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A program has been completed to evaluate ultra-low sulfur diesel fuels and passive diesel particulate filters (DPFs) in truck and bus fleets operating in southern California. The fuels, ECD and ECD-1, are produced by ARCO (a BP Company) and have less than 15 ppm sulfur content. Vehicles were retrofitted with two types of catalyzed DPFs, and operated on ultra-low sulfur diesel fuel for over one year. Exhaust emissions, fuel economy and operating cost data were collected for the test vehicles, and compared with baseline control vehicles. Regulated emissions are presented from two rounds of tests. The first round emissions tests were conducted shortly after the vehicles were retrofitted with the DPFs. The second round emissions tests were conducted following approximately one year of operation. Several of the vehicles retrofitted with DPFs accumulated well over 100,000 miles of operation between test rounds.

As connected and automated vehicle technologies emerge and proliferate, lower frequency vehicle trajectory data is becoming more widely available. In some cases, entire fleets are streaming position, speed, and telemetry at sample rates of less than 10 seconds. This presents opportunities to apply powertrain simulators such as the National Renewable Energy Laboratory’s Future Automotive Systems Technology Simulator to model how advanced powertrain technologies would perform in the real world. However, connected vehicle data tends to be available at lower temporal frequencies than the 1-10 Hz trajectories that have typically been used for powertrain simulation. Higher frequency data, typically used for simulation, is costly to collect and store and therefore is often limited in density and geography. This paper explores the suitability of lower frequency, high availability, connected vehicle data for detailed powertrain simulation.

Understanding in-use fleet operating behavior is of paramount importance when evaluating the potential of advanced/alternative vehicle technologies. Accurately characterizing real world vehicle operation assists in properly allocating advanced technologies, playing a role in determining initial payback period and return on investment. In addition, this information contributes to the design and deployment of future technologies as the result of increased awareness regarding tractive power requirements associated with typical operating behavior. In this presentation, the concept of vehicle duty cycles and their relation to advanced technologies will be presented and explored. Additionally, current research attempts to characterize school bus operation will be examined, and existing computational analysis and evaluation tools associated with these efforts discussed. Presenter Adam Duran, National Renewable Energy Laboratory

The combined anticipated trends of vehicle sharing (ride-hailing), automated control, and powertrain electrification are poised to disrupt the current paradigm of predominately owner-driven gasoline vehicles with low levels of utilization. Shared, automated, electric vehicle (SAEV) fleets offer the potential for lower cost and emissions and have garnered significant interest among the research community. While promising, unmanaged operation of these fleets may lead to unintended negative consequences. One potentially unintended consequence is a high quantity of SAEVs charging during peak demand hours on the electric grid, potentially increasing the required generation capacity. This research explores the flexibility associated with charging loads demanded by SAEV fleets in response to servicing personal mobility travel demands. Travel demand is synthesized in four major United States metropolitan areas: Detroit, MI; Austin, TX; Washington, DC; and Miami, FL.

The goal of this project was to demonstrate a low emissions, high efficiency heavy-duty on-highway natural gas engine. The emissions targets for this project are to demonstrate US 2010 emissions standards on the 13-mode steady state test. To meet this goal, a chemically correct combustion (stoichiometric) natural gas engine with exhaust gas recirculation (EGR) and a three way catalyst (TWC) was developed. In addition, a Sturman Industries, Inc. camless Hydraulic Valve Actuation (HVA) system was used to improve efficiency. A Volvo 11 liter diesel engine was converted to operate as a stoichiometric natural gas engine. Operating a natural gas engine with stoichiometric combustion allows for the effective use of a TWC, which can simultaneously oxidize hydrocarbons and carbon monoxide and reduce NOx. High conversion efficiencies are possible through proper control of air-fuel ratio.

The key hurdles to achieving wide consumer acceptance of battery electric vehicles (BEVs) are weather-dependent drive range, higher cost, and limited battery life. These translate into a strong need to reduce a significant energy drain and resulting drive range loss due to auxiliary electrical loads the predominant of which is the cabin thermal management load. Studies have shown that thermal sub-system loads can reduce the drive range by as much as 45% under ambient temperatures below −10 °C. Often, cabin heating relies purely on positive temperature coefficient (PTC) resistive heating, contributing to a significant range loss. Reducing this range loss may improve consumer acceptance of BEVs. The authors present a unified thermal management system (UTEMPRA) that satisfies diverse thermal and design needs of the auxiliary loads in BEVs.

Due to its high efficiency and superior durability the diesel engine is again becoming a prime candidate for future light-duty vehicle applications within the United States. While in Europe the overall diesel share exceeds 40%, the current diesel share in the U.S. is 1%. Despite the current situation and the very stringent Tier 2 emission standards, efforts are being made to introduce the diesel engine back into the U.S. market. In order to succeed, these vehicles have to comply with emissions standards over a 120,000 miles distance while maintaining their excellent fuel economy. The availability of technologies such as high-pressure common-rail fuel systems, low sulfur diesel fuel, NOx adsorber catalysts (NAC), and diesel particle filters (DPFs) allow the development of powertrain systems that have the potential to comply with the light-duty Tier 2 emission requirements. In support of this, the U.S.

Selected ferritic stainless steel sheets for exhaust applications were tested under thermo-mechanical fatigue (TMF) condition in the temperature range of 400-800 °C with partial constraint. Straight welded tubes were used as the testing coupons to withstand large compression without buckling, and to understand the effect of welding as well. Repeated tests confirmed the observed failure scenario for each material type. The hysteresis loop behaviors were also simulated using the mechanism-based integrated creep and fatigue theory (ICFT) model. Although more development work is needed, for quick material screening purpose this type of testing could be a very cost effective solution for materials and tube weld development for exhaust applications.

Strain controlled thermo-mechanical fatigue (TMF) tests were conducted on a high Silicon ductile cast iron (SiMo) as the baseline material and a similar SiMo cast iron with aluminum addition (SiMoAl). The much improved fatigue life with aluminum addition is analyzed using the integrated creep-fatigue theory (ICFT) in combination with the metallurgical analysis on the tested coupons. Addition of about 3 wt.% Aluminum significantly improved TMF life of the SiMo cast iron. The results are explained by elimination of brittleness at middle temperature range, the higher flow stress, lower creep rate and higher oxidation resistance from Al addition.

In this work, the influences of ethanol and iso-butanol blended with gasoline on engine-out and post three-way catalyst (TWC) particle size distribution and number concentration were studied using a General Motors (GM) 2.0L turbocharged spark ignition direct injection (SIDI) engine. The engine was operated using the production engine control unit (ECU) with a dynamometer controlling the engine speed and the accelerator pedal position controlling the engine load. A TSI Fast Mobility Particle Sizer (FMPS) spectrometer was used to measure the particle size distribution in the range from 5.6 to 560 nm with a sampling rate of 1 Hz. U.S. federal certification gasoline (E0), two ethanol-blended fuels (E10 and E20), and 11.7% iso-butanol blended fuel (BU12) were tested. Measurements were conducted at 10 selected steady-state engine operation conditions. Bi-modal particle size distributions were observed for all operating conditions with peak values at particle sizes of 10 nm and 70 nm.

One of the major sources of chlorine in automobiles is polyvinyl chloride (PVC). When old discarded automobiles enter the recycling loop by far the largest percent of this material finds its way into the solid waste fraction known as automobile shredder residue (ASR). While the majority of this waste is currently disposed of in landfills new processes are currently being evaluated to recycle and recover the valuable resources contained in this solid waste. Pyrolysis, the thermal cracking of the polymeric materials present in ASR, to recover the petrochemical hydrocarbons is one such technology which is receiving attention. However, like combustion with energy recovery, the pyrolysis process is receiving close scrutiny in terms of its environmental impact. These concerns have centered around the fate of the chlorine and the heavy metals present in the ASR.

In this paper, researchers at the National Renewable Energy Laboratory present the results of simulation studies to evaluate potential fuel savings as a result of improvements to vehicle rolling resistance, coefficient of drag, and vehicle weight as well as hybridization for four powertrains for medium-duty parcel delivery vehicles. The vehicles will be modeled and simulated over 1,290 real-world driving trips to determine the fuel savings potential based on improvements to each technology and to identify best use cases for each platform. The results of impacts of new technologies on fuel saving will be presented, and the most favorable driving routes on which to adopt them will be explored.

Determining what exhaust gas recirculation (EGR) control parameters have the largest impact on engine performance and emissions is of critical importance when developing an EGR-equipped engine. These tests studied the effects of varying the net charge mass, the fresh air charge mass, the indicated power, and the oxygen equivalence ratio at various EGR fractions. The research was carried out on a direct-injection, natural gas fuelled, pilot-ignited four-stroke heavy-duty engine using Westport Innovations Inc.'s pilot-ignited, direct injection of natural gas technology. The testing was carried out using a prototype injector and the standard diesel-fuelled engine's combustion chamber. The results indicate that fuel efficiency, as well as emissions of Nitrogen Oxides (NOx) and Carbon Monoxide (CO) depend primarily on the EGR level, and not on the values of the EGR control parameters.

The use of exhaust gas recirculation (EGR) to control NOx emissions from direct-injection engines results in the reintroduction of exhaust particulate matter (PM) into the intake manifold. The influence of this recirculated PM on emissions from a pilot-ignited direct injection of natural gas engine was studied by installing a filter in the EGR system. Comparison tests at fixed engine conditions were conducted to identify differences between filtered and unfiltered EGR. No significant variations in gaseous or PM mass emissions were detected. This indicates that the recirculated PM is not contributing substantially to the increases in PM mass emissions commonly observed with EGR. Reductions in black carbon and ultra-fine particle exhaust concentrations in the exhaust were observed at the highest EGR fractions with the filter installed.

A study has been conducted into icephobic properties of some highly durable “off-the-shelf” elastomer materials using a rotating ice adhesion test rig installed in the NRC’s Altitude Icing Wind Tunnel. This enabled the formation of ice at environmental conditions similar to those experienced during in-flight icing encounters. Initially, the tests indicated some very positive results with ice adhesion shear stress as low as 8KPa. On further examination, however, it became apparent that the test preparation process, in which the samples were cleaned with an ethanol alcohol solution, influenced the results due to absorption and prolonged retention of the cleaning fluid. The uptake of the ethanol alcohol solution by the elastomer was found to be a function of the surface temperature and remained absorbed into the coating during the ice accretion process changing the characteristics of the coating in such a way that led to a reduction in the ice/surface bond strength.

The Advanced Petroleum-Based Fuels - Diesel Emissions Control (APBF-DEC) project is a joint U.S. government/industry research effort to identify optimal combinations of fuels, lubricants, engines, and emission control systems to meet projected emissions regulations during the period 2000 to 2010. APBF-DEC is conducting five separate projects involving light- and heavy-duty engine platforms. Four projects are focusing on the performance of emission control technologies for reducing criteria emissions using different fuels. This project is investigating the effects of lubricant formulation on engine-out emissions (Phase I) and the resulting impact on emission control systems (Phase II). This paper describes the statistical design and analysis methods used during Phase I of the lubricants project.

A study was performed in the spring of 2001 to chemically characterize exhaust emissions from trucks and buses fueled by various test fuels and operated with and without diesel particle filters. This study was part of a multi-year technology validation program designed to evaluate the emissions impact of ultra-low sulfur diesel fuels and passive diesel particle filters (DPF) in several different heavy-duty vehicle fleets operating in Southern California. The overall study of exhaust chemical composition included organic compounds, inorganic ions, individual elements, and particulate matter in various size-cuts. Detailed descriptions of the overall technology validation program and chemical speciation methodology have been provided in previous SAE publications (2002-01-0432 and 2002-01-0433).

Compression ignition engines, including those that use natural gas as the major fuel, produce emissions of NOx and particulate matter (PM). Westport Inc. has developed the pilot-ignited high-pressure direct-injection (HPDI) natural gas engine system. Although HPDI engines produce less soot than comparable conventional diesel engines, further reductions in engine-out soot emissions is desired. In diesel engines, multiple injections can help reduce both NOx and PM. The effect of post injections on HPDI engines was not studied previously. The present research shows that late injection of a second gas pulse can significantly reduce PM and CO from HPDI engines without significantly increasing NOx or fuel consumption. In-cylinder pressure measurements were used to characterize the heat release resulting from the multiple injections. Experiments showed that most close-coupled split injection strategies provided no significant emissions benefit and less stable operation.

Annual fuel use for long-haul truck rest period idling is estimated at 667 million gallons in the United States. The U.S. Department of Energy's National Renewable Energy Laboratory's CoolCab project aims to reduce heating, ventilating, and air conditioning (HVAC) loads and resulting fuel use from rest period idling by working closely with industry to design efficient long-haul truck climate control systems while maintaining occupant comfort. Enhancing the thermal performance of cab/sleepers will enable smaller, lighter, and more cost-effective idle reduction solutions. In order for candidate idle reduction technologies to be implemented at the original equipment manufacturer and fleet level, their effectiveness must be quantified. To address this need, a number of promising candidate technologies were evaluated through experimentation and modeling to determine their effectiveness in reducing rest period HVAC loads.

Ice crystals ingested by a jet engine at high altitude can partially melt and then accrete within the compressor, potentially causing performance loss, damage and/or flameout. Several studies of this ice crystal icing (ICI) phenomenon conducted in the RATFac (Research Altitude Test Facility) altitude chamber at the National Research Council of Canada (NRCC) have shown that liquid water is required for accretion. CFD-based tools for ICI must therefore be capable of predicting particle melting due to heat transfer from the air warmed by compression and possibly also due to impact with warm surfaces. This paper describes CFD simulations of particle melting and evaporation in the RATFac icing tunnel for the former mechanism, conducted using a Lagrangian particle tracking model combined with a stochastic random walk approach to simulate turbulent dispersion. Inter-phase coupling of heat and mass transfer is achieved with the particle source-in-cell method.