Sandro Balestrino

A One-Dimensional Model for Particulate Deposition and Hydrocarbon Condensation in Exhaust Gas Recirculation Coolers

Cooled exhaust gas recirculation (EGR) is widely used in diesel engines to control engine out NOx (oxides of nitrogen) emissions. A portion of the exhaust gases is recirculated into the intake manifold of the engine after cooling it through a heat exchanger. EGR cooler heat exchangers, however, tend to lose efficiency and have increased pressure drop as deposit forms on the heat exchanger surface. This adversely affects the combustion process, engine durability, and emissions. In this study, a 1-D model was developed to simulate soot deposition, soot removal, and condensation of several hydrocarbon (HC) species in a circular tube with turbulent gas flow at constant wall temperature. The circular tube, which makes up the computational domain in the model, represents a single channel from any EGR cooler geometry. The model takes into account soot particle deposition due to thermophoresis, diffusion, turbulent impaction, and gravitational drift. However, thermophoresis was found to be the most dominant deposition mechanism for boundary conditions at which EGR coolers typically operate. Soot removal was modeled by considering a force balance between the drag and van der Waals forces. A lognormal distribution of particles was assumed at the tube inlet. The evolution of the particle distribution in the bulk flow along the tube as well as the mass distribution in the deposit layer on the tube walls is predicted by the model. Condensation of six HC species between C15-C24 alkanes was also modeled. Predictions made by the model are in reasonably good agreement with experimental data obtained from a laboratory reactor under the same boundary conditions. There are several assumptions and simplifications built into the model, which can be refined further to improve it. Copyright 2012 American Association for Aerosol Research

Characterization of Soot Deposition and Particle Nucleation in Exhaust Gas Recirculation Coolers

Cooled exhaust gas recirculation (EGR) is used to control engine out NOx (oxides of nitrogen) emissions from modern diesel engines by re-circulating a portion of the exhaust gases into the intake manifold of an engine after cooling it through a heat exchanger commonly referred to as an EGR cooler. However, EGR cooler fouling due to presence of soot particles and hydrocarbons (HC) in engine exhaust leads to a decrease in cooler efficiency and increased pressure drop across the cooler. This can adversely affect the combustion process, engine durability, and emissions. In this study, a multicylinder diesel engine was used to produce a range of engine out HC and soot concentrations to investigate soot deposition and particle nucleation in an EGR cooler. A portion of the engine exhaust was passed through an EGR cooler, while particle size and HC concentration measurements were made at the cooler inlet and outlet. Tests were conducted over a range of EGR cooler coolant temperatures and engine out soot and HC concentrations to determine the impact on the nucleation and accumulation modes of the exhaust particle size distributions. A reduction in the accumulation mode particle concentration at the EGR cooler outlet was observed for high soot concentrations indicating soot deposition within the EGR cooler. As the EGR coolant temperature was reduced, the outlet accumulation mode particle concentration was reduced further, indicating increased soot deposition in the cooler due to increased thermophoresis. There were no signs of diffusiophoresis due to HC diffusion within the cooler over the range of conditions used in the study. A significant increase in outlet nucleation mode particle concentration was observed for the low soot concentrations. This mode increased with either increasing HC concentration or decreasing coolant temperature, indicating the saturation ratio (SR) dependence of the nucleation mode formation. However, as the soot concentration was increased, the nucleation mode disappeared because of HC adsorption onto the increased soot surface area. Copyright 2012 American Association for Aerosol Research

Deposition of Nanosized Soot Particles in Various EGR Coolers Under Thermophoretic and Isothermal Conditions

This study investigates the performance of various types of exhaust gas recirculation (EGR) coolers, that is, smooth tube, corrugated tube, and plate–fin, when subjected to particulate fouling by soot particles. Experiments were carried out for different temperature gradients of 170 and 320°C (thermophoretic) and 0°C (isothermal). Soot particles with an average diameter of 130 nm were produced by a soot generator. Experimental results showed that generally soot deposition under isothermal conditions is negligible compared to thermophoresis for any given cooler geometry, but is not universal. It may become appreciable when complex coolers with extended surfaces, that is, plate–fin type, are used due to impaction and settlement of soot particles onto the extended surfaces, which act as barrier to the flow. Contrariwise, under thermophoretic conditions, the plate–fin cooler performed best, followed by the corrugated tube and smooth tube cooler. Coolers with larger heat transfer surface area are also found to be less sensitive to the loss in effectiveness, but show a higher pressure drop.

Onset of unsteady flow in wavy walled channels at low Reynolds number

Using computational modeling, we examine the development of an unsteady laminar flow of a Newtonian fluid in a channel with sinusoidal walls. The flow is driven by a constant pressure gradient. The simulations reveal two types of unsteady flows occurring in sinusoidal channels. When the amplitude of the wavy walls is relatively small, vortices forming in the channel furrows are shed downstream. For larger wall wave amplitudes, vortices remain inside the furrows and exhibit periodic oscillations and topological changes. We present a phase diagram in terms of wall amplitude and driving pressure gradient separating different flow regimes. Our simulations establish the optimum wall amplitude and period leading to an unsteady flow at the minimum pressure gradient. The results are important for designing laminar heat/mass exchangers utilizing unsteady flows for enhancing transport processes.