C. Scott Sluder

Low Temperature Urea Decomposition and SCR Performance

Urea-SCR systems are potentially a highly-effective means of NO x reduction for light-duty diesel vehicles. However, use of urea-SCR technologies at low temperatures presents unique technical challenges. This study was undertaken to provide more knowledge about low temperature urea decomposition and the resulting effects on SCR performance. Data are presented for experiments using two SCR catalysts of differing size with a light-duty diesel engine. Analyses of the NO x reduction efficiency, NH 3 storage phenomena, and unregulated emissions are shown. Over production of NO 2 by the oxidation catalyst is demonstrated to be problematic at 25,000 hr-1 space velocity for a range of temperatures. This leads to production of N 2 O by both SCR catalysts that is higher when urea is injected than when NH 3 is injected.

An Estimate of Diesel High-Efficiency Clean Combustion Impacts on FTP-75 Aftertreatment Requirements

A modified Mercedes 1.7-liter, direct-injection diesel engine was operated in both normal and high-efficiency clean combustion (HECC) combustion modes. Four steady-state engine operating points that were previously identified by the Ad-hoc fuels working group were used as test points to allow estimation of the hot-start FTP-75 emissions levels in both normal and HECC combustion modes. The results indicate that operation in HECC modes generally produce reductions in NOX and PM emissions at the expense of CO, NMHC, and H2CO emissions. The FTP emissions estimates indicate that aftertreatment requirements for NOX are reduced, while those for PM may not be impacted. Cycle-average aftertreatment requirements for CO, NMHC, and H2CO may be challenging, especially at the lowest temperature conditions.

Implications of Particulate and Precursor Compounds Formed During High-Efficiency Clean Combustion in a Diesel Engine

Advanced diesel combustion modes offer the promise of reduced engine-out particulate and nitrogen oxide emissions, thereby reducing the demand on post-combustion emission control devices. In this activity, a light-duty diesel engine was operated in conventional and advanced combustion modes. The advanced combustion modes investigated correspond to both clean (i.e., low PM and low NO x ) and clean efficient combustion. The low-NOx, low-PM mode is considered an intermediate condition and the low-NO x , low-PM efficient mode is referred to as high efficiency clean combustion (HECC). Particulate and gaseous emissions were analyzed during all of these experiments. The detailed exhaust chemistry analysis provided significant new information to improving our understanding of these modes as well as identifying potentially important unregulated emissions.

Fuel Property Effects on Emissions from High Efficiency Clean Combustion in a Diesel Engine

High-efficiency clean combustion (HECC) modes provide simultaneous reductions in diesel particulate matter and nitrogen-oxides emissions while retaining efficiencies characteristic of normal diesel engines. Fuel parameters may have significant impacts on the ability to operate in HECC modes and on the emissions produced in HECC modes. In this study, 3 diesel-range fuels and 2 oxygenated blends are burned in both normal and HECC modes at 3 different engine conditions. The results show that fuel effects play an important role in the emissions of hydrocarbons, particulate matter, and carbon monoxide but do not significantly impact NOX emissions in HECC modes. HECC modes are achievable with 5% biodiesel blends in addition to petroleum-based and oil-sands derived fuels. Soot precursor and oxygenated compound concentrations in the exhaust were observed to generally increase with the sooting tendency of the fuel in HECC modes.

Exhaust Chemistry of Low-NOX, Low-PM Diesel Combustion

The exhaust chemistry of combustion regimes characterized by simultaneous low-NOx and low-PM emissions were investigated on a Mercedes 1.7-L diesel engine. Two approaches for entering low-NOx low-PM regimes were explored using a California specification low aromatic certification diesel fuel. Detailed characterizations of gas-phase hydrocarbons, particulate soluble organics, and aldehydes are presented for both approaches. Results indicate significant formation of partially oxygenated hydrocarbons and fuel reformation products during periods of low-NOx, low-PM combustion.

Numerical Modeling and Experimental Investigations of EGR Cooler Fouling in a Diesel Engine

EGR coolers are mainly used on diesel engines to reduce intake charge temperature and thus reduce emissions of NOx and PM. Soot and hydrocarbon deposition in the EGR cooler reduces heat transfer efficiency of the cooler and increases emissions and pressure drop across the cooler. They may also be acidic and corrosive. Fouling has been always treated as an approximate factor in heat exchanger designs and it has not been modeled in detail. The aim of this paper is to look into fouling formation in an EGR cooler of a diesel engine. A 1-D model is developed to predict and calculate EGR cooler fouling amount and distribution across a concentric tube heat exchanger with a constant wall temperature. The model is compared to an experiment that is designed for correlation of the model. Effectiveness, mass deposition, and pressure drop are the parameters that have been compared. The results of the model are in a good agreement with the experimental data.

Characterization of Field-Aged EGR Cooler Deposits

Exhaust gas recirculation (EGR) cooler fouling has become a significant issue for compliance with NOx emissions standards. In order to better understand fouling mechanisms, eleven field-aged EGR coolers provided by seven different engine manufacturers were characterized using a suite of techniques. Microstructures were characterized using scanning electron microscopy (SEM) and optical microscopy following mounting the samples in epoxy and polishing. Optical microscopy was able to discern the location of hydrocarbons in the polished cross-sections. Chemical compositions were measured using thermal gravimetric analysis (TGA), differential thermal analysis (DTA), gas chromatography-mass spectrometry (GC-MS), x-ray photoelectron spectroscopy (XPS), energy dispersive spectroscopy (EDS) and X-ray diffraction (XRD). Mass per unit area along the length of the coolers was also measured. Despite coming from different sources and applications, many common features were observed in the cooler deposits including mud-cracking, hydrocarbon condensation near the metal surface, and erosion of the deposit. Differences and commonalities between the coolers will be discussed in the context of better understanding cooler fouling and ways to prevent it.

Fuels for Advanced Combustion Engines Research Diesel Fuels: Analysis of Physical and Chemical Properties

The CRC Fuels for Advanced Combustion Engines working group has worked to identify a matrix of research diesel fuels for use in advanced combustion research applications. Nine fuels were specified and formulated to investigate the effects of cetane number aromatic content and 90% distillation fraction. Standard ASTM analyses were performed on the fuels as well as GC/MS and /u1H//u1/u3C NMR analyses and thermodynamic characterizations. Details of the actual results of the fuel formulations compared with the design values are presented, as well as results from standard analyses, such as heating value, viscosity and density. Cetane number characterizations were accomplished by using both the engine method and the Ignition Quality Tester (IQT/sT) apparatus.

Catalyzed Diesel Particulate Filter Performance in a Light-Duty Vehicle

Light-duty chassis dynamometer driving cycle tests were conducted on a Mercedes A170 diesel vehicle with various sulfur-level fuels and exhaust emission control systems. Triplicate runs of a modified light-duty federal test procedure (FTP), US06 cycle, and SCO3 cycle were conducted with each exhaust configuration and fuel. Ultralow sulfur (3-ppm) diesel fuel was doped to 30- and 150ppm sulfur so that all other fuel properties remained the same. The fuels used in these experiments met the specifications of the fuels from the DECSE (Diesel Emission Control Sulfur Effects) program. Although the Mercedes A170 vehicle is not available in the United States, its emissions in the as tested condition fell within the U.S. Tier 1 full useful life standards with the OEM catalysts installed. Tests with the OEM catalysts removed showed that the OEM catalysts reduced PM emissions from the engine-out condition by 30–40% but had negligible effects on NOx emissions. Fuel sulfur level had very little effect on the OEM catalyst performance. A prototype catalyzed diesel particulate filter (CDPF) mounted in an underfloor configuration reduced particulate matter emissions by more than 90% compared to the factory emissions control system. The results show that the CDPF did not promote any significant amounts of SO2to-sulfate conversion during these light-duty drive cycles.

An Analytical Study of Thermophoretic Particulate Deposition in Turbulent Pipe Flows

The presence of a cold surface in non-isothermal pipe flows conveying submicron particles causes thermophoretic particulate deposition. In this study, an analytical method is developed to estimate thermophoretic particulate deposition efficiency and its effect on overall heat transfer coefficient of pipe flows in transition and turbulent flow regimes. The proposed analytical solution has been validated against experiments conducted at Oak Ridge National Laboratory. Exhaust gas carrying submicron soot particles was passed through pipes with a constant wall temperature and various designed boundary conditions to correlate transition and turbulent flow regimes. Prediction of the reduction in heat transfer coefficient and particulate mass deposited has been compared with experiments. The results of the analytical method are in a reasonably good agreement with experiments.