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In heavy duty diesel engines, the waste heat recovery has attracted much attention as one of the technologies to improve fuel economy further. In this study, the available energy of the waste heat from a high boosted 6-cylinder heavy duty diesel engine which is equipped with a high pressure loop EGR system (HPL-EGR system) and low pressure loop EGR system (LPL-EGR system) was evaluated based on the second law of thermodynamics. The maximum potential of the waste heat recovery for improvement in brake thermal efficiency and the effect of the Rankine combined cycle on fuel economy were estimated for each single-stage turbocharging system (single-stage system) and 2-stage turbocharging system (2-stage system).

According to previous papers on the combustion process in LHR diesel engines the combustion seems to deteriorate in LHR diesel engines. However it has been unclear whether this was caused by the high temperature gas or high temperature combustion chamber walls. This study was intended to investigate the effect of gas temperature on the rate of heat release through the heat release analysis and other measurements using a rapid compression-expansion machine. Experiments conducted at high gas temperatures which was achieved by the employment of oxygen-argon-helium mixture made it clear that the combustion at a high gas temperature condition deteriorated actually and this was probably due to the poorer mixing rate because of the increase in gas viscosity at a high gas temperature condition.

In heavy duty diesel engines, waste heat recovery systems are remarkable means for fuel consumption improvement. In this paper, Diesel-Rankine combined cycle which is combined diesel cycle with Rankine cycle is studied to clarify the quantitative potential of fuel consumption improvement with a high EGR rate and high boosted diesel engine. The high EGR rate and high boosted diesel engine of a single cylinder research engine was used and it reaches brake specific fuel consumption (BSFC) of 193.3 g/kWh at full load (BMEP=2.0MPa). And its exhaust temperature reaches 370 C. The exhaust gas temperature does not exceed 400 C in high boosted diesel engine even at full load operating condition because of a high excess air ratio. On the other hand, exhaust gas quantity is larger due to a high boosting.

Application of biodiesel fuel (BDF) to diesel engine is very effective to reduce CO2 emission, because bio-diesel is carbon neutral in principle. However, when biodiesel was applied to conventional diesel engines without modification for biodiesel, NOx emission was increased by the change in fuel characteristics. It is necessary to introduce some strategies into diesel engines fuelled with biodiesel for lower NOx emission than conventional diesel fuel case. The purpose of this study is to reveal that exhaust gas recirculation (EGR) is one of the solutions for the reduction of NOx emission and meeting the future emission regulations when using biodiesel. Neat Rapeseed oil methyl ester (RME) as a biodiesel (B100) was applied to diesel engines equipped with high pressure loop (HPL) EGR system and low pressure loop (LPL) EGR system. Cooled HPL EGR was increased during steady-state operations and JE05 transient mode tests.

The purpose of this study is to clarify the state of heat loss to the cylinder liner of the tested engine of which piston and cylinder head were previously measured. The authors' group developed an original measurement technique of instantaneous surface temperature at the cylinder liner wall using thin-film thermocouples. The temperature was measured at 36 points in total. The instantaneous heat flux was calculated by heat transfer analysis using measurement results of the temperature at the wall. As a result, the heat loss ratio to all combustion chamber walls is evaluated except the intake and exhaust valves.

Application of biodiesel fuel (BDF) to diesel engine is very effective to reduce CO2 emission, because biodiesel is carbon neutral in principle. However, biodiesels yield an increase in NOx emission from conventional diesel engine, compared with diesel fuel case. Therefore, some strategies are needed for meeting the future emission regulations when using biodiesel. In this study, rapeseed oil methyl ester (RME) was applied to diesel engine equipped with exhaust gas recirculation (EGR) system and NOx storage reduction (NSR) catalyst. NOx reduction rate of NSR catalyst was drastically decreased by using RME, even if injection quantity of RME for rich spike was enhanced. However, an increase in EGR rate could reduce NOx emission without the deterioration in smoke and PM emissions.

The biomass fuel is expected to solve the global warming due to a carbon neutral. A rapeseed oil methyl ester (RME) as biomass fuel was selected, and also a low sulfur diesel fuel is tested as reference fuel in this study. The experiments were carried out to improve diesel emissions and engine performance using high boost and high rate EGR system and a common rail injection system in a single cylinder engine. The diesel emissions and engine performance have been measured under the experimental conditions such as charging boost pressure from atmospheric pressure to 401.3kPa maximum and changing EGR rate from 0% to 40% maximum. RME contain about 10 mass % oxygen in the fuel molecule. Furthermore, RME does not contain aromatic hydrocarbons in the fuel. Due to these chemical properties, RME can be used at 40% high EGR condition.

The emission reduction from diesel engines is one of major issues in heavy duty diesel engines. Super Clean Diesel (SCD) Engine for heavy-duty trucks has also been researched and developed since 2002. The main specifications of the SCD Engine are six cylinders in-line and 10.5 l with a turbo-intercooled and cooled EGR system. The common rail system, of which the maximum injection pressure is 200 MPa, is adopted. The turbocharger is capable of increasing boost pressure up to 501.3 kPa. The EGR system consists of both a high-pressure loop (HP) EGR system and a low-pressure loop (LP) EGR system. The combination of these EGR systems reduces NOx and PM emissions effectively in both steady-state and transient conditions. The emissions of the SCD Engine reach NOx=0.2 g/kWh and PM=0.01 g/kWh with aftertreatment system. The adopted aftertreatment system includes a Lean NOx Trap (LNT) and Diesel Particulate Filter (DPF).

The bore scope system can visualize not only diesel combustion in the research engine but also in actual diesel combustion in a multi-cylinder engine. The experimental engine has 2.0-liter displacement and has an external supercharger with up to two times the boost pressure of the naturally aspirated engine condition. The video camera used for this study is nac GX-1. From observed data under the several experimental conditions such as increased injection pressures, swirl ratios, and EGR rates, the flame temperature and KL factor were obtained by two-color method analysis. The diesel combustion processes are understood well by analyzing high-speed movies of the diesel flame motion and its temperature. NOx and smoke are mutually related to maximum flame temperature even in an engine with low NOx emission and lean smoke. It is reconfirmed as necessary to maintain a maximum flame temperature of 2,000–2,200K to reduce emissions of NOx and smoke simultaneously.

Lean NOx trap (LNT) and Urea-SCR system are effective aftertreatment systems as NOx reduction device in diesel engines. On the other hand, DPF has already been developed as PM reduction device and it has been used in various vehicles. LNT can absorb and reduce NOx emission in wide range exhaust temperatures, from 150°C to 400°C, and the size of LNT component can be compact in comparison with Urea-SCR system because LNT uses the diesel fuel as a reducing agent and it is needless to install the reducing agent tank in the vehicle. In this study, authors have shown that the NOx conversion rate of LNT is high in the case of extremely low NOx concentration from the engine. Also, the effects of LNT and DPF were examined using the Super Clean Diesel (SCD) Engine, which has low NOx level before aftertreatment and has been finished as Japanese national project.

For reducing NOx emissions, EGR is effective, but an excessive EGR rate causes the deterioration of smoke emission. Here, we have defined the EGR rate before the smoke emission deterioration while the EGR rate is increasing as the limiting EGR rate. In this study, the high rate of EGR is demonstrated to reduce BSNOx. The adapted methods are a high fuel injection pressure such as 200 MPa, a high boost pressure as 451.3 kPa at 2 MPa BMEP, and the air intake port that maintains a high air flow rate so as to achieve low exhaust emissions. Furthermore, for withstanding 2 MPa BMEP of engine load and high boosting, a ductile cast iron (FCD) piston was used. As the final effect, the installations of the new air intake port increased the limiting EGR rate by 5%, and fuel injection pressure of 200 MPa raised the limiting EGR rate by an additional 5%. By the demonstration of increasing boost pressure to 450 kPa from 400 kPa, the limiting EGR rate was achieved to 50%.

Thermodynamic characteristics of premixed compression ignition combustions were clarified quantitatively by heat balance estimation. Heat balance was calculated from temperature, mole fractions of intake and exhaust gases, mass and properties of fuels. Heat balance estimation was conducted for three types of combustion; a conventional diesel combustion, a homogeneous charge compression ignition (HCCI) combustion; fuel is provided and mixed with air in an intake pipe in this case, and an extremely early injection type PREmixed lean DIesel Combustion (PREDIC). The results show that EGR should be applied for premixed compression ignition combustion to complete combustion at lower load conditions and to control ignition timing at higher load conditions. With an application of EGR, both HCCI and PREDIC showed low heat loss characteristics at lower load conditions up to 1/2 load.

Premixed lean Diesel Combustion (PREDIC) provides low NOx, however, it has some challenges associated with high HC emission, high fuel consumption and difficult timing control of compression ignition. To solve these problems, an impingement spray system with two injectors was tested to obtain positional controllability and larger volume of the air-fuel mixture formation in our previous study. The positional controllability means mainly the fuel mixture formation is the center of the cylinder with some space from the cylinder wall. The larger volume means the fuel mixture formation is leaner air-fuel mixture than that of free spray, which results in a possibility of higher thermal efficiency. Thus, the impingement spray system has a possibility of HC reduction and fuel consumption improvement in PREDIC.

HCCI (Homogeneous Charge Compression Ignition) combustion results in very low NOx emissions, however, it is not without problems. One of them is that the heavy load operation range is limited by knock, due to an exceptionally high heat release rate. Knock increases the heat loss to the cylinder walls and piston, reducing thermal efficiency. To help solve these problems, direct (in-cylinder) water injection has been suggested to lower the local temperatures that seem to cause knock in HCCI. Water injection was adapted in an HCCI engine fueled with DME and Propane. Results showed that the indicated thermal efficiency was improved by about 2% (λ = 3.0, NA), and the operation range was expanded from 460kPa to 700kPa (NA) maintaining a low NOx level.

Premixed Lean Diesel Combustion (PREDIC) has very low NOx combustion because of early injection timing, for example, at -120 degrees ATDC; however, it has some problems. One problem is that so much fuel spray reaches the cylinder wall, which causes high HC emission and high fuel consumption. The other problem is that compression ignition timing control is difficult due to the dependence on the in-cylinder temperature. To solve these problems, an impingement spray system with two nozzles is attempted to obtain the spray increasing at the center of the combustion chamber instantaneously. This impingement spray system has two nozzles, which are located diagonally. Two sprays, one injected from each side injector, impinge each other at the center of the cylinder to create an air-fuel mixture.That is,this impingement spray system creates the air-fuel mixture by using the penetration of both sides of the sprays instead of early timing injection.

One of the problems in HCCI combustion is a knocking in higher load conditions. It governs the high load limit, and it is suggested that the knock increases heat loss[1], because it breaks the thermal boundary layer. But it is not clear how much knock affects on heat loss in the HCCI combustion in various conditions, such as ignition timing and load. The motivation of this study is to clarify the ratio of heat loss caused by knock in HCCI engines. The heat loss from zero-dimensional calculations with modified heat transfer coefficient, which is considering the effect of knock by adding a term of cylinder pressure rising rate dp/dt, agreed well with the results from the thermodynamic analysis in various conditions. And the results show that it is possible to avoid heat loss by knock by controlling the ignition timing at appropriate timing after T.D.C. and it will be possible to expand the load range if knock can be avoided.

Regarding measurement of the flow rate of exhaust gas or intake air of engines with several instruments, the pulsating flow in systems causes the error in indicated flow values. Usually a buffer tank is employed for decreasing the pulse. However the tank is rather inconvenient. The authors have developed the named “Surge Tube”, which is composed of a thin silicone rubber film tube having a considerable thermal and mechanical durability. In the conditions near atmospheric pressure, the effective volume as a buffer tank is over 100 times the free real tube volume, without any change in dead volume. The static relations between the inner volume change and the pressure are the most important characteristics, depending on the diameter, thickness, volume, and hardness of the silicone rubber film. The dynamic characteristics of the Surge Tubes are shown as the static pressure configurations at the inlet and outlet of the Surge Tube.

This paper describes the experimental studies of turbocharged and intercooled diesel engines with particular emphasis on combustion characteristics following increase of boost pressure. Through these studies, it has become possible to determine the optimum air quantity for minimizing fuel consumption at each engine speed range under the restrictive conditions of NOx emission, exhaust smoke and maximum cylinder pressure. Discussed also is the lack of air quantity in the low engine speed range of high-boost turbocharged diesel engines. Various turbocharging systems to improve air quantity in this speed range are introduced herein. Practically the engine performance of conventional turbocharging, waste gate control turbocharging and variable geometry turbocharging are discussed from the viewpoint of torque recovery in the low engine speed range.

Reduction of exhaust emissions and BSFC was studied for high pressure, wide range, and high EGR rates in a Super-clean Diesel six-cylinder heavy duty engine. The GVW 25-ton vehicle has 10.52 L engine displacement, with maximum power of 300 kW and maximum torque of 1842 Nm. The engine is equipped with high-pressure fuel injection of a 200 MPa level common-rail system. A variable geometry turbocharger (VGT) was newly designed. The maximum pressure ratio of the compressor is about twice that of the previous design: 2.5. Additionally, wide range and a high EGR rate are achieved by high pressure-loop EGR (HP-EGR) and low pressure-loop EGR (LP-EGR) with described VGT and high-pressure fuel injection. The HP-EGR can reduce NOx concentrations in the exhaust pipe, but the high EGR rate worsens smoke. The HP-EGR system layout has an important shortcoming: it has great differences of the intake EGR gas amount into each cylinder, worsens smoke.

Reduction of exhaust emissions and BSFC has been studied using a high boost, a wide range and high-rate EGR in a Super Clean Diesel, six-cylinder heavy duty engine. In the previous single-turbocharging system, the turbocharger was selected to yield maximum torque and power. The selected turbocharger was designed for high boosting, with maximum pressure of about twice that of the current one, using a titanium compressor. However, an important issue arose in this system: avoidance of high boosting at low engine speed. A sequential and series turbo system was proposed to improve the torque at low engine speeds. This turbo system has two turbochargers of different sizes with variable geometry turbines. At low engine speed, the small turbocharger performs most of the work. At medium engine speed, the small turbocharger and large turbocharger mainly work in series.