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At least 19 records

Light Duty Engine Performance Characteristics with Dimethyl Ether and Propane

Here, this paper explores the performance characteristics of a compression ignition HYUNDAI 2.2L engine operating with Dimethyl Ether (DME). Test are carried out at three operating conditions that weigh heavily in the FTP75 certification cycle (1000rpm-12Nm, 1500rpm-50Nm, 2000rpm-100Nm). The engine features a high-pressure common rail fuel injection system designed to operate with liquified gases. The main component of the fuel system is a high-pressure pump that incorporates an electronic inlet metering valve commanded on a crank-angle base to control the rail pressure. The pump, which requires no pressure regulator, provides the flow needed to the injectors without flow returning to the inlet. This novel fueling system is leveraged in tests that are conducted to examine the impact of EGR, combustion phasing, injection pressure on efficiency and emissions. In addition, the impact of introducing 15% Propane by mass is examined. During the tests, the engine ECU is aided by an Engine Controller High Speed Oversight unit (ECHO) to provide combustion phasing control, improved cylinder-to-cylinder uniformity, and an effective optimization over the testing effort. The use of DME and Propane allowed for peak thermal efficiency of nearly 43%. These fuels enable significant carbon index (CI) reductions over the baseline Diesel fuel, with indications that 50% reduction in CO 2 over the Diesel engine are possible.

33 ADVANCED PROPULSION SYSTEMS↗

Mixing-Controlled Compression Ignition Combustion with Low-Lifecycle-CO 2 Fuels

Reducing lifecycle carbon-dioxide (CO 2 ) and toxic emissions via electrification or switching to carbon-free fuels is not currently feasible for many off-road, rail, and marine applications. This is due to factors including excessive cost, weight, or size of a battery of sufficient capacity to meet the application requirements, lack of infrastructure, insufficient time for recharging, demanding duty cycles, and severe ambient conditions. The guiding vision for the activities described herein is to enable rapid, cost-effective reductions of the environmental impacts of such applications by using improved, high efficiency engine combustion strategies with currently available and emerging low lifecycle-CO 2 fuels (LLCFs). This report summarizes progress toward achieving this vision in two project areas. The first is a Technology Commercialization Fund (TCF) project focused on facilitating the commercialization of ducted fuel injection (DFI) with LLCFs. The second is a more fundamental, Advanced Combustion Engines (ACE) research project focused on elucidating a new strategy called lean mixing-controlled combustion (LMCC) for use with emerging LLCFs.

33 ADVANCED PROPULSION SYSTEMS↗

Computational study of the ECN spray C via one-way coupling of internal nozzle flow and ensuing spray

Here, in this study, computational fluid dynamics simulations of the Engine Combustion Network Spray C injector were performed to investigate the effect of the internal nozzle flow on the development of the ensuing spray in automotive fuel injectors. A set of simulation best practices was first developed to achieve an accurate representation of the internal nozzle flow. Detailed, spatiotemporally defined information was extracted at the injector’s orifice exit and stored in maps that were subsequently employed to initialize a Lagrangian spray by means of a static, one-way coupling (OWC) approach. To highlight the impact of the in-nozzle flow on the spray, the OWC approach was compared with the conventional rate-of-injection (ROI) approach, for which the spray parcels are commonly initialized using a blob injection model. The results indicated that, using the ROI approach, considerable evaporation was observed within the plume in the near-nozzle region. On the other hand, the OWC approach showed evidence of evaporation farther downstream and at the plume periphery. The different behavior observed with the two approaches was mostly due to substantial differences in fuel mass distribution. The liquid fuel concentration predicted by the OWC approach matched well with X-ray tomography measurements of projected fuel mass per unit volume, in terms of both magnitude and distribution. In contrast, an unphysical distribution of fuel mass characterized by an extremely low liquid concentration was predicted by the ROI approach. In the far-field, the effect of the in-nozzle flow was found to be weaker as the spray penetrated and interacted with the ambient gas. In this region, the OWC and ROI approaches provided similar predictions of vapor penetration, spray morphology, and mixing-related characteristics.

33 ADVANCED PROPULSION SYSTEMS↗

Next-Cycle Optimal Fuel Control for Cycle-to-Cycle Variability Reduction in EGR-Diluted Combustion

In this simulation study, cycle-to-cycle fuel control was used to reduce CCV by injecting additional fuel in operating conditions with sporadic misfires and partial burns. An optimal control policy was proposed that utilizes 1) a physics-based model that tracks in-cylinder gas composition and 2) a one-step-ahead prediction of the combustion efficiency based on a kernel density estimator. The optimal solution, however, presents a tradeoff between the reduction in combustion CCV and the increase in fuel injection quantity required to stabilize the charge. Such a tradeoff can be ad- just by a single parameter embedded in the cost function.

Maldonado, BryanP. [Oak Ridge National Lab. (ORNL)↗

Co-optimization of fuel properties, combustion system geometry, and injection strategy for conventional diesel fuel

Here, studies have shown that fuel properties can impact an engine’s operation in several ways, including ignition delay, sooting tendency, mixture formation, and combustion temperature. In mixing-controlled compression ignition (MCCI) engines, the fuel system design and piston bowl geometry significantly affect combustion performance and emissions. Based on current information, it is difficult to draw conclusions about fuel property effects and sensitivities. The central fuel hypothesis approach used in the US Department of Energy Co-Optima program has worked well for spark ignition fuels: identifying critical fuel property ranges is sufficient to screen fuel blends that are expected to maximize efficiency and reduce pollutant emissions. However, for MCCI-relevant fuels, the information gained from past studies is not sufficient to build such a merit function or to allow for performing a similar screening of fuel blends. It is hypothesized that a co-optimization of a fuel’s physical and chemical properties, combustion system geometry, and injection strategy could leverage synergies between the effects of the fuel properties and geometries, resulting in improved performance over state-of-the-art. A machine learning–assisted unconstrained global optimization algorithm was used to explore a design space comprising 23 independent variables. The results show that physical property effects were minimal even for large variations in fuel properties, and the only interaction effect that was observed was the effect of varied fuel density parameters on fuel/air mixture formation. Nevertheless, these interactions were not sufficient in magnitude to significantly affect optimization results. Therefore, analysis of the results suggests that fuel physical properties cannot be leveraged in a co-optimization context to increase engine efficiency.

33 ADVANCED PROPULSION SYSTEMS↗

Mapping ammonia-diesel combustion on a single-cylinder 107 mm bore diesel engine retrofitted for ammonia port-fuel injection

Ammonia is garnering significant interest from the international maritime sector as an alternative fuel. It is attractive as a hydrogen carrier and as a fuel because it has a higher volumetric energy density compared with gaseous or liquid hydrogen, making it easier to store and transport without requiring high pressures or cryogenic storage. Ammonia has significant toxicity concerns, but safe handling procedures have already been established because it is one of the most widely produced chemicals worldwide for use as a fertilizer. Barriers to consuming NH 3 as a fuel in engines include (1) less favorable ignition energy and flame speed compared with conventional fuels; (2) emissions challenges, including potentially high NH 3 , NO X , and N 2 O emissions; and (3) fuel delivery and handling challenges. Although NH 3 has been used to fuel compression-ignition marine engines in limited demonstration projects, technical barriers still exist. The use of NH 3 as a fuel in smaller-bore, high-speed auxiliary engines for large vessels and for smaller inland and coastal marine applications remains unaddressed. This work investigates a late-injection diesel pilot ignition dual-fuel NH 3 strategy using a single-cylinder, high-speed Cummins four-stroke diesel engine platform with a 107 mm bore and 1.1 L displacement per cylinder. The engine was modified for port fuel injection of heated gaseous anhydrous NH 3 . The diesel fuel injection system and the combustion geometry were unmodified to represent a retrofit application, which would minimize additional hardware to maximize diesel fuel displacement with NH 3 . Furthermore, the results show the applicability of a late injection diesel pilot strategy to overcome the challenging fuel properties of NH 3 over the engine operating envelope. Mapping results focusing on emissions are presented, and comparisons are made to a conventional diesel combustion baseline.

Ship engines↗

Simultaneous Control of Unburned NH 3 and NO x Emissions From High Load Dual-Fuel Ammonia Operation on a High-Speed Diesel Engine Using a Cu-SCR System

Dual-fuel ammonia strategies are being investigated as a promising way to utilize NH 3 as an alternative fuel for internal combustion engines in the maritime sector. One of the remaining barriers to implementing dual-fuel NH 3 combustion strategies is understanding ways to minimize unburned NH 3 and nitrogen oxide (NO x ) emissions from these engines, both of which are elevated relative to a conventional diesel baseline. Selective catalytic reduction (SCR) systems are widely used for lean NO x emission controls for engines across transportation and stationary energy applications. SCR systems use a reducing agent, such as NH 3 , to react with NO x in the exhaust, converting it into nitrogen and water. Typically, NH 3 is injected into the exhaust as a urea solution. In dual-fuel NH 3 engines, where unburned NH 3 is present in the exhaust, an SCR system could be used to mitigate both NH 3 and NO x emissions. The presented work evaluates a commercial copper-zeolite SCR and ammonia slip catalyst system, designed for on-road diesel engine applications, for controlling unburned NH 3 and NO x emissions from a dual-fuel NH 3 combustion engine. The aftertreatment system was installed downstream of a single-cylinder four-stroke diesel engine that has been modified for dual-fuel ammonia use. Furthermore, the emissions were characterized by using a Fourier transform infrared spectrometer for both late- and early-injection diesel pilot strategies over three air–fuel equivalence ratios spanning from 1.6 to 1.0 at 1200 rpm and 12.6 bar IMEP g condition (with greater than 95% ammonia energy fraction). Initial findings indicate that the SCR achieves more than 99% NO x conversion with less than 50 ppm NH 3 slip at air–fuel equivalence ratios greater than 1.4 at the operating conditions investigated. However, these benefits are accompanied by additional N 2 O emissions that are formed over the Cu-SCR.

Catalysts↗

Core plasma fueling by fast inward particle transport after hydrogen pellet injection in Wendelstein 7-X

A large database of more than 1000 individual cryogenic hydrogen pellets injected into Wendelstein 7-X for plasma fueling was analyzed to improve the understanding of the three phases of the process: the ablation, deposition and transport of the pellet material. Kilohertz-sampled electron density and temperature measurements revealed a more complex drift behavior than predicted by numerical code simulation. It could be explained by the poloidal plasma E r x B- drift rotation, which plays a significant role in stellarators, but was not previously considered in pellet injection codes like HPI2. The drift results in a fast poloidal rotation of the pellet material around the plasma core, leading to an almost homogeneous deposition over the involved flux surfaces regardless of magnetic high and low field side injection geometry. Additionally, a novel fast inward directed transport mechanism (‘FIT-effect’) was observed. The effect occurs on timescales of tens of milliseconds and cannot be explained by neoclassical transport or diffusion. It might be linked to the turbulence pinch recently found in Wendelstein 7-X. When the FIT-effect occurs, the pellet particles are rapidly transferred from the deposition flux surfaces to the plasma core, causing the plasma density profile to peak, which is beneficial for confinement in Wendelstein 7-X. The large pellet injection database was statistical analyzed with regard to pellet and plasma parameters, which delivered some starting points towards developing an understanding of the physics behind the FIT-effect. The results indicate, that plasma core fueling via pellet injection is largely independent of the injection geometry in stellarators under certain conditions, reducing the technical complexity of the injection system.

Wendelstein 7-X↗

An analysis of alcohol compression ignition strategies on different engine platforms

Strategies that enable ignition of the low cetane alcohol fuels (methanol and ethanol) include intake heating (direct or via hot residual trapping), increased compression ratio (CR), multi-injection strategies, ignition enhancers, and active prechambers. The literature consistently shows alcohol compression ignition (CI) is more efficient than diesel at high loads irrespective of ignition strategy but shows contradictory results at low loads. To understand this, this work combines data from four different engine platforms ranging from a displaced volume of 0.4 to 2.1 L/cyl. using different alcohol CI ignition strategies. Using modeling to support experimental analysis, alcohol-specific efficiency penalties are highlighted to inform alcohol combustion system development. The alcohols’ lower energy density means more fuel must be injected near top dead center to achieve a given load, increasing the relative penalty of sensible/latent heating. Pilot injections help reduce this penalty. Intake heating incurs both a heat transfer penalty and a thermodynamic penalty due to a reduced ratio of specific heats during compression. A strategy that combines elevated CR, large pilot injections, and ignition enhancers can avoid this penalty. Alternatively, a prechamber strategy can achieve this without changing the CR, nor needing ignition enhancers in the fuel. At low loads, diesel burns in a partially premixed mode characterized by high burn rates and low heat losses, reducing alcohol-specific combustion benefits. Alcohol CI on the light-duty platform showed abnormally high heat transfer over diesel compared to other platforms, favoring a more premixed/partially premixed strategy despite a combustion efficiency tradeoff.

33 ADVANCED PROPULSION SYSTEMS↗

Investigating the Role of Accident Tolerant Cladding on Source Term Reduction for High-Burnup PWRs Using MELCOR

The use of accident tolerant fuel (ATF) cladding can increase coping times during and beyond design basis accidents. While such gains may be incremental, they provide a margin that can potentially be recovered to enable high-burnup (HBU) operation. Realizing such a margin requires demonstrating that the combination of HBU and ATF has not led to an overall increase in source term. This study investigates the influence of cladding technology (Zr-based, Cr-coated Zr, and FeCrAl) and fuel cycle length (18 and 24 months) on radiological dose at the boundary of the exclusion zone for a four-loop pressurized water reactor to investigate whether ATF claddings can provide such benefits. We analyze a recovered large break loss-of-coolant accident scenario to investigate the impact of transient timescale on the benefits of such coping time increases. The simulations have been performed using the MELCOR and MELCOR Accident Consequence Code System codes. For the cases analyzed, increased fuel cycle length did not necessarily increase radionuclide release and hydrogen generation, as these were found to be sensitive to the core power distribution. Similarly, off-site dose consequence is dominated by short-lived radionuclides that tend to saturate earlier in the burnup, so higher burnup operation did not necessarily increase the source term for the phenomena and transients analyzed here. Delays in recovery of the lowpressure safety injection system increase hydrogen production and radionuclide release, especially between 780 s and 1620 s, due to the nonlinear oxidation and core degradation behavior. Results show that Cr-coated Zr enhances safety by delaying heatup and gap release. Here, when uncertainty propagation on oxidation properties is considered, FeCrAl exhibits the lowest overall radionuclide release and off-site dose throughout the spectrum. However, while the considered “base model” performance is superior under delayed injection scenarios, upper-bound cases display hydrogen generation risk comparable to the Zr-based cladding.

Accident Tolerant Fuel↗

CarbonSAFE Phase II: Optimizing Alabama’s CO 2 Storage in Shelby County, Alabama (Project OASIS), Milestone M3 - Site Specific Drilling Report

The Phase II Storage Complex Feasibility project, entitled "Optimizing Alabama's CO 2 Storage in Shelby County, Alabama (Project OASIS)," is a part of the DOE/NETL's CarbonSAFE initiative. The Project is managed by the Southern States Energy Board (SSEB), and includes participation from Advanced Resources International, Inc. (ARI), Crescent Resource Innovation, Southern Company, Alabama A&M University, Auburn University, and Oklahoma State University. Project OASIS is working to establish the foundation for a commercial-scale geologic storage complex for CO 2 captured from Plant Gaston (home of the National Carbon Capture Center) and surrounding industrial sources of CO 2 located in Shelby County, Alabama. The Project objectives are: • Demonstrate that the subsurface saline formations at the storage complex can store commercial volumes of CO 2 safely and permanently. • Develop a comprehensive Community Benefits Plan. • Develop the infrastructure framework for a CO 2 storage hub. • Develop a rigorous risk registry and to conduct a comprehensive risk assessment. • Develop a monitoring plan. • Develop a comprehensive site characterization plan to support an Underground Injection Control Class VI Permit in a future Phase III program. • Evaluate the commercial viability of the project. Project OASIS is about 30 miles southeast of Birmingham, Alabama within a geologic province called the Valley and Ridge (Figure 1.1). The Valley and Ridge Province comprises a sequence of Paleozoic carbonate and clastic rocks that underwent structural deformation during the Alleghanian Orogeny. Storage prospects occur in relatively flat lying structural panels located between thrust faults. Available geologic studies related to hydrocarbon exploration suggest that Cambro-Ordovician carbonates and Cambrian clastic units offer multiple potential storage intervals, and that regional confining systems are present, such as the tectonically thickened Floyd-Parkwood Shale. The surface property is owned by a timber and land stewardship company, The Westervelt Company, Inc., who worked with the Project Team to select and prepare adequate sites for geologic assessment. The purpose of drilling the Westover Stratigraphic Test Well #2 was to collect geologic data to model the feasibility of commercial scale CO 2 injection and storage. This includes geological and geophysical evaluations, reservoir engineering analyses, and risk assessments.

20 FOSSIL-FUELED POWER PLANTS↗

Assessing Edge Localized Mode (ELM) Mitigation by Pellet Triggering in Smallest-Possible Affordable Robust Compact (SPARC) Low-Collisionality Discharges

Simulations of pellet edge-localized mode (ELM) triggering with the M3D-C1 code confirmed experimentally observed pellet mass thresholds in low-collisionality DIII-D discharges and predicted extremely large thresholds in ITER [A. Wingen et al, Nucl. Fusion 64, 066015(2024)]. The linear (static) and nonlinear (dynamic) workflows developed in this previous work are now applied to the SPARC tokamak. Multiple synthetic equilibria for the high-performance H-mode scenario are tested for MHD stability without pellets using the linear workflow and ELITE simulations; a stable one is identified. Pellets of various mass are injected along an inboard, near-midplane trajectory in the M3D-C1 simulation. No pellet mass threshold for ELM triggering can be found for realistic pellet masses, concluding that fueling from this injection location would not trigger ELMs. A poloidal scan of possible injection locations shows very high thresholds on the high-field side and reasonable thresholds on the low-field-side (LFS). Based on results of this work the location for a LFS injection was finalized in the SPARC design. For this LFS injection the pellet mass threshold is determined using the linear workflow, aligning well with the poloidal scan.

70 PLASMA PHYSICS AND FUSION TECHNOLOGY↗

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

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

De Ojeda, William [WM International Engineering, L↗

Assessing Edge Localized Mode (ELM) Mitigation by Pellet Triggering in Smallest-Possible Affordable Robust Compact (SPARC) Low-Collisionality Discharges

Simulations of pellet edge-localized mode (ELM) triggering with the M3D-C1 code confirmed experimentally observed pellet mass thresholds in low-collisionality DIII-D discharges and predicted extremely large thresholds in ITER. The linear (static) and nonlinear (dynamic) workflows developed in this previous work are now applied to the SPARC tokamak. Multiple synthetic equilibria for the high-performance H-mode scenario are tested for MHD stability without pellets using the linear workflow and ELITE simulations; a stable one is identified. Pellets of various mass are injected along an inboard, near-midplane trajectory in the M3D-C1 simulation. No pellet mass threshold for ELM triggering can be found for realistic pellet masses, concluding that fueling from this injection location would not trigger ELMs. A poloidal scan of possible injection locations shows very high thresholds on the high-field side and reasonable thresholds on the low-field-side (LFS). Based on results of this work the location for a LFS injection was finalized in the SPARC design. For this LFS injection the pellet mass threshold is determined using the linear workflow, aligning well with the poloidal scan.

70 PLASMA PHYSICS AND FUSION TECHNOLOGY↗

Examination of entrainment, combustibility, and heat transfer due to cell venting inside simplified battery energy storage enclosures

Battery energy storage systems (ESS) assembled of modules containing lithium-ion batteries can pose fire and explosion hazards during thermal runaway because vented gases may accumulate, combust, or escape enclosures. Here, we propose a prototypical configuration composed of the main components of an ESS rack, where modules are represented as rectangles within an enclosure and vent gas is injected steadily through the top of a module. This idealized geometry allows for exploration of how rack-level characteristics can influence smaller single-cell or module-level scales. Through this geometry, we conduct numerical simulations to understand how variations in the vent velocity, temperature, and vertical location affect entrainment rates, fraction of uncombusted fuel, rich-gas coverage, and heat flux to other modules. At lower vent velocities and vertical positions, buoyancy drives enough entrainment and mixing to react with most of the vent gases on the converging plenum. As jet momentum increases and/or buoyancy decreases via higher vent position in the rack, vent gases can propagate into and burn in the divergence plenum. Heat flux to the impinged module scales strongly with vent momentum and temperature, while heat transfer to upper modules peaks when flames in the diverging plenum reach the surface and declines when combustion is suppressed.

Computational fluid dynamics↗

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↗

Inference of Rock Flow and Mechanical Properties from Injection-Induced Microseismic Events During Geologic CO 2 Storage

Monitoring microseismic activities during CO 2 injection into geologic formations is important for ensuring the safety of the storage operations. The resulting data provide insight into the response of the storage formation to CO 2 injection and can be used to infer the underlying rock flow and mechanical properties. In this paper, assimilation of microseismic data is performed for dynamic characterization of the storage formation by using a stochastic simulation model to forecast the microseismic response of a geologic formation during CO 2 injection. Two modeling approaches are adopted to predict the space-time distribution of the injection-induced microseismicity. The first model is based on pore pressure relaxation assumption, while the second model uses coupled flow and geomechanics simulation to establish the complex physical relation between the storage formation properties and the corresponding microseismic responses during CO 2 injection. The stochastic predictive models in each case are used in ensemble data assimilation frameworks to estimate rock properties from the observed microseismic data. Two data assimilation methods are considered: (i) a new ensemble-based stochastic point process filter (EnPPF) that can directly integrate discrete microseismic events, and (ii) a variant of ensemble smoother, known as the ensemble smoother with multiple data assimilation (ES-MDA), which requires continuous representation of microseismic events for assimilation. The two methods are successfully applied to a geologically realistic model of the Farnsworth Field in Texas, with complex geologic flow units and interacting fault systems.

42 ENGINEERING↗