natural gas end-gas autoignition in CFD engine simulations

Natural gas (NG) represents a promising low-cost/low-emission alternative to diesel fuel when used in high-efficiency internal combustion engines. Advanced combustion strategies utilizing high EGR rates and controlled end-gas autoignition can be implemented with NG to achieve diesel-like efficiencies; however, to support the design of these next-generation NG ICEs, computational tools, including single- and multi-dimensional simulation packages will need to account for the complex chemistry that can occur between the reactive species found in EGR (including NOx) and the fuel. Research has shown that NOx plays an important role in the promotion/inhibition of large hydrocarbon autoignition and when accounted for in CFD engine simulations, can significantly improve the prediction of end-gas autoignition for these fuels. However, reduced NOx-enabled NG mechanisms for use in CFD engine simulations are lacking, and as a result, the influence of NOx chemistry on NG engine operation remains unknown. Here, we analyze the effects of NOx chemistry on the prediction of NG/oxidizer/EGR autoignition and generate a reduced mechanism of a suitable size to be used in engine simulations. Results indicate that NG ignition is sensitive to NOx chemistry, where it was observed that the addition of EGR, which included NOx, promoted NG autoignition. The modified mechanism captured well all trends and closely matched experimentally measured ignition delay times for a wide range of EGR rates and NG compositions. Here, the importance of C2-C3 chemistry is noted, especially for wet NG compositions containing high fractions of ethane and propane. Finally, when utilized in CFD simulations of a Cooperative Fuels Research (CFR) engine, the new reduced mechanism was able to predict the knock onset crank angle (KOCA) to within one crank angle degree of experimental data, a significant improvement compared to previous simulations without NOx chemistry.

33 ADVANCED PROPULSION SYSTEMS↗

Time and space resolved diagnostics for plasma thermal-chemical instability of fuel oxidation in nanosecond plasma discharges

Here, an instability in a nanosecond pulsed dielectric barrier discharge plasma occurring in methane–oxygen–argon mixtures is experimentally observed and measured by 1D time-resolved in situ electric field measurements. This instability, which seems to be created by the positive feedback between plasma kinetics and plasma-assisted low temperature fuel oxidation, is studied using electric field induced second harmonic generation and direct ICCD imaging. The rapid formation of streamers from an originally uniform discharge appears to be caused by the chemical kinetics of plasma-assisted low temperature methane oxidation, which may be resulting in a new type of plasma instability: a thermal-chemical instability. The results also revealed that the occurrence of this possible thermal-chemical instability in a reactive flow drastically changes the plasma properties by forming multiple secondary discharges and possibly leads to micron-sized non-uniform electric distributions. Single shot uncalibrated measurements of the electric field of the micron sized streamers appears to show much greater strengths than the average electric field. Furthermore, one-dimensional data analysis shows the positive feedback loop between the streamers and the low temperature plasma assisted oxidation chemistry in the plasma thermal-chemical instability. The present finding advances the understanding plasma instability growth and provides a new way to control plasma uniformity in plasma-assisted combustion and plasma fuel reforming.

70 PLASMA PHYSICS AND FUSION TECHNOLOGY↗

Simulation of Premixed and Partially Premixed Jet-in-Crossflow Flames at High Pressure

In this paper, we explore the operational map of a lean axial-staged combustor of premixed and partially premixed reacting jet-in-crossflow flames at high -pressure (5 atm). This study attempts to expand the data to relatively high pressure and could significantly aid scaling to real gas turbine engine conditions at 20–30 atm. High-speed camera, particle image velocimetry (PIV), CH* chemiluminescence, temperature, and pressure measurements were taken and processed to allow accurate reconstruction of six operating points relative to computational fluid dynamics (CFD) simulations under minimal adjustments. Variation of lean main stage (φ = 0.575 and 0.73) and rich jet (φ = 1.1, 4, and 8) equivalence ratio has been investigated for a four mm axial jet. The fully premixed flames were found to be controlled by the crossflow temperature before ignition and the crossflow oxygen content during combustion. Analysis of flame shape and position for the partially premixed operating points describes a lee stabilized as well as a more unsteady windward flame branch. Adjustment of added jet fuel and crossflow temperature along with its corresponding oxygen level is required to attain a compact flame body. Here, the risk of delaying combustion progress is significantly increased at a richer jet φ = 8 and an overshooting, spatially divided flame was attained with a main stage φ = 0.73. Control toward a compact flame body is critical to allow combustion at reasonable reaction rate.

03 NATURAL GAS↗

MODELING AND PARAMETRIC STUDY OF END-GAS AUTOIGNITION TO ALLOW THE REALIZATION OF ULTRA-LOW EMISSIONS, HIGH-EFFICIENCY HEAVY-DUTY SPARK-IGNITED NATURAL GAS ENGINES

Engine knock and misfire are barriers to pathways leading to high-efficiency Spark-Ignited (SI) Natural Gas (NG) engines. The general tendency to knock is highly dependent on engine operating conditions and the fuel reactivity. The problem is further complicated by the low emission limits and the wide range of chemical reactivity in pipeline-quality natural gas. Depending on the region and the source of the natural gas, its reactivity, described by its Methane Number (MN), which is analogous to the Octane Number for liquid SI fuels, can span from 65 to 95. In order to realize diesel-like efficiencies, SI NG engines must be designed to operate at high Brake Mean Effective Pressures (BMEP), near or beyond knock limits, over a wide range of fuel reactivity. This requires a deep understanding of the combustion-engine interactions pertaining to flame propagation and End-Gas Autoignition (EGAI), i.e., the autoignition of the unburned gas (end gas) ahead of the flame front. However, EGAI, if controlled, provides an opportunity to increase SI NG engine efficiency by increasing the combustion rate and the total fraction of burned fuel, mitigating the effects of the slow flame speeds characteristic of natural gas fuels, which generally reduce BMEP and increase unburned hydrocarbon emissions. For this reason, to realize diesel-like efficiencies and ultra-low emissions on SI NG engines, this work proposes the study of the main parameters influencing the modeling and prediction of NG EGAI to allow for its control. In this work, a novel EGAI detection and onset determination method was developed to reliably quantify EGAI for data analysis and engine control. The new method allowed the prediction of EGAI on SI NG engines without the need to use engine- and operating-condition-dependent thresholds and reduced the error in quantifying the fraction of the total energy released by the EGAI event by up to 40%pts. One- and three-dimensional engine models were then developed to study the engine/fuel interactions that lead to NG EGAI and its performance benefits. These models, although having decent agreement with experimental data, showed the need to account for NOx chemistry when predicting NG EGAI due to a consistently later prediction of the EGAI onset (~1.65 crank-angle degrees) and thus, a new reduced chemical mechanism for real NG fuels was developed containing NOx chemistry. The new reduced mechanism improved the EGAI onset prediction agreement to within ±0.5 crank-angle degrees and decreased simulation time during combustion by nearly 50% when using the further reduced AREIS50NOx chemical mechanism. These models were then used to study the role of NG composition on EGAI, evaluate the engine/fuel interactions leading to NG EGAI, and perform engine optimization while leveraging EGAI to increase thermal efficiency. Piston design optimization combined with a Controlled EGAI (C-EGAI) combustion mode allowed a Heavy-Duty (HD) SI NG engine to operate at diesel-like efficiencies, i.e., Brake Thermal Efficiency (BTE) ≥44%. Experimental and modeling data analysis revealed that earlier and faster heat release increases combustion efficiency by an average of 1%pts, increases work transferred to the piston resulting in a decrease in exhaust losses by 50% depending on the engine operating condition while slightly increasing heat losses. Finally, the simulation results revealed an opportunity to further enhance the BTE (up to 50%) by enabling C-EGAI combustion at leaner conditions, λ=1.4-1.6.

Bestel, Diego Bernardi↗

Improving Efficiency of Off-Road Vehicles by Novel Integration of Electric Machines and Advanced Combustion Engines

Modern off-road equipment will increasingly rely on electrified implements that will deliver precision control with a smaller footprint than hydraulics. The primary energy converter, however, will be an onboard reciprocating internal combustion engine because of the power density of hydrocarbon fuels in comparison to electrical energy storage and the remote locations where much of this equipment is deployed. Adding energy storage and electric machines creates opportunities to improve efficiency while reducing emissions. This program investigated approaches to take advantage of the extra flexibility that an enhanced electrical system to enable high-efficiency, low-emissions combustion technologies. The current program evaluated hybridization of both the torque application and air-handling systems to maximize efficiency while minimizing cost. This program designed, analyzed and tested a hybrid off-road vehicle consisting of a series electric powertrain with energy storage, an electrified air system, and a 33% downsized diesel engine. Detailed comparisons were made between the base powertrain and the developed powertrain using powertrain simulations, engine testing, and vehicle testing. The key results of the study are: • The resulting vehicle reduces fuel consumption by 5% to 15% at equal productivity. The primary improvements were due to recovery of regenerative braking losses for cycles where large transients are encountered. • The electrified air system was an enabler to allow engine downsizing. This was most important for duty-cycles where the engine primarily operated at moderate loads and had few low speed high torque conditions. • Engine level improvements showed re-optimization of the powertrain is possible when electrified air handing is available. Increased exhaust gas recirculation and advanced injection timing allowed up to a 15% reduction in brake specific fuel consumption at equal NOx and transient response. Compared to the larger engine, the downsized engine achieves up to an 18% reduction in brake specific fuel consumption over the non-road transient cycle. • The life cycle analysis and total cost of ownership study showed that the hybrid powertrain has the potential to reduce 5-year CO2 and total cost of ownership by ~6% over the baseline vehicle. The results also indicated that a pure battery electric vehicle is not feasible in this application and is likely to increase the CO2 emissions due to the CO2 from battery production. A hybrid powertrain with low carbon fuels shows the potential to substantially reduce CO2 and total cost of ownership.

02 PETROLEUM↗

Development and evaluation of a skeletal mechanism for EHN additized gasoline mixtures in large Eddy simulations of HCCI combustion

Advanced Low Temperature Combustion modes, such as the Sandia proposed Additive-Mixing Fuel Injection (AMFI), can unlock significant potential to boost fuel conversion efficiency and ultimately improve the energy conversion of internal combustion engines. This is a novel improved combustion process that is enabled by supplying small (<5%) variable amounts of autoignition improver to the fuel to enhance the engine operation and control. Common, diesel-fuel ignition-quality enhancing additive, 2-ethylexyl nitrate (EHN), is doped into gasoline to enable Sandia LTGC + AMFI combustion. This manuscript focuses on the development of a reduced sub-mechanism for EHN chemical kinetics at engine relevant conditions that is implemented into a skeletal mechanism for chemical kinetic studies of gasoline surrogate fuels. The mechanism validation utilized zero-dimensional numerical simulations and comparison to shock tube ignition-delay data of pure and EHN-doped n-heptane. Additional validation is presented with Homogeneous Charge Compression-Ignition (HCCI) engine data of pure and EHN-doped research-grade E10 gasoline. Then, the mechanism was deployed in a 3-D computational fluid dynamics (CFD) using Large Eddy Simulations (LES) to model the HCCI engine experiments of 0.4% vol EHN additized E10 gasoline at several equivalence ratios. Simulations showed a very good performance of the mechanism, and the model accurately reproduced (a) the ignition point, (b) combustion phasing, (c) combustion duration, and (d) the peak of the heat release rates of the engine experiments. The results show that EHN promotes Low-Temperature Heat Release, ultimately driving the gasoline to autoignite at thermodynamic conditions where the fuel would not otherwise ignite. Overall, this work demonstrates a viable reduced chemical-kinetic mechanism for EHN and shows that it can be combined with a skeletal gasoline mechanism for CFD-LES analysis of well-mixed LTGC that matches well with experimental results. The CFD-LES analysis also shows the spatial distribution of EHN-fuel interactions that control the autoignition throughout the combustion chamber.

Guleria, Gaurav↗

Impact of Intersection Control on Battery Electric Vehicle Energy Consumption

Battery electric vehicle (BEV) sales have significantly increased in recent years. They have different energy consumption patterns compared to the fuel consumption patterns of internal combustion engine vehicles (ICEVs). This study quantified the impact of intersection control approaches—roundabout, traffic signal, and two-way stop controls—on BEVs’ energy consumption. The paper systematically investigates BEVs’ energy consumption patterns compared to the fuel consumption of ICEVs. The results indicate that BEVs’ energy consumption patterns are significantly different than ICEVs’ patterns. For example, for BEVs approaching a high-speed intersection, the roundabout was found to be the most energy-efficient intersection control, while the two-way stop sign was the least efficient. In contrast, for ICEVs, the two-way stop sign was the most fuel-efficient control, while the roundabout was the least efficient. Findings also indicate that the energy saving of traffic signal coordination was less significant for BEVs compared to the fuel consumption of ICEVs since more regenerative energy is produced when partial or poorly coordinated signal plans are implemented. The study confirms that BEV regenerative energy is a major factor in energy efficiency, and that BEVs recover different amounts of energy in different urban driving environments. The study suggests that new transportation facilities and control strategies should be designed to enhance BEVs’ energy efficiency, particularly in zero emission zones.

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATI↗

A review on the application of machine learning for combustion in power generation applications

Abstract Although the world is shifting toward using more renewable energy resources, combustion systems will still play an important role in the immediate future of global energy. To follow a sustainable path to the future and reduce global warming impacts, it is important to improve the efficiency and performance of combustion processes and minimize their emissions. Machine learning techniques are a cost-effective solution for improving the sustainability of combustion systems through modeling, prediction, forecasting, optimization, fault detection, and control of processes. The objective of this study is to provide a review and discussion regarding the current state of research on the applications of machine learning techniques in different combustion processes related to power generation. Depending on the type of combustion process, the applications of machine learning techniques are categorized into three main groups: (1) coal and natural gas power plants, (2) biomass combustion, and (3) carbon capture systems. This study discusses the potential benefits and challenges of machine learning in the combustion area and provides some research directions for future studies. Overall, the conducted review demonstrates that machine learning techniques can play a substantial role to shift combustion systems towards lower emission processes with improved operational flexibility and reduced operating cost.

Engineering↗

Technology Enablers for Advanced Gasoline Compression Ignition Engines

To meet current emission regulations and increasingly demanding global fleet CO2 standards on fuel economy and future trends towards life cycle GHG emissions, advanced combustion engines remain significant in the passenger vehicle sector to achieve high efficiency and low emissions over the full operating range. Lean burn gasoline compression ignition (GCI) technology has shown to have the most potential in reaching these goals, although it faces challenges in the operating range. In this study, an advanced GCI engine is considered with the capability to operate under two combustion modes, namely low temperature combustion (LTC) and GCI. They are enabled with the use of two Hyundai in-house developed technologies; an advanced valve control mechanism known as continuously variable valve duration (CVVD) and a high-pressure gasoline injection system. At low load, the engine utilizes dual CVVD and dual CVVT (continuously variable valve timing) mechanisms for both intake and exhaust valvetrains to enable NVO (negative valve overlap) to trap hot residuals. The hot residuals enable low load auto-ignition, and the phasing control of that auto-ignition is achieved by varying the degrees of NVO, and in turn, the amount of hot residuals. This is done in real time with respect to the changes in engine loads or operating conditions, significantly improving cylinder-phasing control in LTC mode, and subsequently is able to realize a fuel economy gain and reduced emission benefits. Early direct injection during NVO or intake stroke is used to form homogenous or quasi-homogenous air-fuel mixture for LTC. At mid to high loads, late direct injection of gasoline or GCI mode is employed to take advantage of the high volatility and high resistance to auto-ignition of gasoline fuel, so that diesel-engine like high combustion efficiency can be achieved with lower soot emissions for the same NOx level as diesel combustion. In this paper, the key control and fueling technologies that enable this multiple mode combustion are introduced, and the resultant analysis on engine test and CFD simulation at LTC and GCI operating conditions are presented in detail.

Gasoline compression ignition, low temperature com↗

An Integrated High Pressure SOFC and Premixed Compression Ignition (PCI) Engine System

Components for a transformative, high pressure, intermediate temperature solid oxide fuel cell (SOFC) and premixed compression ignition (PCI) engine system were developed. The resulting system is a 1 MWe natural gas fueled hybrid SOFC and reciprocating internal combustion engine system capable of achieving over 70% electrical efficiency at a cost of $0.87/W. To achieve 70% electric efficiency, the SOFC system operates at 80% fuel utilization; however, when operating at this high level of fuel utilization, fuel to the engine (anode tailgas) is extremely dilute. Accordingly, a substantial portion of the effort focused on development and assessment of the combustion strategy capable of consuming this dilute fuel mixture. The engine testing effort showed that pre-chamber assisted compression ignition provides the best combination of controllability, efficiency and emissions. The engine experiments showed that high efficiency combustion can be achieved with near zero criteria pollutants. It is likely that the engine system could operate with minimal aftertreatment requirements, reducing complexity, cost, and precious metal usage. System level modeling was used to assess the overall efficiency, determine cost and efficiency tradeoffs, and demonstrate the potential to perform load following with the hybrid system. Finally, advanced manufacturing was used to demonstrate the potential to fabricate heat exchangers needed for the hybrid system from low chromium materials, which addresses the issue of chromium poisoning of the SOFC stack material.

03 NATURAL GAS↗

High Speed Data Acquisition for Real Time Feedback in a Light Duty Engine Combustion-Mode Switching Application

The paper describes the integration of a high-speed data acquisition and diagnostics controller used in an advanced engine platform. The controller enables ultra-low emissions and new benchmarks of engine efficiency while running a Gasoline Compression Ignition (GCI) cycle on a 2.2L, 4-cylinder engine. The system enables real-time combustion feedback and vibration analysis in engines. The paper focuses on: (1) the development of an interpolative sampling algorithm for transposition of time acquired data to the crank angle domain using a production crank sensor (60-2 tooth wheel); (2) the control unit, high-speed data acquisition, communication rates between the dedicated data acquisition and base controller to ensure cycle-to-cycle feedback; and, (3) validation exercises using cylinder pressure measurements. Here, the study shows how the algorithm resolves cylinder pressure information over an engine cycle, validating its robustness across acquisition rates of 50 and 200 kHz, with crank angle resolutions of 0.5° and 0.1°. Results show that the 50 kHz, 0.5° hardware yield combustion phasing and torque estimates within 0.1° and 1% torque of those attained with the 200 kHz, 0.1° hardware. Finally, study shows the dedicated controller and communication speeds allow for next-cycle fuel injection correction for speeds above 5000 rpm.

42 ENGINEERING↗

Elucidating Arsenic and Selenium Speciation in Coal Fly Ashes

Coal fly ash (CFA) is produced during the coal combustion process and contains trace elements (<100 ppm) including selenium (Se) and arsenic (As), both detrimental for environmental and human health. Existing management strategies for CFAs involve disposal in landfills and ash ponds, as well as beneficial usage in other applications such as in concrete. Both the direct disposal and beneficial usage of CFA raise concerns for environmental hazards due to the potential leaching of Se and As. CFAs were classified as reusable material by the U.S. Environmental Protection Agency (EPA) with the first federal regulation (Disposal of Coal Combustion Residuals from Electric Utilities, CCR) for its disposal established six years ago. During coal combustion process, parameters such as furnace firing type, emissions controls, coal rank, use of additives, and particulate matter controls, could contribute to significant variability in As/Se concentrations and their speciation. Although there have been a handful of studies on As/Se speciation on small sets of samples, they do not fully represent the current state of coal-fired electrical generating units. Little information exists on the detailed speciation (e.g. oxidation state, complexation state) of As/Se in large set of fly ash samples. To better investigate the role of the potential contributing parameters, a large-scale survey study with representative samples of typical coal source and combustion conditions is highly desired. The overall goal of this research is to systematically characterize As and Se speciation of representative coal fly ash samples using state-of-the-art synchrotron based spectroscopic and microscopic techniques, in order to develop a correlation between coal source/type, operation condition, As/Se speciation, and As/Se mobility. A detailed survey study was conducted documenting the current state-of-knowledge on fossil power generating units as a function of coal type/source, operating conditions, environmental control systems, additive use, and fly ash handling methods. Based on this survey, a matrix of fly ash samples representing a range of conditions were chosen and collected. The collected ash samples were analyzed for bulk characteristics such as elemental composition, microstructure, chemical and mineralogical composition, surface area, and particle size distribution. State-of-the-art synchrotron X-ray microscopy and spectroscopy techniques were applied to reveal the molecular scale speciation information of As and Se, such as oxidation state, association with other elements/minerals, and complexation states.

01 COAL, LIGNITE, AND PEAT↗