Review of the 21st Century Truck Partnership Third Report (2015) / Chapter Skim
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3 Engine Systems, Aftertreatment, Fuels, Lubricants, and Materials
3 Engine Systems, Aftertreatment, Fuels, Lubricants, and Materials
Pages 26-63
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From page 26... ...
laboratories, although the need to be addressed to facilitate reduced fuel consumption volumes produced will be small. Facilities for the production in diesels are also of value for spark-ignition engines, and of renewable diesel fuel from biomass resources continue vice versa (e.g., spray characterization, vaporization and to be developed, and the production and sale of biodiesel is mixing phenomena, autoignition, combustion and emission growing in the United States at a modest rate.1 The use of kinetics, and cost-effective lean-emissions control systems)
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From page 27... ...
Exhaust Emissions ENGINE SYSTEMS PROGRAM: STATE OF TECHNOLOGY AND GOALS The considerable effort and research funding focused on improving emissions control systems is complementary to As with any power generation device using chemical reac- the development of engine combustion processes. To meet tions to provide energy, both diesel and gasoline engines have US2007 HD regulations, exhaust gas recirculation (EGR)
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From page 28... ...
(Approximate proportions of this nonuseful energy within the heat transfer and exhaust have been marked on the figure.a) Thus, even though there is significant energy flow leaving the cylinder as heat transfer and exhaust flow, it is not possible to convert all of that energy into work using additional energy conversion devices such as waste heat recovery, which use the heat transfer and/or exhaust flow as the energy input.
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From page 29... ...
Figure 3-1-1 Bitmapped The above challenges motivate the fundamental research Goal 2 segues into the discussion of the individual DOE and development projects in the 21CTP. and DOD programs nicely because of the extent to which Although SuperTruck is discussed at greater length in the SuperTruck programs will be relying on the advanceChapter 8, its engine development activities in SuperTruck ments made within the individual DOE and DOD projects are discussed here separately, before the individual DOE to achieve the 55 percent goal.
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From page 30... ...
The extension of this effort to reach 55 percent technologies into a complex vehicle powertrain system, and BTE entails a fundamental research program to explore and the committee congratulates the Partnership and SuperTruck quantify the potential of using advanced combustion/fuel teams for this accomplishment. and engine technologies that are currently being explored within research laboratories, with an eye on showing tech- Goal 2: Research and develop technologies that achieve a nical potential.
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From page 31... ...
thermal management FMEP reduction optimization Fuel system HPCR with reduced Amplified HPCR HPCR (converted from Amplified HPCR parasitic fuel pump unit injector baseline) Combustion refinement Very high CR, piston bowl, High CR, piston bowl, Increased CR, advanced Looking at 6 g engine-out injector match, low EGR, injector match, piston bowl design, NOx, higher injection press, 4.3 g/hp-hr engine- conventional diffusion conventional diffusion revised piston bowl and high out NOx, conventional burn, higher engine- burn, same engine-out NOx CR, evaluating diesel and dual diffusion burn out NOx, model- based as US2010 fuel options, low swirl controls Electric drive components Electric HVAC Electric dual-zone HVAC Electric HVAC, 48 V Waste heat recovery Rankine cycle, R245 Rankine cycle, ethanol Turbocompound plus Turbocompound, Rankine working fluid, mechanical working fluid, electric Rankine cycle with ethanol cycle, and e-turbo are being drive, uses EGR and drive, uses EGR and working fluid, mechanical evaluated exhaust heat, turbine exhaust heat, scroll drive, uses EGR and expander expander exhaust heat Aftertreatment High conversion efficiency, High conversion efficiency, High conversion efficiency, High conversion efficiency, low back pressure low back pressure low back pressure low back pressure Turbo technology High efficiency VG Asymmetric High efficiency Possible e-turbo EGR loop Reduced flow and HPL Reduced flow HPL Reduced flow and restriction restriction HPL HPL Variable valve actuation No No No Being evaluated Cooling system Conventional cooling Angled cooling package, Variable speed engine- 3-speed engine-driven fan, package, engine-driven fan hydraulic motor fan drive, driven fan, variable-speed electronic stat, high coolant active grill shutters cooling pump temp., variable-speed cooling pump, variable coolant pressure Accessory power demand Clutched air compressor Clutched air compressor Variable displacement oil with active controls, with active controls, pump, clutched air compressor clutched power steering low-energy power with intelligent dryer pump with reservoir, cab steering, look-ahead smart control, accessories run on insulation, solar reflective alternator, LED lighting, deceleration/coasting paint cab insulation NOTE: FMEP, friction mean effective pressure; PCP, peak cylinder pressure; HPCR, high-pressure common rail; CR, compression ratio; HVAC, heating, ventilation, and air conditioning; LED, light-emitting diode; EGR, exhaust gas recirculation; VG, variable geometry; HPL, high-pressure loop.
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From page 32... ...
in the Cummins cylinder.2 Lower temperatures and leaner mixtures within the cylinder result in values of gamma (γ) that are larger The Cummins approach to the 55 percent BTE requirethan when the temperatures are higher or the mixtures are ment is described in its 2014 DOE Annual Merit Review stoichiometric.
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From page 33... ...
SuperTruck Annual Merit Review Presentations, temperature combustion; HRR, heat release rate; WHR, waste heat Cummins, Inc. recovery; EGR, exhaust gas recirculation.
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From page 34... ...
is preparing to launch a program called the Virtual As seen in the descriptions of the SuperTruck team's Engine Research Institute and Fuels Initiative (VERIFI) ,4 activities, advanced combustion strategies and sophisticated an organization that will be available to industry and that CFD modeling are essential parts of their technical roadmaps integrates high-performance computing, fuel chemistry, and to achieving 55 percent BTE.
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From page 35... ...
The projects from that list that the committee has lb/bhp-hr, interpreted as falling within the advanced engines arena are (3) A rated speed air:fuel ratio not to exceed 30:1, listed in Table 3-4.
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From page 36... ...
ACE052 Neutron Imaging of Advanced Transportation Technologies ORNL 200,000 200,000 200,000 ACE054 Collaborative Combustion Research with Basic Energy ANL 400,000 320,000 325,000 Sciences ACE075 Advancement in Fuel Spray and Combustion Modeling for ANL 350,000 500,000 350,000 Compression Ignition Engine Applications ACE076 Improved Solvers for Advanced Engine Combustion LLNL 340,000 340,000 475,000 Simulation ACE077 Cummins ORNL\FEERC Combustion CRADA: ORNL 300,000 300,000 300,000 Characterization and Reduction of Combustion Variations Total federal dollars 7,705,000 7,848,000 6,520,000 NOTE: Information provided includes project number, title, lead organization, and federal dollars supporting the program.
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From page 37... ...
The simulation of advanced com pression ignition combustion processes, often generically referred to as LTC, requires detailed high-fidelity kinetic 5 See Vehicle Technologies Office: Annual Merit Review and Peer Evalu ation at http://energy.gov/eere/vehicles/vehicle-technologies-office-annualmerit-review-and-peer-evaluation. 6 See the Engine Combustion Network at http://www.sandia.gov/ecn/.
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From page 38... ...
They are developing models mental data that will be used to develop and evaluate kinetic for FACE, which include blends that have been specified for routines for transportation-relevant fuels at conditions represearchers to represent a matrix of fuels in which the proper- resentative of advanced combustion regimes (Goldsborough ties vary over a range that might be expected in the future as et al., 2014)
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From page 39... ...
are also involved in the rest of the VTP R&D program (the advanced combustion MOU, the advanced engine crosscut team, and the Annual Merit Review) , and are thus made
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From page 40... ...
DOE's Annual Merit Review included the Super- Integral to this effort is the continued advancement of the Truck team members as active participants, and presented base computer program itself and the solvers that facilitate the entire research portfolio to them. This ensures that Su- rapid computational turnaround time.
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From page 41... ...
This resulted FTP cycle, both of which depend on additional innovations in in filters with less PM mass and lower back pressure. An emissions control technology.
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From page 42... ...
Expected OBD requirements at these very low tail pipe NOx levels are not achievable with Aftertreatment Projects today's sensor and modeling technology. Although 21CTP has no specific aftertreatment goals, in The NRC Phase 2 report (2012)
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From page 43... ...
ACE023 CLEERS aftertreatment modeling Pacific Northwest 750,000 750,000 750,000 and analysis National Laboratory (PNNL) ACE026 Enhanced high- and low- PNNL 300,000 300,000 300,000 Funding matched by temperature performance of NOx reduction Cummins in CRADA materials ACE028 Experimental studies for CPF Michigan 607,000 Project completed in FY and SCR model, control system, and OBD Technological 2012; 323,000 matched development for engines using diesel and University funding biodiesel fuels ACE032 Cummins/ORNL-FEERC CRADA: ORNL 450,000 595,000 232,000 *
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From page 44... ...
ment for Engines Using Diesel and Biodiesel Fuels" was Samples can be heated in situ up to 1,000°C and follow a completed in September 2012. A core aspect of the project catalytic reaction in a controlled atmosphere.
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From page 45... ...
and SCR materials. formation mechanisms of the greenhouse gas N2O from Hydrothermal aging was done at elevated temperatures for advanced combustion and emission control systems is lacklifetime prediction and to evaluate degradation mechanisms.
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From page 46... ...
The NRC Phase 2 review committee commented that significant progress was being achieved on emissions control Recommendation 3-3. The Partnership should continue understanding either through formal work in the program or work on aftertreatment and emissions control, but the DOE through industry efforts.
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From page 47... ...
SOURCE: B Zigler, "Fuels for Advanced Combus Figure 3-8 tion Engines," DOE Annual Merit Review FJ002, May 15, 2012.
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From page 48... ...
Research targeted at utilizing renewable waiver to allow up to 15 percent ethanol in gasoline used fuels in spark-ignition engines may not be as critical as that to fuel 2001 through 2006 model-year, light-duty vehicles. targeted at diesel engine fuel efficiency strategies and the use The EPA cannot force fuel stations to provide gasoline of biodiesel or renewable diesel fuel blending components in blends containing 15 percent ethanol without the approval advanced combustion engines.
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From page 49... ...
well-to-wheel (WTW) energy and emissions analyses that, Significant commercial effort has been directed toward even taking into account increased methane emissions from the production of renewable diesel fuels, as described by the natural gas vehicles, total GHG emissions will be lower than second option, although such fuels are currently not much from pure gasoline- or diesel-fueled vehicles (NRC, 2014)
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From page 50... ...
FACE fuels and other sur- fuel projects have the objective of evaluating the effects of rogate diesel fuels are being used in several DOE laboratory fuel composition (including both hydrocarbons and biofuels) programs designed to quantify advanced combustion engine on advanced combustion strategies and emissions control performance and efficiencies when using fuels having well- systems performance (McCormick and Ratcliff, 2014; defined characteristics.
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From page 51... ...
/ Title Recipient Funding Funding Funding Note FT001 Fuel and Lubricant Effects ORNL 1,400,000 1,250,000 1,465,000 FT002 Advanced Combustion and Fuels NREL 935,000 822,000 697,000 FT003 Performance of Biofuels and Biofuel Blends NREL 800,000 700,000 400,000 FT004 Fuel Effects on Mixing-Controlled SNL 800,000 800,000 800,000 Combustion Strategies for High-Efficiency CleanCombustion Engines FT007 Fuel and Lubricant Effects on Emissions ORNL 1,445,000 700,000 825,000 Control Technologies FT008 Gasoline-Like Fuel Effects on Advanced ORNL 615,000 400,000 450,000 Combustion Regimes FT010 Chemical Kinetic Modeling of Non- LLNL 750,000 – 500,000 Petroleum Based Fuels FT011 Impact of Biodiesel Metals on Aftertreatment NREL 400,000 – – Project ended in 2012 System Durability FT015 Demonstration/Development of RCCI Univ. of 500,000 640,000 360,000 Project ends in 2015 Combustion for High Efficiency, Low Emissions WisconsinVehicle Applications Madison FT016 High Compression Ratio Turbo Gasoline MIT 408,000 235,000 320,000 Engine Operation Using Alcohol Enhancement FT017 Fuel Properties to Enable Lifted‐Flame Ford Motor 436,904 406,000 694,000 Combustion Company FT022 CFD Simulations and Experiments to ANL 150,000 150,000 – Determine the Feasibility of Various Alternate Fuels for Compression Ignition Engine Applications Natural Gas Engine Development with CEC and NREL – – – No project number.
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From page 52... ...
. The RCCI DOE laboratories, but the research is being conducted on operating range was expanded to 75 percent of its theoretical a variety of advanced combustion engines using different maximum while maintaining low soot and NOx emissions fuels.
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From page 53... ...
Goal 3 in the Engine Systems chapter of the 21CTP 2013 Roadmap and Technical White Papers identi 21CTP Response: We are continually open to re-evaluation of fies the objective of determining the essential fuel properties our goals in light of budget changes. Recent budgets have been required to enable advanced combustion systems that can volatile, which complicates the effort -- e.g., between the FY12 achieve 55 percent BTE.
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From page 54... ...
Tests with reduced ing the next 25 years, while diesel fuel demand is expected HTHS viscosity oils instead of SAE 15W-40 oils have to grow. If regulators continue in their efforts to meet the shown modest reductions in fuel consumption while other Renewable Fuel Standard goals, production of biodiesel and traditional additive components continue to protect durability renewable diesel will need to increase.
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From page 55... ...
These include the following: Response to Recommendation from the NRC Phase 2 • Evaluate performance of traditional lubricant formula- Report tions in engines using advanced combustion regimes. NRC Phase 2 Recommendation 3-5.
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From page 56... ...
in Modern Internal Combustion Engines FT021 Can Hard Coatings and Lubricant Anti- ORNL – 250,000 250,000 wear Additives Work Together? NWU/ANL Novel Lube Formulations ANL – – 286,000 No project number Hyperbranched Polymers as Lubricants PNNL – 519,375 200,000 No project number Lubricant Formulations to Enhance Fuel TARDEC – 500,000 500,000 No project number Efficiency Advanced Lubricants TARDEC – – 900,000 No project number VSS058 Development of High Power Density ANL 350,000 300,000 350,000 Driveline for Vehicles Total 3,653,000 NOTE: Acronyms are defined in Appendix E
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From page 57... ...
in FY 2008, is a CRADA with Caterpillar and PNNL. Its PNNL work on materials for advanced diesel engines objective is to develop and deploy engineered surfaces via aims to develop and deploy engineered surfaces with friction stir processing (FSP)
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From page 58... ...
/ Novel Manufacturing Technologies for High Power Induction and Permanent Magnet Electric Motors (FY 14) Friction and Wear Enhancement of PM007 ORNL 125,000 – – Project ended Titanium Alloy Engine Components FY 2012 HD-Cast Fe Alloys for High PCP N/A NETL – 3,477,000 – Fully funded Engines FY 2013, 3 yr project Materials for HCCI Engines PM018 ORNL 225,000 – – Project ended FY 2012 Materials for Advanced PM038 ORNL 300,000 – 250,000 Turbocharger Designs High-Temperature Aluminum Alloys PM044 PNNL 395,000 300,000 125,000 Design-Optimization of PM051 ORNL 300,000 190,000 175,000 Piezoceramic Multilayer Actuators for Heavy-Duty Diesel Engine Fuel Injector Friction Reduction through Surface PM052 ORNL – 260,000 150,000 Project end Modification FY 2014 High-Temperature Materials for PM053 ORNL – 200,000 – High Efficiency Engines Applied ICME for New Propulsion PM057 ORNL – 68,711 825,176 Materials HD, High-Performance Cast Steels PM058 (ANL)
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From page 59... ...
The project supports tion in a reciprocating piston ring/liner configuration, (3) the Advanced Combustion Engine goal for the 2015 com- wear-resistant thin coatings for textured bearing surfaces mercial engine with a 20 percent improvement in efficiency were selected, and (4)
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From page 60... ...
DOE Annual Merit Review ACE014, June 17. http:// ing for HTML, and for the research specialists who oversee and energy.gov/eere/downloads/vehicle-technologies-office-merit-review operate the facility, to enable continued research collaboration 2014-2014-kiva-development.
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From page 61... ...
Jeremie Dernotte and ZSM5 as a low-temperature SCR catalyst to remove NOx from diesel Chunsheng Ji, Sandia National Laboratories. DOE Annual Merit Review engine exhaust.
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From page 62... ...
Argonne National Laboratory. DOE Annual Merit Review integrated into diesel particulate filters.
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From page 63... ...
2012. Fuels for Advanced Combustion Engines.
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