Fy 2006 Progress Report for Advanced Combustion Engine Research аnd Development

341 Pages·25.001 MB·English

U.S. Department of Energy
1000 Independence Avenue, S.W.
Washington, D.C. 20585-0121
FY 2006 Progress rePort For

AdvAnced combustion engine technologies

Energy Efficiency and Renewable Energy

Office of FreedomCAR and Vehicle Technologies

Approved by Gurpreet Singh
Team Leader, Advanced Combustion Engine R&D

Office of FreedomCAR and Vehicle Technologies

December 2006
Acknowledgement

We would like to express our sincere appreciation to Alliance Technical Services, Inc. and Oak Ridge
National Laboratory for their technical and artistic contributions in preparing and publishing this report.
In addition, we would like to thank all the participants for their contributions to the programs and all the
authors who prepared the project abstracts that comprise this report.
FY 2006 Progress Report ii Advanced Combustion Engine Technologies
TableofContents
Table of Contents

I. Introduction .................................................................................1

Developing Advanced Combustion Engine Technologies . . . . . . . . . . . . . . . .. . .. . . . . . . . . . . . . . . . .. . .. . . . .3

Project Highlights. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10

Future Directions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .17

II. Advanced Combustion and Emission Control Research for High-Efficiency Engines . . . . . . . . . . . . . . . . . . . 25

II.1 Stretch Efficiency in Combustion Engines with Implications of New Combustion Regimes

(Oak Ridge National Laboratory). . . . . . . . . .. . .. . . . . . . . . . . . . . . . .. . .. . . . . . . . . . . . . . . . .. . .. . . .27

II.A Combustion and Related In-Cylinder Processes.............................................33

II.A.1 Light-Duty Diesel Spray Research Using X-Ray Radiography

(Argonne National Laboratory). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33

II.A.2 Low-Temperature Automotive Diesel Combustion (Sandia National Laboratories) .. . . . . . .37

II.A.3 Multi-Diagnostic In-Cylinder Imaging and Multi-Dimensional Modeling of

Low-Temperature Heavy-Duty Compression-Ignition Combustion

(Sandia National Laboratories) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .41

II.A.4 Fuel Effects on Conventional and Low-Temperature, Compression-Ignition

Combustion Processes (Sandia National Laboratories) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .47

II.A.5 Soot Formation under High-EGR LTC Conditions (Sandia National Laboratories) . . . . . . .53

II.A.6 Achieving High Efficiency Clean Combustion (HECC) in Diesel Engines

(Oak Ridge National Laboratory) . .. . .. . . . . . . . . . . . . . . . .. . .. . . . . . . . . . . . . . . . .. . .. . . .57

II.A.7 Large Eddy Simulation Applied to Low-Temperature and Hydrogen Engine

Combustion Research (Sandia National Laboratories) . . . .. . .. . . . . . . . . . . . . . . . .. . .. . . .61

II.A.8 Detailed Modeling of HCCI and PCCI Combustion and Multi-Cylinder HCCI

Engine Control (Lawrence Livermore National Laboratory) . . . . . . . . . . . . . . . . . . . . . . . . . . .67

II.A.9 HCCI and Stratified-Charge CI Engine Combustion Research

(Sandia National Laboratories) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .72

II.A.10 Automotive HCCI Combustion Research (Sandia National Laboratories) . . . . . . . .. . .. . . .77

II.A.11 Spark-Assisted HCCI Combustion (Oak Ridge National Laboratory) . . . . . . . . . . . .. . .. . . .82

II.A.12 Development of High Efficiency Clean Combustion Engine Designs for

Spark-Ignition and Compression-Ignition Internal Combustion Engines

(GM Powertrain Advanced Engineering) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .86

II.A.13 KIVA-4 Development (Los Alamos National Laboratory) . .. . .. . . . . . . . . . . . . . . . .. . .. . . .90

II.A.14 Chemical Kinetic Modeling of Combustion of Automotive Fuels

(Lawrence Livermore National Laboratory). . . . . . . . . . . . . .. . .. . . . . . . . . . . . . . . . .. . .. . . .93

II.A.15 Achieving and Demonstrating FreedomCAR Engine Fuel Efficiency Goals

(Oak Ridge National Laboratory) . .. . .. . . . . . . . . . . . . . . . .. . .. . . . . . . . . . . . . . . . .. . .. . . .97

II.A.16 Free-Piston Engine Research (Sandia National Laboratories) .. . . . . . . . . . . . . . . . .. . .. . .101

II.A.17 In-Cylinder Hydrogen Combustion Visualization in a Non-Optical Engine

(Argonne National Laboratory) . . . .. . .. . . . . . . . . . . . . . . . .. . .. . . . . . . . . . . . . . . . .. . .. . .104

II.A.18 OH* Chemiluminescence Measurements in a Direct-Injection Hydrogen Engine

(Sandia National Laboratories) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .107

II.A.19 Low-Temperature Combustion Using Pre-Mixed Charge Compression Ignition

(Cummins Inc.). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .112

II.A.20 High Efficiency Clean Combustion Advanced Combustion Report (Caterpillar, Inc.) . . . . .116

II.A.21 Low Temperature Combustion Demonstrator for High Efficiency Clean Combustion

(International Truck and Engine Corporation) . . . . . . . . . . .. . .. . . . . . . . . . . . . . . . .. . .. . .122

II.A.22 Heavy-Duty Stoichiometric Compression Ignition Engine with Improved Fuel

Economy over Alternative Technologies for Meeting 2010 On-Highway Emissions

(John Deere Power Systems). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .127

Advanced Combustion Engine Technologies iii FY 2006 Progress Report
Table of Contents
II. Advanced Combustion and Emission Control Research for High-Efficiency Engines (Continued)
II.A Combustion and Related In-Cylinder Processes (Continued)
II.A.23 Demonstration of Air-Power-Assist (APA) Engine Technology for Clean

Combustion and Direct Energy Recovery in Heavy-Duty Applications

(Volvo Powertrain North America) .. . .. . . . . . . . . . . . . . . . .. . .. . . . . . . . . . . . . . . . .. . .. . .132

II.B Energy Efficient Emission Controls ......................................................135

II.B.1 Fundamental Studies of NOx Adsorber Materials (Pacific Northwest National

Laboratory, Cummins Inc., and Johnson Matthey) . . . . . . . .. . .. . . . . . . . . . . . . . . . .. . .. . .135

II.B.2 Mechanisms of Sulfur Poisoning of NOx Adsorber Materials (Pacific Northwest

National Laboratory). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .142

II.B.3 Characterizing Lean NOx Trap Regeneration and Desulfation (Oak Ridge National

Laboratory) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .147

II.B.4 Development of Chemical Kinetics Models for Lean NOx Traps (Sandia National

Laboratories) . .. . . . . . . . . . . . . . . . .. . .. . . . . . . . . . . . . . . . .. . .. . . . . . . . . . . . . . . . .. . .. . .152

II.B.5 Advanced Engine/Aftertreatment System R&D (Oak Ridge National Laboratory

and International Truck and Engine Corporation) . . . . . . . .. . .. . . . . . . . . . . . . . . . .. . .. . .156

II.B.6 Advanced CIDI Emission Control System Development (Ford Research &

Advanced Engineering) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .160

II.B.7 Fundamental Sulfation/Desulfation Studies of Lean NOx Traps, DOE Pre-Competitive

Catalyst Research (Oak Ridge National Laboratory and Cummins, Inc.) . . . . . .. . .. . . . . .164

II.B.8 NOx Control and Measurement Technology for Heavy-Duty Diesel Engines

(Oak Ridge National Laboratory) . .. . .. . . . . . . . . . . . . . . . .. . .. . . . . . . . . . . . . . . . .. . .. . .170

II.B.9 Off-Highway Engine Emission Control with High System Efficiency (Oak Ridge

National Laboratory and Deere & Company) . . . . . . . . . . . .. . .. . . . . . . . . . . . . . . . .. . .. . .173

II.B.10 Discovery of New NOx Reduction Catalysts for CIDI Engines Using Combinatorial

Techniques (General Motors Corporation, Research and Development Center) . . . . . . . . . .176

II.B.11 Efficient Emissions Control for Multi-Mode Lean DI Engines (Oak Ridge National

Laboratory) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .179

II.B.12 NOx Control for High Power Density Hydrogen Engine (Oak Ridge National

Laboratory) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .184

II.B.13 Cross-Cut Lean Exhaust Emission Reduction Simulation (CLEERS) (Oak Ridge

National Laboratory). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .189

II.B.14 CLEERS DPF Modeling (Pacific Northwest National Laboratory). . . . . . . . . . . . . . . . . . . . .196

II.B.15 Innovative Emission Control Device Renewal (General Motors Corporation –

Powertrain Division) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .201

II.C Critical Enabling Technologies. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .204

II.C.1 Variable Valve Actuation (Delphi Automotive Systems). . . . . . . . . . . . . . . . . . . . . . . . . . . . . .204

II.C.2 Low-Cost Fast-Response Actuator for Variable Compression Ratio Engines

(Envera LLC) . .. . . . . . . . . . . . . . . . .. . .. . . . . . . . . . . . . . . . .. . .. . . . . . . . . . . . . . . . .. . .. . .207

III. Heavy Truck Engine. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .211

III.1 Heavy-Duty Truck Engine Program (Cummins Inc.) . . . . . .. . .. . . . . . . . . . . . . . . . .. . .. . .213

III.2 Heavy Truck Engine Project (Heavy Truck Clean Diesel, HTCD) (Caterpillar Inc.) . . . . . .216

III.3 Heavy-Duty Engine Technology for High Thermal Efficiency at EPA 2010 Emissions

Regulations (Detroit Diesel Corporation) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .219

IV. Waste Heat Recovery........................................................................225

IV.1 Developing Thermoelectric Technology for Automotive Waste Heat Recovery

(GM Research and Development Center). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .227

IV.2 High-Efficiency Thermoelectric Waste Energy Recovery System for Passenger

Vehicle Applications (BSST LLC) . .. . .. . . . . . . . . . . . . . . . .. . .. . . . . . . . . . . . . . . . .. . .. . .232

IV.3 Cost-Effective Fabrication Routes for the Production of Quantum Well Structures

and Recovery of Waste Heat from Heavy Duty Trucks (United Technologies

Research Center) . . . . . . . . . . . . . . . .. . .. . . . . . . . . . . . . . . . .. . .. . . . . . . . . . . . . . . . .. . .. . .237

FY 2006 Progress Report iv Advanced Combustion Engine Technologies
Table of Contents
IV. Waste Heat Recovery (Continued)
IV.4 Thermoelectric Conversion of Waste Heat to Electricity in an IC Engine

Powered Vehicle (Michigan State University) . . . . . . . . . . . .. . .. . . . . . . . . . . . . . . . .. . .. . .242

IV.5 Exhaust Energy Recovery (Cummins Inc.) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .247

IV.6 Very High Fuel Economy, Heavy Duty, Constant Speed, Truck Engine Optimized

via Unique Energy Recovery Turbines and Facilitated by a High Efficiency

Continuously Variable Drivetrain (Mack Trucks Inc.) . . . . .. . .. . . . . . . . . . . . . . . . .. . .. . .251

V. Off-Highway Engine Efficiency R&D ..........................................................255

V.1 Exhaust Aftertreatment and Low-Pressure Loop EGR Applied to an Off-Highway

Engine (John Deere Product Engineering Center) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .257

V.2 Electrically Coupled Exhaust Energy Recovery System Using a Series Power

Turbine Approach (John Deere Product Engineering Center) . .. . . . . . . . . . . . . . . . .. . .. . .260

VI. Health Impacts .............................................................................265

VI.1 Health Effects from Heavy-Duty Diesel Emissions at the Watt Road Environmental

Laboratory (Oak Ridge National Laboratory) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .267

VI.2 Weekend Ozone Effect Studies (National Renewable Energy Laboratory) . . . . . . . .. . .. . .271

VI.3 Health Impacts: Respiratory Response (Lovelace Respiratory Research Institute) .. . . . . .275

VI.4 The Advanced Collaborative Emissions Study (ACES) (Health Effects Institute) . .. . . . . .280

VII. University Research .........................................................................283

VII.1 University Consortium On Low-Temperature Combustion For High-Efficiency,
Ultra-Low Emission Engines (University of Michigan). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .285
VII.2 Optimization of Low-Temperature Diesel Combustion (University of

Wisconsin-Madison) . . . . . . . . . . . . .. . .. . . . . . . . . . . . . . . . .. . .. . . . . . . . . . . . . . . . .. . .. . .292

VII.3 Low Temperature Combustion with Thermo-Chemical Recuperation to Maximize
In-Use Engine Efficiency (West Virginia University). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .298
VII.4 Kinetic and Performance Studies of the Regeneration Phase of Model Pt/Ba/Rh NOx

Traps for Design and Optimization (University of Houston) . . . . . . . . . . . . . . . . . . . . . . . . . .302

VII.5 Investigation of Aging Mechanisms in Lean-NOx Traps (University of Kentucky) . .. . . . . .306

VII.6 Improved Engine Design Concepts Using the Second Law of Thermodynamics:

Reducing Irreversibilities and Increasing Efficiencies (Texas A&M University) .. . .. . . . . .310

VII.7 High-Compression-Ratio Atkinson-Cycle Engine Using Low-Pressure Direct

Injection and Pneumatic-Electronic Valve Actuation Enabled by Ionization Current

and Forward-Backward Mass Air Flow Sensor Feedback (Michigan State University) . . . .315

VIII. Abstracts of Newly Awarded Projects . . . . . . . . . . . .. . .. . . . . . . . . . . . . . . . .. . .. . . . . . . . . . . . . . . . .. . .. . .319

VIII.1 Application of Wide Spectrum Voltammetric Sensors to Exhaust NOx Measurement

(Streamline Automation, LLC) . . . .. . .. . . . . . . . . . . . . . . . .. . .. . . . . . . . . . . . . . . . .. . .. . .321

VIII.2 Start-of-Combustion Sensor for HCCI Engines (TIAX, LLC) . .. . . . . . . . . . . . . . . . .. . .. . .322

VIII.3 On-Board Engine Exhaust Particulate Matter Sensor for HCCI and Conventional

Diesel Engines (The University of Texas at Austin & Cummins Engine Company) .. . . . . .323

VIII.4 The Development of a Robust Accelerometer-Based Start of Combustion Sensing

System (Westport Power, Inc.) . . . .. . .. . . . . . . . . . . . . . . . .. . .. . . . . . . . . . . . . . . . .. . .. . .324

IX. Acronyms and Abbreviations .................................................................325

X. Index of Primary Contacts ....................................................................331

Advanced Combustion Engine Technologies  FY 2006 Progress Report
FY 2006 Progress Report vi Advanced Combustion Engine Technologies
i. introduction

Advanced Combustion Engine Technologies  FY 2006 Progress Report
FY 2006 Progress Report 2 Advanced Combustion Engine Technologies
I. INTRODUCTION
Developing Advanced Combustion Engine Technologies
On behalf of the Department of Energy’s Office of FreedomCAR and Vehicle Technologies, we are
pleased to introduce the Fiscal Year (FY) 2006 Annual Progress Report for the Advanced Combustion
Engine R&D Sub-Program. The mission of the FreedomCAR and Vehicle Technologies (FCVT)
Program is to develop more energy-efficient and environmentally friendly highway transportation
technologies that enable America to use less petroleum. The Advanced Combustion Engine R&D Sub-
Program supports this mission and the President’s initiatives by removing the critical technical barriers
to commercialization of advanced internal combustion engines for light-, medium-, and heavy-duty
highway vehicles that meet future Federal and state emissions regulations. The primary goal of the
Advanced Combustion Engine R&D Sub-Program is to improve the brake thermal efficiency of internal
combustion engines:
• for passenger vehicles, from 30% (2002 baseline) to 45% by 2010, and
• for commercial vehicle applications, 40% (2002 baseline) to 55% by 2013,
while meeting cost, durability, and emissions constraints. R&D activities include work on combustion
technologies that increase efficiency and minimize in-cylinder formation of emissions, as well as
aftertreatment technologies that further reduce exhaust emissions. Research is also being conducted on
approaches to produce useful work from waste engine heat through the development and application
of thermoelectrics, electricity generation from exhaust-driven turbines, and incorporation of energy-
extracting bottoming cycles.
Advanced internal combustion engines are a key element in the pathway to achieving the goals of
the President’s FreedomCAR and Fuel Partnership for transportation. Advanced engine technologies
being researched will allow use of hydrogen as a fuel in highly efficient and low-emission internal
combustion engines, providing an energy-efficient interim hydrogen-based powertrain technology
during the transition to hydrogen/fuel-cell-powered transportation vehicles. Hydrogen engine
technologies being developed have the potential to provide diesel-like engine efficiencies with near-zero
air pollution and greenhouse gas emissions.
This introduction serves to outline the nature, recent progress, and future directions of the
Advanced Combustion Engine R&D Sub-Program. The research activities of this Sub-Program are
planned in conjunction with the FreedomCAR and Fuel Partnership and the 21st Century Truck
Partnership and are carried out in collaboration with industry, national laboratories, and universities.
Because of the importance of clean fuels in achieving low emissions, R&D activities are closely
coordinated with the relevant activities of the Fuel Technologies Sub-Program, also within the Office of
FreedomCAR and Vehicle Technologies.
Background
The compression ignition direct injection (CIDI) engine, an advanced version of the commonly
known diesel engine, is a promising advanced combustion engine technology for achieving dramatic
energy efficiency improvements in light-duty vehicle applications, where it is suited to both
conventional and hybrid-electric powertrain configurations. Light-duty vehicles with CIDI engines
can compete directly with gasoline engine hybrid vehicles in terms of fuel economy and consumer-
friendly driving characteristics; also, they are projected to have energy efficiencies that are competitive
with hydrogen fuel cell vehicles. The primary hurdles that must be overcome to realize increased use
of CIDI engines in light-duty vehicles are the higher cost of these engines compared to conventional
engines and compliance with the U.S. Environmental Protection Agency’s (EPA’s) Tier 2 regulations
which are phasing in from 2004–2009. The Tier 2 regulations require all light-duty vehicles to meet
the same emissions standards, regardless of the powertrain. Compliance can be achieved with CIDI
engines through the addition of catalytic emission control technologies, though these technologies
Advanced Combustion Engine Technologies  FY 2006 Progress Report