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Applied Energy 210 (2018) 138–151

Contents lists available at ScienceDirect

Applied Energy
journal homepage: www.elsevier.com/locate/apenergy

Improvement in high load ethanol-diesel dual-fuel combustion by Miller T


cycle and charge air cooling

Vinícius B. Pedrozo , Hua Zhao
Centre for Advanced Powertrain and Fuels Research (CAPF), Brunel University London, Kingston Lane, Uxbridge, Middlesex UB8 3PH, United Kingdom

H I G H L I G H T S

• The maximum ethanol energy fraction was increased from 0.26 to 0.79.
• Miller cycle effectively delayed the ethanol autoignition process without EGR.
• ADual-fuel
lower intake air temperature also retarded the early ignition of the ethanol fuel.
• NOx emissions
combustion yielded a better trade-off between efficiency and NOx emissions.
• were reduced by 44% while increasing net indicated efficiency by 4.1%.

A R T I C L E I N F O A B S T R A C T

Keywords: At high load, dual-fuel compression ignition engines often rely on exhaust gas recirculation (EGR) to avoid
Ethanol excessive in-cylinder pressure rise rates caused by the autoignition of the premixed fuel. This can adversely affect
Dual-fuel combustion the net indicated efficiency depending on the resulting fuel/air equivalence ratio and pressure differential across
High load the cylinder used to drive the requested amounts of EGR. In this work, advanced combustion control strategies
Miller cycle
have been experimentally investigated to improve ethanol-diesel dual-fuel operation at a high engine load of 1.8
LIVC
Autoignition
MPa net indicated mean effective pressure. Miller cycle and charge air cooling have been explored to reduce the
in-cylinder gas temperature and help control the ethanol autoignition process, potentially minimising the EGR
requirements and increasing net indicated efficiency. Experiments were carried out on a single-cylinder heavy-
duty engine equipped with a high pressure common rail diesel injection, an ethanol port fuel injection, and a
variable valve actuation system on the intake camshaft. Exhaust emissions and net indicated efficiency were
measured and discussed for different ethanol energy fractions. Early autoignition of the premixed ethanol fuel at
the baseline intake valve lift profile resulted in high levels of pressure rise rate, which limited the ethanol energy
fraction to 0.26. The application of a Miller cycle strategy via late intake valve closing events effectively delayed
the ethanol autoignition process. The reduction of the intake manifold air temperature via an air-to-water charge
air cooler also suppressed the early ignition of ethanol. Both approaches allowed for a substantial improvement
in terms of the maximum ethanol energy fraction, which was increased to 0.79 without EGR. Moreover, high
load dual-fuel operations with Miller cycle and charge air cooling attained higher net indicated efficiency and
lower nitrogen oxides emissions than conventional diesel combustion. These improvements can help generate a
viable business case of dual-fuel combustion as a technology for future compression ignition engines.

1. Introduction products, waste, and residues from agriculture, forestry, and related
industries [3]. The analysis of the GHG emissions associated with the
The vast majority of the transportation sector’s energy needs is met production, transport, and distribution of different biofuels [4,5] re-
by oil [1]. Increased global energy demand and greenhouse gas (GHG) vealed that ethanol produced from sugar cane results in lower overall
emissions regulations are driving the use of renewable energy sources GHG emissions than the life cycle GHG intensity of fossil fuels [6].
and advances in powertrain technology. The introduction of biofuels to Dual-fuel combustion has been proven as an effective means of
highly efficient internal combustion engines can help reduce the utilising alternative fuels in conventional diesel engines [7]. This
transport sector’s GHG emissions and petroleum dependence [2]. strategy can be achieved via the installation of a low cost port fuel
Biofuels are gaseous or liquid fuels produced from biomass, which is injection system for the formation of a low reactivity mixture of air and
the biodegradable fraction of municipal and industrial waste as well as fuel, such as natural gas (NG), gasoline, or ethanol [8]. The stock diesel

Corresponding author.
E-mail address: vinicius.pedrozo@brunel.ac.uk (V.B. Pedrozo).

http://dx.doi.org/10.1016/j.apenergy.2017.10.092
Received 27 March 2017; Received in revised form 10 October 2017; Accepted 26 October 2017
Available online 04 November 2017
0306-2619/ © 2017 Elsevier Ltd. All rights reserved.
V.B. Pedrozo, H. Zhao Applied Energy 210 (2018) 138–151

Nomenclature ISCO Net Indicated Specific Emissions of CO


ISHC Net Indicated Specific Emissions of Actual Unburnt HC
ATDC After Firing Top Dead Centre ISNOx Net Indicated Specific Emissions of NOx
BMEP Break Mean Effective Pressure ISsoot Net Indicated Specific Emissions of Soot
CA10 Crank Angle of 10% Cumulative Heat Release IVC Intake Valve Closing
CA10-CA50 10–50% Cumulative Heat Release IVO Intake Valve Opening
CA10-CA90 Combustion Duration or 10–90% Cumulative Heat LHVCO Lower Heating Value of Carbon Monoxide
Release LHVDF Actual Lower Heating Value in Dual-Fuel Mode
CA50 Crank Angle of 50% Cumulative Heat Release LHVdiesel Lower Heating Value of Diesel
CA90 Crank Angle of 90% Cumulative Heat Release LHVethanol Lower Heating Value of Ethanol
CAD Crank Angle Degrees LIVC Late Intake Valve Closing
CDC Conventional Diesel Combustion ṁ diesel Mass Flow Rate of Diesel
CO Carbon Monoxide ṁ ethanol Mass Flow Rate of Ethanol
CO2 Carbon Dioxide MFB Mass Fraction Burnt
COV_IMEP Coefficient of Variation of IMEP NG Natural Gas
DAQ Data Acquisition NOx Nitrogen Oxides
DF Dual-Fuel O2 Oxygen
E85 Gasoline with 85% Ethanol in a Volume Basis Pind Net Indicated Power
ECR Effective Compression Ratio PFI Port Fuel Injector
ECU Engine Control Unit Pmax Maximum In-cylinder Gas Pressure
EF Ethanol Energy Fraction PMEP Pumping Mean Effective Pressure
EGR Exhaust Gas Recirculation PRR Pressure Rise Rate
EIVC Early Intake Valve Closing SOC Start of Combustion
FID Flame Ionisation Detector SOI Actual Start of Diesel Injection
GCR Geometric Compression Ratio SOI_main Actual Start of Main Diesel Injection
GHG Greenhouse Gas TDC Firing Top Dead Centre
HC Hydrocarbons VVA Variable Valve Actuation
HRR Apparent Net Heat Release Rate γ Ratio of Specific Heats
IAT Intake Manifold Air Temperature Φ Global Fuel/Air Equivalence Ratio
IMEP Net Indicated Mean Effective Pressure

combustion and fuel injection systems can be retained in the dual-fuel can be quite demanding due to the sensitivity to fluctuations in the EGR
engine. Direct injected diesel fuel serves as the ignition source for the rate [29]. Furthermore, the use of a low GCR piston can lead to less
premixed charge [9]. The use of different fuels as well as variations in efficient dual-fuel combustion at light engine loads [28].
the diesel injection timing and energy fraction of each fuel can change Alternatively, Miller cycle can be used to lower the effective com-
the dual-fuel combustion characteristics, emissions, and efficiencies. pression ratio (ECR) via an early or late intake valve closing event
Optimised dual-fuel combustion can attain lower nitrogen oxides [30–32]. The strategy delays the actual initiation of the compression
(NOx) and soot emissions than conventional diesel combustion (CDC) process, reducing the charge density and decreasing both the in-cy-
[10,11]. Improvements in efficiency are also achievable [12–14]. linder gas temperature and pressure prior to the start of combustion
However, relatively high levels of carbon monoxide (CO) and unburnt [33]. The approach also allows for a more flexible combustion control
hydrocarbon (HC) emissions are usually reported at low engine loads when the stock piston and original compression ratio are retained and
[15]. Furthermore, dual-fuel operation at high load conditions have the intake valve timings are varied according to engine operating
been proved extremely challenging due to peak in-cylinder pressure condition. However, the reduction in charge density observed with
[16] and/or pressure rise rate limitations [17,18]. This is associated Miller cycle can increase the mean in-cylinder gas temperature during
with the autoignition of the low reactivity fuel. combustion, as the heat is released into a lower in-cylinder mass
A number of studies have investigated combustion control strategies trapped. Ickes et al. [34] have shown that this can potentially increase
to allow for safe high load dual-fuel operation, such as the direct dual heat transfer losses, as supported by lower gross net indicated efficiency
fuel stratification [19–21] and the use of high EGR rates [22–25]. for the cases with lower ECRs.
However, these approaches often require relatively complex and ex- Previous Miller cycle research with an early intake valve closing
pensive engine hardware modifications and/or high levels of boost (EIVC) showed gasoline-diesel dual-fuel combustion can be used over
pressure in order to supply enough fresh air for lean operation. the entire engine speed-load map while maintaining NOx emissions
Therefore, experimental research has been mostly focused on the use of below 0.4 g/kWh [35]. The maximum engine load was increased from
a lower compression ratio to decrease the in-cylinder gas pressure and 1.2 MPa to 2.2 MPa break mean effective pressure (BMEP) when the
temperature during the compression stroke. This delays the ignition of ECR was reduced from 14.4 to 11. However, the study also relied on the
the fuel and allows for longer fuel–air mixing process [26]. use of high levels of EGR, which can decrease the actual engine effi-
A reduction in compression ratio is typically attained via a modified ciency depending on the resulting fuel/air equivalence ratio and pres-
piston [27]. High load gasoline-diesel dual-fuel combustion has been sure differential across the cylinder (e.g. pumping losses) used to drive
achieved on a medium-duty engine using a piston with a lower geo- the requested amounts of EGR [23].
metric compression ratio (GCR) of 12.75 [28]. Despite the improve- The introduction of premixed fuels with high knock resistance such
ment, it is likely challenging to simultaneously attain high levels of as ethanol and NG potentially allows for the use of relatively higher
boost pressure and EGR rate at an intake charge temperature of 293 K in GCRs/ECRs as well as lower EGR and boost requirements. The sub-
a production engine. Additionally, experiments and computational stitution of gasoline for a blend of 85% ethanol content in gasoline (E85)
optimisations performed on a heavy-duty engine with a GCR of 12 extended the dual-fuel operating range from 1.16 MPa to 1.9 MPa BMEP
showed that controlling the dual-fuel combustion process at high loads [36]. This was accomplished with an E85 mass fraction of 0.90 and a

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V.B. Pedrozo, H. Zhao Applied Energy 210 (2018) 138–151

high EGR rate of 41% in a heavy-duty diesel engine with a GCR of 14. indicated efficiency and NOx emissions was discussed.
Goldsworthy [17] fumigated wet ethanol mixtures on a heavy-duty
diesel engine with a GCR of 17.2. In this case, the investigation was 2. Experimental setup
carried out without EGR at high loads of 1.7 and 2.0 MPa BMEP. How-
ever, wet ethanol energy fractions were limited to approximately 0.30 2.1. Engine specifications and experimental facilities
due to rapid premixed combustion and excessive pressure rise rates.
Similarly, Hanson et al. [37] achieved a maximum NG mass fraction of A schematic diagram of the single cylinder heavy-duty engine ex-
0.29 at 2.2 MPa BMEP when performing dual-fuel experiments without perimental setup is shown in Fig. 1. Fresh intake air was supplied to the
EGR on heavy-duty diesel engine with a GCR higher than 17. engine via an external supercharger with closed loop for the boost
Even though research has been carried out at high load conditions, pressure. A throttle valve located upstream of a large-volume surge tank
most dual-fuel studies have required a number of modifications to the provided fine control over the intake manifold pressure. The fresh air
engine as well as the use of high EGR rates in order to control the au- flow rate was measured with an Endress+Hauser Proline t-mass 65F
toignition of the low reactivity fuel, adversely affecting the net in- thermal mass flow meter. Another surge tank was installed in the ex-
dicated efficiency. Additionally, the majority of them have utilised haust manifold to damp out pressure fluctuations prior to the EGR
gasoline and NG as substitute for diesel fuel although ethanol can offer circuit. An electronically controlled exhaust back pressure valve located
lower overall GHG emissions. downstream of the exhaust surge tank was used to set the required
In response to these issues, advanced combustion control strategies exhaust manifold pressure. In some test conditions, high-pressure loop
were systematically evaluated to minimise the EGR requirements and cooled external EGR was supplied to the engine intake system via an
improve upon the net indicated efficiency of high load dual-fuel operation EGR valve. Boosted air and EGR temperatures were controlled using
using ethanol as a low reactivity fuel. To the best of our knowledge, this water cooled heat exchangers. Engine coolant and oil temperatures
study is the first attempt to experimentally explore the effect of Miller were kept at 353 ± 3 K. Oil pressure was set at 450 kPa throughout the
cycle via late intake valve closing events and charge air cooling via an air- experiments. The engine features a variable valve actuation (VVA)
to-water heat exchanger on high load ethanol-diesel dual-fuel combustion. system on the intake camshaft, incorporating a hydraulic tappet on the
Experiments were carried out on a heavy-duty diesel engine oper- valve side of the rocker arm [38]. This system allows for the use of
ating at 1.8 MPa net indicated mean effective pressure (IMEP). The Miller cycle via modification of the intake valve closing (IVC) event as
influence of ethanol energy fraction, EGR rate, and global fuel/air well as an intake valve re-opening during the exhaust stroke [11]. Base
equivalence ratio was also analysed. The overall trade-off between net hardware specifications are outlined in Table 1.

Fig. 1. Schematic diagram of the engine experimental setup.

Table 1
Single cylinder heavy-duty engine specifications.

Parameter Value

Displaced Volume 2.026 dm3


Stroke 155 mm
Bore 129 mm
Connecting Rod Length 256 mm
Number of Valves 4
Piston Type Re-entrant bowl
Geometric Compression Ratio 16.8
Maximum In-cylinder Pressure 18 MPa
Diesel Injection System Bosch common rail, injection pressure of 50–220 MPa, 8 holes with nominal diameter of 0.176 mm, included spray angle of 150°
Ethanol Injection System PFI Marelli IWP069, included spray angle of 15°

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V.B. Pedrozo, H. Zhao Applied Energy 210 (2018) 138–151

Table 2 Two National Instruments data acquisition (DAQ) cards were used
Fuel properties. to acquire the signals from the measurement device. A high speed DAQ
card received the crank angle resolved data synchronised with an op-
Property Red diesel (gas oil) Ethanol
tical encoder of 0.25 crank angle degrees (CAD) resolution. A lower
Product/standard specification BS 2869 Class A2 Absolute ethanol 100 speed DAQ card acquired the low frequency data, such as engine speed,
Density at 293 K 0.827 kg/dm3 0.790 kg/dm3 [39] torque, as well as temperatures and pressures at relevant locations. The
Cetane number > 45 n/a
data were calculated and displayed live by an in-house developed
Research octane number (RON) n/a [40] ∼107 [40]
Alcohol content in volume n/a 99.9% software.
Water content < 0.2 g/kg [41] < 1.7 g/kg [39] Crank angle based in-cylinder pressure traces were averaged for 200
Heat of vaporisation 270 kJ/kg [40] 840 kJ/kg [40] consecutive cycles for each operating point and used to calculate the
Carbon mass content 86.6% 52.1% [40] IMEP and the apparent net heat release rate (HRR). The pressure rise
Hydrogen mass content 13.2% 13.1% [40]
rate (PRR) was represented by the average of the maximum pressure
Oxygen mass content 0.2% 34.8% [40]
Lower Heating Value (LHV ) 42.9 MJ/kg 26.9 MJ/kg [40] variations of 200 cycles of cylinder pressure versus crank angle. Cycle-
to-cycle variability was measured by the coefficient of variation of
IMEP (COV_IMEP) over the sampled cycles. Pumping mean effective
pressure (PMEP) was calculated by the subtraction of the gross in-
2.2. Fuel properties and delivery dicated mean effective pressure from the IMEP.
Since the absolute value of the heat released is not as important to
Fuel properties are shown in Table 2. Under dual-fuel operation, this study as the bulk shape of the curve with respect to crank angle, a
ethanol was injected through a port fuel injector (PFI). An injector constant ratio of specific heats (γ) of 1.33 was assumed throughout the
driver controlled the PFI pulse width, which was adjusted according to engine cycle. The mass fraction burnt (MFB) was calculated by in-
the desired ethanol energy fraction. The ethanol mass flow rate tegrating the HRR. Combustion phasing (CA50) was determined by the
(ṁ ethanol ) was obtained from an injector calibration curve determined crank angle of 50% MFB. The mean in-cylinder gas temperature was
with a semi-microbalance with an accuracy of ± 0.1 mg. Ethanol in- calculated by the ideal gas law [40]. Finally, the average in-cylinder
jection pressure was continuously monitored, so that a constant relative pressure and the resulting HRR were post-processed using a third order
pressure of 300 kPa could be maintained across the injector. A heat Savitzky-Golay filter with a window size of five data points.
exchanger held the ethanol temperature at 295 ± 4 K. A current probe was used to acquire the electric current signal sent
The diesel fuel was supplied to the engine using a high pressure from the ECU to the diesel injector solenoid. The signal was corrected
common rail injection system. The diesel injections were controlled via by adding the energising time delay of 0.344 ms (e.g. ∼2.5 CAD at
a dedicated engine control unit (ECU) with the ability to support up to 1200 rpm) measured in a constant volume chamber. The resulting
three shots per cycle. Two Endress+Hauser Promass 83A Coriolis flow diesel injector current signal allowed for the determination of the actual
meters were used to determine the diesel flow rate (ṁ diesel ) by mea- start of diesel injection (SOI). Ignition delay was defined as the period
suring the total fuel supplied to and from the diesel high pressure pump of time between the SOI or actual start of main diesel injection
and injector. (SOI_main) in the case of a split injection strategy and the start of
The stoichiometric air/fuel ratio was determined by the conserva- combustion (SOC), set to 0.3% MFB point of the average cycle.
tion of mass of each chemical element in the reactants [40]. The global Net indicated efficiency was determined by calculating the ratio of
fuel/air equivalence ratio (Φ) was calculated using the intake air and the work done to the rate of fuel energy supplied to the engine as
fuel flow rates. The algorithm developed by Brettschneider-Spindt [42],
3.6 Pind
which is based on the exhaust emissions, was used to confirm the re- Net Indicated Efficiency [%] = ⎡ ⎤
⎢ (ṁ diesel LHVdiesel ) + (ṁ ethanol LHVethanol ) ⎦
⎣ ⎥
sults. The ethanol energy fraction (EF) was defined as the ratio of the
energy content of the ethanol to the total fuel energy by × 100 (2)
ṁ ethanol LHVethanol where Pind is the net indicated power in kW.
EF =
(ṁ ethanol LHVethanol ) + (ṁ diesel LHVdiesel ) (1) Combustion efficiency calculations were based on the emissions
products not fully oxidised during the combustion process except soot
by
2.3. Exhaust emissions measurement
Combustion Efficiency [%]
Gaseous emissions such as CO, CO2, NOx, and unburnt HC were P (ISCO LHVCO ) + (ISHC LHVDF ) ⎤ ⎫
taken using a Horiba MEXA-7170 DEGR gas analyser system. The EGR = ⎧1− ind3 ⎡ × 100

⎩ 10 ⎢
⎣ diesel LHVdiesel ) + (ṁ ethanol LHVethanol ) ⎥
(ṁ ⎦⎬⎭ (3)
rate was determined by calculating the ratio of the intake to the exhaust
CO2 concentration measured by the same analyser. Hydrocarbon where ISCO and ISHC are the net indicated specific emissions of CO and
emissions measured with its flame ionisation detector (FID) can lead to actual unburnt HC, respectively, in g/kWh; LHVCO is equivalent to
misinterpretation of unburnt HC trends as a result of the relative in- 10.1 MJ/kg; and LHVDF is the actual lower heating value for the in-
sensitivity of the device towards alcohols and aldehydes [43]. There- cylinder fuel mixture in dual-fuel mode given by
fore, the actual unburnt HC emissions were calculated using the method
(ṁ ethanol LHVethanol ) + (ṁ diesel LHVdiesel )
shown in [11]. An AVL 415SE smoke meter was used for soot emissions LHVDF =
ṁ ethanol + ṁ diesel (4)
measurements.

2.4. Data acquisition and analysis 3. Methodology

The in-cylinder pressure was measured using a Kistler 6125C pie- 3.1. Engine testing
zoelectric pressure sensor. Intake and exhaust pressures were measured
with two Kistler 4049A water cooled piezoresistive absolute pressure Table 3 summarises the baseline engine operating conditions and
sensors. The intake valve lift profile was continuously monitored by a highlights the optimised parameters. Testing was performed at a con-
LORD Microstrain linear differential variable reluctance transducer stant engine speed of 1200 rpm and a high load of 1.8 MPa IMEP. The
located on the top of the valve spring retainer. maximum in-cylinder gas pressure (Pmax) and PPR were limited to

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V.B. Pedrozo, H. Zhao Applied Energy 210 (2018) 138–151

18 MPa and 2.0 MPa/CAD, respectively. The PRR limit was relaxed to
3.0 MPa/CAD on a few cases to allow for the demonstration of a given
trend. Stable engine operation was quantified by a COV_IMEP below
3%.
The ethanol energy fraction and diesel injection timings were varied
when required. The exhaust back pressure was also varied when per-
forming sweeps of intake pressure to maintain a constant pressure
differential across the cylinder of 10 kPa and a comparable PMEP.
Diesel fuel was introduced using a single injection near firing top dead
centre (TDC). However, there were some cases where a small pre-in-
jection of an estimated volume of 3 mm3 and a constant dwell time of
1 ms (e.g. 7.2 CAD at 1200 rpm) between pre- (SOI_pre) and main
(SOI_main) diesel injection timings was employed to reduce the levels
of PRR, as revealed in [14].

3.2. Miller cycle and the pressure-based ECR calculation

Some experiments were carried out using late intake valve closing
(LIVC) events, where the intake valves were left open for longer in Fig. 2. In-cylinder pressure, intake manifold pressure, and polytropic compression curve
duration than those of the baseline intake valve lift profile. This de- as a function of in-cylinder volume depicting the method used for computation of the
creased the actual in-cylinder mass trapped as the piston expelled part volume-based (A) and pressure-based (B) ECRs.

of the inducted mass back into the intake port.


The later initiation of the compression process resulted in a lower
ECR, which can be calculated as the ratio of the instantaneous in-cy-
linder volume at IVC (e.g. 0.5 mm valve lift) to the clearance volume at
TDC. However, this volume-based approach might not represent the
actual compression ratio due to the flow resistance across the intake
valves [26] and inertia of the gas in the intake port before the inlet
valves are closed [40].
Therefore, a pressure-based ECR calculation was employed in order
to better account for the gas exchange process. The method used the
effective in-cylinder volume at IVC obtained from the intersection of
the average intake manifold pressure and an extrapolated polytropic
compression curve fitted to the experimental in-cylinder pressure
[26,34].
Fig. 2 shows the determination of the effective volume at IVC (B) for
an intake valve lift profile with an IVC at −108 CAD after firing top
dead centre (ATDC), which resulted in a pressure-based ECR of 14.4.
The use of the instantaneous volume at IVC (A) would provide a vo-
lume-based ECR of 12.4.
Fig. 3 depicts the intake and exhaust valve lift profiles used in this
study. The intake valve opening (IVO) was set at −354 CAD ATDC as
Fig. 3. Intake and exhaust valve lift profiles used in this study.
determined at 0.5 mm valve lift, maintaining the maximum lift con-
stant. The IVC event was set at −154, −126, and −108 CAD ATDC,
attaining pressure-based ECRs of 16.8, 15.7, and 14.4, respectively. The
expansion ratio remained constant as a result of the fixed exhaust
camshaft timing.

Table 3
Engine operating conditions.

Parameter Baseline condition Optimisation

Engine speed 1200 rpm


Load 1.8 MPa IMEP
Diesel injection pressure 155 MPa
Diesel injection strategy Single Pre- and main injection near TDC
Ethanol energy fraction (EF) 0.00 Swept
Intake manifold pressure 260 kPa Swept
Exhaust manifold pressure 270 kPa Varied with the intake pressure
Intake manifold air temperature (IAT) 324 K Swept
EGR rate 0% Swept
EGR temperature NA 383 ± 3 K
Intake valve closing (IVC) −154 CAD ATDC Swept
Effective Compression Ratio (ECR) 16:8 Swept

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V.B. Pedrozo, H. Zhao Applied Energy 210 (2018) 138–151

4. Results and discussion Dec’s study [46], which revealed the ethanol autoignition occurred as
the mean in-cylinder gas temperature reached more than 900 K. The
4.1. The effect of ethanol energy fraction on high load dual-fuel combustion ignition is followed by the production of water and heat release due to
the reaction between hydroxyl (OH) radicals and fuel molecules [47].
Initially, experiments were performed to characterise high load The OH radicals are rapidly produced by the thermal decomposition of
ethanol-diesel dual-fuel combustion with the default intake valve tim- hydrogen peroxide (H2O2) as the in-cylinder gas temperature ap-
ings. The engine was operated using the baseline condition showed in proaches the autoignition temperature. The H2O2 is formed and accu-
Table 3 and ethanol energy fractions that varied from 0.00 to 0.30. The mulated by low and intermediate temperature kinetic pathways during
diesel injection timing was held constant at 4.75 CAD ATDC to ensure the compression stroke [44].
the diesel-only baseline would have a complete compression process
(without combustion) up to firing top dead centre. Any heat release
before the diesel injection would be produced by the autoignition of 4.2. The effect of EGR on high load dual-fuel combustion
ethanol in the dual-fuel mode.
Fig. 4 shows that homogeneous charge compression ignition (HCCI) External EGR rate was varied from 0% to 21.2% in an attempt to
of the ethanol fuel occurred prior to the start of the diesel injection. The delay the ethanol autoignition process. The intake and exhaust mani-
premixed peak heat release increased with the ethanol content, fold pressures were held constant. Fig. 5 demonstrates that increased
reaching a PRR of 2.2 MPa/CAD at the ethanol energy fraction of 0.30. EGR percentage delayed the SOC, lowered the peak heat release, and
The increase in the total in-cylinder mass trapped and cooling effect slowed the diesel mixing-controlled combustion. This was a result of the
achieved with higher EFs helped decrease the compression tempera- lower oxygen (O2) concentration and higher heat capacity of the in-
tures. However, the port fuel injected ethanol autoignited prior to the cylinder charge with EGR rates of 15.7% and 21.2%, which delayed the
direct injection of diesel because of the high mean in-cylinder gas early ignition of ethanol by 1.25 CAD and 1.50 CAD respectively when
temperatures, which were above 950 K after −10 CAD ATDC. compared to the dual-fuel operation without EGR.
Fuel autoignition in internal combustion engines is predicted to take In a previous study by Sjöberg and Dec [46], it was shown that
place between 900 and 950 K [44,45]. This is supported by Sjöberg and replacing inducted air with EGR and its different constituents could
decrease the compression temperatures and slow down the inter-
mediate-temperature heat-release rate (e.g. SOC-CA10) of the ethanol
autoignition process. However, in the present study the ignition of the
ethanol fuel exhibited a relatively low sensitivity to variations in the in-
cylinder O2 concentration when using the actual engine EGR. This re-
duced sensitivity towards different levels of EGR can be partially at-
tributed to the slightly higher intake charge temperatures. The use of
recycled exhaust gas increased the intake manifold air temperature
(IAT) by up to 4 K when operating with an EGR rate of 21.2%.

Fig. 4. In-cylinder pressure, mean in-cylinder gas temperature, HRR, and diesel injector Fig. 5. In-cylinder pressure, HRR, and diesel injector current signal for high load dual-
current signal for high load dual-fuel operation with different EFs at an ECR of 16.8. fuel operation with different EGR rates.

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V.B. Pedrozo, H. Zhao Applied Energy 210 (2018) 138–151

4.3. The effect of global fuel/air equivalence ratio on high load dual-fuel 4.4. The effect of Miller cycle on high load dual-fuel combustion
combustion
The next approach aimed at retarding the autoignition timing was
In this subsection, intake manifold pressure was varied from Miller cycle via an LIVC strategy. Fig. 7 depicts the effect of different
240 kPa to 290 kPa to characterise the effect of global fuel/air pressure-based ECRs on high load dual-fuel operation. The ethanol
equivalence ratio (Φ) on high load dual-fuel combustion. External EGR energy fraction was maintained at 0.30. The diesel injection timing was
was not used and the exhaust manifold pressure was adjusted so as to set at 4.75 CAD ATDC and the intake pressure was held constant at
maintain a constant pressure differential across the cylinder of 10 kPa 260 kPa.
(with the exhaust being higher than the intake manifold pressure). A reduction in ECR decreased the in-cylinder pressure as well as the
Fig. 6 shows that the autoignition of ethanol was practically un- mean in-cylinder gas temperature during the compression stroke. This
affected as the intake manifold pressure was swept. This was attributed successfully delayed the autoignition process of ethanol. The tempera-
to the similar compression temperatures, which were sufficiently high ture prior to the SOC was reduced to less than 950 K at an ECR of 14.4.
to ignite the premixed charge despite the difference in global fuel/air Despite the improvement and the later SOC, the premixed charge still
equivalence ratio. autoignited before the introduction of the diesel fuel. Engine experi-
The excess of air at highest intake manifold pressure of 290 kPa ments using ECRs lower than 14.4 were not performed due to low net
diluted the in-cylinder charge, decreased the first peak heat release, indicated efficiencies at a constant intake manifold pressure.
and reduced the mean in-cylinder gas temperature as the combustion
progressed. However, the increased O2 availability led to a faster
oxidation of the diesel fuel, as supported by the higher second peak 4.5. The effect of intake manifold air temperature (IAT) on high load dual-
heat release. In comparison, the use of a lower intake manifold pres- fuel combustion
sure of 240 kPa increased slightly the premixed peak heat release due
to the relatively higher in-cylinder gas temperatures during combus- This subsection investigates whether a colder intake manifold air is
tion at a Φ of 0.61. effective at delaying the ethanol autoignition process without EGR at an
ECR of 16.8. The IAT was controlled using an air-to-water charge air

Fig. 6. In-cylinder pressure, mean in-cylinder gas temperature, HRR, and diesel injector Fig. 7. In-cylinder pressure, mean in-cylinder gas temperature, HRR, and diesel injector
current signal for high load dual-fuel operation with different global fuel/air equivalence current signal for high load dual-fuel operation with different ECRs.
ratios.

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4.6.1. Overview of the high load dual-fuel operating range with Miller cycle
Fig. 9 shows the dual-fuel operating range can be enlarged when
using lower ECRs. At an ECR of 16.8, the maximum ethanol energy
fraction was PRR limited to 0.26 and the most advanced CA50 was at 8
CAD ATDC. The reduction of the ECR to 15.7 allowed for higher
ethanol fractions of 0.40. However, combustion phasing needed to be
retarded because of the relatively longer ignition delay and faster
premixed combustion phase. A single diesel injection strategy could
only be used at the ECRs of 16.8 and 15.7 due to excessive PRRs at the
ECR of 14.4.
The introduction of a pre-injection with an estimated volume of
3 mm3 and a constant dwell time of 7.2 CAD to the main diesel injection
effectively decreased PRRs at the ECRs of 15.7 and 14.4. The use of
Miller cycle combined with a diesel pre-injection substantially in-
creased the maximum ethanol energy fraction to 0.79 at an ECR of 14.4.
The ratio of the volume of diesel pre-injection to the total volume of
diesel injected per cycle varied from 2% to 9% due to changes in net
indicated efficiency as well as ethanol energy fraction.
Overall, the split diesel injection strategy was the key enabler for
advancing the combustion process and allowing for more efficient dual-
fuel operation at lower ECRs. Peak in-cylinder pressure was only a
concern for the most advanced cases performed with low EFs.

4.6.2. Combustion characteristics for optimised high load dual-fuel


operation with Miller cycle
Fig. 10 depict the diesel injection timings and combustion char-
acteristics for the most efficient cases attained with varied EFs and
diesel injection strategies at different ECRs. The optimum SOIs were
delayed as the ethanol energy fraction was increased in order to avoid
excessive PRRs.
The operation at the lowest ECR of 14.4 was very sensitive to the
start of injection. Slightly earlier diesel injections resulted in PRRs
above the acceptable limit. This is the reason for the retarded SOI_main
and lower PRR when using ethanol energy fractions above 0.60.
Fig. 8. In-cylinder pressure, mean in-cylinder gas temperature, HRR, and diesel injector
current signal for high load dual-fuel operation with different IATs and ECRs.

cooler. The intake manifold pressure was held constant at 260 kPa. The
ethanol energy fraction was set to 0.30 and the diesel injection timings
were maintained at 4.75 CAD ATDC.
Fig. 8 shows that a reduction in IAT from 324 K to 304 K decreased
the mean in-cylinder gas temperature during the compression stroke
and delayed the premixed fuel autoignition timing. The end-of-com-
pression temperature and heat release process with a colder intake
charge were comparable to the results attained with a higher IAT of
324 K at an ECR of 14.4. These similarities were attributed to the lower
gas temperature and higher in-cylinder charge density at IVC for the
case with an IAT of 304 K at an ECR of 16.8. These findings highlight
the sensitivity of high load dual-fuel operation to variations in IAT and
in-cylinder gas temperature, as the ignition of the premixed fuel is
mainly controlled by chemical kinetics [8].

4.6. Exploring the high load potential of the dual-fuel operation with Miller
cycle

The objectives of this subsection were to map the dual-fuel opera-


tion with Miller cycle at 1.8 MPa IMEP and optimise the dual-fuel
combustion process for the maximum net indicated efficiency. The
experiments were carried out without EGR while varying the ethanol
energy fraction and diesel injection timings at the ECRs of 16.8, 15.7,
Fig. 9. Operating range for high load ethanol-diesel dual-fuel combustion with different
and 14.4. The latest CA50 was limited to 16 CAD ATDC due to rela-
ECRs and ethanol energy fractions.
tively lower net indicated efficiencies.

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V.B. Pedrozo, H. Zhao Applied Energy 210 (2018) 138–151

Fig. 11. In-cylinder pressure, HRR, and diesel injector current signal for optimised high
load dual-fuel operation with a diesel pre-injection at an ECR of 14.4.

injection at the ECRs of 16.8 and 15.7. The introduction of a diesel pre-
injection at the ECRs of 15.7 and 14.4 modified the trends slightly
depending on the ethanol energy fraction. At an ECR of 14.4, the use of
high EFs (e.g. above 0.40) yielded relatively longer ignition delays due
to the low reactivity of the ethanol fuel.
Fig. 10. Main diesel injection timings and combustion characteristics for optimised high
The first part of the heat release process between CA10 and CA50
load dual-fuel operation with different ECRs.
was affected by the ECR, ethanol energy fraction, and diesel injection
strategy. The most noticeable change was observed at an ECR of 14.4,
where the CA10-CA50 period became shorter as the EF was raised to
0.40. This was probably caused by rapid simultaneous combustion of
The later combustion process at high EFs combined with a lower diesel and ethanol fuels. However, there was a reversal of the trend as
ECR of 14.4 can reduce the peak in-cylinder pressure, as shown in the ethanol energy fraction was increased to 0.79 due to charge cooling
Fig. 11. The heat release profile changed from typical mixing-controlled and slower reaction rates of the premixed fuel [14].
combustion in CDC to a shorter combustion process with higher peak Combustion phasing was retarded with the increase of ethanol en-
heat release in the dual-fuel mode. ergy fraction despite the partial recovery of the CA10-CA50 period at an
Fig. 10 also revealed that higher amounts of premixed ethanol fuel ECR of 14.4. This was necessary to control the levels of PRR caused by
increased the COV_IMEP. This was likely as a result of the autoignition the more homogenous combustion process in the dual-fuel mode, which
process of ethanol, which seemed more sensitive to variations in the in- is supported by shorter combustion duration (CA10-CA90) and higher
cylinder gas temperature than a diesel mixing-controlled combustion. peak heat release.
The cycle-to-cycle variability was lower at the highest ECR of 16.8 due There were exceptions when more ethanol was used at an ECR of
to the relatively higher compression temperatures and more stable ig- 16.8 and for the dual-fuel case with a diesel pre-injection and an EF of
nition of ethanol and diesel fuels. 0.39 at an ECR of 15.7. In the first condition, the early ignition of
In dual-fuel mode, the period of time between the SOI_main and ethanol resulted in a practically constant CA50 position and slightly
SOC remained below the interval measured for the diesel-only cases, as longer CA10-CA90 period. In the second case, the increase in com-
shown in Fig. 12. In addition, the ignition delay was shortened as the EF bustion duration was due to the late diesel injection timings used to
was increased towards 0.40, independent of the ECR. This was mainly a prevent the simultaneous combustion of the pre-injected diesel and
result of the early autoignition of ethanol when using a single diesel premixed ethanol fuel.

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V.B. Pedrozo, H. Zhao Applied Energy 210 (2018) 138–151

Fig. 12. Heat release characteristics for optimised high load dual-fuel operation with Fig. 13. Net indicated specific emissions for optimised high load dual-fuel operation with
different ECRs. different ECRs.

4.6.3. Engine-out emissions and performance for optimised high load dual- smoke [33]. The highest ISsoot was 0.0024 g/kWh for an ethanol en-
fuel operation with Miller cycle ergy fraction of 0.79 at an ECR of 14.4, which is well below the Euro VI
Fig. 13 depicts the net indicated specific emissions for the most emission limit for particulate matter of 0.010 g/kWh [48].
efficient cases. The dual-fuel combustion with a diesel pre-injection and The unburnt HC and CO emissions increased as more ethanol was
an ethanol energy fraction of 0.79 achieved 7.4 g/kWh of NOx at an injected, reaching ∼3.6 g/kWh at an ethanol energy fraction of 0.79.
ECR of 14.4. This is equivalent to an ISNOx reduction of 57% when This phenomenon likely occurs due to premixed fuel trapped in the
compared against the 17.3 g/kWh produced by the diesel-only opera- crevice volumes of the stock diesel piston, as shown in the computa-
tion at an ECR of 16.8. This improvement was likely a result of the later tional fluid dynamics modelling performed by Kokjohn et al. [49].
CA50 position and more homogeneous combustion (e.g. lower local The use of Miller cycle via an LIVC strategy reduced the compres-
temperatures), as less diesel fuel was burnt during the mixing-con- sion pressures, which possibly minimised the amount of ethanol fuel
trolled combustion phase. The use of a single diesel injection strategy pushed into these crevice volumes. Additionally, the adoption of a
delayed the optimum CA50s at an ECR of 15.7, attaining similar levels lower ECR at a constant intake manifold pressure increased the global
of NOx emissions to those measured with EFs between 0.20 and 0.40 at fuel/air equivalence ratio and the mean in-cylinder gas temperature
an ECR of 14.4. during combustion (see Fig. 7). This allowed for higher combustion
Later diesel injection timings and thus delayed combustion process efficiencies than those achieved with the baseline ECR of 16.8, as
increased the soot emissions as the ethanol energy fraction was in- shown in Fig. 14.
creased. Lower in-cylinder gas temperatures and shorter ignition delays The highest net indicated efficiency of 47.5% was attained by a
at such conditions are probably linked to the elevation in the levels of dual-fuel operation with an EF of 0.25 at the baseline ECR of 16.8. This

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V.B. Pedrozo, H. Zhao Applied Energy 210 (2018) 138–151

Variation in Net Indicated Eff . [%]


Net Indicated Efficiency
= ⎜⎛ −1⎟⎞ × 100
⎝ Net Indicated Efficiencybaseline ⎠ (5)

ISNOx
Variation in NOx emissions [%] = ⎛ ⎜ −1⎞ × 100 ⎟

⎝ ISNOxbaseline ⎠ (6)

where Net Indicated Efficiencybaseline and ISNOxbaseline are the net in-
dicated efficiency and specific emissions of NOx of the most efficient
CDC case at an ECR of 16.8. Negative values represent a decrease in net
indicated efficiency or NOx emissions when utilising dual-fuel opera-
tion with Miller cycle over the diesel-only combustion at the baseline
ECR.
Figs. 15 and 16 depict the variation in net indicated efficiency and
NOx emissions when operating the engine with different EFs and CA50
positions. Combustion phasing was adjusted by performing sweeps of

Fig. 14. Performance for optimised high load dual-fuel operation with different ECRs.

was likely a result of lower heat transfer losses [49], which increased
net indicated efficiency by 2.9% when compared to the 46.1% achieved
during the diesel-only operation at the same ECR of 16.8 (see red circle
in Fig. 14). However, a reduction in the ECR at a constant intake
Fig. 15. Variation in net indicated efficiency of high load dual-fuel operation at an ECR of
manifold pressure slightly decreased the net indicated efficiency for a 14.4 over the most efficient CDC case at the baseline ECR of 16.8.
given ethanol energy fraction. This was a result of the lower in-cylinder
mass trapped and formation of a relatively richer mixture, which re-
duced the ratio of specific heats and probably increased the heat
transfer and exhaust losses [50].
Despite the losses observed with Miller cycle, the use of an EF of
0.79 yielded a net indicated efficiency of 46.85% at an ECR of 14.4,
which was 1.6% higher than that of the most efficient diesel-only op-
eration at the baseline ECR of 16.8. This improvement was possibly
attributed to a reduction in heat transfer/exhaust losses via shorter
burn rate and lower local in-cylinder gas temperatures [49].

4.7. Improvements brought about by the high load dual-fuel operation with
Miller cycle

This subsection includes a comparison of high load dual-fuel op-


eration at an ECR of 14.4 and conventional diesel combustion at the
baseline ECR of 16.8 with respect to net indicated efficiency and NOx
emissions, as these factors can adversely affect the engine operational
cost [14].
The variation in net indicated efficiency and NOx emissions were
Fig. 16. Variation in NOx emissions of high load dual-fuel operation at an ECR of 14.4
calculated as
over the most efficient CDC case at the baseline ECR of 16.8.

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V.B. Pedrozo, H. Zhao Applied Energy 210 (2018) 138–151

Fig. 17. Trade-off between the variation in net indicated effi-


ciency and NOx emissions for high load dual-fuel operation with
Miller cycle.

diesel injection timings with a constant dwell time between pre- and
main diesel injections, as outlined in Section 4.6.
The analysis revealed that high load dual-fuel operation with Miller
cycle can achieve higher net indicated efficiencies and lower NOx
emissions than CDC at an ECR of 16.8. The alternative combustion
strategy increased the net indicated efficiency by up to 1.6% and de-
creased the levels of ISNOx by up to 60%. This is a significant im-
provement over a retarded diesel-only combustion at an ECR of 14.4,
which reduced the NOx emissions by 50% at the expense of 5.5% lower
net indicated efficiency.
Fig. 17 combines Figs. 15 and 16 to show the trade-off between the
variation in net indicated efficiency and NOx emissions as the ethanol
energy fraction and CA50 position were varied. The plot highlights the
effectiveness of the dual-fuel operation with Miller cycle as a way to
control engine-out NOx emissions and increase net indicated efficiency,
particularly at high EFs. The reasoning behind the best overall perfor-
mance and emissions was discussed in Subsection 4.6.

4.8. Improvements brought about by the high load dual-fuel operation with
charge air cooling

A one-off test was carried out to determine whether charge air


cooling has the potential to enable the use of a high EF of 0.65 at the
baseline ECR of 16.8 while achieving the efficiency and emissions
benefits of a dual-fuel operation with Miller cycle. The investigation
was performed with an increased water flow rate into the charge air
cooler in order to reduce the intake manifold air temperature by 20 K to
304 K. The diesel injection timings were optimised for the maximum
net indicated efficiency. A pre-injection of diesel was used to maintain
the PRR within the limit of 2.0 MPa/CAD, as described in previous
subsections. The intake pressure was held constant at 260 kPa and no
cooled external EGR was used.
Fig. 18 depicts a comparison between optimised dual-fuel opera-
tions with charge air cooling (EF of 0.65) and Miller cycle (EFs of 0.60
and 0.70). The earlier IVC/higher ECR and lower IAT of the dual-fuel
case with charge air cooling resulted in a relatively longer compression
process and higher in-cylinder mass trapped, as supported by the lower
global fuel/air equivalence ratio. This diluted mixture decreased the
mean in-cylinder gas temperature during combustion despite the higher Fig. 18. In-cylinder pressure, mean in-cylinder gas temperature, HRR, and diesel injector
peak heat release when compared against the dual-fuel cases with current signal for optimised high load dual-fuel operations with Miller cycle and charge
air cooling.
Miller cycle (ECR of 14.4). Similar trend occurred with the decreasing

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V.B. Pedrozo, H. Zhao Applied Energy 210 (2018) 138–151

of the global fuel/air equivalence ratio via higher intake manifold 6. Optimised high load dual-fuel operation with Miller cycle attained
pressure in Subsection 4.3. higher net indicated efficiencies at an ECR of 14.4 (up to 46.85%)
The leaner dual-fuel combustion with an IAT of 304 K and an ECR of than the most efficient diesel-only case at the baseline ECR of 16.8
16.8 allowed for more advanced burn rate and higher peak heat release. (46.1%). This improvement was achieved while reducing NOx
As a result, net indicated efficiency was increased from 46.3% and emissions by up to 57% (from 17.3 g/kWh to 7.4 g/kWh).
46.8% in the dual-fuel cases with Miller cycle to 48% in the dual-fuel 7. A reduction of 20 K in the intake manifold air temperature effec-
case with charge air cooling. Additionally, high load dual-fuel operation tively decreased the compression temperatures and suppressed the
with an IAT of 304 K increased the net indicated efficiency by 4.1% early autoignition of ethanol, allowing for use of an EF of 0.65 at the
over the most efficient conventional diesel combustion case (46.1%) at baseline ECR of 16.8.
an ECR of 16.8. This improvement was probably attributed to lower 8. Optimised high load dual-fuel operation with charge air cooling
heat transfer losses of the dual-fuel combustion. increased the net indicated efficiency by 4.1% to 48% and decreased
ISsoot (0.003 g/kWh), ISCO (4.9 g/kWh), and ISHC (6.7 g/kWh) NOx emissions by 44% to 9.7 g/kWh when compared against the
were higher in the dual-fuel operation with charge air cooling as a re- most efficient conventional diesel combustion case at the baseline
sult of lower mean in-cylinder gas temperatures during combustion ECR of 16.8.
caused by the increased in-cylinder mass trapped. NOx emissions were
also increased from 7.6 and 7.8 g/kWh in the Miller cycle cases to 9.7 g/ Overall, the current study highlights the sensitivity of ethanol au-
kWh in the dual-fuel case with a lower IAT. This was likely due to the toignition to variations in the mean in-cylinder gas temperature and
earlier CA50 position (e.g. higher local temperatures) and lower global demonstrates Miller cycle and charge air cooling can improve ethanol-
fuel/air equivalence ratio (e.g. higher O2 availability). Nevertheless, diesel dual-fuel combustion at high load conditions. This raises the
optimised dual-fuel operation with charge air cooling effectively re- importance of intake manifold and in-cylinder gas temperature control
duced the levels of NOx by 44% when compared against the 17.3 g/ to enable highly efficient and clean dual-fuel operation, helping gen-
kWh of the diesel-only baseline. erate a commercially viable technology for future compression ignition
Despite the relatively high net indicated efficiency and low NOx engines.
emissions brought about by the dual-fuel operation with charge air
cooling, a further analysis was not performed as low IATs might not be Acknowledgments
achievable from a practical standpoint. Finally, it is important to bear in
mind that high load dual-fuel operation with IATs higher than 324 K V. Pedrozo would like to acknowledge CAPES Foundation
can potentially cause unacceptable combustion noise (e.g. knock) and (Coordenação de Aperfeiçoamento de Pessoal de Nível Superior) for
low engine efficiency. supporting his PhD study at Brunel University London under super-
vision of Prof. Hua Zhao.
5. Conclusions
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