ReFuel – Tulevaisuuden
dieselpalamistekniikat synteettisille
ja uusiutuville polttoaineille
Kalle Lehto, Aalto-yliopisto
26.1.2012 VI Liekkipäivä, Lappeenranta
Aalto University, School of Engineering,
Deparment of Energy Technology
• Internal Combustion Engine Research
Group
• Located in Otaniemi, Espoo
• Staff of about 25
• Research Focus
– experimental
research
• alternative fuels
• extreme values
• fuel sprays
– computational
research
• spray simulation
• process simulation
VI Liekkipäivä, Lappeenranta
26.1.2012 Kalle Lehto
ReFuel
• a three year research project (2009-2011)
• goal
– utilize the potential of the renewable high cetane number
parafinic fuels and their oxygenate blends  develop optimum
combustion technologies for them
• tools
–
-
literature study
simulations (CFD)
emission mapping calculations
spray measurements
engine tests with medium- and high-speed engines
VI Liekkipäivä, Lappeenranta
26.1.2012 Kalle Lehto
ReFuel
• a three year research project (2009-2011)
• goal
– utilize the potential of the renewable high cetane number
parafinic fuels and their oxygenate blends  develop optimum
combustion technologies for them
• tools
–
-
literature study
simulations (CFD)
emission mapping calculations
spray measurements
engine tests with medium- and high-speed engines
VI Liekkipäivä, Lappeenranta
26.1.2012 Kalle Lehto
ReFuel
• research partners
–
–
–
–
• industry partners
–
–
–
–
Aalto
VTT
ÅA
TUT
Neste Oil
Agco Sisu Power
Wärtsilä
Aker Arctic
• financing
– Tekes
– Industry
– Universities and VTT
VI Liekkipäivä, Lappeenranta
26.1.2012 Kalle Lehto
ReFuel – High-speed engine tests, LEO
VI Liekkipäivä, Lappeenranta
26.1.2012 Kalle Lehto
EN590 vs.
Hydrogenated Vegetable Oil (HVO)
• commercial EN590 summer grade diesel as a reference
fuel
• 100 % HVO as a test fuel
Quantity
Unit
Cetane number (IQT)
EN590
HVO
56
88,2
Density
kg/m3
837,3
779,9
Total aromatics
wt-%
18,7
0,3
6,4
5,6
3,587
2,985
C/H ratio
Viscosity (at 40 °C)
mm2/s
VI Liekkipäivä, Lappeenranta
26.1.2012 Kalle Lehto
ReFuel – High-speed engine tests, LEO
• goal
– a 70 % reduction in emissions (NOx, PM) by using
Hydrotreaded Vegetable Oil (HVO) together with Exhaust Gas
Recirculation (EGR) and Miller timing
• test run campaigns
–
–
–
–
reference tests with both EN590 and HVO
separate miller- and EGR-test runs
combined miller and EGR with injection parameter optimization
test runs with HVO + oxygenate blend
VI Liekkipäivä, Lappeenranta
26.1.2012 Kalle Lehto
ReFuel - LEO
• LEO is a single-cylinder
high-speed diesel
research engine
• perfectly suited for this
sort of test runs
– Electro Hydraulic Valve
Actuators enable easy miller
cycle operation
– easily controllable simulated
EGR rate with neat nitrogen
– fully adjustable fuel injection
parameters (SOI, Inj.p, Inj.dur.,
pilot- and post injections...)
LEO electro hydraulic valve actuators (EHVA)
VI Liekkipäivä, Lappeenranta
26.1.2012 Kalle Lehto
LEO – Miller timing with an Electro
Hydraulic Valve Actuator system (EHVA)
Miller Timing Valve Lift Curves
Exhaust
Intake ref
Miller 30
Miller 50
Valve Lift
Miller 70
90
180
270
360
450
540
630
Crank Angle [deg]
VI Liekkipäivä, Lappeenranta
26.1.2012 Kalle Lehto
ReFuel – LEO, Results from the separate
EGR- and miller test runs
VI Liekkipäivä, Lappeenranta
26.1.2012 Kalle Lehto
ReFuel LEO – Reducing NOx and FSN
emission by using HVO, EGR + Miller
• EN590 reference
NOx - FSN
LEO - 50 % Load
1,4
1,2
Smoke [FSN]
1
0,8
0,6
0,4
0,2
0
0
50
100
150
200
250
300
350
NOx [ppm]
VI Liekkipäivä, Lappeenranta
26.1.2012 Kalle Lehto
ReFuel LEO – Reducing NOx and FSN
emission by using HVO, EGR + Miller
• EN590 reference
• HVO (NExBTL)
Reference
NOx - FSN
LEO - 50 % Load
1,4
1,2
Smoke [FSN]
1
0,8
0,6
0,4
0,2
0
0
50
100
150
200
250
300
350
NOx [ppm]
VI Liekkipäivä, Lappeenranta
26.1.2012 Kalle Lehto
ReFuel LEO – Reducing NOx and FSN
emission by using HVO, EGR + Miller
• EN590 reference
• HVO (NExBTL)
Reference
• HVO + 2,5 % EGR
NOx - FSN
LEO - 50 % Load
1,4
1,2
Smoke [FSN]
1
0,8
0,6
0,4
0,2
0
0
50
100
150
200
250
300
350
NOx [ppm]
VI Liekkipäivä, Lappeenranta
26.1.2012 Kalle Lehto
ReFuel LEO – Reducing NOx and FSN
emission by using HVO, EGR + Miller
• EN590 reference
• HVO (NExBTL)
Reference
• HVO + 2,5 % EGR
• HVO + 2,5 % EGR,
Miller 70
NOx - FSN
LEO - 50 % Load
1,4
1,2
Smoke [FSN]
1
0,8
0,6
0,4
0,2
0
0
50
100
150
200
250
300
350
NOx [ppm]
VI Liekkipäivä, Lappeenranta
26.1.2012 Kalle Lehto
ReFuel LEO – Reducing NOx and FSN
emission by using HVO, EGR + Miller
NOx - FSN
LEO - 50 % Load
1,4
1,2
1
Smoke [FSN]
• EN590 reference
• HVO (NExBTL)
Reference
• HVO + 2,5 % EGR
• HVO + 2,5 % EGR,
Miller 70
• HVO + 10 % EGR,
Miller 70, Inj.p +100
bar
0,8
0,6
0,4
0,2
0
0
50
100
150
200
250
300
350
NOx [ppm]
VI Liekkipäivä, Lappeenranta
26.1.2012 Kalle Lehto
ReFuel – LEO
Optimized process (combined EGR + Miller)
• Three engine loads (50, 75, and 100 %)
• for each load a ”Low NOx”, ”Low Smoke” and an ”Opt”
setup was created by varying EGR, miller, and fuel
injection
• The target was a 70 % reduction in one emission
component without the other being higher than in the
reference run with EN590
• The charge air mass flow was kept constant by
adjusting the charge air pressure and the load was kept
constant by adjusting injection duration
VI Liekkipäivä, Lappeenranta
26.1.2012 Kalle Lehto
ReFuel – High-speed engine tests, LEO – 50 % Load
Emission
EGR
Miller
Inj. p var.
SOI var.
NOx
FSN
Opt.
5%
70
+100 bar
0
-31 %
-54 %
Low NOx
10 %
70
+100 bar
0
-60 %
+2 %
Low Smoke
2,5 %
70
+100 bar
-3
-1%
-73 %
EN590 reference
NOx - Smoke
50 % Load
HVO refefence
HVO Optimized
1,4
1,2
1,0
Smoke [FSN]
50 % Load
Point
0,8
0,6
0,4
0,2
0,0
0,0
0,5
1,0
1,5
2,0
2,5
3,0
3,5
NOx [g/kWh]
VI Liekkipäivä, Lappeenranta
26.1.2012 Kalle Lehto
ReFuel – High-speed engine tests, LEO – 75 % Load
Emission
EGR
Miller
Inj. p var.
SOI var.
NOx
FSN
Opt
10 %
70
+400 bar
0
-52 %
-53 %
Low NOx
10 %
70
+400 bar
+2
-64 %
-19 %
Low Smoke
2,5 %
70
+200 bar
0
-12 %
-75 %
EN590 reference
NOx - Smoke
75 % Load
HVOreference
HVO Optimized
1,4
1,2
1,0
Smoke [FSN]
75 % Load
Point
0,8
0,6
0,4
0,2
0,0
0,0
0,5
1,0
1,5
2,0
2,5
3,0
3,5
4,0
NOx [g/kWh]
VI Liekkipäivä, Lappeenranta
26.1.2012 Kalle Lehto
ReFuel – High-speed engine tests, LEO – 100 % Load
Emission
EGR
Miller
Inj. p var.
SOI var.
NOx
FSN
OK
10 %
70
+600 bar
0
-54 %
-58 %
Low NOx
12 %
70
+ 600 bar
+1
-66 %
-13 %
Low Smoke
2,5 %
70
+ 400 bar
0
-10 %
-85 %
EN590 reference
NOx - Smoke
100 % Load
HVO reference
HVO Optimized
0,8
0,7
0,6
Smoke [FSN]
100 % Load
Point
0,5
0,4
0,3
0,2
0,1
0,0
0
1
2
3
4
5
6
NOx [g/kWh]
VI Liekkipäivä, Lappeenranta
26.1.2012 Kalle Lehto
Specific Fuel Consumption - 100 % Load
Specific Fuel
Consumption
[g/kWh]
250
Low Smoke
Low NOx
50
OK
100
HVO ref
150
EN590 ref
SFC [g/kWh]
200
0
200
0
Low NOx
50
OK
100
HVO ref
150
EN590 ref
Low NOx
50
OK
100
HVO ref
150
SFC [g/kWh]
200
Low Smoke
250
EN590 ref
SFC [g/kWh]
250
Low Smoke
Specific Fuel Consumption - 75 % Load
Specific Fuel Consumption - 50 % Load
0
VI Liekkipäivä, Lappeenranta
26.1.2012 Kalle Lehto
Summary
• at least 70 % reduction in smoke emissions was
achieved at each load point without NOx penalty
• at least 60 % reduction in NOx emissions was achieved
at each load point without smoke penalty
• with 75 % and 100 % loads over 50 % reduction in
smoke and NOx emissions was achieved at the same
time
• improved SFC in all load points
VI Liekkipäivä, Lappeenranta
26.1.2012 Kalle Lehto
Publications
•
•
•
•
•
•
Kaario et al. ”Analyzing local combustion
environment with a flamelet model and
detailed chemistry ”
Kaario et al. ”Studying Local Conditions in a
Heavy-Duty Diesel Engine by Creating Phi-T
Maps”
Gong et al. ” A computational investigation
of hydrotreated vegetable oil sprays using
RANS and a modified version of the RNG kepsilon model in OpenFOAM”
Imperato et al. ”Large-Bore CompressionIgnition Engines: High NOx Reduction
Achieved at Low Load with Hydro-Treated
Vegetable Oil”
Imperato et al. ”Hydrotreated Vegetable Oil
and Miller Timing in a Medium-Speed CI
Engine”
Hulkkonen et al. ”Experimental Study of
Spray Characteristics between Hydrotreated
Vegetable Oil (HVO) and Crude Oil Based
EN 590 Diesel Fuel”
•
•
•
•
•
•
•
VI Liekkipäivä, Lappeenranta
Lehto et al. ”Emission Reduction Using
Hydrotreated Vegetable Oil (HVO) With Miller
Timing and EGR in Diesel Combustion”
Erkkilä et al. ”Emission performance of
paraffinic HVO diesel fuel ”
Tilli et al. ”High Cetane Number Paraffinic
Diesel Fuels and Emission Reduction in
Engine Combustion”
Kaario et al. ”Studying Equivalence ratio –
Temperature Maps in a Heavy-Duty Diesel
Engine”
Gong et al. ”Large eddy simulations of
hydrotreated vegetable oil sprays using
OpenFOAM”
Imperato et al. “High NOx Reduction
Achieved at Low Load Using Very Advanced
Valve Timing with Hydro-Treated Vegetable
Oil”
Hulkkonen et al. ” Spray Studies and Diesel
Fuel Comparison”
26.1.2012 Kalle Lehto
Thank you for your time!
Any questions?
Contact
kalle.lehto@aalto.fi
VI Liekkipäivä, Lappeenranta
26.1.2012 Kalle Lehto