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SAE 2011 High Efficiency IC Engines Symposium - Session 1- Pathways to High Efficiency Presenter Rolf D. Reitz, Univ. of Wisconsin

EGR coolers are used in combustion engines to reduce NOx emissions. However, heat transfer in these coolers also results in thermophoresis-temperature-gradient driven motion of suspended particles towards cooler regions-which leads to significant soot deposition. Presenter Meisam Mehravaran

Diesel Dual Fuel, DDF, is a concept which promises the possibility to utilize CNG/biogas in a compression ignition engine maintaining a high compression ratio, made possible by the high knock resistance of methane, and the resulting benefits in thermal efficiency associated with Diesel combustion. Presenter Fredrik K�nigsson, AVL Sweden

Developing relatively cheap and widely available resources for heterogeneous solid catalyst synthesis is a promising approach for biodiesel fuel industry. Seashell which is essentially calcium carbonate can be used as a basic support for transesterification heterogeneous catalysts. In the present investigation, the alcoholysis of waste frying oil has been carried out using seashell-supported K3 PO4 as solid catalyst. Presenter Essam Oun Al-Zaini, PhD student, UNSW

Propane autogas, the world?s third most-used engine fuel, powers vehicles, transit buses, and now school buses. Blue Bird has recently launched the Next Generation Vision type C school bus, powered by a ROUSH CleanTech liquid propane autogas fuel system and a Ford 6.8L V10 engine. The bus reduces operating costs by up to 40%, greenhouse gas emissions by up to 24%, and maintains the factory horsepower, torque, and towing capacity ratings. Learn about how school districts are saving over $.30 / mile using this clean, domestically-produced fuel. Presenter Brian Carney, Roush CleanTech.

OBD requirements for aftertreatment system components require monitoring of the individual system components. One such component can be an NH3-SCR catalyst for NOx reduction. An OBD method that has been suggested is to generate positive or negative spikes in the inlet NH3 concentration, and monitor the outlet NOx transient response. A slow response indicates that the catalyst is maintaining its NH3 storage capacity, and therefore it is probably not degraded. A fast response indicates the catalyst has lost NH3 storage capacity, and may be degraded. The purpose of the work performed at Southwest Research Institute was to assess this approach for feasibility, effectiveness and practicality. The presentation will describe the work performed, results obtained, and implications for applying this method in test laboratory and real-world situations. Presenter Gordon J. Bartley, Southwest Research Institute

A combination of laboratory reactor measurements and vehicle FTP testing has been combined to demonstrate a method for diagnosing the formation of NO2 from a diesel oxidation catalyst (DOC). Using small cores from a production DOC and simulated diesel exhaust, the laboratory reactor experiments are used to support a model for DOC chemical reaction kinetics. The model we propose shows that the ability to produce NO2 is chemically linked to the ability of the catalyst to oxidize hydrocarbon (HC). For thermally damaged DOCs, loss of the HC oxidation function is simultaneous with loss of the NO2 production function. Since HC oxidation is the source of heat generated in the DOC under regeneration conditions, we conclude that a diagnostic of the DOC exotherm is able to detect the failure of the DOC to produce NO2. Vehicle emissions data from a 6.6 L Duramax HD pick-up with DOC of various levels of thermal degradation is provided to support the diagnostic concept.

The presentation describes technology developments and the integration of these technologies into new emission control systems. As in other years, the reader will find a wide range of topics from various parts of the world. This is reflective of the worldwide scope and effort to reduce diesel exhaust emissions. Topics include the integration of various diesel particulate matter (PM) and Nitrogen Oxide (NOx) technologies as well as sensors and other emissions related developments. Presenter Atsuo Kondo, NGK Insulators, Ltd.

The fatty acid methyl esters (FAME's) - in Europe mostly RME (Rapeseed methyl ester) - are used in several countries as alternative biogene Diesel fuels in various blending ratios with fossil fuels (Bxx). Questions often arise about the influences of these biocomponents on the modern exhaust aftertreatment systems and especially on the regeneration of Diesel particle filters (DPF). In the present work different regeneration procedures of DPF systems were investigated with biofuels B0, B20 & B100. The tested regeneration procedures were: passive regenerations: DOC + CSF; CSF alone, active regenerations: standstill burner; fuel injections & DOC. During each regeneration on-line measurements of regulated and unregulated emission components (nanoparticles & FTIR) were conducted. It can be stated that the increased portion of RME in fuel provokes longer time periods to charge the filter with soot.

The Pennsylvania State University is one of 16 North American universities that participated in the EcoCAR advanced vehicle technology competition (http://www.ecocarchallenge.org/). A series-hybrid-electric vehicle based on a General Motors crossover SUV platform has been designed, built and tested for this purpose. The powertrain features a 1.3 L turbodiesel engine running on a B20 fuel system, a 75kW generator directly coupled to the engine and advanced lithium-ion batteries. In this paper, the vehicle architecture and control strategy are detailed and performance predictions (e.g., acceleration, fuel consumption and emissions) are presented. This includes discussion of the development process that led to the selected designs. The predicted performance is compared with data obtained on a chassis dynamometer and during on-road measurements over specified drive cycles. Presenter Shawn Getty

The Hybrid Electric Vehicle Team of Virginia Tech participated in the three-year EcoCAR Advanced Vehicle Technology Competition organized by Argonne National Laboratory, and sponsored by General Motors and the U.S. Department of Energy. The team established goals for the design of a plug-in, range-extended hybrid electric vehicle that meets or exceeds the competition requirements for EcoCAR. The challenge involved designing a crossover SUV powertrain to reduce fuel consumption, petroleum energy use, regulated tailpipe emissions, and well-to-wheel greenhouse gas emissions. To interface with and control the hybrid powertrain, the team added a Hybrid Vehicle Supervisory Controller, which enacts a torque split control strategy. This paper builds on an earlier paper [1] that evaluated the petroleum energy use, criteria tailpipe emissions, and greenhouse gas emissions of the Virginia Tech EcoCAR vehicle and control strategy from the 2nd year of the competition.

The need for light-weighting of automotive structures has spurred on a tremendous amount of interest in and development of low cost carbon fiber composite materials and manufacturing. This presentation provides a description of the commercial carbon fiber concept compared to traditional aerospace and specialty carbon fiber products. A specific update is presented on the development and commercialization of new low cost carbon fiber based on lignin / PAN precursor technology. The second focus of the presentation is on carbon fiber composite manufacturing processes, including carbon SMC, RTM, prepregs, and thermoplastic processes. Advantages and disadvantages of these processes are discussed, especially related to low cost manufacturing. Presenter George Husman, Zoltek Companies Inc.

This paper reports solubility, diffusivity and permeability data for soy and rapeseed methyl esters in polyethylene together with comparisons with methyl oleate and linoleate. These data were used to discuss the reliability of predictive models for diffusion and solubility of additive type molecules into semi-crystalline thermoplastic polymers. Presenter Emmanuel Richaud

Who are the people who know the most about the buses in your fleet? They are most likely the operators and the servicing technicians. They are also the key people whose knowledge, level of training and attitude can determine the success or failure of new powertrain technologies. Training and recruitment of both need to be held to a higher standard than we have seen in the past. I will argue that even the culture of those involved in fleet operations needs to be changed. The bar for technical competence and product knowledge needs to be raised for operators and technicians. In return managers should find ways to include them as stakeholders, investing them with both additional responsibility and accountability. This will require greater access to training and recognition of achievement. Where are the busses stored and serviced? Most likely in an all-purpose state/county/municipal service facility servicing a variety of equipment.

A 2007 Cummins ISL 8.9L direct-injection common rail diesel engine rated at 272 kW (365 hp) was used to load the filter to 2.2 g/L and passively oxidize particulate matter (PM) within a 2007 OEM aftertreatment system consisting of a diesel oxidation catalyst (DOC) and catalyzed particulate filter (CPF). Having a better understanding of the passive NO2 oxidation kinetics of PM within the CPF allows for reducing the frequency of active regenerations (hydrocarbon injection) and the associated fuel penalties. Being able to model the passive oxidation of accumulated PM in the CPF is critical to creating accurate state estimation strategies. The MTU 1-D CPF model will be used to simulate data collected from this study to examine differences in the PM oxidation kinetics when soy methyl ester (SME) biodiesel is used as the source of fuel for the engine.

The development of PM and NOx reduction system with the combination of DOC included DPF and SCR catalyst in addition to the AOC sub-assembly for NH3 slip protection is described. DPF regeneration strategy and manual regeneration functionality are introduced with using ITH, HCI device on the EUI based EGR, VGT 12.3L diesel engine at the CVS full dilution tunnel test bench. With this system, PM and NOx emission regulation for JPNL was satisfied and DPF regeneration process under steady state condition and transient condition (JE05 mode) were successfully fulfilled. Manual regeneration process was also confirmed and HCI control strategy was validated against the heat loss during transient regeneration mode. Presenter Seung-il Moon

Manganese oxides show high catalytic activity for CO and HC oxidation without including platinum group metals (PGM). However, there are issues with both thermal stability and resistance to sulfur poisoning. We have studied perovskite-type YMnO3 (YMO) with the aim of simultaneously achieving both activity and durability. This paper describes the oxidation activity of PGM-free Ag/i-YMO, which is silver supported on improved-YMO (i-YMO). The Ag/i-YMO was obtained by the following two methods. First, Mn4+ ratio and specific surface area of YMO were increased by optimizing composition and preparation method. Second, the optimum amount of silver was supported on i-YMO. In model gas tests and engine bench tests, the Ag/i-YMO catalyst showed the same level of activity as that of the conventional Pt/?-Al2O3 (Pt = 3.0 g/L). In addition, there was no degradation with respect to either heat treatment (700°C, 90 h, air) or sulfur treatment (600°C to 200°C, total 60 h, 30 ppm SO2).

This paper reports results of an experimental investigation performed on a commercial diesel engine supplied with fuel blends having low cetane number to attain a simultaneous reduction in NOx and smoke emissions. Blends of 20% and 40% of n-butanol in conventional diesel fuel have been tested, comparing engine performance and emissions to diesel ones. Taking advantage of the fuel blend higher resistance to auto ignition, it was possible to extend the range in which a premixed combustion is achieved. This allowed to match the goal of a significant reduction in emissions without important penalties in fuel consumption. The experimental activity was carried on a turbocharged, water cooled, 4 cylinder common rail DI diesel engine. The engine equipment included an exhaust gas recirculation system controlled by an external driver, a piezo-quartz pressure transducer to detect the in-cylinder pressure signal and a current probe to acquire the energizing current to the injector.

Nitrous Oxide (N2O) is a greenhouse gas with a Global Warming Potential (GWP) of 298-310 [1,2] (298-310 times more potent than carbon dioxide (CO2)). As a result, any aftertreatment system that generates N2O must be well understood to be used effectively. Under low temperature conditions, N2O can be produced by Selective Catalytic Reduction (SCR) catalysts. The chemistry is reasonably well understood with N2O formed by the thermal decomposition of ammonium nitrate [3]. Ammonium nitrate and N2O form in oxides of nitrogen (NOx) gas mixtures that are high in nitrogen dioxide (NO2)[4]. This mechanism occurs at a relatively low temperature of about 200°C, and can be controlled by maintaining the nitric oxide (NO)/NO2 ratio above 1. However, N2O has also been observed at relatively high temperatures, in the region of 500°C.

Four-way, integrated, diesel emission control systems that combine selective catalytic reduction for NOx control with a continuously regenerating trap to remove diesel particulate matter were evaluated under real-world, on-road conditions. Tests were conducted using a semi-tractor with an emissions year 2000, 6-cylinder, 12 L, Volvo engine rated at 287 kW at 1800 rpm and 1964 N-m. The emission control system was certified for retrofit application on-highway trucks, model years 1994 through 2002, with 4-stroke, 186-373 kW (250-500 hp) heavy-duty diesel engines without exhaust gas recirculation. The evaluations were unique because the mobile laboratory platform enabled evaluation under real-world exhaust plume dilution conditions as opposed to laboratory dilution conditions. Real-time plume measurements for NOx, particle number concentration and size distribution were made and emission control performance was evaluated on-road.