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The development of future gasoline engines is dominated by the study of new technologies aimed at reducing the engine negative environmental impact and increase its thermal efficiency. One common trend is to develop smaller engines able to operate in stoichiometric conditions across the whole engine map for better efficiency, lower fuel consumption, and optimal conversion rate of the three-way catalyst (TWC). Water injection is one promising technique, as it significantly reduces the engine knock tendency and avoids fuel enrichment for exhaust temperature mitigation at high power operation.
With the focus on reducing the carbon footprint of the automotive sector, another vital topic of research is the investigation of new alternative CO2-neutral fuels or so-called eFuels. Several studies have already shown how these new synthetic fuels can be produced by exploiting renewable energy sources and can significantly reduce engine emissions.
This work is part of the FVV project number 1367, “Water Injection in Spark-Ignition Engines II”, which investigates the coexistence of two different engine technologies that heads towards the same direction of sustainability of the internal combustion engine: water injection and eFuels. The goal is to assess the advantages that the adoption of an eFuel in combination with water injection strategies can bring, with respect to the same strategies applied in combination with commercial gasoline.
Several water injection strategies, including direct water injection, indirect water injection, injection timing, and pressure variations, are considered for a better understanding of the benefits brought by the combination of an eFuel with water injection. For this purpose, experimental tests and 3D-CFD engine simulations have been performed. The physical properties of the investigated eFuel have been experimentally measured for accurate modelling in the simulation environment, and the thermodynamic properties have been evaluated utilizing detailed chemistry calculations.
The use of complex reaction schemes is accompanied by high computational cost in 3D CFD simulations but is particularly important to predict pollutant emissions in internal combustion engine simulations. One solution to tackle this problem is to solve the chemistry prior the CFD run and store the chemistry information in look-up tables. The approach presented combines pre-tabulated progress variable-based source terms for auto-ignition as well as soot and NOx source terms for emission predictions. The method is coupled to the 3D CFD code CONVERGE v2.4 via user-coding and tested over various speed and load passenger-car Diesel engine conditions. This work includes the comparison between the combustion progress variable (CPV) model and the online chemistry solver in CONVERGE 2.4. Both models are compared by means of combustion and emission parameters. A detailed n-decane/α-methyl-naphthalene mechanism, comprising 189 species, is used for both online and tabulated chemistry simulations. The two chemistry solvers show very good agreement between each other and equally predict trends derived experimentally by means of engine performance parameters as well as soot and NOx engine-out emissions. The CPV model shows a factor 8 speed-up in run-time compared to the online chemistry solver without compromising the accuracy of the solution.
Spray modeling is among the main aspects of mixture formation and combustion in internal combustion engines. It plays a major role in pollutant formation and energy efficiency although adequate modeling is still under development. Strong grid dependence is observed in the droplet-based stochastic spray model commonly used. As an alternative, an interactive model called 'SprayLet' is being developed for spray simulations based on one-dimensional integrated equations for the gas and liquid phases, resulting from cross-sectionally averaging of multi-dimensional transport equations to improve statistical convergence. The formulated one-dimensional cross-section averaged system is solved independently of the CFD program to provide source terms for mass, momentum and heat transfer between the gas and liquid phases. The transport processes take place in a given spray cone where the nozzle exit is automatically resolved. In the 1D program, the conservation equations are for droplet diameter, droplet temperature, as well as for continuity and momentum of the liquid and the gaseous phase are solved. The source terms between the phases are conservatively embedded into the spray region of the CFD program. In CFD program, the transport equations are solved for gas phase only. The SprayLet model is validated using standard Sandia sprays by comparing penetration lengths and fuel mixture fractions with experimental data.
Meeting strict current and future emissions legislation necessitates development of computational tools capable of predicting the behaviour of combustion and emissions with an accuracy sufficient to make correct design decisions while keeping computational cost of the simulations amenable for large-scale design space exploration. While detailed kinetics modelling is increasingly seen as a necessity for accurate simulations, the computational cost can be often prohibitive, prompting interest in simplified approaches allowing fast simulation of reduced mechanisms at coarse grid resolutions appropriate for internal combustion engine simulations in design context. In this study we present a simplified Well-stirred Reactor (WSR) implementation coupled with 3D CFD Ricardo VECTIS solver. A detailed evaluation of benchmark ECN spray problem is presented demonstrating that a single point calibration of such a model using a bulk reaction multiplier approach can provide correct representation of the solution across a wide range of temperatures on grid sizes typically employed for RANS internal combustion engine simulations with tabulated kinetics or zonal combustion models.
The present work provides new insight into NH3single bondNO interaction under low-temperature conditions. The oxidation process of neat NH3 and NH3 doped with NO (450, 800 ppm) was experimentally investigated in a Jet Stirred Flow Reactor at atmospheric pressure for the temperature range 900–1350 K. Results showed NO concentration is entirely controlled by DeNOx reactions in the temperature range 1100–1250 K, while NH3single bondNO interaction does not develop through a sensitizing NO effect, for these operating conditions.
A detailed kinetic model was developed by systematically updating rate constants of controlling reactions and declaring new reactions for N2H2 isomers (cis and trans). The proposed mechanism well captures target species as NO and H2 profiles. For NH3single bondNO mixtures, NO profiles were properly reproduced through updated DeNOx chemistry, while NH2 recombination reactions were found to be essential for predicting the formation of H2. The role of ammonia as a third-body species is implemented in the updated mechanism, with remarkable effects on species predictions. For neat NH3 mixture, the reaction H+O2(+M)=HO2(+M) was crucial to predict NO formation via the reaction NH2+HO2double bondH2NO+OH.
In the SAE article 2023-24-0083: SprayLet: One-dimensional interactive cross-sectionally averaged spray model, we formulatet a one-dimensional Spray model in interaction with the surrounding gas phase. We could demonstrate, that the model predicted liquid and gaseous penetration length in good aggreement with ECN spray experiments. In this paper we use this model in engine CFD (CONVERGE CFD) and demonstrate a strong reduction in CPU time (50%). We can show a strong decrease in grid dependency, which allows a further reduction of CPU time (90%). We will present engine CFD simulations, comparing detailed spray with SpayLet simulations. This includes pressure traces, heat release, and emissions.
State of the art spark ignited gasoline engines achieve thermal efficiencies above 46 % e.g. due to friction optimized crank trains, high in-cylinder tumble flow and direct fuel injection. Further improvements of thermal efficiency are expected from lean combustion, higher compression ratio and new knock-resistant fuel blends. One of the limitations to these improvements are set by the autoignition in the end gas, which can develop to knocking combustion and severely damage the internal combustion engine. The auto-ignition is enhanced by high cylinder gas temperatures and reactive species in the end gas composition. Quasi-dimensional Stochastic Reactor Model simulations with detailed chemistry allow to consider the thermochemistry properties of surrogates and complex end gas compositions. Based on the detailed reaction scheme and surrogate model, an innovative tabulated chemistry approach is utilized to generate dual-fuel laminar flame speed and combustion chemistry look-up tables. This reduces the simulation duration to seconds per cycle, while the loss in accuracy compared to solving the chemistry “online” is marginal. The auto-ignition events predicted by the tabulated chemistry simulation are evaluated using the Detonation Diagram developed by Bradley and co-workers. This advanced methodology for quasi-dimensional models evaluates the resonance between the shock wave and reactionfront velocity from auto-ignition in the end gas and determines if it is a harmful developing detonation or normal deflagration. The aim of this work is to evaluate the auto-ignition characteristics of different fuel blends. The Stochastic Reactor Model with tabulated chemistry is applied to perform a numerical analysis of the autoignition of the fuel blends and operating conditions. Experimental measurements of a single cylinder research engine operated with RON95 E10 fuel are used to train and validate the simulation model. The RON95 E10 fuel is blended with Methanol, Hydrogen and Toluene. The knock tendency based on the evaluation of auto-ignition events of the different fuel blends are analysed for three operating points at 1500 rpm 15 bar IMEP, 2000 rpm 20 bar IMEP and 2500 rpm 15 bar IMEP with advanced spark timings.
The aim of this work is to evaluate the influence of the n-heptane/toluene ratio on the reactivity of binary toluene reference fuels (TRFs), through a combined experimental and numerical work. Novel experimental ignition delay time (IDT) data of three binary TRFs of varying n-heptane/toluene ratios have been obtained in a high-pressure shock tube and in a rapid compression machine at conditions relevant to novel engine operation. Measurements have been performed at two pressures (10 and 30 bar), and at three fuel/air equivalence ratios (0.5, 1.0 and 2.0) for TRF mixtures of 50%, 75% and 90% by volume toluene concentration, over the temperature range of 650–1450 K. It was found that, increasing the n-heptane content, led to an increase in reactivity and shorter measured IDTs. Reduced sensitivity to the equivalence ratio was observed at high temperatures, especially for high toluene content mixtures. A …
"Chemical Kinetic Modelling of Combustion in Internal Combustion Engines using Reduced Chemistry"
(2002)
The use of chemical kinetic mechanisms in computer aided engineering tools for internal combustion engine simulations is of high importance for studying and predicting pollutant formation of conventional and alternative fuels. However, usage of complex reaction schemes is accompanied by high computational cost in 0-D, 1-D and 3-D computational fluid dynamics frameworks. The present work aims to address this challenge and allow broader deployment of detailed chemistry-based simulations, such as in multi-objective engine optimization campaigns. A fast-running tabulated chemistry solver coupled to a 0-D probability density function-based approach for the modelling of compression and spark ignition engine combustion is proposed. A stochastic reactor engine model has been extended with a progress variable-based framework, allowing the use of pre-calculated auto-ignition tables instead of solving the chemical reactions on-the-fly. As a first validation step, the tabulated chemistry-based solver is assessed against the online chemistry solver under constant pressure reactor conditions. Secondly, performance and accuracy targets of the progress variable-based solver are verified using stochastic reactor models under compression and spark ignition engine conditions. Detailed multicomponent mechanisms comprising up to 475 species are employed in both the tabulated and online chemistry simulation campaigns. The proposed progress variable-based solver proved to be in good agreement with the detailed online chemistry one in terms of combustion performance as well as engine-out emission predictions (CO, CO2, NO and unburned hydrocarbons). Concerning computational performances, the newly proposed solver delivers remarkable speed-ups (up to four orders of magnitude) when compared to the online chemistry simulations. In turn, the new solver allows the stochastic reactor model to be computationally competitive with much lower order modeling approaches (i.e., Vibe-based models). It also makes the stochastic reactor model a feasible computer aided engineering framework of choice for multi-objective engine optimization campaigns.
It is important to understand the low-temperature chemistry of 1-hexene as it is used as a representative alkene component in gasoline surrogate fuels. Ignition delay times (IDTs) of 1-hexene measured in rapid compression machines (RCMs) can be used to validate its low-temperature chemistry. However, volume history profiles are not available for published RCM IDT data. This has restricted the validation of the low-temperature chemistry of 1-hexene at engine-relevant conditions (i.e. at low temperatures and high pressures). Thus, new RCM IDT data with associated volume history profiles are needed. In this study, both an RCM and a high-pressure shock tube (ST) are employed to measure IDTs of 1-hexene at equivalence ratios of 0.5, 1.0 and 2.0 in ‘air’ and at pressures of 15 and 30 atm. A cool-flame (first stage) and total (second stage) ignition was observed in the RCM experiments. Moreover, carbon monoxide and water versus time histories produced during 1-hexene oxidation at highly diluted conditions were measured in a ST. A new detailed chemical kinetic model describing 1-hexene oxidation is proposed and validated using these new measured data together with various experimental data available in the literature. The kinetic model can predict well the auto-ignition behavior and oxidation processes of 1-hexene at various conditions. The rate constants and branching ratio for hydroxyl radical addition to the double bond of 1-hexene are particularly important and discussed based on the experimental and theoretically calculated results from previous studies as well as validation results from jet-stirred reactor (JSR) species profiles. Flux and sensitivity analyses are performed to determine the important reaction classes for 1-hexene oxidation and show that the reactions associated with hydroxy radical addition to the double bond contribute most to the low-temperature reactivity of 1-hexene. In the negative temperature coefficient (NTC) regime, the isomerization of hexenyl-peroxy radicals promotes fuel reactivity due to its associated chain branching pathways.
The reduction of greenhouse gasses such as CO2 and CH4 is becoming necessary due to global environmental problems. The reforming of light hydrocarbons is a particularly efficient process for producing synthesis gas, H2 and CO, from greenhouse gasses [1]. The steam reforming of methane is the most important method to produce syngas in industry by using a nickel catalyst. Nickel-based catalysts are the conventional catalysts in industrial applications due to their fast turnover rates, good availability, and low costs, however, limited by their tendency towards coke formation. In this study, a detailed surface reaction mechanism is developed for steam reform-ing of methane over nickel and results are compared with the reference data.
A detailed surface reaction mechanism to investigate oxidation of methane over nickel catalyst
(2023)
We have developed a kinetically consistent detailed surface reaction mechanism for modeling the oxidation of methane over a nickel-based catalyst. A one-dimensional model, LOGEcat based on the single-channel 1D catalyst model, is used to perform the simulations. The original multi-step reaction mechanism is thermodynamically consistent and consists of 52 reactions. By thermodynamic consistency, we mean that the equilibrium is achieved with the support of the Arrhenius parameters and does not depend on the thermochemistry of the species involved in the considered reactions. The detailed mechanism developed in this investigation contains 26 reversible reactions. These reactions are obtained with the use of the thermochemistry of the species. The study focuses on ensuring kinetic consistency and this is done with the help of thermodynamic analysis by bringing the thermochemistry of the species in play in order to develop a surface reaction mechanism. The new mechanism can be used to understand the other processes, for example, steam- and dry-reforming of methane over nickel, however, the main focus of the paper is to check the performance of the detailed mechanism for catalytic partial oxidation of methane. The applicability of the mechanism is checked for various reactor conditions in terms of parameters such as temperature and pressure by comparing the results with the available reference data. The detailed mechanism developed in this study is able to accurately express oxidation of methane over the nickel catalyst for the considered reactor conditions.
In the field of catalysis, dry reforming, that is, methane reforming with CO2, is in the focus due to growing environmental concerns about oil depletion and global warming with a desire to produce synthesis gas. However, this process can lead to the formation of carbon, which can cause catalyst deactivation, especially at industrial conditions. Nevertheless, the key to develop a more coke-resistant catalyst is a better comprehension of the reforming process at a molecular level. Regardless of all the investigations available in literature, the detailed path for the conversion of methane to syngas and carbon remains a controversial issue. Another problem in setting up a reaction mechanism is the difficulty to define the thermodynamic data for intermediate surface species and this leads to the development of thermodynamic consistent surface reaction mechanisms in literature where the thermodynamic data are not used to calculate the rate coefficients of the reverse reactions. Rather the Arrhenius parameters for the forward as well as backward reactions are explicitly given in the reaction mechanism to establish thermodynamic equilibrium. In this investigation, a kinetically consistent detailed surface reaction mechanism is developed which consists of 26 reversible reactions with the help of a one-dimensional model, LOGEcat. Our previous work constructs the basis of the present investigation. Further, a detailed sensitivity analysis of reversible reactions and reaction pathways is performed to understand the mechanism better. The mechanism is validated for dry reforming of methane over nickel catalyst, however, it can also be used for other processes, such as, steam reforming and partial oxidation. The mechanism is tested by comparing the simulation results with the literature experiments and simulations in a wide range of temperature. The new developed kinetically consistent surface reaction mechanism is able to accurately express the dry reforming of methane over the nickel catalyst for complete range of temperature and also provide a useful insight into the key rate determining steps.
The reforming of light hydrocarbons to produce synthesis gas, H2 and CO, is an important intermediate for manufacturing valuable basic chemicals and synthesis fuels. In order to understand these reforming processes better, elementary step reaction mechanisms are developed. In the available literature, the surface reaction mechanisms are usually achieved with the help of reaction kinetic parameters without using the thermochemistry of the species referred to kinetic models due to the unavailability of the thermochemistry of the intermediate species involved in the multi-step reaction mechanism. In this work, investigations are made to obtain the thermochemistry of the intermediate species to establish thermodynamic equilibrium in order to develop a thermodynamic model for steam reforming of methane over nickel. The thermochemistry of the surface bound species is taken from different sources available in the literature and after that a detailed sensitivity analysis is performed to match the results with experiments. The simulation set up is adapted from the literature experiments given in [1]. The results produced with the one-dimensional tool using the thermodynamic model developed in the present investigation consisting of 21 reversible reactions are compared with the kinetic scheme with 42 irreversible reactions from reference simulation along with their experimental results. Both the models show some major differences in the reaction pathways which provides a useful insight into the key rate determining steps and needs further investigations.
Steam reforming of hydrocarbons is a well established chemical process which provides synthesis gas (H2 and CO). These synthesis products can hence be converted to numerous valuable basic chemicals. For the industrial application of steam reforming, a detailed understanding of the process is a prerequisite. Models that capture the detailed homogeneous and heterogeneous reaction kinetics and the comprehensive transport processes as well as their interaction have the potential to optimize the catalytic process without expensive experimental campaigns.
In this paper, a detailed investigation has been done using a multi-step reaction mechanism for modeling steam reforming of methane over nickel-based catalyst using a one-dimensional (1D) model, LOGEcat [1]. The model is applicable to the simulation of all standard after-treatment catalytic processes of combustion exhaust gas along with other chemical processes involving heterogeneous catalysis, such as, the Sabatier process [27]. It is a 1D tool, thus is computationally cost effective and is based on a series of perfectly stirred reactors (PSR).
The model is used to perform the simulations for various reactor conditions in terms of temperature, pressure, flow rates and steam-to-carbon (S/C) ratio. Several chemical reaction terms, such as, selectivity, yield, conversion, and mole fraction have been shown with respect to the varied parameters and the results are compared with 2D simulations and experimental reference data. We report a very good agreement of the various profiles produced with 1D model as compared to the reference data.
Note that the main aim of this study is to check how far the 1D model can capture the basic chemistry for modeling steam reforming of methane over nickel-based catalysts. It is interesting to note that the cost effective reduced order model is capable to capture the physics and chemistry involved with a multi-step reaction mechanism showing the predictive capability of the model. This study forms the basis for further analysis towards the thermochemistry of the species to develop a kinetically consistent reaction mechanism.
A thermodynamic model is developed using a one-dimensional model, LOGEcat to understand the dry reforming of methane over nickel-based catalysts. To do so, we have extended our previously developed mechanism (Rakhi and Shrestha in React Kinet, Mech Catal 135:3059–3083, 2022) which contains 21 reversible reactions by adding 5 more reversible reactions and updating the thermochemistry of one intermediate species. The adjusted mechanism contains 26 reversible reactions obtained with the help of thermodynamic analysis. This study focuses on using the thermodynamic model for dry reforming of methane and insights into the reaction pathways and sensitivity analysis for the kinetically consistent surface reaction mechanism. The applicability of the mechanism is examined for reactor conditions in terms of parameters such as temperature by comparing the results with the available reference data. The mechanism is able to accurately express the reforming conditions of methane over the nickel catalyst for complete range of temperature and also provide useful insights into the reaction pathways established with the thermodynamic model.