Lambda 1 High Load Operation via Water Injection
- 1. Engine Expo 2016 – Messe Stuttgart, Germany – May 31st to June 2nd 2016 Lambda 1 High Load Operation via Water Injection Sam Barros Director of Research and Development Nostrum Energy, LLC 1
- 2. Engine Expo 2016 – Messe Stuttgart, Germany – May 31st to June 2nd 2016 • Motivation • Experimental Setup ⁃Engine Setup ⁃Water Injection ⁃Controls • Simulation • Experimental Results • Conclusions • Next Steps 2 Outline
- 3. Engine Expo 2016 – Messe Stuttgart, Germany – May 31st to June 2nd 2016 3 Motivation • Avoiding this! • Enabling the next generation of high efficiency engines
- 4. Engine Expo 2016 – Messe Stuttgart, Germany – May 31st to June 2nd 2016 • Despite increasing popularity, engine “downsizing” does not delivery dramatic real-world fuel economy benefits. • Downsized engines must be operated at higher loads, often into regions where spark retard and/or over fueling is used to control knock. • Maximum engine output in SI engines is limited by knock (auto-ignition) • Mitigation of knock is an enabler for aggressive downsizing AND increased performance 4 Motivation
- 5. Engine Expo 2016 – Messe Stuttgart, Germany – May 31st to June 2nd 2016 5 Experimental Setup Baseline Engine • SIDI 2.0L GM Ecotec LTG • Twin Scroll Turbocharger • Dual Independent Cam Phasing • Large Aftermarket Support
- 6. Engine Expo 2016 – Messe Stuttgart, Germany – May 31st to June 2nd 2016 • Injectors installed in intake manifold • Direct Injection also an option 6 Experimental Setup – Water Injection Water Rail Injector with Bosses welded to manifold
- 7. Engine Expo 2016 – Messe Stuttgart, Germany – May 31st to June 2nd 2016 • Test water is generated through Reverse Osmosis • High Pressure supply (250 bar) for Direct Injection testing • Low Pressure supply (10 bar) for Port Injection testing • Flow measured with Coriolis meter 7 Experimental Setup – Water Injection Building Water Supply RO Water Reservoir High Pressure Pump Flow Metering Device Air Supply ~110psi 12V Signal I/O Drain to Sewer System Reverse Osmosis Filtration System Filter PWI Water Tank Vent to Atmosphere Temperature and Pressure Transducers Port Injectors Data Acquisition System Intake Manifold Exhaust System Engine Temperature and Pressure Transducers Port Injection Controller Exhaust System Air Supply ~200psi Direct Injection Controller Engine Direct Injectors
- 8. Engine Expo 2016 – Messe Stuttgart, Germany – May 31st to June 2nd 2016 8 Experimental Tests To Be Discussed Test Number Fuel Water Injection Spark Timing / Combustion Phasing I-Cam E-Cam Lambda Test 1 91 AKI (Engine manufacturer req.) None Production Production Production Production Test 2 110 AKI None 10° CA50 or KLSA* Production Production Production Test 3 87 AKI Port Injection 10° CA50 or KLSA* Production Production 1.0
- 9. Engine Expo 2016 – Messe Stuttgart, Germany – May 31st to June 2nd 2016 9 Experimental Results: Combustion 0 5 10 15 20 25 30 1500 2000 2500 3000 3500 4000 4500 5000 5500 CA50 EA; 91 AKI, Baseline CA50 EA; 110 AKI, MBT / KLSA CA50 EA; 87 AKI, MBT / KLSA, Lambda 1 Combustion Phasing Baseline Engine Engine Speed (RPM)Engine Speed (RPM) CA50(°ATDC) 0 5 10 15 20 25 30 35 40 45 1500 2000 2500 3000 3500 4000 4500 5000 5500 BD10-90_EA; 91 AKI, Baseline BD10-90_EA; 110 AKI, MBT / KLSA BD10-90_EA; 87 AKI, MBT / KLSA, Lambda 1 Burn Duration Baseline Engine Engine Speed (RPM)Engine Speed (RPM) BD10-90 MBT
- 10. Engine Expo 2016 – Messe Stuttgart, Germany – May 31st to June 2nd 2016 10 Experimental Results; Output 0 5 10 15 20 25 30 35 1500 2000 2500 3000 3500 4000 4500 5000 5500 NMEP EA; 91 AKI, Baseline NMEP EA; 110 AKI, MBT / KLSA NMEP EA; 87 AKI, MBT / KLSA, Lambda 1 Mean Effective Pressure Baseline Engine Engine Speed (RPM) NETMEP(bar)
- 11. Engine Expo 2016 – Messe Stuttgart, Germany – May 31st to June 2nd 2016 11 Experimental Results; Efficiency 0 5 10 15 20 25 30 35 40 1500 2000 2500 3000 3500 4000 4500 5000 5500 Net Thermal Efficiency; 91 AKI, Baseline Net Thermal Efficiency; 110 AKI, MBT / KLSA Net Thermal Efficiency; 87 AKI, MBT / KLSA, Lambda 1 Net Thermal Efficiency Baseline Engine Engine Speed (RPM) NETThermalEfficiency(%)
- 12. Engine Expo 2016 – Messe Stuttgart, Germany – May 31st to June 2nd 2016 12 Experimental Results: Exhaust Gas Temperatures
- 13. Engine Expo 2016 – Messe Stuttgart, Germany – May 31st to June 2nd 2016 Simulation 13 • 1D Engine Simulation was utilized to scope the High BMEP Build (Target 50 bar BMEP) ⁃ Determination of required air pressure and flow ⁃ Investigation of peak cylinder pressure over a range of compression ratios ⁃ The same simulation model will be used to evaluate the impact of water injection
- 14. Engine Expo 2016 – Messe Stuttgart, Germany – May 31st to June 2nd 2016 14 • Fuel Enrichment and Combustion Phasing both have large impact on Net Thermal Efficiency • Good opportunity for efficiency improvements Simulation Results
- 15. Engine Expo 2016 – Messe Stuttgart, Germany – May 31st to June 2nd 2016 Simulation Results 15 3 3.25 3.5 3.75 4 4.25 4.5 4.75 5 700 750 800 850 900 950 Airflow (kg/hr) PressureRatio(:) Airflow and Pressure Requirement Over a Range of Lambda and Compression Ratio (3000 RPM, 50 bar BMEP) • Required P/R and mass flow are challenging for a single compressor • Boost pressure is currently supplied via an external compressor • Good candidate for alternative boosting systems (multi-stage, compounded)
- 16. Engine Expo 2016 – Messe Stuttgart, Germany – May 31st to June 2nd 2016 16 11.0:1 chosen as a compromise between efficiency, peak cylinder pressure, and unburned gas temperature (knock propensity) 200 300 400 500 600 700 800 900 1000 -75 -55 -35 -15 5 25 45 65 85 105 125 CR = 9.2:1 CR = 10.0:1 CR = 11.0:1 CR = 12.0:1 Auto-Ignition Temperature; Iso-Octane Theta (Crank Angle) UnburnedGasTemperature(K) Impact of Compression Ratio on Unburned Gas Temperature (3000 RPM, 50 bar BMEP) A/F = 12.0 CA50 = 10° ATDC Simulation Results
- 17. Engine Expo 2016 – Messe Stuttgart, Germany – May 31st to June 2nd 2016 5/26/2016 17 • Patented jet-to-jet collision breakup mechanism • Reduced spray penetration and improved liquid atomization allow faster water vaporization rates Water Injectors
- 18. Engine Expo 2016 – Messe Stuttgart, Germany – May 31st to June 2nd 2016 5/26/2016 18 • Spray Targeted Nostrum KiWi; Kinetic Water Injector • Nostrum Water DI injector (next phase) Water Injectors used on this project
- 19. Engine Expo 2016 – Messe Stuttgart, Germany – May 31st to June 2nd 2016 PFI Spray Targeting – Symmetric Spray 19 Intake port impingement due to wider, non targeted-symmetric spray plume
- 20. Engine Expo 2016 – Messe Stuttgart, Germany – May 31st to June 2nd 2016 PFI Spray Targeting – Directional Spray 20 Intake port impingement avoided significantly by a narrower, directional spray plume targeted to the back of the intake valve
- 21. Engine Expo 2016 – Messe Stuttgart, Germany – May 31st to June 2nd 2016 PFI Spray Targeting – Directional Spray Movie 21
- 22. Engine Expo 2016 – Messe Stuttgart, Germany – May 31st to June 2nd 2016 Liner & Piston Impingement 22 Fuel impingement on the liner due to improper spray targeting Piston Impingement film
- 23. Engine Expo 2016 – Messe Stuttgart, Germany – May 31st to June 2nd 2016 23 Conclusions • Port water injection has been successfully demonstrated near current production best in class full load levels (~27 bar BMEP) ⁃ Enabled near MBT Combustion Phasing (water flow limited by instrumentation) on “Regular” 87 AKI Fuel and stoichiometric operation ⁃ Resulted in a significant increase in Net Thermal Efficiency over production across all speeds • 34% @ 3000 RPM ⁃ Resulted in a significant increase in NMEP over production across all speeds
- 24. Engine Expo 2016 – Messe Stuttgart, Germany – May 31st to June 2nd 2016 • Evaluate water injection at higher levels of BMEP • Evaluate water injection at increased compression ratio • Compare Direct Water Injection to Port Water Injection • 1D Simulation of Water Injection • Reduce water usage though spray targeting and reduction in droplet size 24 Next Steps (Near Term)
- 25. Engine Expo 2016 – Messe Stuttgart, Germany – May 31st to June 2nd 2016 25 High BMEP Engine Components • Currently no production engine at this cylinder pressure • Production intent ⁃ Forged Pistons & Connecting Rods ⁃ High Strength head studs ⁃ 10W40 High ZDDP Synthetic Oil ⁃ Increased valve lift ⁃ Increased valve spring stiffness ⁃ Larger High Pressure Fuel Pump • 83% increase in fuel flow
- 26. Engine Expo 2016 – Messe Stuttgart, Germany – May 31st to June 2nd 2016 Q&A 26 Sam Barros Director of Research and Development Nostrum Energy, LLC info@nostrumenergy.com www.nostrumenergy.com For full powerpoint