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Three high-speed semi-diesel engines are examined through the use of indicator diagrams. Different fuel nozzles and fuels are investigated and conclusions are drawn.
Three questions relating to the technical progress in the utilization of heavy oils are discussed. The first question considers solid injection in high-speed automobile engines, the second concerns the development of the hot-bulb engine, and the third question relates to the need for a more thorough investigation of the processes on which the formatation of combustible, rapidly-burning mixtures depend.
The engines of diesel cars marketed in the United States were examined. Prominent design features, performance characteristics, fuel economy and emissions data were compared. Specific problems, in particular those of NO and smoke emissions, the effects of increasing dieselization on diesel fuel price and availability, current R&D work and advanced diesel concepts are discussed. Diesel cars currently have a fuel economy advantage over gasoline engine powered cars. Diesel drawbacks (noise and odor) were reduced to a less objectionable level. An equivalent gasoline engine driveability was obtained with turbocharging. Diesel manufacturers see a growth in the diesel market for the next ten years. Uncertainties regarding future emission regulation may inhibit future diesel production investments. With spark ignition engine technology advancing in the direction of high compression ratios, the fuel economy advantages of the diesel car is expected to diminish. To return its fuel economy lead, the diesel's potential for future improvement must be used.
Commercial use of thermal barrier coatings in diesel engines began in the mid 70's by Dr. Ingard Kvernes at the Central Institute for Industrial Research in Oslo, Norway. Dr. Kvernes attributed attack on diesel engine valves and piston crowns encountered in marine diesel engines in Norwegian ships as hot-corrosion attributed to a reduced quality of residual fuel. His solution was to coat these components to reduce metal temperature below the threshold of aggressive hot-corrosion and also provide protection. Roy Kamo introduced thermal barrier coatings in his 'Adiabatic Diesel Engine' in the late 70's. Kamo's concept was to eliminate the engine block water cooling system and reduce heat losses. Roy reported significant performance improvements in his thermally insulated engine at the SAE Congress in 1982. Kamo's work stimulates major programs with insulated engines, particularly in Europe. Most of the major diesel engine manufacturers conducted some level of test with insulated combustion chamber components. They initially ran into increased fuel consumption. The German engine consortium had Prof. Woschni of the Technical Institute in Munich. Woschni conducted testing with pistons with air gaps to provide the insulation effects. Woschni indicated the hot walls of the insulated engine created a major increase in heat transfer he refers to as 'convection vive.' Woschni's work was a major factor in the abrupt curtailment of insulated diesel engine work in continental Europe. Ricardo in the UK suggested that combustion should be reoptimized for the hot-wall effects of the insulated combustion chamber and showed under a narrow range of conditions fuel economy could be improved. The Department of Energy has supported thermal barrier coating development for diesel engine applications. In the Clean Diesel - 50 Percent Efficient (CD-50) engine for the year 2000, thermal barrier coatings will be used on piston crowns and possibly other components. The primary purpose of the thermal barrier coatings will be to reduce thermal fatigue as the engine peak cylinder pressure will nearly be doubled. As the coatings result in higher available energy in the exhaust gas, efficiency gains are achieved through use of this energy by turbochargers, turbocompounding or thermoelectric generators.
Diesel-powered vehicles emit several times more nitrogen oxides than comparable gasoline-powered vehicles, leading to ambient nitrogen dioxide (NO2) pollution and adverse health impacts. The COVID-19 pandemic and ensuing changes in emissions provide a natural experiment to test whether NO2 reductions have been starker in regions of Europe with larger diesel passenger vehicle shares. Here we use a semi-empirical approach that combines in-situ NO2 observations from urban areas and an atmospheric composition model within a machine learning algorithm to estimate business-as-usual NO2 during the first wave of the COVID-19 pandemic in 2020. These estimates account for the moderating influences of meteorology, chemistry, and traffic. Comparing the observed NO2 concentrations against business-as-usual estimates indicates that diesel passenger vehicle shares played a major role in the magnitude of NO2 reductions. European cities with the five largest shares of diesel passenger vehicles experienced NO2 reductions ∼ 2.5 times larger than cities with the five smallest diesel shares. Extending our methods to a cohort of non-European cities reveals that NO2 reductions in these cities were generally smaller than reductions in European cities, which was expected given their small diesel shares. We identify potential factors such as the deterioration of engine controls associated with older diesel vehicles to explain spread in the relationship between cities’ shares of diesel vehicles and changes in NO2 during the pandemic. Our results provide a glimpse of potential NO2 reductions that could accompany future deliberate efforts to phase out or remove passenger vehicles from cities.
The Block Island Power Company (BIPCO), on Block Island, Rhode Island, operates an isolated electric power system consisting of diesel generation and an experimental wind turbine. The 150-kW wind turbine, designated MOD-OA by the U.S. Department of Energy is typically operated in parallel with two diesel generators to serve an average winter load of 350 kW. Wind generation serves up to 60 percent of the system demand depending on wind speed and total system load. Results of diesel fuel consumption measurements are given for the diesel units operated in parallel with the wind turbine and again without the wind turbine. The fuel consumption data are used to calculate the amount of fuel displaced by wind energy. Results indicate that the wind turbine displaced 25,700 lbs. of the diesel fuel during the test period, representing a calculated reduction in fuel consumption of 6.7 percent while generating 11 percent of the total electric energy. The amount of displaced fuel depends on operating conditions and system load. It is also shown that diesel engine throttle activity resulting from wind gusts which rapidly change the wind turbine output do not significantly influence fuel consumption.
An understanding of delamination mechanisms in thermal barrier coatings has been developed for diesel engine applications through rig tests, structural analysis modeling, nondestructive evaluation, and engine evaluation of various thermal barrier coatings. This knowledge has resulted in improved thermal barrier coatings which survive abusive cyclic fatigue tests in high output diesel engines. Although much conflicting literature now exists regarding the impact of thermal barrier coatings on engine performance and fuel consumption, the changes in fuel consumption appear to be less than a few percent and can be negative for state-of-the-art diesel engines. The ability of the thermal barrier coating to improve fuel economy tends to be dependent on a number of factors including the fuel injection system, combustion chamber design, and the initial engine fuel economy. Limited investigations on state-of-the-art diesel engines have indicated that the surface connected porosity and coating surface roughness may influence engine fuel economy. Current research efforts on thermal barrier coatings are primarily directed at reducing in-cylinder heat rejection, thermal fatigue protection of underlying metal surfaces and a possible reduction in diesel engine emissions. Significant efforts are still required to improve the plasma spray processing capability and the economics for complex geometry diesel engine components.
Experimental tests with diesel number 2 and Jet A fuels were conducted in a combustor segment to obtain comparative data on exhaust emissions and blowout limits. An air-atomizing nozzle was used to inject the fuels. Tests were also made with diesel number 2 fuel using a pressure-atomizing nozzle to determine the effectiveness of the air-atomizing nozzle in reducing exhaust emissions. Test conditions included fuel-air ratios of 0.008 to 0.018, inlet-air total pressures and temperatures of 41 to 203 newtons per square centimeter and 477 to 811 K, respectively, and a reference velocity of 21.3 meters per second. Smoke number and unburned hydrocarbons were twice as high with diesel number 2 as with Jet A fuel. This was attributed to diesel number 2 having a higher concentration of aromatics and lower volatility than Jet A fuel. Oxides of nitrogen, carbon monoxide, and blowout limits were approximately the same for the two fuels. The air-atomizing nozzle, as compared with the pressure-atomizing nozzle, reduced oxides-of-nitrogen by 20 percent, smoke number by 30 percent, carbon monoxide by 70 percent, and unburned hydrocarbons by 50 percent when used with diesel number 2 fuel.
Cummins Engine Company completed an analytical study to identify an advanced automotive (light duty) diesel (AAD) power plant for a 3,000-pound passenger car. The study resulted in the definition of a revolutionary diesel engine with several novel features. A 3,000-pound car with this engine is predicted to give 96.3, 72.2, and 78.8 MPG in highway, city, and combined highway-city driving, respectively. This compares with current diesel powered cars yielding 41.7, 35.0, and 37.7 MPG. The time for 0-60 MPH acceleration is 13.9 sec. compared to the baseline of 15.2 sec. Four technology areas were identified as crucial in bringing this concept to fruition. They are: (1) part-load preheating, (2) positive displacement compounding, (3) spark assisted diesel combustion system, and (4) piston development for adiabatic, oilless diesel engine. Marketing and planning studies indicate that an aggressive program with significant commitment could result in a production car in 10 years from the date of commencement.
The potential of utilizing fluidized bed heat exchangers in place of conventional counter-flow heat exchangers for heat recovery from adiabatic diesel engine exhaust gas streams was studied. Fluidized bed heat recovery systems were evaluated in three different heavy duty transport applications: (1) heavy duty diesel truck; (2) diesel locomotives; and (3) diesel marine pushboat. The three applications are characterized by differences in overall power output and annual utilization. For each application, the exhaust gas source is a turbocharged-adiabatic diesel core. Representative subposed exhaust gas heat utilization power cycles were selected for conceptual design efforts including design layouts and performance estimates for the fluidized bed heat recovery heat exchangers. The selected power cycles were: organic rankine with RC-1 working fluid, turbocompound power turbine with steam injection, and stirling engine. Fuel economy improvement predictions are used in conjunction with capital cost estimates and fuel price data to determine payback times for the various cases.
Commercial use of thermal barrier coatings in diesel engines began in the mid 70's by Dr,. Ingard Kvernes at the Central Institute for Industrial Research in Oslo, Norway. Dr. Kvernes attributed attack on diesel engine valves and piston crowns encountered in marine diesel engines in Norwegian ships as hot-corrosion attributed to a reduced quality of residual fuel. His solution was to coat these components to reduce metal temperature below the threshold of aggressive hot-corrosion and also to provide protection. The Department of Energy has supported thermal barrier coating development for diesel engine applications. In the Clean Diesel - 50 Percent Efficient (CD-50) engine for the year 2000, thermal barrier coatings will be used on piston crowns and possibly other components. The primary purpose of the thermal barrier coatings will be to reduce thermal fatigue as the engine peak cylinder pressure will nearly be doubled. As the coatings result in higher available energy in the exhaust gas, efficiency gains are achieved through use of this energy by turbochargers, turbocompounding or thermoelectric generators.
Air-atomizing, splash-groove injectors were shown to improve primary-zone fuel spreading and reduce combustor exhaust emissions for Jet A and diesel number 2 fuels. With Jet A fuel large-orifice, splash-groove injectors the oxides-of-nitrogen emission index was reduced, but emissions of carbon monoxide, unburned hydrocarbons, or smoke were unaffected. Small-orifice, splash-groove injectors did not reduce oxides of nitrogen, but reduced the smoke number and carbon monoxide and unburned-hydrocarbon emission indices. With diesel number 2 fuel, the small-orifice, splash-groove injectors reduced oxides of nitrogen by 19 percent, smoke number by 28 percent, carbon monoxide by 75 percent, and unburned hydrocarbons by 50 percent. Smoke number and unburned hydrocarbons were twice as high with diesel number 2 as with Jet A fuel. Combustor blowout limits were similar for diesel number 2 and Jet A fuels.
The effect of fuel properties on exhaust emissions and blowout limits of a high-pressure combustor segment is evaluated using a splash-groove air-atomizing fuel injector and a pressure-atomizing simplex fuel nozzle to burn both diesel number 2 and Jet A fuels. Exhaust emissions and blowout data are obtained and compared on the basis of the aromatic content and volatility of the two fuels. Exhaust smoke number and emission indices for oxides of nitrogen, carbon monoxide, and unburned hydrocarbons are determined for comparison. As compared to the pressure-atomizing nozzle, the air-atomizing nozzle is found to reduce nitrogen oxides by 20%, smoke number by 30%, carbon monoxide by 70%, and unburned hydrocarbons by 50% when used with diesel number 2 fuel. The higher concentration of aromatics and lower volatility of diesel number 2 fuel as compared to Jet A fuel appears to have the most detrimental effect on exhaust emissions. Smoke number and unburned hydrocarbons are twice as high with diesel number 2 as with Jet A fuel.
An understanding of delamination mechanisms in thermal barrier coatings has been developed for diesel applications through nondestructive evaluation, structural analysis modeling and engine evaluation of various thermal barrier coatings. This knowledge has resulted in improved thermal barrier coatings which survive abusive cyclic fatigue tests in high output diesel engines. Significant efforts are still required to improve the plasma spray processing capability and the economics for complex geometry diesel engine components. Data obtained from advanced diesel engines on the effect of thermal barrier coatings on engine fuel economy and emission has not been encouraging. Although the underlying metal component temperatures have been reduced through the use of thermal barrier coating, engine efficiency and emission trends have not been promising.
In-cylinder components and tribological system concepts were designed, fabricated and tested at conditions anticipated for a 55% thermal efficiency heavy duty diesel engine for the year 2000 and beyond. A Cummins L10 single cylinder research engine was used to evaluate a spherical joint piston and connecting rod with 19.3 MPa (2800 psi) peak cylinder pressure capability, a thermal fatigue resistant insulated cylinder head, radial combustion seal cylinder liners, a highly compliant steel top compression ring, a variable geometry turbocharger, and a microwave heated particulate trap. Components successfully demonstrated in the final test included spherical joint connecting rod with a fiber reinforced piston, high conformability steel top rings with wear resistant coatings, ceramic exhaust ports with strategic oil cooling and radial combustion seal cylinder liner with cooling jacket transfer fins. A Cummins 6B diesel was used to develop the analytical methods, materials, manufacturing technology and engine components for lighter weight diesel engines without sacrificing performance or durability. A 6B diesel engine was built and tested to calibrate analytical models for the aluminum cylinder head and aluminum block.
A system is provided for operating a solid oxide fuel cell generator on diesel fuel. The system includes a hydrodesulfurizer which reduces the sulfur content of commercial and military grade diesel fuel to an acceptable level. Hydrogen which has been previously separated from the process stream is mixed with diesel fuel at low pressure. The diesel/hydrogen mixture is then pressurized and introduced into the hydrodesulfurizer. The hydrodesulfurizer comprises a metal oxide such as ZnO which reacts with hydrogen sulfide in the presence of a metal catalyst to form a metal sulfide and water. After desulfurization, the diesel fuel is reformed and delivered to a hydrogen separator which removes most of the hydrogen from the reformed fuel prior to introduction into a solid oxide fuel cell generator. The separated hydrogen is then selectively delivered to the diesel/hydrogen mixer or to a hydrogen storage unit. The hydrogen storage unit preferably comprises a metal hydride which stores hydrogen in solid form at low pressure. Hydrogen may be discharged from the metal hydride to the diesel/hydrogen mixture at low pressure upon demand, particularly during start-up and shut-down of the system.
The thorough investigation of a Dorner four-cylinder, four-stroke-cycle Diesel engine with mechanical injection led me to investigate more thoroughly the operation of the Diesel as a vehicle engine. Aside from the obvious need of reliability of functioning, a high rotative speed, light weight and economy in heat consumption per horsepower are also indispensable requirements.
The feasibility of converting a spark ignition aircraft engine to the diesel cycle was investigated. Procedures necessary for converting a single cylinder GTS10-520 are described as well as a single cylinder diesel engine test program. The modification of the engine for the hot port cooling concept is discussed. A digital computer graphics simulation of a twin engine aircraft incorporating the diesel engine and Hot Fort concept is presented showing some potential gains in aircraft performance. Sample results of the computer program used in the simulation are included.