The Use of Exhaust Gas Recirculation to Optimize Fuel Economy and Minimize Emission in Engines Operating on E85 Fuel

Abstract

This report summarizes activities conducted for the project “The Use of Exhaust Gas Recirculation to Optimized Fuel Economy and Minimize Emissions in Engines Operating on E85 Fuel” under COOPERATIVE AGREEMENT NUMBER DE-FC26-07NT43271, which are as outlined in the STATEMENT OF PROJECT OBJECTIVES (SOPO) dated March 2007 and in the supplemental SOPO dated October 2010. The project objective was to develop and demonstrate an internal combustion engine that is optimized for E85 (85% ethanol and 15% gasoline) fuel operation to achieve substantially improved fuel economy while operating with E85 fuel and that is also production viable in the near- to medium-term. The key engine technology selected for research and development was turbocharging, which is known to improve fuel economy thru downsizing and is in particular capable of exploiting ethanol fuel’s characteristics of high octane number and high latent heat of vaporization. The engine further integrated synergistic efficiency improving technologies of cooled exhaust gas recirculation (EGR), direct fuel injection and dual continuously variable intake and exhaust cam phasers. On the vehicle level, fuel economy was furthered thru powertrain system optimization by mating a state-of-the-art six-speed automatic transmission to the engine. In order to achieve the project’s objective of near- to medium-term production viability, it was essential to develop the engine to be flex-fuel capable of operating with fuels ranging from E0 (0% ethanol and 100% gasoline) to E85 and to use three-way type of catalyst technology for exhaust aftertreatment. Within these scopes, various technologies were developed through systems approach to focus on ways to help accelerate catalyst light-off. Significant amount of development took place during the course of the project within General Motors, LLC. Many prototype flex-fuel engines were designed, built and developed with various hardware configurations selected to achieve the project goals. Several flex-fuel demonstration vehicles were designed and built for carrying out calibration development and final testing to quantify the technology merits. Based on the extensive test results collected from dynamometer and vehicle testing, the fuel economy benefits of cooled EGR from the intended level of turbocharger technology were quantified. When combined with turbo downsizing, the FE benefits are considered large enough for E0 fuel as well as for E85 fuel to warrant further development of the technology beyond the current proof-of-concept level to a level that can meet production driveability quality and durability requirements in order to meet customers’ expectations. Cold-start cart test results from the emissions segment of the project were positive, confirming the assumption of faster thermal response of turbo exhaust system for emissions reductions for both E0 and E85 fuels. Vehicle emissions test results directionally correlated to the cold-start cart findings. The limited number of test runs did demonstrate the potentials of meeting stringent emission standards, however, they did not comprehend the factors such as hardware variability and long-term durability, 3 which are essential for mass production to satisfy customers’ expectations. It is therefore recommended, moving forward, durability concerns over turbocharger, EGR system and aftertreatment system, which would likely impact production viability, should be addressed. The data moreover suggested that further FE increase is likely with turbocharger technology advancement.