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One in-cylinder strategy for reducing soot emissions from diesel engines while maintaining fuel efficiency is the use of close-coupled post injections, which are small fuel injections that follow the main fuel injection after a short delay. While the in-cylinder mechanisms of diesel combustion with single injections have been studied extensively and are relatively well understood, the in-cylinder mechanisms affecting the performance and efficacy of post injections have not been clearly established. Here, experiments from a single-cylinder heavy-duty optical research engine incorporating close- coupled post injections are modeled with three dimensional (3D) computational fluid dynamics (CFD) simulations. The overall goal is to complement experimental findings with CFD results to gain more insight into the relationship between post-injections and soot. This paper documents the first stage of CFD results for simulating and analyzing the experimental conditions.

The objective of this investigation is to optimize a light-duty diesel engine in order to minimize soot, NOx, carbon monoxide (CO), unburned hydrocarbon (UHC) emissions and peak pressure rise rate (PPRR) while improving fuel economy in a low oxygen environment. Variables considered are the injection timings, fractional amount of fuel per injection, half included spray angle, swirl, and stepped-bowl piston geometry. The KIVA-CHEMKIN code, a multi-dimensional computational fluid dynamics (CFD) program with detailed chemistry is used and is coupled to a multi-objective genetic algorithm (MOGA) along with an automated grid generator. The stepped-piston bowl allows more options for spray targeting and improved charge preparation. Results show that optimal combinations of the above variables exist to simultaneously reduce emissions and fuel consumption. Details of the spray targeting were found to have a major impact on the combustion process.

The objective of this investigation is to optimize light-duty diesel engine operating parameters using Adaptive Injection Strategies (AIS) for optimal fuel preparation. A multi-dimensional Computational Fluid Dynamics (CFD) code with detailed chemistry, the KIVA-CHEMKIN code, is employed and a Multi-Objective Genetic Algorithm (MOGA) is used to study a Two-Stage Combustion (TSC) concept. The combustion process is considered at a light load operating condition (nominal IMEP of 5.5 bar and high speed (2000 rev/min)), and two combustion modes are combined in this concept. The first stage is ideally Homogeneous Charge Compression Ignition (HCCI) combustion and the second stage is diffusion combustion under high temperature and low oxygen concentration conditions. Available experimental data on a 1.9L single-cylinder research engine is used for model validation.

In a recent study, quantitative measurements were presented of in-cylinder spatial distributions of mixture equivalence ratio in a single-cylinder light-duty optical diesel engine, operated with a non-reactive mixture at conditions similar to an early injection low-temperature combustion mode. In the experiments a planar laser-induced fluorescence (PLIF) methodology was used to obtain local mixture equivalence ratio values based on a diesel fuel surrogate (75% n-heptane, 25% iso-octane), with a small fraction of toluene as fluorescing tracer (0.5% by mass). Significant changes in the mixture's structure and composition at the walls were observed due to increased charge motion at high swirl and injection pressure levels. This suggested a non-negligible impact on wall heat transfer and, ultimately, on efficiency and engine-out emissions.

We propose a novel dual-fuel combustion model for simulating heavy-duty engines with the G-Equation. Dual-Fuel combustion strategies in such engines features direct injection of a high-reactivity fuel into a lean, premixed chamber which has a high resistance to autoignition. Distinct combustion modes are present: the DI fuel auto-ignites following chemical ignition delay after spray vaporization and mixing; a reactive front is formed on its surroundings; it develops into a well-structured turbulent flame, which propagates within the premixed charge. Either direct chemistry or the flame-propagation approach (G- Equation), taken alone, do not produce accurate results. The proposed Dual-Fuel model decides what regions of the combustion chamber should be simulated with either approach, according to the local flame state; and acts as a “kernel” model for the G- Equation model. Direct chemistry is run in the regions where a premixed front is not present.

A droplet vaporization model has been developed for use in high pressure spray modeling. The model is a modification of the common Spalding vaporization model that accounts for the effects of high pressure on phase equilibrium, transport properties, and surface tension. The new model allows for a nonuniform temperature within the liquid by using a simple 2-zone model for the droplet. The effects of the different modifications are tested both for the case of a single vaporizing droplet in a quiescent environment as well as for a high pressure spray using the KIVA II code. Comparisons with vaporizing spray experiments show somewhat improved spray penetration predictions. Also, the effect of the vaporization model on diesel combustion predictions was studied by applying the models to simulate the combustion process in a heavy duty diesel engine. In this case the standard and High Pressure vaporization models were found to give similar heat release and emissions results.

A three-dimensional homogeneous equilibrium model (HEM) has been developed and implemented into an engine computational fluid dynamics (CFD) code KIVA-3V. The model was applied to simulate cavitating flow within injector nozzle passages. The effects of nozzle passage geometry and injection conditions on the development of cavitation zones and the nozzle discharge coefficient were investigated. Specifically, the effects of nozzle length (L/D ratio), nozzle inlet radius (R/D ratio) and K or KS factor (nozzle passage convergence) were simulated, and the effects of injection and chamber pressures, and time-varying injection pressure were also investigated. These effects are well captured by the nozzle flow model, and the predicted trends are consistent with those from experimental observations and theoretical analyses.

The physical in-cylinder processes and ignition during cold starting have been studied using computational models, with particular attention to the influences of blowby, heat transfer during the compression stroke, spray development, vaporization and fuel/air mixture formation and ignition. Two different modeling approaches were used. A thermodynamic zero dimensional cycle analysis program in which the fuel injection effects were not modeled, was used to determine overall and gas exchange effects. The three-dimensional KIVA-II code was used to determine details of the closed cycle events, with modified atomization, blowby and spray/wall impingement models, and a simplified model for ignition. The calculations were used to obtain an understanding of the cold starting process and to identify practical methods for improving cold starting of direct injection diesel engines.

Experiments were performed on a single-cylinder heavy-duty Caterpillar SCOTE 3401E engine at high speed (1737 rev/min) and loads up to 60% of full load for fully Premixed Charge Compression Ignition (PCCI) combustion. The engine was equipped with a high pressure (150 MPa) Caterpillar 300B HEUI fuel injection system. The engine was run with EGR levels up to 75% and with equivalence ratios up to 0.95. These experiments resulted in compliance of NOx and PM emissions to 2010 emissions mandates levels up to the tested load. The set of experiments also demonstrated the importance of cylinder charge preparation by way of optimized start-of-combustion timing for sufficient in-cylinder mixing. It was found that increased EGR rates, even with the correspondingly increased equivalence ratios, increase mixing time and substantially decrease PM emissions.

A transport equation residual model incorporating refined G-equation and detailed chemical kinetics combustion models has been developed and implemented in the ERC KIVA-3V release2 code for Gasoline Direct Injection (GDI) engine simulations for better predictions of flame propagation. In the transport equation residual model a fictitious species concept is introduced to account for the residual gases in the cylinder, which have a great effect on the laminar flame speed. The residual gases include CO2, H2O and N2 remaining from the previous engine cycle or introduced using EGR. This pseudo species is described by a transport equation. The transport equation residual model differentiates between CO2 and H2O from the previous engine cycle or EGR and that which is from the combustion products of the current engine cycle.

Homogeneous low temperature combustion is believed to be a promising approach to resolve the conflict of goals between high efficiency and low exhaust emissions. Disadvantageously for this kind of combustion, the whole process depends on chemical kinetics and thus is hard to control. Reactivity controlled combustion can help to overcome this difficulty. In the so-called RCCI (reactivity controlled compression ignition) combustion concept a small amount of pilot diesel that is injected directly into the combustion chamber ignites a highly diluted gasoline-air mixture. As the gasoline does not ignite without the diesel, the pilot injection timing and the ratio between diesel and gasoline can be used to control the combustion process. A phenomenological multi-zone model to predict RCCI combustion has been developed and validated against experimental and 3D-CFD data. The model captures the main physics governing ignition and combustion.

Homogeneous Charge Compression Ignition (HCCI) combustion is being considered as a practical solution for diesel engines due to its high efficiency and low NOx and PM emissions. However, for diesel HCCI operation, there are still several problems that need to be solved. One is the spay-wall impingement issue associated with early injection, and a further problem is the extension of HCCI operation from low load to higher engine loads. In this study, a combination of Adaptive Injection Strategies (AIS) and a Two-Stage Combustion (TSC) strategy are proposed to solve the aforementioned problems. A multi-dimensional Computational Fluid Dynamics (CFD) code with detailed chemistry, the KIVA-CHEMKIN-GA code, was employed in this study, where Genetic Algorithms (GA) were used to optimize heavy-duty diesel engine operating parameters. The TSC concept was applied to optimize the combustion process at high speed (1737 rev/min) and medium load (57% load).

The simulation of combustion chemistry in internal combustion engines is challenging due to the need to include detailed reaction mechanisms to describe the engine physics. Computational times needed for coupling full chemistry to CFD simulations are still too computationally demanding, even when distributed computer systems are exploited. For these reasons the present paper proposes a time scale separation approach for the integration of the chemistry differential equations and applies it in an engine CFD code. The time scale separation is achieved through the estimation of a characteristic time for each of the species and the introduction of a sampling timestep, wherein the chemistry is subcycled during the overall integration. This allows explicit integration of the system to be carried out, and the step size is governed by tolerance requirements.

With recent increases in global fuel prices there has become a growing interest in expanding the use of diesel engines in the transportation industry. However, new engine development is costly and time intensive, requiring many hours of expensive engine tests. The ability to accurately predict an engine's performance based on existing models would reduce the expense involved in creating a new engine of different size. In the present study experimental results from two single-cylinder direct injection diesel engines were used to examine previously developed engine scaling models. The first scaling model was based on an equal spray penetration correlation. The second model considered both equal spray penetration and flame lift-off length. The engines used were a heavy-duty Caterpillar engine with a 2.44L displacement and a light-duty GM engine with a 0.48L displacement.

Optimizations were performed on a single-cylinder heavy-duty Caterpillar SCOTE 3401E engine for NOx, PM and BSFC reductions. The engine was equipped with a Caterpillar 300B HEUI fuel injection system capable of up to four injections with timings from 90 BTDC to 90 ATDC. The engine was operated at a medium load (57%), high speed (1737 rev/min) operation point. A micro-genetic algorithm was utilized to optimize a hybrid, double-injection strategy, which incorporated an early, premixed pilot injection with a late main injection. The fuel injection parameters, intake boost pressure, and EGR were considered in the optimization. The optimization produced a parameter set that met the 2007 and 2010 PM emissions mandate of 0.0134 g/kW-hr, and was within the 1.5x not to exceed NOx + HC mandate of 2.694 g/kW-hr. Following the optimization exercise, further parametric interaction studies were performed to reveal the underlying interactions and phenomena.

An experimental study was conducted on an air cooled high-speed, direct-injection diesel generator that investigated the use of gasoline in a dual fuel PCCI strategy. The single-speed generator used in the study has an effective compression ratio of 17 and runs at 3600 rev/min. Varying amounts of gasoline were introduced into the combustion chamber through a port injection system. The generator uses an all-mechanical diesel fuel injection system that has a fixed injection timing. The experiments explored variable intake temperatures and fuel split quantities to investigate different combustion phasing regimes. Results from the study showed low combustion efficiency at low load. Low load operation was also characterized by high levels of HC and CO (in excess of 20 g/kwh and 50 g/kwh respectively). Operation at 75% load was more efficient, and displayed three different combustion regimes that are possible with PIG (port injected gasoline) dual fuel PCCI.

Current automotive diesel engine research is motivated by the need to meet more-and-more strict emission regulations. The major target for future HSDI combustion research and development is to find the most effective ways of reducing the soot particulate and NOx emissions to the levels required by future emission regulations. Recently, a variety of statistical optimization tools have been proposed to optimize engine-operating conditions for emissions reduction. In this study, a micro-genetic algorithm technique, which locates a global optimum via the law of “the survival of the fittest”, was applied to a high-speed, direct-injection, single-cylinder (HSDI) diesel engine. The engine operating condition considered single-injection operation using a common-rail fuel injection system was at 1757 rev/min and 45% load.

An experimental and numerical characterization has been conducted for high-pressure hydraulically actuated fuel injection systems. One single and one double-guided multi-hole Valve-Covered-Orifice (VCO) type injector was used with a Common Rail (CR) injection system, and two mini-sac injectors for Hydraulic electronic Unit Injection system (HEUI) were used with different orifice diameters. The purpose of the study was to explore the effects of the injection system and the operating conditions on the engine emissions for a direct injection small bore diesel engine. The diesel spray was injected into a pressurized chamber with optical access at ambient temperature. The gas density inside the chamber was representative of the density in a High Speed Direct Injection (HSDI) diesel engine at the time of injection. The experimental spray parameters included: injection pressure, injection duration, nozzle type, and nozzle diameter.

Lagrangian-Droplet and Eulerian-Fluid (LDEF) based spray models are widely used in engine and combustion system computations. Numerical grid and time-step-dependencies of Discrete Droplet Lagrangian spray models have been identified by previous researchers [1, 2]. The two main sources of grid-dependency are due to errors in predicting the droplet-gas relative velocity, and errors in describing droplet-droplet collision and coalescence processes. For reducing grid-dependency due to the relative velocity effects, results from gas jet theory are introduced along with a Lagrangian collision model [1, 3] and applied to model diesel sprays. The improved spray model is implemented in the engine simulation code KIVA-3V [4] and is tested under various conditions, including constant volume chambers and various engine geometries with vaporizing and combusting sprays with detailed chemistry.

The ignition process of fuel reactivity controlled PCCI combustion was investigated using engine experiments and detailed CFD modeling. The experiments were performed using a modified all metal heavy-duty, compression-ignition engine. The engine was fueled using commercially available gasoline (PON 91.6) and ULSD diesel delivered through separate port and direct injection systems, respectively. Experiments were conducted at a steady state-engine load of 4.5 bar IMEP and speed of 1300 rev/min. In-cylinder optical measurements focused on understanding the fuel decomposition and fuel reactivity stratification provided through the charge preparation. The measurement technique utilized point location optical access through a modified cylinder head with two access points in the firedeck. Optical measurements of natural thermal emission were performed with an FTIR operating in the 2-4.5 μm spectral region.