Exhaust Gas Recirculation System Research Articles

Reducing real driving fuel consumption and emissions with a hydraulic hybrid vehicle

We have successfully prototyped and tested the real-driving performance of a hydraulic hybrid heavy commercial vehicle. Hydraulic hybrid driveline technology was fitted to a Euro IV diesel truck equipped with a diesel particulate diffuser/filter and an exhaust gas recirculation system. An AVL portable emissions measurement system was fitted to the test vehicle to quantify gaseous and particle phase emissions species and an on-board diagnostic scan tool was used to obtain data from the trucks electronic control unit. Fuel consumption savings up to 17 % were accomplished in hydraulic hybrid mode when testing on a short urban driving route featuring a high intensity of stop-start activity. Average reductions in solid particle number concentration of 40 % were achieved along with increases in NOx, Hydrocarbons (THCs) and CO. Future work could target improved control system integration of the various driveline components to further reduce fuel consumption and emissions in an improved prototype design.

Parameter optimisation of marine four-stroke engine EGR systems using RSM and NSGA-III

ABSTRACT To reduce NOx emission of marine engines, an engine parameter optimisation method combining response surface method (RSM), Bayesian neural network and non-dominated sequence genetic algorithm (NSGA-III) is proposed. First, a simulation model of a marine four-stroke engine with an external exhaust gas recirculation (EGR) system was established and validated in AVL-BOOST software. Then, the five parameters of EGR valve opening, ignition advance angle, compression ratio (CR), intake valve opening (IVO) and exhaust valve closing (EVC) are selected as the decision parameters, and the three parameters of engine power, brake specific fuel consumption (BSFC) and NOx emission are taken as the target parameters to be optimised. In Design-Expert software, the response surface model is established by using the experimental design approach of central composite design (CCD), and the impact of decision parameters on target parameters are discussed by using response surface analysis. NSGA-III was used for the multi-objective optimisation of parameters, and the accuracy of NSGA-III was improved by the Bayesian neural network. The optimal solution is selected and verified by the technique for order of preference by similarity to the ideal solution (TOPSIS) approach. The results show that when the EGR valve opening is 47.5%, ignition advance angle is −18.99°CA, CR is 14.995, IVO is 15.27°CA and EVC is 7.68°CA, compared with the standard setting, the optimised power is increased by 4.17%, BSFC is reduced by 4.27%, and NOx emissions are reduced by 12.37%. Therefore, the combination of the Bayesian neural network and NSGA-III multi-objective optimisation can improve engine performance while reducing fuel consumption and NOx emissions.

Control strategies for mode switching of a large marine two-stroke engine equipped with exhaust gas recirculation and turbocharger cut-off systems

To meet the stringent nitrogen oxides emissions regulations, the recent marine two-stroke engines are equipped with exhaust gas recirculation (EGR) systems. Crossing the boundaries of exhaust control areas requires switching between the engine operating modes associated with the activation or deactivation the EGR system, which imposes challenges to the engine operation. This study aims to develop and numerically test effective control strategies for improving the mode switching of marine two-stroke engines with EGR systems. The investigated engine dynamic model is developed by integrating a zero-dimensional thermodynamic model developed in GT-POWER and the control model developed in MATLAB/Simulink. This model is first validated against the experimentally measured engine performance parameters, and subsequently employed to simulate the engine dynamic operation with mode switching. The simulation results are assessed to quantify the impact of several control strategies on the engine performance. The derived perrformannce parameters time variations demonstrate that the deactivation of the EGR branch and the small engine–turbocharger result in exceeding the manufacturer limits at high loads and increasing the fuel consumption. The proposed load-based control strategies, which employ load thresholds and time delays for the control of the EGR and turbocharging systems activation/deactivation, are proved effective, as the engine performance parameters are retained within their limits and fuel consumption penalties are minimised. This study provides insights for developing the control of the marine engines after-treatment systems, hence contributing towards enhancing shipping sustainability.

Multi-mode operation of a novel dual-pressure steam rankine cycle system recovering multi-grade waste heat from a marine two-stroke engine equipped with the high-pressure exhaust gas recirculation system

As a promising technology for marine two-stroke engines satisfying the IMO Tier Ⅲ NOx regulation, the high-pressure exhaust gas recirculation (HP-EGR) systems in multi-mode operation significantly redistribute the waste heat, thereby complicating the design and control of the waste heat recovery (WHR) systems. In this paper, a novel dual-pressure steam Rankine cycle (SRC) is proposed to recover multi-grade waste heat from marine engines in multi-mode operation. The HP-EGR system is designed on the 6EX340 engine, followed by the evaluation of waste heat distribution in multi-modes. Detailed thermodynamic and economic analyses of the designed SRC and the combined cycle power plant are then conducted. The results show that the thermal efficiency of the designed SRC is 8.1 %–13.3 % in Tier II mode, increasing to 10.1 %–15.7 % in Tier III mode, attributable to a 16 %–42 % increase in waste heat exergy. Considering typical propulsion profiles, the reduction in weighted average fuel consumption for the combined cycle power plant reaches up to 3.4 % in Tier II operation and 6.1 % in Tier III operation. When 12.5 % of sailing time is spent within ECAs, the combined cycle power plant is expected to yield up to 4 % in annual fuel cost savings.

Optimization and 4E analysis of integration of waste heat recovery and exhaust gas recirculation for a marine diesel engine to reduce NOx emissions and improve efficiency

This paper proposes an integration of waste heat recovery system and exhaust gas recirculation system to break the inherent trade-offs between NOx and carbon emissions of marine low-speed diesel engine. It is significant important to break these trade-offs, because Energy Efficiency Existing Ship Index may not be met, though Energy Efficiency Design Index and Tier III can be already achieved for old ships. The waste heat recovery system consists of supercritical carbon dioxide Brayton cycle and Kalina cycle, where the integration of supercritical carbon dioxide Brayton cycle and Kalina cycle is achieved in the parallel style. This paper uses the classical thermodynamics in terms of engineering approach to carry out the parameter analysis of combined system first. The optimization is conducted in terms of efficiency, energy density and techno-economy with the introduction of global optimal policy. The results showed that the highest efficiency of 52.32% at Tier III mode can be achieved, at which the net power, exergy efficiency, area per unit power output and levelized energy cost can be achieved by 1568.57 kW, 45.75%, 0.589 m2/kW and 0.114$/kWh at main engine load of 85%. Further, the net power output of waste heat recovery system can reach 1085.76 kW and 2043 kW at Tier II mode and Tier III mode, while the recovering rate of waste heat recovery system can reach over 5% at Tier III mode. Finally, the Energy Efficiency Existing Ship Index of a container ship equipping with such combined system can be reduced from 9.50 to 9.05.

Effect of exhaust gas recirculation on the performance and emission characteristics of diesel engine with hydrogen fuel and nano additives

One of the most popular techniques for reducing emissions, in particular nitrogen oxide (NOX), carbon monoxide (CO), carbon dioxide (CO2), and particulate matter (PM), is exhaust gas recirculation (EGR). In an EGR system, the intake manifold is used to re-introduce some of the exhaust gases into the combustion chamber. Diesel engine performance could be enhanced by employing the right number of nano additives. Nano additions aid in increasing efficiency when using hydro fuel. The following systems are impacted by the use of EGR: brake specific fuel consumption (BSFC), diesel engine combustion characteristics, brake thermal efficiency (BTE), engine speed, CO2 and HC emissions, turbocharged diesel engine performance characteristics, fuels, temperature, and on EGR.

Effect of Variable-Nozzle-Turbocharger-Coupled Exhaust Gas Recirculation on Natural Gas Engine Emissions and Collaborative Optimization

Equivalent combustion natural gas engines typically utilize exhaust gas recirculation (EGR) systems to tackle their high thermal burden and NOx emissions. Variable nozzle turbochargers (VNT) can increase the engine intake and EGR rate simultaneously, resulting in NOx reduction while ensuring robust power performance. Using a VNT along with engine bench testing, the impact of VNT- and EGR-coordinated control on the performance and emissions of equivalent combustion natural gas engines was investigated under different operating conditions. Subsequently, multi-objective optimization was performed using a support vector machine. The results demonstrated that the use of VNTs in equivalent combustion natural gas engines could bolster the capacity to introduce EGR under several operative conditions and extend the scope of EGR regulation, thereby decreasing the engine’s thermal burden, improving fuel efficiency, and curbing emissions. Owing to the implementation of a multi-objective optimization method based on a support vector regression model and NSGA-II genetic algorithm, VNT and EGR control parameters could be optimized to slightly improve the economy and significantly reduce NOx emissions while maintaining the original engine power performance. At 20 operating points optimized for validation, brake-specific fuel consumption (BSFC) and NOx decreased by 0.94% and 47.0%, respectively, and CH4 increased by 3.7%, on average.

Evaluation of selected combustion parameters in a compression-ignition engine powered by hydrogenated vegetable oil (HVO)

The article carries out a detailed analysis and evaluation of indicators related to the combustion process (pressure and temperature in the engine combustion chamber, heat release rate, heat release fraction) in a JCB 444 TA4i compression-ignition engine fuelled with diesel and hydrogenated vegetable oil (HVO). During the empirical tests, the operation of the exhaust gas recirculation (EGR) system was stopped and no other changes were made to the engine settings (factory settings were used). In the first stage, the empirical tests were carried out at speed characteristics on an engine dynamometer. Then, an experiment was carried out at the engine crankshaft speed corresponding to the maximum torque - which consisted of determining the indicators related to the combustion process at a constant mass flow of fuel: diesel and HVO fuel. This provided information on the effect of hydrogenated vegetable oil on the combustion process in relation to the diesel engine feed. The conclusions drawn from the empirical study can be used to develop guidelines to change the operating map of a compression-ignition engine when it is fed with hydrogenated vegetable oil.

Study on the Optimized Matching of VNT and EGR Systems in a Diesel Engine

An experimental investigation of the coupling relationship between the VNT (Variable Nozzle Turbine) and EGR (Exhaust Gas Recirculation) systems was carried out in this study on a four-valve common-rail diesel engine in bench tests, as well as a transient optimization of the VNT and EGR control strategies. It was found that the overall level of NOX and flue gas emissions decreased with decreasing VNT opening. When the opening of the EGR valve was in the range of 5%-10%, the NOX and soot emissions could be reduced simultaneously by decreasing the VNT opening; the response of the intake volume was greatly improved by modifying the coordinated control strategy by boosting the control strategy under the acute load step condition; the NOX emission was significantly reduced by 6% overall, and the soot was reduced by 22.8% and the CO2 emission was improved in the transient-optimized WLTC test cycle. Therefore, by coupling the VNT and EGR systems and optimizing them transiently, emissions of pollutants during rapid engine acceleration can be decreased.

Effects of exhaust gas recirculation on nitrogen oxides, brake torque and efficiency in a hydrogen direct injection spark ignition engine

This study investigated the effects of exhaust gas recirculation (EGR) on emission and efficiency in a hydrogen direct injection spark ignition engine. EGR was supplied as the low-pressure (LP)-EGR system by controlling EGR valve from zero to 18.7% in terms of mass fraction. The result showed that EGR effect on nitrogen oxides (NOx) reduction became enlarged as higher engine speed due to increasing residual gas fraction. Also, under the same excessive air ratio (λ:2.2), EGR addition made NOx reduction from 89.9 to 98.7 % as varying engine speed. As NOx limit was low, the maximum brake torque was also reduced. However, by using appropriate EGR, NOx margin could be converted to increasing brake torque under the same NOx concentration level from 1.9% to 18.2% as varying engine speeds. From this result, to achieve the maximum output when reaching the turbocharger’s limit in a hydrogen engine and effectively reduce nitrogen oxide emissions, it is not only dependent on lean combustion but also effective to incorporate approximately 20% EGR into the operating strategy.

Numerical studies on the flow characteristic of the marine two-stroke engine integrated with the high-pressure exhaust gas recirculation system

The high-pressure exhaust gas recirculation (HP-EGR) has been well-proven for marine engines complying with the IMO Tier Ⅲ NOx regulation. Considering different turbocharged scavenging schemes and emission control modes, intake and exhaust gas management is critical to the HP-EGR design. However, few theoretical studies on it were reported. This paper aims at providing a case study on the flow characteristic of the turbocharged HP-EGR system. With the proposed topology structure of the typical HP-EGR layout, numerical studies on the turbocharged scavenging and EGR design were conducted based on the 6EX340 two-stroke engine. The result showed that the flow characteristic of the turbocharged two-stroke engine can be graphically depicted by simplifying the cylinder and turbine as multi-nozzle in series. According to the nozzle flow equation of uniflow scavenging, there exists an optimum turbine flow area to maximize the scavenging mass flow. Effects of EGR, cylinder bypass, and exhaust gas bypass on the flow characteristic of the two-stroke engine depend on the turbocharger matching. The out-cylinder scavenging and in-cylinder combustion should be optimized interactively to fully explore the fuel economy and NOx trade-off. Finally, the proposed design procedure can provide good guidance for the design and control of the HP-EGR system.

Physically-based control-oriented modeling for turbocharged stoichiometric spark-ignited engine with cooled EGR and flexible VVT systems

Accurate estimation and prediction of engine gas exchange system and in-cylinder conditions are critical for spark-ignited engine control and diagnostic algorithm development. In this paper, a physically-based, control-oriented model for a 2.8 l turbocharged, variable valve timing (VVT) and low pressure (LP) exhaust gas recirculation (EGR)-utilizing SI engine was developed. The model includes the impact of modulation to any combination of 10 actuators, including the throttle valve, compressor bypass valve, fueling rate, waste-gate, LP EGR valve, number of deactivated cylinders, intake valve open (IVO) timing, intake valve close (IVC) timing, exhaust valve open (EVO) timing and exhaust valve close (EVC) timing. The accuracy of the model in capturing engine dynamics was demonstrated by validating it against high-fidelity engine GT-Power simulation results for various drive cycles, particularly emphasizing elevated loads. In comparison to the open literature, novel contributions of the effort described in this paper includes in-cylinder gas composition modeling and turbine-out pressure estimation.

Prediction of Condensation in the Heat Exchangers of Engine Intake Systems according to External Environmental and Operating Conditions

Low-pressure exhaust gas recirculation (LP-EGR) systems are applied to diesel engines because they reduce nitrogen oxide emission by lowering the internal temperature of the cylinder by mixing the oxides with intake air. However, low-temperature ambient conditions include a large amount of vapor in the mixed gas flowing into the intercooler; when heat is exchanged, the water vapor condenses and is adsorbed on the surface of the intercooler fin to form a liquid film. Condensation occurs as the thermal resistance between the vapor and solid surface increases with the thickness of the liquid film and causing a corrosion due to condensation of the surface. In this study, the amount of condensation was predicted through calculations based on thermodynamic studies. Factors that can cause condensation inside the intercooler (fuel, air, and LP-EGR) were selected as variables. A mathematical formula was established to predict the convergence form of condensation or the amount of condensation over time at various temperature and relative humidity conditions. The formula predicted the condensation amount in the intercooler of the diesel engine, compared it to the actual amount of condensation in the test evaluation with an error of less than 4%. Additionally, because the formula can predict the amount of condensation by changing the heat exchange area of the intercooler, the application range of the formula was expanded to predict the condensation in the intercoolers of gasoline vehicles with different heat exchange areas and fuel types. The condensation error was within 2%, indicating a high consistency. Validation of the formula predicts a reliable amount of condensation under various operating and ambient temperature conditions, which means that both the time and cost of the test evaluation require the determination of the cause before solving the actual condensation problem.

An Experimental Examination into the Efficiency of a Shell-and-Tube Heat Exchanger for an EGR Cooler

The increasing concerns over environmental pollution and stringent regulations on emission have led to the widespread adoption of exhaust gas recirculation (EGR) systems in interna combustion engines. EGR systems help reduce nitrogen oxide (NOx) emissions by recirculating a portion of exhaust gaes back into the combustion chamber. Howerver, the elevated temperature of exhaust gases poses challenges related to thermal management, necessitating the use of exhaust gas recirculation cooler. The experimental setup allows for the controlled circulation of exhaust gases and cooling fluids, thereby facilitating the measurement of heat transfer rates, pressure drops and overall thermal efficiency. These parameters encompass the inlet and outlet temperatures of both the exhaust gases and the cooling fluids flow rates for both fluids resulting pressure drops. By systematically altering these factors, the intricate, interplay between the various parameters and their inputs on the heat exchangers thermal performances are comprehensively explored. Addition, the research develops into critical aspects often overshadowed in EGR cooler studies on fouling. Overtime, the accumulation of deposits in the heat exchanger surface can led to reduced heat transfer efficiency. The outcomes of this study are instrumental for the advancement of EGR cooler technologies fostering more sustainable and environmentally friendly and automotive engines.

Thermo-economic optimization of an ORC system for a dual-fuel marine engine

The Organic Rankine Cycle (ORC) is one of the most promising systems to recover the waste heat sourced from internal combustion engines. In this study, thermodynamic, economic and environmental analyses of the scavenge air cooling water-driven Waste Heat Recovery System (WHRS) based on the organic Rankine cycle are conducted for a dual-fuel marine engine integrated with exhaust gas recirculation (EGR) system. Zero ozone-depleting and low global warming potential working fluids; R245fa, R236ea from hydrofluorocarbons, R600a, R601a from hydrocarbons, R1234ze and R1234yf from hydrofluoroolefins are selected for the low-grade WHRS. In addition to the thermal analyses, the mass and volume of the system along with the safety factors of the working fluids are evaluated to judge the physical applicability of the system for ships. Thermo-economic performances of the fluids are analyzed, optimized and compared under various engine loads, Tier II and Tier III modes to reveal the effects of different engine operating conditions on the parameters. According to the results, scavenge air has a significant amount of waste heat at medium and heavy loads and switching the engine mode remarkably affects the performance of the WHRS. R601a shows the best thermo-economic performance, however, considering the applicability of the system R236ea is the most suitable working fluid for the ORC WHRS. The overall thermal efficiency of the power generation system can be increased by about 2.8%.

Efficiency of limiting nitrogen oxides emissions by exhaust gas recirculation systems of marine internal combustion engines

The subject of this study is systems for ensuring environmental safety of marine internal combustion engines, in particular, technologies for limiting emissions of nitrogen oxides (NOx). The regulatory requirements for reducing emissions are presented in the paper. The main theoretical aspects of the problem of nitrogen oxides formation during combustion in a diesel engine are considered. On the basis of these theoretical aspects the effectiveness of using various methods to achieve the requirements for the permissible level of NOx concentration in the exhaust gases is assessed. Exhaust gas recirculation (EGR) systems and selective catalytic reduction (SCR) systems are considered as the main technologies; they allow achieving the highest indicators of nitrogen oxide emissions control in accordance with the requirements of the Tier 3 standard. Taking into account the peculiarities of the requirements for the design and layout of systems as part of a ship power plant, as well as operational and investment costs, the main attention in the work is paid to systems of indirect influence on the engine in-cylinder processes, which include exhaust gas recirculation systems. Based on the comparison of high and low pressure EGR, the advantages and disadvantages of the designs are determined. It is noted that high-pressure exhaust gas recirculation systems have a number of advantages, which primarily include the compactness and high speed of the system response to changes in operational conditions. On the example of the leading manufacturers developments, the potential capabilities of the high-pressure EGR system and the engine characteristics confirming the effectiveness of its use are demonstrated. Based on the results of the work, a conclusion about the high efficiency and expediency of using exhaust gas recirculation systems to meet the requirements of the current environmental safety standards of ship power plants is made.

Efficacy of performance and mitigate pollution of CI engine: Delonix regia biodiesel with n‐butanol and exhaust gas recirculation

AbstractThe primary aim of this research study was to examine the effectiveness and environmental consequences of using Delonix regia biodiesel (DRB) in combination with butanol (BUT), exhaust gas recirculation (EGR), and diesel fuel (D) on a direct injection compression ignition engine operating at a constant speed. This study involved the formulation of five distinct biodiesel blends, namely DRB10% + D90%, DRB20% + D80%, DRB10% + BUT10% + D80%, DRB10% + BUT20% + D70%, and DRB20% + D80% + EGR10%. The inclusion of n‐butanol in a biodiesel blend serves to tackle the problem of inadequate combustion in fuel blends by alleviating the oxygen deficiency that occurs during the combustion process. The findings of the study revealed that the combination of DRB at 10%, BUT at 20%, and D at 70% produced in a significant reduction in specific fuel consumption (SFC) by 11.19% and brake thermal efficiency by 2.62%. Additionally, this combination led to a decrease in exhaust emissions of CO and Smoke, with the exception of HC and NOx, when compared to the use of diesel fuel. The control of HC and NOx emissions can be achieved through the implementation of an exhaust gas recirculation system. The results of this investigation suggest that Delonix regia biodiesel, in combination with a 20% concentration of n‐butanol, has potential as a viable alternative fuel choice that may be utilized without necessitating any engine modifications.

Methane Emission Reduction Technologies for Natural Gas Engines: A Review

This review summarizes technologies to reduce methane emissions from natural gas engines with a focus on exhaust treatment. As regulations on methane emissions from natural gas facilities become more restrictive, methane emission reduction technologies become increasingly important. Methane is the second most prevalent human-generated greenhouse gas. In 2020, 197,000 metric tons of methane were released as a result of methane slip. In-cylinder methods such as optimized valve timing and crevice volume reduction are effective in reducing methane slip. Exhaust treatment methods such as catalytic oxidizers and regenerative thermal oxidizers can achieve near 100% methane reduction under certain conditions. Implementation of hydrogen blending and exhaust gas recirculation systems results in a decrease in methane emissions of between 20 and 30%. Future research should focus on testing full-scale catalytic oxidation systems on lean-burn natural gas engines. Research should also focus on implementing regenerative thermal oxidizers on natural gas engines, as well as combining hydrogen blending with these techniques.

Effect of Exhaust Gas Recirculation on a CRDI Engine fuelled with Biodiesel, Ethanol and Butanol

The global community has focused on the sustainability of petroleum-based fuel supply due to increased usage in various sectors, depletion of petroleum resources, and volatile crude oil market prices. We are looking for alternative fuel. As a result, we have chosen biodiesel. In this paper, a diesel blend containing biodiesel, ethanol, and butanol was created to test the characteristics of a common rail direct injection (CRDI) diesel engine equipped with an exhaust gas recirculation (EGR) system. The blends of diesel-biodiesel and diesel-biodiesel-ethanol-butanol were designated as B40 and B40-E10-BUT10 respectively. The experiment is carried out at a rate of 20% EGR. The experimental results show that the mechanical efficiency is higher in biodiesel blends than in diesel. The use of an EGR system with these blends reduces NOx by lowering the oxygen concentration in the combustion chamber.

Evaluation of the influence of fuel pressure pulsation in the Common Rail system on the economic and environmental performance of a diesel engine

BACKGROUND: At present, all the worlds diesel engine manufacturers have directed their development strategy towards reducing harmful emissions, improving fuel efficiency and increasing power per liter. To achieve this, using only the Common Rail system is not sufficient. It is necessary to apply new additional devices, such as an exhaust gas converter, an exhaust gas recirculation system, the injection of additional fluids together with diesel fuel, as well as to improve existing ones. Increasing the accuracy of fuel delivery for an injector will make it possible to adjust the engine fuel system more precisely, leading to a positive effect on all areas of development of the diesel industry.
 In this article, the possibility of increasing fuel efficiency and reducing harmful emissions through exhaust gases of a diesel engine with a decrease in pressure pulsation in the accumulator of the Common Rail system is considered on the example of the D-442-59I-1 (4ChN 13/14) experimental four-cylinder diesel engine with a two-valve gas distribution system manufactured by Altai Motor Plant.
 AIMS: Study of the effect of fuel pressure pulsation in the Common Rail fuel system on the economic and environmental performance of a diesel engine.
 METHODS: On a non-motorized test rig, the dependence of the fuel delivery of the injector on the pressure in the accumulator was determined. To assess the effect of fuel pressure at the injector inlet on the performance of a diesel internal combustion engine, experimental designs of diesel engines were simulated using the specialized software. Theoretical studies have been carried out to assess the influence of fuel pressure in the fuel system.
 RESULTS: Data have been obtained on the effect of fuel pressure fluctuations in the high-pressure line on the injector cycling, harmful emissions and fuel efficiency.
 CONCLUSIONS: As a result of the study of the process of fuel supply and combustion in a 4CHN 13/14 diesel engine, it was found that with a pressure fluctuation range of 50 bar in the fuel accumulator, the concentration of wet NOx decreases by 11%. The concentration of solid particles increases to 13.4%, fuel efficiency deteriorates to 0.5% when the operating pressure of the fuel deviates 160 MPa in any direction from the set value.