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2010 Advanced Combustion Engine R&D Report 20annual progress 10report Advanced Combustion Engine Research and Development For more information DOE-ACE-2010AR March 2011 1-877-EERE-INFO (1.877.337.3463) Printed with a renewable-source ink on paper containing eere.energy.gov at least 50% wastepaper, including 10% post consumer waste. U.S. Department of Energy 1000 Independence Avenue, S.W. Washington, D.C. 20585-0121 FY 2010 PROGRESS REPORT FOR ADVANCED COMBUSTION ENGINE RESEARCH AND DEVELOPMENT Energy Efficiency and Renewable Energy Vehicle Technologies Program Approved by Gurpreet Singh Team Leader, Advanced Combustion Engine R&D Vehicle Technologies Program December 2010 DOE-ACE-2010AR Acknowledgement We would like to express our sincere appreciation to Alliance Technical Services, Inc. and Oak Ridge National Laboratory for their technical and artistic contributions in preparing and publishing this report. In addition, we would like to thank all the participants for their contributions to the programs and all the authors who prepared the project abstracts that comprise this report. Advanced Combustion Engine R&D ii FY 2010 Annual Progress Report Table of Contents I. Introduction . 1 I.1 Subprogram Overview and Status. .3 I.2 Project Highlights . 10 I.3 Honors and Special Recognitions/Patents . .20 I.4 Future Project Directions. .22 II. Advanced Combustion and Emission Control Research for High-Efficiency Engines. 31 II.A Combustion and Related In-Cylinder Processes. 33 II.A.1 Argonne National Laboratory: Fuel Injection and Spray Research Using X-Ray Diagnostics . .33 II.A.2 Sandia National Laboratories: Low-Temperature Automotive Diesel Combustion. 38 II.A.3 Sandia National Laboratories: Heavy-Duty Low-Temperature and Diesel Combustion & Heavy-Duty Combustion Modeling. .44 II.A.4 Sandia National Laboratories: Low-Temperature Diesel Combustion Cross-Cut Research. .50 II.A.5 Oak Ridge National Laboratory: High-Efficiency Clean Combustion in Light-Duty Multi-Cylinder Diesel Engines . .55 II.A.6 Sandia National Laboratories: Large Eddy Simulation (LES) Applied to Low Temperature and Diesel Engine Combustion Research . 59 II.A.7 Lawrence Livermore National Laboratory: Computationally Efficient Modeling of High Efficiency Clean Combustion Engines . .64 II.A.8 Sandia National Laboratories: HCCI and Stratified-Charge CI Engine Combustion Research. 70 II.A.9 Sandia National Laboratories: Automotive HCCI Combustion Research . 76 II.A.10 Oak Ridge National Laboratory: Achieving and Demonstrating Vehicle Technologies Engine Fuel Efficiency Milestones. 80 II.A.11 Los Alamos National Laboratory: KIVA Development. 83 II.A.12 Lawrence Livermore National Laboratory: Chemical Kinetic Models for HCCI and Diesel Combustion. .88 II.A.13 Sandia National Laboratories: Hydrogen Free-Piston Engine. 93 II.A.14 Argonne National Laboratory: Optimization of Direct Injection Hydrogen Combustion Engine Performance, Efficiency and Emissions . .97 II.A.15 Sandia National Laboratories: Advanced Hydrogen-Fueled ICE Research. .102 II.A.16 Oak Ridge National Laboratory: Stretch Efficiency – Exploiting New Combustion Regimes . .108 II.A.17 Ford Motor Company: Advanced Boost System Development For Diesel HCCI Application . 113 II.A.18 Argonne National Laboratory: Visualization of In-Cylinder Combustion R&D. 117 II.A.19 Volvo Powertrain North America: Very High Fuel Economy, Heavy-Duty, Truck Engine Utilizing Biofuels and Hybrid Vehicle Technologies. .120 II.A.20 Oak Ridge National Laboratory: Expanding Robust HCCI Operation with Advanced Valve and Fuel Control Technologies. .124 II.A.21 Cummins Inc.: Light-Duty Vehicle Efficient Clean Combustion . .127 II.B Energy Efficient Emission Controls. 130 II.B.1 Pacific Northwest National Laboratory: CLEERS Aftertreatment Modeling and Analysis . .130 II.B.2 Pacific Northwest National Laboratory: Enhanced High Temperature Performance of NOx Storage/Reduction (NSR) Materials. 136 II.B.3 Oak Ridge National Laboratory: Emissions Control for Lean Gasoline Engines. 142 FY 2010 Annual Progress Report iii Advanced Combustion Engine R&D Table of Contents II. Advanced Combustion and Emission Control Research for High-Efficiency Engines (Continued) II.B Energy Efficient Emission Controls (Continued) II.B.4 Sandia National Laboratories: Development of Chemical Kinetics Models for Lean-NOx Traps. 145 II.B.5 Oak Ridge National Laboratory: Advanced Engine/Aftertreatment System R&D CRADA with Navistar, Inc. 149 II.B.6 Oak Ridge National Laboratory: Fundamental Sulfation/Desulfation Studies of Lean NOx Traps, DOE Pre-Competitive Catalyst Research . .154 II.B.7 Oak Ridge National Laboratory: NOx Control and Measurement Technology for Heavy-Duty Diesel Engines . 159 II.B.8 Oak Ridge National Laboratory: Efficient Emissions Control for Multi-Mode Lean DI Engines . 164 II.B.9 Oak Ridge National Laboratory: Cross-Cut Lean Exhaust Emission Reduction Simulation (CLEERS): Administrative Support. .168 II.B.10 Oak Ridge National Laboratory: Cross-Cut Lean Exhaust Emissions Reduction Simulations (CLEERS): Joint Development of Benchmark Kinetics. .172 II.B.11 Argonne National Laboratory: Development of Advanced Diesel Particulate Filtration Systems . 178 II.B.12 Pacific Northwest National Laboratory: Combination and Integration of DPF-SCR After-Treatment. 183 II.B.13 Pacific Northwest National Laboratory: Degradation Mechanisms of Urea Selective Catalytic Reduction Technology. .187 II.C Health Impacts. 191 II.C.1 Oak Ridge National Laboratory: Health Effects from Advanced Combustion and Fuel Technologies . .191 II.C.2 National Renewable Energy Laboratory: Collaborative Lubricating Oil Study on Emissions (CLOSE) Project . .196 II.C.3 Health Effects Institute: The Advanced Collaborative Emissions Study (ACES) . .199 III. Solid State Energy Conversion. 203 III.1 BSST LLC: High-Efficiency Thermoelectric Waste Energy Recovery System for Passenger Vehicle Applications. .205 III.2 Michigan State University: Thermoelectric Conversion of Waste Heat to Electricity in an IC Engine Vehicle. .209 III.3 General Motors Global Research & Development: Improving Energy Efficiency by Developing Components for Distributed Cooling and Heating Based on Thermal Comfort Modeling. 213 III.4 Ford Motor Company: Ford Thermoelectric HVAC Project. 217 III.5 General Motors Global Research & Development: Advanced Thermoelectric Technology for Automotive Waste Heat Recovery. .221 IV. University Research. 225 IV.1 University of Michigan: University Consortium on Efficient and Clean High-Pressure Lean-Burn (HPLB) Engines. .227 IV.2 University of Wisconsin-Madison: Optimization of Advanced Diesel Engine Combustion Strategies. .233 IV.3 Michigan State University: Flex-Fuel Optimized SI and HCCI Engine . .240 IV.4 University of Houston: Development of Optimal Catalyst Designs and Operating Strategies for Lean NOx Reduction in Coupled LNT-SCR Systems. .245 IV.5 University of Connecticut: Three-Dimensional Composite Nanostructures for Lean NOx Emission Control . .251 IV.6 Michigan Technological University: Experimental Studies for DPF, and SCR Model, Control System, and OBD Development for Engines Using Diesel and Biodiesel Fuels. .257 Advanced Combustion Engine R&D iv FY 2010 Annual Progress Report Table of Contents V. New Projects . 261 American Recovery and Reinvestment Act Funded New Projects . 263 V.1 Cummins, Inc.: Technology and System Level Demonstration of Highly Efficient and Clean, Diesel-Powered Class 8 Trucks . .263 V.2 Daimler Trucks North America LLC: Systems Level Technology Development and Integration for Efficient Class 8 Trucks. .264 V.3 General Motors Company: Lean Gasoline System Development for Fuel Efficient Small Cars. .264 V.4 Chrysler Group LLC: A MultiAir®/Multi-Fuel Approach to Enhancing Engine System Efficiency . .264 Other New Projects. 265 V.5 Navistar, Inc.: Development and Demonstration of a Fuel-Efficient Class 8 Tractor and Trailer. .265 V.6 Delphi Automotive Systems, LLC: Gasoline Ultra Fuel Efficient Vehicle with Advanced Low-Temperature Combustion. .265 V.7 Ford Motor Company: Advanced Gasoline Turbocharged Direct Injection (GTDI) Engine Development. 266 V.8 Robert Bosch: Advanced Combustion Controls - Enabling Systems and Solutions (ACCESS) for High Efficiency Light-Duty Vehicles . 266 V.9 Cummins, Inc.: Cummins Next Generation Tier 2 Bin 2 Diesel. .267 V.10 Ohio State University: Project SEEBECK: Saving Energy Effectively By Engaging in Collaborative research and sharing Knowledge. .267 V.11 Purdue University: Thermoelectrics for Automotive Waste Heat Recovery . 268 V.12 Stanford University: Automotive Thermoelectric Modules with Scalable Thermo- and Electro-Mechanical Interfaces. 268 V.13 Stony Brook University: Integrated Design and Manufacturing of Cost-Effective and Industrial-Scalable TEG for Vehicle Applications. 269 V.14 Texas A&M University: Inorganic-Organic Hybrid Thermoelectrics. .269 V.15 University of California, Los Angeles: Advanced Nanocomposite Materials and Interfaces for Thermoelectric Vehicle Waste Heat Recovery. .270 V.16 University of California, Santa Cruz: High Performance Thermoelectric System Based on Zintl Phase Materials with Embedded Nanoparticles. 270 V.17 University of Texas at Austin: High-Performance Thermoelectric Devices Based on Abundant Silicide Materials for Vehicle Waste Heat Recovery . 271 V.18 Virginia Tech: Efficient, Scalable, and Low-Cost Thermoelectric Waste Heat Recovery Devices for Vehicles. 271.
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