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The work focuses on studying ethanol spray behavior injected directly inside a spark ignited internal combustion engine in the compression stroke. An experimental procedure for measuring spray penetration and spray overall cone angle produced by a multi-hole direct injector was developed by means of computational codes written in Matlab environment for working with images of spray injections and to acquire calculated results in an automatic way. The shadowgraph technique with back continuous illumination associated with a high speed recording image process was used in a single cylinder optical research engine for acquiring images of Brazilian ethanol fuel injected at 120° before the top dead center of compression stroke. The process of spray injections occurred with engine speeds of 1000 rpm, 2000 rpm and 3000 rpm. The results showed that spray penetrations decrease and spray cone angle increase when the engine speed is raised.

The growing demand for more efficient and less polluting engines has lead the scientific community to further develop the road map engine technologies, including direct fuel injection. Direct injection research demands the investigation of spray formation and its characteristics. The present work performs the characterization of the macroscopic parameters of ethanol sprays (E100) produced with a fuel gauge pressure of 80 bar and gauge back pressures of 0, 5 and 10 bar. The sprays analysis was performed using high speed filming by means of Shadowgraph technique. Computational routines of matrix analysis were applied to measure the spray cone angles, penetration and penetration rate. The spray visualization demanded an experimental apparatus composed of a pressurized cylinder with nitrogen, a fuel tank as pressure vessel, an injection driver equipped with a peak and hold module controlled by a MoteC M84, a Phantom V7.3 high speed camera and LEDs for illumination.

The trends in the development of spark ignition engines leads to the adoption of lean mixtures in the combustion chamber. Torch ignition systems have potential to reduce simultaneously the NOx and CO emissions, while keeping the fuel conversion efficiency at a high level. This study aims to design and analyze a torch ignition system running with ethanol on lean homogeneous charge, adapted to an Otto cycle single-cylinder engine with optical visualization. The main objective is to achieve combustion stability under lean burn operation and to expand the flammability limit for increasing engine efficiency by means of redesigning the ignition system adapting a pre-chamber to the main combustion chamber. Experiments were conducted at constant speed (1000 rpm) using ethanol (E100) as fuel, for a wide range of injection, ignition and mixture formation parameters. Specific fuel consumption and combustion stability were evaluated at each excess air ratio.

The Stratified Torch Ignition (STI) engine is capable of operating with lean mixture and low cyclic variability. These characteristic significantly decreases fuel consumption and emission levels. In the STI engine the combustion starts at a pre-combustion chamber where a stoichiometric mixture is ignited by an electrical spark. Pressure increase in the pre-combustion chamber push the combustion jet flames through a calibrated nozzle to be precisely targeted into the main chamber. These combustion jet flames endowed with high thermal and kinetic energy assures a fast and stable combustion of a lean mixture formed at the main chamber. A STI prototype were built and tested. The main combustion parameters were obtained from the in-cylinder pressure measured during the experiments. A combustion analysis is carried out to explain the significant improvement of the STI engine in regard to the baseline engine which was used as workhorse for the prototype engine construction.

The emission of nitric oxide (NOx) is the most difficult to limit among numerous harmful exhaust gas components. The NOX emission of internal combustion engines is mainly NO, but it will be oxidized into NO2 quickly after entering the air. NO is formed inside the combustion chamber in post-flame combustion by the oxidation of nitrogen from the air in conditions that are dependent on the chemical composition of the mixture, temperature and pressure. The correlation between NO emissions and temperature in the combustion chamber is a result of the endothermic nature of these reactions and can be described by extended Zeldovich Mechanism. The stratified torch ignition engine is able to run with lean mixture and low cyclic variability. Due to lean operation, the in-cylinder temperature of the STI engine is significantly lower than the conventional spark ignited one. This fact lead to a substantial reduction in NOx specific emission.

Global climate change and an increasing energy demand are driving the scientific community to further advance internal combustion engine technology. Invented by Sr. Henry Ricardo in 1918 the torch ignition system was able to significantly decrease engine’s fuel consumption and emission levels. Since the late 70s, soon after the Compound Vortex Controlled Combustion (CVCC) created by Honda, the torch ignition system R&D almost ceased due to the issues encountered by very complex and costly mechanic control systems that time. This work presents a stratified torch ignition prototype endowed with a sophisticated electronic control systems and components such as electro-injectors from direct injection systems placed on the pre-combustion chamber. The torch ignition prototype was tested and its performance are presented and compared with the baseline engine, which was used as a workhorse for the prototype engine construction.

A global effort has been made by the scientific community to promote significant reduction in vehicle engine out-emission. To comply with this goal a stratified torch ignition (STI) engine is built from a commercial existing baseline engine. In this system, combustion starts in a pre-combustion chamber, where the pressure increase pushes the combustion jet flames through calibrated nozzles to be precisely targeted into the main chamber. These combustion jet flames are endowed with high thermal and kinetic energy, being able to generate a stable lean combustion process. The high kinetic and thermal energy of the combustion jet flame results from the load stratification. The engine out-emissions of CO, HC and CO2 of the STI engine are presented, analyzed and compared with the baseline engine. The STI engine showed a significant decrease in the specific emissions of CO and CO2.