annual progress report 2009 ADVANCED COMBUSTION ENGINE RESEARCH AND DEVELOPMENT 2009 For more information 1-877-EERE-INF (1.877.337.3463) programname.energy.gov U.S. Department of Energy 1000 Independence Avenue, S.W. Washington, D.C. 20585-0121 FY 2009 PROGRESS REPORT FOR ADVANCED COMBUSTION ENGINE RESEARCH AND DEVELOPMENT Energy Efficiency and Renewable Energy Office of Vehicle Technologies Approved by Gurpreet Singh Team Leader, Advanced Combustion Engine R&D Office of Vehicle Technologies December 2009 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 Technologies ii FY 2009 Annual Progress Report Table of Contents Table of Contents I. Introduction .................................................................................1 II. Advanced Combustion and Emission Control Research for High-Efficiency Engines. 35 II.A Combustion and Related In-Cylinder Processes .............................................37 II.A.1 Argonne National Laboratory: Light-Duty Diesel Spray Research Using X-Ray Radiography ...................................................................37 II.A.2 Sandia National Laboratories: Low-Temperature Automotive Diesel Combustion ........42 II.A.3 Sandia National Laboratories: Heavy-Duty Low-Temperature and Diesel Combustion and Heavy-Duty Combustion Modeling .................................48 II.A.4 Sandia National Laboratories: Low-Temperature Diesel Combustion Cross-Cut Research ......................................................................54 II.A.5 Oak Ridge National Laboratory: High Efficiency Clean Combustion in Light-Duty Multi-Cylinder Diesel Engine .....................................................59 II.A.6 Sandia National Laboratories: Large Eddy Simulation (LES) Applied to LTC/Diesel/Hydrogen Engine Combustion Research .................................64 II.A.7 Lawrence Livermore National Laboratory: Computationally Efficient Modeling of High Efficiency Clean Combustion Engines ......................................68 II.A.8 Sandia National Laboratories: HCCI and Stratified-Charge CI Engine Combustion Research ......................................................................73 II.A.9 Sandia National Laboratories: Automotive HCCI Combustion Research . .80 II.A.10 Oak Ridge National Laboratory: Achieving and Demonstrating Vehicle Technologies Engine Fuel Efficiency Goals .....................................................85 II.A.11 Los Alamos National Laboratory: KIVA-4 Development .............................89 II.A.12 Lawrence Livermore National Laboratory: Chemical Kinetic Models for HCCI and Diesel Combustion . .94 II.A.13 Sandia National Laboratories: Hydrogen Free-Piston Engine .........................99 II.A.14 Argonne National Laboratory: Optimization of Direct Injection Hydrogen Combustion Engine Performance, Efficiency and Emissions . .104 II.A.15 Sandia National Laboratories: Advanced Hydrogen-Fueled ICE Research. 111 II.A.16 Cummins Inc.: Advanced Diesel Engine Technology Development for High Efficiency, Clean Combustion. 117 II.A.17 Caterpillar, Inc.: High Efficiency Clean Combustion (HECC) Advanced Combustion Report ............................................................121 II.A.18 Navistar, Inc.: Low-Temperature Combustion Demonstrator for High Efficiency Clean Combustion . .125 II.A.19 Oak Ridge National Laboratory: Stretch Efficiency – Exploiting New Combustion Regimes . .129 II.A.20 Detroit Diesel Corporation: Advancements in Engine Combustion Systems to Enable High-Efficiency Clean Combustion for Heavy-Duty Engines . .134 II.A.21 General Motors: Development of High Efficiency Clean Combustion Engine Designs for Spark-Ignition and Compression-Ignition Internal Combustion Engines. .138 II.A.22 Cummins Inc.: Light Duty Efficient Clean Combustion .............................142 II.A.23 Ford Motor Company: Advanced Boost System Development for Diesel HCCI Application . 145 II.A.24 Argonne National Laboratory: Light Duty Combustion Visualization .................148 II.A.25 Oak Ridge National Laboratory: Spark-Assisted HCCI Combustion. .150 II.B Energy Efficient Emission Controls ......................................................155 II.B.1 Pacific Northwest National Laboratory: CLEERS Aftertreatment Modeling and Analysis 155 II.B.2 Pacific Northwest National Laboratory: Enhanced High Temperature Performance of NOx Storage/Reduction (NSR) Materials .......................................164 FY 2009 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.3 Oak Ridge National Laboratory: Characterizing Lean-NOx Trap Regeneration and Desulfation ...............................................................169 II.B.4 Sandia National Laboratories: Development of Chemical Kinetics Models for Lean NOx Traps. 173 II.B.5 Oak Ridge National Laboratory: NOx Abatement Research and Development CRADA with Navistar, Inc. .....................................................178 II.B.6 Oak Ridge National Laboratory: Fundamental Sulfation/Desulfation Studies of Lean NOx Traps, DOE Pre-Competitive Catalyst Research. .183 II.B.7 Oak Ridge National Laboratory: NOX Control and Measurement Technology for Heavy-Duty Diesel Engines .....................................................187 II.B.8 Oak Ridge National Laboratory: Efficient Emissions Control for Multi-Mode Lean DI Engines ...................................................................191 II.B.9 Oak Ridge National Laboratory: Cross-Cut Lean Exhaust Emission Reduction Simulation (CLEERS): Administrative Support. .195 II.B.10 Oak Ridge National Laboratory: Cross-Cut Lean Exhaust Emission Reduction Simulation (CLEERS): Joint Development of Benchmark Kinetics. .198 II.B.11 Argonne National Laboratory: Development of Advanced Diesel Particulate Filtration Systems .............................................................203 II.B.12 Pacific Northwest National Laboratory: Diesel Soot Filter Characterization and Modeling for Advanced Substrates ...............................................207 II.B.13 Pacific Northwest National Laboratory: Degradation Mechanisms of Urea Selective Catalytic Reduction Technology. 210 II.B.14 Pacific Northwest National Laboratory: Low-Temperature Oxidation Catalyst Development Supporting Homogeneous Charge Compression Ignition (HCCI) Development. 215 II.C Critical Enabling Technologies . 219 II.C.1 Cummins Inc.: Exhaust Energy Recovery . .219 II.C.2 Caterpillar, Inc.: An Engine System Approach to Exhaust Waste Heat Recovery ........222 II.C.3 Volvo Powertrain North America: Very High Fuel Economy, Heavy-Duty, Narrow-Speed Truck Engine Utilizing Truck Engine Utilizing Biofuels and Hybrid Vehicle Technologies ....................................................225 II.C.4 TIAX LLC: Advanced Start of Combustion Sensor – Phase II: Pre-Production Prototyping . .230 II.C.5 Westport Power, Inc.: The Development of a Robust Accelerometer-Based Start of Combustion Sensing System. .232 II.C.6 Envera LLC: Variable Compression Ratio Engine ..................................236 II.D Health Impacts .......................................................................240 II.D.1 Oak Ridge National Laboratory: Health Effects from Advanced Combustion and Fuel Technologies . .240 II.D.2 National Renewable Energy Laboratory: Collaborative Lubricating Oil Study on Emissions (CLOSE) Project ..................................................244 II.D.3 Health Effects Institute: The Advanced Collaborative Emissions Study (ACES) . .247 III. Solid State Energy Conversion .................................................................253 III.1 General Motors Research and Development: Develop Thermoelectric Technology for Automotive Waste Heat Recovery .............................................255 III.2 BSST LLC: High-Efficiency Thermoelectric Waste Energy Recovery System for Passenger Vehicle Applications ..................................................260 III.3 Michigan State University: Thermoelectric Conversion of Waste Heat to Electricity in an Internal Combustion Engine Vehicle. .264 Advanced Combustion Engine R&D iv FY 2009 Annual Progress Report Table of Contents IV. University Research .........................................................................271 IV.1 University of Michigan: University Consortium on Low-Temperature Combustion For High-Efficiency, Ultra-Low Emission Engines ..................................273 IV.2 University of Houston: Kinetic and Performance Studies of the Regeneration Phase of Model Pt/Ba/Rh NOx Traps for Design and Optimization ...................279 IV.3 University of Kentucky: Investigation of Aging Mechanisms in Lean-NOX Traps ........286 IV.4 University of Texas at Austin: On-Board Engine Exhaust Particulate Matter Sensor for HCCI and Conventional Diesel Engines ........................................292 V. New Projects . 297 V.1 University of Wisconsin-Madison: Optimization of Advanced Diesel Engine Combustion Strategies. .299 V.2 University of Michigan: A University Consortium on High Pressure Lean Combustion