Near Zero Emissions at 50 Percent Thermal Efficiency
Detroit Diesel Corporation (DDC) has successfully completed a 10 year DOE sponsored heavy-duty truck engine program, hereafter referred to as the NZ-50 program. This program was split into two major phases. The first phase was called Near-Zero Emission at 50 Percent Thermal Efficiency, and was completed in 2007. The second phase was initiated in 2006, and this phase was named Advancements in Engine Combustion Systems to Enable High-Efficiency Clean Combustion for Heavy-Duty Engines. This phase was completed in September, 2010. The key objectives of the NZ-50 program for this first phase were to: Quantify thermal efficiency degradation associated with reduction of engine-out NOx emissions to the 2007 regulated level of ~1.1 g/hp-hr. Implement an integrated analytical/experimental development plan for improving subsystem and component capabilities in support of emerging engine technologies for emissions and thermal efficiency goals of the program. Test prototype subsystem hardware featuring technology enhancements and demonstrate effective application on a multi-cylinder, production feasible heavy-duty engine test-bed. Optimize subsystem components and engine controls (calibration) to demonstrate thermal efficiency that is in compliance with the DOE 2005 Joule milestone, meaning greater than 45% thermal efficiency at 2007 emission levels. Develop technology roadmap for meeting emission regulations of 2010 and beyond while mitigating the associated degradation in engine fuel consumption. Ultimately, develop technical prime-path for meeting the overall goal of the NZ-50 program, i.e., 50% thermal efficiency at 2010 regulated emissions. These objectives were successfully met during the course of the NZ-50 program. The most noteworthy achievements in this program are summarized as follows: Demonstrated technologies through advanced integrated experiments and analysis to achieve the technical objectives of the NZ-50 program with 50.2% equivalent thermal efficiency under EPA 2010 emissions regulations. Experimentally demonstrate brake efficiency of 48.5% at EPA 2010 emission level at single steady-state point. Analytically demonstrated additional brake efficiency benefits using advanced aftertreatment configuration concept and air system enhancement including, but not limited to, turbo-compound, variable valve actuator system, and new cylinder head redesign, thus helping to achieve the final program goals. Experimentally demonstrated EPA 2010 emissions over FTP cycles using advanced integrated engine and aftertreatment system. These aggressive thermal efficiency and emissions results were achieved by applying a robust systems technology development methodology. It used integrated analytical and experimental tools for subsystem component optimization encompassing advanced fuel injection system, increased EGR cooling capacity, combustion process optimization, and advanced aftertreatment technologies. Model based controls employing multiple input and output techniques enabled efficient integration of the various subsystems and ensured optimal performance of each system within the total engine package. . The key objective of the NZ-50 program for the second phase was to explore advancements in engine combustion systems using high-efficiency clean combustion (HECC) techniques to minimize cylinder-out emissions, targeting a 10% efficiency improvement. The most noteworthy achievements in this phase of the program are summarized as follows: Experimentally and analytically evaluated numerous air system improvements related to the turbocharger and variable valve actuation. Some of the items tested proved to be very successful and modifications to the turbine discovered in this program have since been incorporated into production hardware. The combustion system development continued with evaluation of various designs of the 2-step piston bowl. Significant improvements in engine emissions have been obtained, but fuel economy improvements have been tougher to realize. Development of a neural network control system progressed to the point that the system was fully functional and showing significant fuel economy gains in transient engine testing. Development of the QuantLogic injector with the capability of both a hollow cone spray during early injection and conventional diesel injection at later injection timings was undertaken and proved to be problematic. This injector was designed to be a key component in a PCCI combustion system, but this innovative fuel injector required significantly more development effort than this programâ's resources or timing would allow.
- Research Organization:
- Detroit Diesel Corporation
- Sponsoring Organization:
- USDOE
- DOE Contract Number:
- FC26-00OR22805
- OSTI ID:
- 1054511
- Country of Publication:
- United States
- Language:
- English
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