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Diesel engines were tested to determine if they are influenced by the presence of electrostatic and magnetic fields. Field forces were applied in a variety of configurations including pretreatment of the fuel and air, however, no affect on engine performance was observed.
Oxides of nitrogen in the form of nitric oxide (NO) and nitrogen dioxide (NO 2 ) commonly referred to as NOx, is one of the two chemical precursors that lead to ground-level ozone, a ubiquitous air pollutant in urban areas. A major source of NOx is generated by equipment and vehicles powered by diesel engines, which have a combustion exhaust that contains NOx in the presence of excess O 2 . Vehicular emission control catalysts are ineffective in eliminating CO, hydrocarbons, and NO x during engine cold-start when exhaust temperatures are below 200°C. The objective of the project was to develop and demonstrate a multi-functional, catalyzed trap that enables vehicles with advanced combustion strategies to meet Tier 3 emissions standards while achieving the 150 °C challenge for sustained co-oxidation of HCs and CO and ≥90% NO trapping and release during warmup. Specifically, the multi-functional Lean HC+NOx (LHCNT) was developed for application in the exhaust aftertreatment of conventional diesel engines and engines having low temperature combustion (LTC) regimes. Activities included the design and synthesis of adsorbents and catalysts, screening and evaluation. Passive NOx absorbers (PNA), hydrocarbon (HC) traps, and oxidation catalysts (OC) were evaluated for use in series or as integrated devices. Predictive tools were developed utilizing the characterization and analysis of these materials, and an emission system was designed and optimized utilizing the catalyst systems. Microkinetic models were developed for the PNA for the simple NO-only feed and complex feed containing CO, H 2 , and model hydrocarbons (ethylene and dodecane). A first-principles, mechanistic-based model of the PNA was developed which utilized molecular-scale estimates (density functional theory) of energy barriers, mechanistic-based kinetics and realistic treatments of the flow and transport processes. Two new oxidation catalysts were developed (PdCu alloy, mixed copper-ceria-cobalt oxide), both of which significantly lessened the detrimental inhibition by CO on hydrocarbon and NO oxidation. A method for lessening the detrimental impact of CO on PNA activity was developed that involves use of an oxidation catalyst upstream of the PNA. The SwRI Ectolab TM burner system was applied to evaluate the baseline PNA material and confirmed performance comparable to the benchflow PNA studies using simulated exhaust. Spatially-resolved mass spectrometry (SpaciMS) was used to measure the transient spatial profiles of reacting species spanning the length of a three-function LHCNT containing PNA, HCT, and OC. The findings from this study provide diesel vehicle and catalyst companies valuable information to develop more cost effective emission control catalysts which helps to expand the use of more fuel efficient diesel power. The fundamental modeling and experimental tools and findings from this project can be applied to catalyst technologies used in the energy and chemical industries. The project led to 14 publications in the peer-reviewed literature with 2 additional currently under review. Finally, the project also led to training of several doctoral students who were placed in research jobs in industry and academia. Specifically, Mugdha Ambast (UH) has joined Cummins, Kevin Gu (UVa) has joined GM, and Abhay Gupta (UH) is to join Caterpillar.
Oxides of nitrogen in the form of nitric oxide (NO) and nitrogen dioxide (NO 2 ) commonly referred to as NOx, is one of the two chemical precursors that lead to ground-level ozone, a ubiquitous air pollutant in urban areas. A major source of NOx is generated by equipment and vehicles powered by diesel engines, which have a combustion exhaust that contains NOx in the presence of excess O 2 . Vehicular emission control catalysts are ineffective in eliminating CO, hydrocarbons, and NOx during engine cold-start when exhaust temperatures are below 200°C. The objective of the project was to develop and demonstrate a multi-functional, catalyzed trap that enables vehicles with advanced combustion strategies to meet Tier 3 emissions standards while achieving the 150 °C challenge for sustained co-oxidation of HCs and CO and ≥90% NO trapping and release during warmup. Specifically, the multi-functional Lean HC+NOx (LHCNT) was developed for application in the exhaust aftertreatment of conventional diesel engines and engines having low temperature combustion (LTC) regimes. Activities included the design and synthesis of adsorbents and catalysts, screening and evaluation. Passive NOx absorbers (PNA), hydrocarbon (HC) traps, and oxidation catalysts (OC) were evaluated for use in series or as integrated devices. Predictive tools were developed utilizing the characterization and analysis of these materials, and an emission system was designed and optimized utilizing the catalyst systems. Microkinetic models were developed for the PNA for the simple NO-only feed and complex feed containing CO, H 2 , and model hydrocarbons (ethylene and dodecane). A first-principles, mechanistic-based model of the PNA was developed which utilized molecular-scale estimates (density functional theory) of energy barriers, mechanistic-based kinetics and realistic treatments of the flow and transport processes. Two new oxidation catalysts were developed (PdCu alloy, mixed copper-ceria-cobalt oxide), both of which significantly lessened the detrimental inhibition by CO on hydrocarbon and NO oxidation. A method for lessening the detrimental impact of CO on PNA activity was developed that involves use of an oxidation catalyst upstream of the PNA. The SwRI Ectolab TM burner system was applied to evaluate the baseline PNA material and confirmed performance comparable to the benchflow PNA studies using simulated exhaust. Spatially-resolved mass spectrometry (SpaciMS) was used to measure the transient spatial profiles of reacting species spanning the length of a three-function LHCNT containing PNA, HCT, and OC. The findings from this study provide diesel vehicle and catalyst companies valuable information to develop more cost effective emission control catalysts which helps to expand the use of more fuel efficient diesel power. The fundamental modeling and experimental tools and findings from this project can be applied to catalyst technologies used in the energy and chemical industries. The project led to 14 publications in the peer-reviewed literature with 2 additional currently under review. Finally, the project also led to training of several doctoral students who were placed in research jobs in industry and academia. Specifically, Mugdha Ambast (UH) has joined Cummins, Kevin Gu (UVa) has joined GM, and Abhay Gupta (UH) is to join Caterpillar.
Combustion technology and its environmental concerns are being considered with increasing attention, not only for global-scale effects, but also for toxicological implications, particularly in the lift conditions of traffic-congested areas and industrial sites. Majority combustion by-products (CO, NO(sub x)) and unburned hydrocarbons (HC), are already subject to increasingly severe regulations; however other, non-regulated minority species, mainly soot and heavy aromatic molecules, involve higher health risks, as they are suspected to be agents of serious pathologies and even mutagenic effects. This is but one of the reasons why much research work is being carried out worldwide on the physical properties of these substances. Correspondingly, the need arises to detect their presence in urban environments, with as high a sensitivity as is required by their low concentrations, proper time- and space-resolutions, and 'real-time' capabilities. Lidar techniques are excellent candidates to this purpose, although severe constraints limit their applicability, eye-safety problems and aerosol Mie scattering uncertainties above all. At CNR's Istituto Motori in Napels, a Lidar-like diagnostic system is being developed, aimed primarily at monitoring the dynamic behavior of internal combustion engines, particularly diesel exhausts, and at exploring the feasibility of a so-called 'Downtown Lidar'.
Heavy-Duty diesel engine manufacturers are continuously in pursuit of simple and low-cost technologies that can reduce emissions. Ducted fuel injection (DFI) and Cooled Spray (CS) technologies are two technologies that continue to show promise for significant particulate emissions reductions. These technologies represent a breakthrough in diesel engine combustion from the potential of nearly sootless diesel combustion. This can provide a significant decrease in harmful PM emissions and may enable further system optimization for reduced NOx emissions and increased efficiency. Combustion vessel experiments and engine demonstrations at Sandia, together with the large bore engine tests performed by Wabtec show that this technology may be applicable to heavy duty diesel engines across a wide range of engine sizes and speeds representing the majority of off-road diesel engines. However, very little is known about the ideal geometry, scaling properties or effectiveness of these technologies over the engine operating map. This project will address those uncertainties through a series of experiments performed in an optical and a metal single-cylinder engine.
The combustion chamber of a single-cylinder, direct-injected diesel engine was insulated with ceramic coatings to determine the effect of low heat rejection (LHR) operation on engine performance, emissions, and combustion. In comparison to the baseline cooled engine, the LHR engine had lower thermal efficiency, with higher smoke, particulate, and full load carbon monoxide emissions. The unburned hydrocarbon emissions were reduced across the load range. The nitrous oxide emissions increased at some part-load conditions and were reduced slightly at full loads. The poor LHR engine performance was attributed to degraded combustion characterized by less premixed burning, lower heat release rates, and longer combustion duration compared to the baseline cooled engine.
Real driving emission (RDE) test conducted in sub-zero temperature conditions has been acting as a severe emission regulation over the existing test methods for diesel engines. In order to cope with this tightened regulation, many studies have been conducted to interpret the factors causing the deteriorated diesel engine combustion in cold operation conditions. The deteriorated fuel injection performance has been regarded as one of the key contributing factors but the governing mechanisms are not thoroughly understood so far. This study aims to provide a comprehensive understanding of the effects of fuel temperature including sub-zero conditions on fuel injection performance by measuring the transient needle motion and injection velocity of a diesel injector using synchrotron X-ray imaging techniques. Here, the factors causing the deteriorated injector performance and their contributions are discussed thoroughly based on the results. The results showed that the injection duration was shortened as the fuel temperature decreased as a result of decreased needle opening speed and increased needle closing speed. The increase of fuel viscosity and bulk modulus was discussed as the main factors associated with these results. The total injection mass was reduced by lowering the fuel temperature not only by the shortened injection duration but also by the decreased injection velocity. These factors exerted near equivalent contribution to the reduced injection mass at low fuel temperatures.
Caterpillar's approach to applying Thick Thermal Barrier Coatings (TTBC's) to diesel engine combustion chambers has been to use advanced modeling techniques to predict engine conditions and combine this information with fundamental property evaluation of TTBC systems to predict engine performance and TTBC stress states. Engine testing has been used to verify the predicted performance of the TTBC systems and provide information on failure mechanisms. The objective of Caterpillar's subcontract with ORNL is to advance the fundamental understanding of thick thermal barrier coating systems. Previous reviews of thermal barrier coating technology concluded that the current level of understanding of coating system behavior is inadequate and the lack of fundamental understanding may impede the application of TTBC's to diesel engines. Areas of TTBC technology being examined in this program include powder characteristics and chemistry; bond coat composition; coating design, microstructure, and thickness as they affect properties, durability, and reliability; and TTBC 'aging' effects (microstructural and property changes) under diesel engine operating conditions. Methods to evaluate the reliability and durability of TTBC's have been developed that attempt to understand the fundamental strength of TTBC's for particular stress states.
Caterpillar's approach to applying thick thermal barrier coatings (TTBC's) to diesel engine combustion chambers has been to use advanced modeling techniques to predict engine conditions and combine this information with fundamental property evaluation of TTBC systems to predict engine performance and TTBC stress states. Engine testing has been used to verify the predicted performance of the TTBC systems and provide information on failure mechanisms. The objective Caterpillar's program to date has been to advance the fundamental understanding of thick thermal barrier coating systems. Previous reviews of thermal barrier coating technology concluded that the current level of understanding of coating system behavior is inadequate and the lack of fundamental understanding may impeded the application of TTBC's to diesel engines. Areas of TTBC technology being examined in this program include powder characteristics and chemistry; bond coat composition; coating design, microstructure, and thickness as they affect properties, durability, and reliability; and TTBC 'aging' effects (microstructural and property changes) under diesel engine operating conditions. Methods to evaluate the reliability and durability of TTBC's have been developed that attempt to understand the fundamental strength of TTBC's for particular stress states.
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.
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.
Lewis' High Speed Research (HSR) Propulsion Project Office initiated a targeted outreach effort to market combustion-related technologies developed at Lewis for the next generation of supersonic civil transport vehicles. These combustion-related innovations range from emissions measurement and reduction technologies, to diagnostics, spray technologies, NOx and SOx reduction of burners, noise reduction, sensors, and fuel-injection technologies. The Ohio Aerospace Institute and the Great Lakes Industrial Technology Center joined forces to assist Lewis' HSR Office in this outreach activity. From a database of thousands of nonaerospace firms considered likely to be interested in Lewis' combustion and emission-related technologies, the outreach team selected 41 companies to contact. The selected companies represent oil-gas refineries, vehicle/parts suppliers, and manufacturers of residential furnaces, power turbines, nonautomobile engines, and diesel internal combustion engines.
A principal component analysis (PCA) and artificial neural network (ANN) based chemistry tabulation approach is presented. ANNs are used to map the thermochemical state onto a low-dimensional manifold consisting of five control variables that have been identified using PCA. Three canonical configurations are considered to train the PCA-ANN model: a series of homogeneous reactors, a nonpremixed flamelet, and a two-dimensional lifted flame. The performance of the model in predicting the thermochemical manifold of a spatially-developing turbulent jet flame in diesel engine thermochemical conditions is a priori evaluated using direct numerical simulation (DNS) data. The PCA-ANN approach is compared with a conventional tabulation approach (tabulation using ad hoc defined control variables and linear interpolation). The PCA-ANN model provides higher accuracy and requires several orders of magnitude less memory. Here, these observations indicate that the PCA-ANN model is superior for chemistry tabulation, especially for modelling complex chemistries that present multiple combustion modes as observed in diesel combustion. The performance of the PCA-ANN model is then compared to the optimal estimator, i.e. the conditional mean from the DNS. The results indicate that the PCA-ANN model gives high prediction accuracy, comparable to the optimal estimator, especially for major species and the thermophysical properties. Higher errors are observed for the minor species and reaction rate predictions when compared to the optimal estimator. It is shown that the prediction of minor species and reaction rates can be improved by using training data that exhibits a variation of parameters as observed in the turbulent flame. The output of the ANN is analysed to assess mass conservation. It is observed that the ANN incurs a mean absolute error of 0.05% in mass conservation. Furthermore, it is demonstrated that this error can be reduced by modifying the cost function of the ANN to penalise for deviation from mass conservation.
The opposed-piston two-stroke (OP2S) engine is a promising alternative powertrain technology that can offer thermal and brake efficiency improvements over conventional four-stroke engines. In recent years, many of the technical barriers of the OP2S engine architecture have been overcome. However, there is still a need for fundamental studies to provide insight into the scavenging and combustion processes of the OP2S engine to help design and operate the most efficient combustion systems using this engine architecture. This work aims to provide such insights by analyzing experimental data collected on a 3-cylinder, 4.9 L OP2S engine. Specifically, a scavenging efficiency sweep, an engine speed sweep with a constant scavenging efficiency, and an engine speed with a constant pressure differential across the engine were studied in detail. It was found that in diesel combustion, as the scavenging efficiency decreased, the increase in temperature of the hot, internal residuals resulted in a significant increase in heat transfer. Despite lowering pumping losses, this resulted in an overall decrease in brake efficiency. When the bulk thermodynamic conditions of two different scavenging efficiency cases (67% and 72%) were matched at port closing, the lower scavenging efficiency case still displayed a 0.7 percentage point penalty in net thermal efficiency and an increase in engine-out indicated specific emissions of NOx of 18% due to residual stratification in the cylinder. The results presented in this work show that the optimal breathing strategy in diesel combustion on an OP2S engine architecture is one that results in a slightly under-scavenged environment at port closing. However, the results did show potential system-level efficiency benefits of decreasing scavenging efficiency, meaning that alternative fuels and combustion strategies without the constraints of diesel combustion could achieve system-level efficiency gains by running significantly under-scavenged.
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In compressorless Diesel engines and in explosion engines using fuels with high boiling points it is difficult to effect a good combustion of the fuel mixture. This report presents different methods for calculating the size and uniformity of fuel droplets and mixtures.
This study presents a cradle-to-grave lifecycle analysis of energy use and greenhouse gas (GHG) emissions for U.S. medium- and heavy-duty vehicles across current (2021) and future (2035) technologies using the Greenhouse gas, Regulated Emissions, and Energy use in Technologies (GREET) model with industry-vetted assumptions. Results vary across vehicle classes but point to common trends: today, battery electric vehicles (BEVs) offer significant (10–60%) GHG emissions reduction compared to diesel internal combustion engine vehicles and are the lowest emissions option per ton-mile of cargo movement, followed by hydrogen fuel cell electric vehicles (FCEVs) (5–50% emissions reduction). Emissions savings depend largely on the duty cycle and fuel economy of the vehicle type. Future vehicle technology advancements result in comparable emission reductions associated with BEVs and hydrogen FCEVs. Weight-limited BEV trucks see less per-ton-mile emissions reduction due to the impact of battery weight on increased vehicle weight and reduced payload capacity. By 2035, improvements in vehicle efficiency can reduce emissions across all powertrains. However, very low levels of emissions require switching vehicles’ use-phase fuel/energy to low-carbon fuels and electricity. Renewable diesel, e-fuels, hydrogen produced from natural gas with carbon capture and storage or renewables, and use of low-carbon electricity can all achieve over 70% reduction in GHG emissions from the current day diesel-based internal combustion engine vehicle.