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A project has been undertaken to optimize the engine control software calibration of a modern heavy-duty diesel engine for operation with gas-to-liquids (GTL) diesel fuel, with the objective of developing an understanding of the scope for optimization with this fuel, which has different physical and combustion properties to that of conventional, crude-derived diesel. A data-driven, model-based calibration technique utilizing artificial neural networks was used to develop optimized transient and steady-state calibrations with both conventional diesel fuel, as well as neat GTL fuel. The engine control parameters that were optimized were injection timing, exhaust gas recirculation rate, rail pressure, and charge mass. The optimization aimed to minimize fuel consumption without deterioration in engine-out nitrogen oxide (NOx) and soot emissions. This paper reports on the calibration optimization methodology employed and the results achieved to date.

Regulatory standards on diesel engines emissions will decidedly become more restrictive in coming years. This has led to the development and implementation of alternative fuels. The objective of this paper is to evaluate the potential of Sasol Fischer-Tropsch (FT) diesel fuel to improve the reduction of emissions in a direct injection diesel engine with a high pressure common-rail injection system (HDI engine from PSA Peugeot-Citroën). In principle, FT diesel fuel shows significant advantages in reducing emissions over a standard diesel fuel due to its low aromaticity, high cetane rating and high H/C rating. Initial tests with two 406 HDI Euro 2 vehicles with standard calibration showed very favourable trends on exhaust emissions in comparaison with reference fuel (CEC RF73-A-93 type). Sasol FT diesel fuel gave significant improvement on specific fuel consumption, and decreased the HC, CO, CO2 and particulate emissions without degrading NOx emissions.

The Fischer-Tropsch (FT) process can be used to synthesize diesel fuels from a variety of energy sources, including coal, natural gas and biomass. Diesel fuels produced from the FT process are essentially sulfur-free, have very low aromatic content, and have excellent ignition characteristics. Because of these favorable attributes, FT diesel fuels may offer environmental benefits over transportation fuels derived from crude oil. Previous tests have shown that FT diesel fuel can be used in unmodified engines and have been shown to lower regulated emissions. Whereas exhaust emissions reductions from these previous studies have been impressive, this paper demonstrates that far greater exhaust emissions reductions are possible if the diesel engine is optimized to exploit the properties of the FT fuels. A Power Stroke 7.3 liter turbocharged diesel engine has been modified for use with FT diesel.

A Mercedes E320 CDI vehicle has been modified for more optimal operation on Gas-To-Liquids (GTL) diesel fuel, in order to demonstrate the extent of exhaust emission reductions which are enabled by the properties of this fuel. The engine hardware changes employed comprised the fitment of re-specified fuel injectors and the reduction of the compression ratio from 18:1 to 15:1, as well as a re-optimisation of the software calibration. The demonstration vehicle has achieved a NOx emission of less that 0.08 g/km in the NEDC test cycle, while all other regulated emissions still meet the Euro 4 limits, as well as those currently proposed for Euro 5. CO2 emissions and fuel consumption, were not degraded with the optimised engine. This was achieved whilst employing only cost-neutral engine modifications, and with the standard vehicle exhaust system (oxidation catalyst and diesel particulate filter) fitted.

The results of an optical investigation into the combustion characteristics of GTL (Gas-To-Liquids) diesel fuel are presented. The investigation was carried out using a high pressure, constant volume combustion chamber with optical access, fitted with a modern diesel injection system. Combustion images were captured under conditions which simulate those present in a diesel engine. A low sulphur diesel fuel meeting the European EN590 specification was used as a reference. Image capture and subsequent analysis was performed by means of an AVL Visioscope system which used the two-colour method to yield quantitative information regarding flame temperature and soot concentration. Conditions in the combustion chamber are preset by combusting a pre-charge to generate the necessary pressure, temperature, and residual gas fraction. This allowed the effect of varying oxygen concentration at the start of diesel combustion to be investigated.

In view of limited crude oil resources, alternative fuels for internal combustion engines are currently being intensively researched. Synthetic fuels from natural gas offer a promising interim option before the development of CO2-neutral fuels. Up to a certain degree, these fuels can be tailored to the demands of modern engines, thus allowing a concurrent optimization of both the engine and the fuel. This paper summarizes investigations of a Gas-To-Liquid (GTL) diesel fuel in a modern, post-EURO 4 compliant diesel engine. The focus of the investigations was on power output, emissions performance and fuel economy, as well as acoustic performance, in comparison to a commercial EU diesel fuel. The engine investigations were accompanied by injection laboratory studies in order to assist in the performance analyses.