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Partially Premixed Combustion (PPC) for Low Load Conditions in Marine Engines Using Computational and Experimental Techniques

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Partially Premixed Combustion (PPC) for Low Load Conditions in Marine Engines Using Computational and Experimental Techniques Aalto University School of Engineering Department of Energy Technology Kendra Shrestha Partially Premixed Combustion (PPC) for low load conditions in marine engines using computational and experimental techniques Espoo, May 31, 2013 Supervisor: Professor Martti Larmi Instructor: D.Sc. (Tech.) Ossi Kaario Aalto University, P.O. BOX 11000, 00076 AALTO www.aalto.fi Abstract of master's thesis Author Kendra Shrestha Title of thesis Partially Premixed Combustion (PPC) for low load conditions in marine engine using computational and experimental techniques Department Department of Energy Technology Professorship Internal Combustion Engine Code of professorship Kul-14 Thesis supervisor Professor Martti Larmi Thesis advisor(s) D.Sc. (Tech.) Ossi Kaario Date 31.05.2013 Number of pages 68 Language English Abstract Diesel Engine has been the most powerful and relevant source of power in the automobile industry for decades due to their excellent performance, efficiency and power. On the contrary, there are numerous environmental issues of the diesel engines hampering the environment. It has been a great challenge for the researchers and scientists to minimize these issues. In the recent years, sev- eral strategies have been introduced to eradicate the emissions of the diesel engines. Among them, Partially Premixed Combustion (PPC) is one of the most emerging and reliable strategies. PPC is a compression ignited combustion process in which ignition delay is controlled. PPC is intended to endow with better combustion with low soot and NOx emission. The engine used in the present study is a single-cylinder research engine, installed in Aalto Univer- sity Internal Combustion Engine Laboratory with the bore diameter of 200 mm. The thesis presents the validation of the measurement data with the simulated cases followed by the study of the spray impingement and fuel vapor mixing in PPC mode for different injection timing. A detailed study of the correlation of early injection with the fuel vapor distribution and wall impingement has been made. The simulations are carried out with the commercial CFD software STAR CD. Different injection parameters have been considered and taken into an account to lower the wall impingement and to produce better air-fuel mixing with the purpose of good combustion and reduction of the emissions. The result of the penetration length of the spray and the fuel vapor distribution for different early injection cases have been illustrated in the study. Comparisons of different thermodynamic proper- ties and spray analysis for different injection timing have been very clearly illustrated to get insight of effect of early injection. The parameters like injection timing, injection period, injection pres- sure, inclusion angle of the spray have an influence the combustion process in PPC mode. Exten- sive study has been made for each of these parameters to better understand their effects in the com- bustion process. Different split injection profiles have been implemented for the study of better fuel vapor distribution in the combustion chamber. The final part of the thesis includes the study of the combustion and implementation of EGR to control the temperature so as to get more prolonged ignition delay to accompany the PPC strategy for standard piston top and deep bowl piston top. With the injection optimization and implementa- tion of EGR, NOx has been reduced by around 44%, CO by 60% and Soot by 66% in the standard piston top. The piston optimization resulted in more promising result with 58% reduction in NOx, 55% reduction in CO and 67% reduction in Soot. In both cases the percentage of fuel burnt was increased by around 8%. Keywords PPC, CFD, Split Injection, Ignition delay, EGR Acknowledgement This master’s thesis has been carried out in Aalto University, Internal Combustion Engine Research Laboratory. This work has been carried out for Wärtislä as a research project to obtain optimal point using the PPC mode of combustion in the existing engine. I would like to express my gratitude to my Master’s thesis instructor D.Sc. (Tech) Ossi Kaario for his continuous support and guidance. I would also like to thank my thesis supervisor Prof. Martti Larmi for providing me the opportunity to work on this topic. Beside this, I would also like to thank Star CD support for answering my queries. I acknowledge Olli Ranta for his technical support to keep my computers and accessories updated. Furthermore, I would like to thank Matteo, Karri and Ville for their cooperation and constant assist. I would like to thank entire combustion research group for their invariable motivation and inspiration. I would like to thank my parents and all the family members for their continuous encouragement, love and care. Finally, I would like to share my thanks to Anju, Kendip, Santosh and the entire Nepalese community at the Aalto University for their continuous support and motivation. Special thanks to people of Finland for making life in Finland interesting and exciting. Espoo, May 31 2013 Table of Contents 1. INTRODUCTION .................................................................................................. 1 1.1 Motivation ....................................................................................................... 1 1.2 Hercules C Project ........................................................................................... 2 1.3 Overview of the Document .............................................................................. 3 2. BACKGROUND.................................................................................................... 4 2.1 Literature Review ............................................................................................ 4 3. COMPUTATIONAL MODEL ............................................................................... 8 3.1 Engine Specification........................................................................................ 8 3.2 Computational Grid ......................................................................................... 8 3.3 Turbulence Model ........................................................................................... 9 3.4 Nozzle Flow Model ....................................................................................... 10 3.5 Atomization and Break-up Model for spray ................................................... 11 3.6 Spray Impingement Model ............................................................................ 12 3.7 Combustion Model ........................................................................................ 13 3.8 Emission Modeling ....................................................................................... 15 3.9 Computational Technique .............................................................................. 16 3.10 Initial Condition ............................................................................................ 17 3.11 Boundary Conditions ..................................................................................... 17 4. VALIDATION OF THE COMPUTATIONAL MODEL ...................................... 19 5. SPRAY-WALL IMPINGEMENT AND FUEL VAPOR DISTRIBUTION ANALYSIS ................................................................................................................. 24 5.1 Current EVE Injection system ....................................................................... 24 5.2 Effect of Increased Injection Pressure ............................................................ 31 5.3 Sweep of Inclusion Angle with increased injection pressure .......................... 35 5.4 Spray-wall impingement and fuel vapor analysis in various piston bowl shapes 40 6. COMBUSTION MODE STUDY FOR PPC STRATEGY .................................... 43 6.1 Combustion Analysis in standard piston top .................................................. 43 6.2 Combustion Analysis in Deeper bowl piston top............................................ 51 7. CONCLUSIONS .................................................................................................. 61 7.1 Fuel Vapor and Spray-Wall Impingement Analysis ....................................... 61 7.2 Combustion Analysis .................................................................................... 61 8. RECOMMENDATION FOR FUTURE WORK ................................................... 64 9. BIBILIOGRAPHY ............................................................................................... 65 1. INTRODUCTION 1.1 Motivation Diesel Engines have been the most relevant source of power in the automobile industries from decades because of their excellent performance, efficiency and power which is extensively used in transportation. The capability of energy conversion efficiency of diesel engines from the fuel combustion to mechanical output has been very high. On the other hand, the emissions produced by the engines are hampering the environment, causing global warming, greenhouse effect, acid rain and climate change. This has been the major environmental issue for researchers and scientists. Numerous studies focusing on the reduction of these negative impacts of diesel engines are evolving. In the recent years, several strategies and methods have been introduced to eradicate the emission of diesel engines in order to protect the earth from such environmental issues. The major sources of emission inhibiting the pollution are nitrogen oxides (NOx), carbon monoxide (CO), hydrocarbons (HCs) and the particulate
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