4-4 Blaxill, Hugh - CRC 2014 Lean Combustion of Liquid and Gaseous Fuels

The Development of a Pre-Chamber
Combustion System for Lean Combustion of

Liquid
q and Gaseous Fuels
Hugh Blaxill, Michael Bunce,

MAHLE Powertrain LLC,
LLC
Farmington Hills, MI, USA
1
© MAHLE
Table of Contents
 Lean Combustion Overview
 Natural Gas Application Overview
 TJI Background
 MPT-DOE Project – Phase 1
 Other TJI Gaseous Fuel Work
 Summary
2
MAHLE Powertrain LLC, 25-Feb-2014 © MAHLE
Lean Combustion Overview
Lean Combustion Approaches
pp
Lean
Combustion
 Comb. stability limited to  λ= 1.8
Homogenous Spark
Ignition  Ignition energy limited
 Lean NOx trap required
Stratified Spark  Close spaced injector & plug

Ignition  Lean
L NOx trap
t required
i d
 Multi spark needed for full potential
 High energy ignition from a pre-

Homogenous
chamber turbulent igniter
Turbulent Jet Ignition
 Enables λ> 2.5 hence low NOx
 Multiple
M lti l ignition
i iti points
i t iin main
i
chamber
3
Natural Gas Application Overview
Natural Gas Application
pp Approaches
pp
 Typically run stoich

Spark Ignition CNG
 3-way catalyst required
or LNG
 Oil formulation is critical
Bi-Fuel  2 separate fueling systems

CNG/gasoline
Natural Gas
Applications
High Pressure Direct  High efficiency
Injection (HPDI) LNG  DPF and SCR required
w/ Diesel Pilot
Dual Fuel
 Can substitute up to ~70% CNG
CNG/diesel
TJI CNG pre-  CNG used for pre-chamber only or

chamber or CNG g fuel
as single
single fuel  Enhanced pre-chamber mixing
Acknowledgement: Anthony Greszler – Volvo Trucks
enables further lean limit extension
4
TJI Background
MAHLE Powertrain Turbulent Jet Ignition
g System
y
 Turbulent Jet Ignition (TJI) assembly simply replaces the spark plug in a modern engine design
Main chamber PFI Pre-chamber DI Direct injector

(~98% total fuel energy) (~2% total fuel energy) installation
Spark
S k plug
l sleeve
l
lead
Pre-chamber
direct injector
Spark Plug
Pre-chamber Pre-chamber
Spark
p plug
p g housing
Main combustion
chamber fuelled
from PFI
5
TJI Background
MAHLE Powertrain Turbulent Jet Ignition
g System
y
 Pre-chamber assembly has minimal volume and is fuelled to λ  1 by DI injector

 Pre-chamber fuelling is up to 4% of total fuel flow
 Pre-chamber mixture is ignited by conventional spark plug
 Partially burned combustion gases forced through 6 nozzle orifices into the main chamber
 Nozzle orifices targeted to direct jets throughout main chamber
 Main chamber combustion p
proceeds from ignition
g sites initiated by
yppartially
y burned contents of
these jets
6
MPT-DOE Project
DOE Project
j Objectives
j
 US Dept. of Energy project: optimize pre-chamber geometry and

hardware in order to achieve:
– 45% Thermal Efficiency
– 30% predicted drive cycle fuel economy improvement
– Cost effectiveness with minor modification to engine
g hardware
– Demonstrate potential to meet US EPA emissions
 Enabling Technology: TJI + boosting
 Phase 1 focus
– Optical and thermo engine testing focus on combustion sensitivity
to TJI hardware variations
– CFD focus on mixing/scavenging
7
MPT-DOE Project
Phase 1 Approach
pp
Optical Engine Jet velocity as a function of TJI hardware

Testing
Single Cylinder
Phase 1
Thermo Engine Efficiency/emissions as functions of jet velocity
Testing TJI design
optimization
1-D and 3-D

simulations Validation of experiments, helps drive design optimization
8
MPT-DOE Project
Phases 2 and 3 Approaches
pp
Boosted Single
Cylinder Thermo Fuel injection timing/quantity and spark timing sweeps Phase 2
Engine Testing
TJI design
validation
validation,
Validation of experiments operating
3-D simulations
parameterization
Boosted Multi-
Cylinder Thermo Mini-map generation provides input to 1-D simulation Phase 3
Engine Testing
Map
generation and
Predict TJI vehicle drive cycle fuel economy improvement drive cycle
1-D simulations
simulation
9
MPT-DOE Project
Testing:
g TJI Variations
 Phase 1 optical and thermo engine

testing focus on pre-chamber mixing
and combustion as a result of TJI
design variations
– 2 distinct TJI geometry variations
– 11 distinct nozzle variations
10
MPT-DOE Project
Optical
p Engine
g Testing
g
 Optical engine successfully designed and

assembled in-house
 Purpose:
p determine TJI design
g effects on
jet characteristics
Custom head incorporating TJI
Optical combustion chamber
Hydraulic assembly
Ford 4-cylinder bottom end
High speed camera
11
MPT-DOE Project
Optical
p Engine
g Results
 Base TJI hardware w/ fueled pre-chamber Shown: Bottom-to-top view of cylinder
 Operating conditions
– 1500 rpm, 3.5 bar IMEPg, λ = 1.1
 Color contours show light intensity and
represent cylinder temperature
12
MPT-DOE Project
Optical
p Engine
g Results
 Data analyzed in terms of jet velocity/penetration/variability and main chamber ignition site count
and distribution through the use of correlation tables
 Findings:
– Jet p
penetration p
prior to ignition
g strongly
g y correlated to jjet velocity
y
– Low jet velocity low degree of penetration longer combustion duration
– High jet velocity high max penetration fewer ignition sites due to wall quenching
 Conclusion: Necessary to target jet velocity in order to maximize ignition site distribution while
preventing jets from traveling to walls and quenching
 Next step: identify the relationship between jet characteristics and engine performance
parameters Synthesize optical engine data with metal engine data
13
MPT-DOE Project
Single Thermodynamic Engine Overview
 Single cylinder thermodynamic engine designed and assembled in-house

 Metal engine counterpart to optical engine
Prototype Ford 2.3L

Cylinder Head
Custom Connecting
g
C t
Custom C
Crankshaft
k h ft
Rod And Piston
10:1 12:1 14:1

Production Ford 2.0L Block
14
MPT-DOE Project
Thermodynamic
y Single
g Cylinder
y Testing
g
 Purpose:
– Test multiple pre-chamber and
nozzle geometries and analyze
performance variations TJI in Cylinder #4
– Synthesize combustion
performance with jet
characteristic data from optical
engine
– Provide correlation data for
CFD analysis
 Data processed and synthesized

with optical data
15
MPT-DOE Project
Thermo Engine
g Results
 TJI effectively extends the lean limit of a Speed: 2500 rpm

Air flow*: 47 kg/hr (WOT)
standard SI engine by maintaining
stable combustion
– Enables ultra-lean (λ>2) operation
 Results demonstrate:
– Significant thermal efficiency gain
over base engine
– Results comparable to previous
TJI experiments
DOE project goal
– Propane-fueled p/c demonstrates
p
superior thermal efficiency
y Previous TJI experiments
 Further analysis ongoing Base engine efficiency @ λ=1
*Note: 47 kg/hr = 8.7 bar IMEPg @ stoich
16
MPT-DOE Project
Liquid
q Fueled Pre-Chamber Case – CO2 Fraction
Speed: 2500 rpm

Ai flow:
Air fl 47 kg/hr
k /h (WOT)
λ = 1.8
CR = 10:1
17 MAHLE Powertrain LLC, 25-Feb-2014 © MAHLE

Other TJI Gaseous Fuel Work
Single Cylinder Test Engine
Engine Basis GM Ecotec LE5

E i T
Engine Type Si l Cylinder
Single C li d N
Naturally
ll aspirated
i d
Main Chamber Fuelling Port fuel injection
Displacement 0.6 liter
Bore x Stroke 88 x 98 mm
Compression ratio 10.4
Octane number 91
12
Valve Lift (mm)

EXHAUST
EXHAUSTMOP
MOP INTAKE MOP
INTAKE MOP
125°↔75° 10 85°↔135°
0
-240 -180 -120 -60 0 60 120 180 240
Crank Angle (deg)
TJI single cylinder Dual VVT – Cam Phasers

MOP= Maximum Opening Point
18
Other TJI Gaseous Fuel Work
TJI Results: Various Fuels
 Split fuel (gaseous pre-

chamber) approach offers some
efficiency benefits vs. single
liquid fuel
– Higher degree of 3.3 bar IMEPn 20.6%
Relative to λ=1 Spark Ignittion.

20
ment
g
homogeneityy in p
pre- 4.7 bar IMEPn 17.8% 17.8%
18.7% 18.5% 18.8% 18.4%
conomy Improvem
chamber
15
– No wall impingement
10
Fuel Ec
 Highest efficiency gain with 5

single gaseous fuel
0 0% 0%
Spark Jet Ignition Jet Ignition Jet Ignition Jet Ignition Jet Ignition
I iti
Ignition (G
(Gasoline-
li (G
(Gasoline-
li (G
(Gasoline-
li (G
(Gasoline-
li (N t
(Natural lG
Gas-
(Gasoline) Gasoline) Propane) Vaporized Natural Gas) Natural Gas)
Gasoline)
19
Summary
TJI: Lean Combustion of Liquid
q and Gaseous Fuels
TJI assembly
 TJI is an effective enabling technology for ultra lean
combustion Machining cuts
– High thermal efficiency

– Low NOx
 MPT researching fundamental characteristics of TJI

– Optical and thermodynamic single cylinder engines
– CFD investigation of mixing/scavenging
 Synthesized data will describe correlation among TJI

g variations,, jjet characteristics,, and p
design performance
– SAE Technical Paper 2014-01-1195
 TJI provides excellent platform for dual fuel

(liquid/gaseous) and single gaseous fuel applications
20
Thank you
Hugh.Blaxill@us.mahle.com
Mike Bunce@us mahle com
Mike.Bunce@us.mahle.com
www.mahle-powertrain.com
21
© MAHLE
Back Up Slides
22
© MAHLE
MPT-DOE Project
Optical
p Engine
g Testing
g
 Design proved to robust, test

procedure proved to be effective
High speed camera
High-speed
 Test Setup
– High-speed
g p camera acquired
q
chemiluminescent images at
10kHz (~1 frame per CAD @
test speed)
– High speed spectrometer
High-speed
acquired spectra (primarily
OH, CH)
 Spectral Energies LLC supplied

high-speed camera and
spectrometer setup and assisted High-speed
with test setup spectrometer
23
MPT-DOE Project
Optical
p Engine
g Results
Small nozzle hole diameter Large nozzle hole diameter

24

4-4 Blaxill, Hugh - CRC 2014 Lean Combustion of Liquid and Gaseous Fuels

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Formate disponibile

The Development of a Pre-Chamber

Combustion System for Lean Combustion of

Hugh Blaxill, Michael Bunce,

 Lean Combustion Overview

 Natural Gas Application Overview

 MPT-DOE Project – Phase 1

 Other TJI Gaseous Fuel Work

Stratified Spark  Close spaced injector & plug

 High energy ignition from a pre-

 Typically run stoich

Bi-Fuel  2 separate fueling systems

TJI CNG pre-  CNG used for pre-chamber only or

Main chamber PFI Pre-chamber DI Direct injector

 Pre-chamber assembly has minimal volume and is fuelled to λ  1 by DI injector

 US Dept. of Energy project: optimize pre-chamber geometry and

 Enabling Technology: TJI + boosting

Optical Engine Jet velocity as a function of TJI hardware

1-D and 3-D

 Phase 1 optical and thermo engine

 Optical engine successfully designed and

Custom head incorporating TJI

Optical combustion chamber

Ford 4-cylinder bottom end

High speed camera

 Base TJI hardware w/ fueled pre-chamber Shown: Bottom-to-top view of cylinder

 Single cylinder thermodynamic engine designed and assembled in-house

Prototype Ford 2.3L

10:1 12:1 14:1

 Data processed and synthesized

 TJI effectively extends the lean limit of a Speed: 2500 rpm

 Further analysis ongoing Base engine efficiency @ λ=1

*Note: 47 kg/hr = 8.7 bar IMEPg @ stoich

Speed: 2500 rpm

17 MAHLE Powertrain LLC, 25-Feb-2014 © MAHLE

Engine Basis GM Ecotec LE5

Valve Lift (mm)

TJI single cylinder Dual VVT – Cam Phasers

 Split fuel (gaseous pre-

Relative to λ=1 Spark Ignittion.

 Highest efficiency gain with 5

– High thermal efficiency

 MPT researching fundamental characteristics of TJI

 Synthesized data will describe correlation among TJI

 TJI provides excellent platform for dual fuel

 Design proved to robust, test

 Spectral Energies LLC supplied

Small nozzle hole diameter Large nozzle hole diameter

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