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Complexity of the modern diesel engine has increased to meet the stringent future emission regulations especially for NO (nitrogen oxide) and PM (particulate matter). Air management system including exhaust gas recirculation (EGR), turbocharger and variable valve actuation (VVA) must be optimized of its design and control algorithm for combustion improvement coupled with precision control of fuel injection. As a matter of course, the optimization of aftertreatment system is extremely important for the exhaust emissions reduction. In addition, improvement of fuel consumption is very important from the standpoint of response to energy security and reduction of CO₂ (carbon dioxide) emission as the greenhouse gas. However an enormous amount of energy will be required to develop such kind of the complex engine system by conventional actual testing.

Single cylinder engine testing was carried out to clearly understand the test results of multi-cylinder engines reported by the Diesel WG in JCAP (Japan Clean Air Program) (1), (2), (3) and (4). In this tests, engine specifications such as fuel injection pressure, nozzle hole diameter, turbo-charging pressure, EGR rate, and fuel properties such as 1-, 2-, 3-ring aromatics content, n-,i-paraffins content, and T90 were parametrically changed and their influence on the emissions were studied. PM emission generally increased in each engine condition with increased aromatic contents and T90. In particular, multi ring aromatics brought about large increases in PM regardless of the engine conditions. The influence of fuel properties on NOx emission is smaller than the influence on PM emission. Some other fuels that have various side chain structures of 1-ring aromatics, normal paraffins only and various naphthene contents were also investigated.

An exhaust turbocharging system makes it possible to increase the brake mean effective pressure (BMEP) and lower emissions levels for a diesel engine while further improving the thermal efficiency. However, in order to meet future emission regulations, further reductions in NOx and particle matter (PM) emissions are necessary. In addition, the diesel engine should have further reductions in fuel consumption to reduce CO₂, which is one of the main greenhouse gases. Authors participated in a program for the comprehensive technological development of innovative, next-generation, low-pollution vehicles with the New Energy and Industrial Technology Development Organization (NEDO) from 2004 through 2008 in cooperation with the National Institute of Advanced Industrial Science and Technology (AIST). A low-emission and high-efficiency diesel engine system was developed to meet the target of NEDO project.

Previous research in our laboratory has shown that NOx emissions can be sharply reduced by PREDIC (PRE-mixed lean DIesel Combustion), in which fuel is injected very early in the compression process. However some problems still remain, such as higher fuel consumption, a lack of ignition timing control, and a large increase in THC and CO, compared to conventional diesel combustion. Appropriate mixture formation is necessary to solve these problems. In this paper, the influence of mixture formation on PREDIC was investigated. It was found that the pintle type injection nozzle was shown to be suitable for PREDIC, because it produced a comparatively uniform mixture in the combustion chamber and avoided collision of the fuel spray with the cylinder liner. Modeling by the KIVA-II software package was carried out to improve our understanding of the mixture formation process.

Typical DI diesel engines operate with fuel injection taking place within a range of about 30 crank angle degrees before top dead center, at the end of the compression stroke. When injection takes place far earlier, at the beginning of the compression stroke, another form of combustion occurs, which we termed PREmixed lean Diesel Combustion, or PREDIC. With PREDIC operation, self-ignition occurs near top dead center and NOx emissions are drastically lower. When ignition occurs, the fuel-air mixture is thought to be nearly homogeneous, with only slight heterogeneity. Appropriate fuel spray formation is very important for successful PREDIC operation. Using a single-zone NOx formation model, calculations showed that the mean excess air ratio in the PREDIC combustion zone was 1.87, which resulted in very low (20 ppm) NOx emissions. Conventional combustion at the same conditions resulted in a mean combustion zone excess air ratio of 0.88.

Low NOx combustion is possible by PREDIC (PREmixed lean DIesel Combustion) in which fuel is injected at a very early stage of the compression stroke and the combustion starts at near the top dead center by self-ignition. To simplify the phenomenon of the PREDIC process, the test engine was operated with gaseous fuels added to intake air to realize combustion of a perfectly homogeneous mixture. The rich limit was observed around λ=2.0∼2.4. This limit was determined by considering the increase in NOx, and the steep pressure rise. During high load operations is not only the ignition timing but also the combustion rate should be controlled. By comparing the homogeneous charge and direct injection case, the mixture heterogeneity could be found to have an influence on the ignition timing and combustion rate, the engine speed and injection timing also had an influenced on these.

Previous research in our laboratory has shown that NOx emissions can be sharply reduced by PREDIC (PRE-mixed lean DIesel Combustion), in which fuel is injected very early in the compression process. However some points of concern remained unsolved, such as a large increase in THC and CO, higher fuel consumption, and an operating region narrowly limited to partial loads, compared to conventional diesel operation. In this paper, the causes of PREDIC's problem areas were analyzed through engine performance tests and combustion observation with a single cylinder engine, through fuel spray observation with a high-pressure vessel, and through numerical modeling. Subsequently, measurable improvements were achieved on the basis of these analyses. As a result, the ignition and combustion processes were clarified in terms of PREDIC fuel-air mixture formation. Thus, THC and CO emissions could be decreased by adopting a pintle type injection nozzle, or a reduced top-land-crevice piston.