IPSY - Innovative Particle Trap System for Future Diesel Combustion Concepts
Overview
Background & policy context:
Advanced diesel combustion processes for passenger car diesel engines, such as homogeneous charge compression ignition (HCCI), or partial homogeneous combustion, are developed for their potential to achieve near zero particulate and NOx emissions. One of the drawbacks of this technology is the difficult combustion control at medium and high loads and consequently a limited operating range where NOx and particulate emissions are at a very low level. For this purpose, novel exhaust cleaning devices are necessary to process the different loading areas with its specific emissions well below the Euro 5 emission level.
To ensure soot regeneration for the needed particulate trap at the low NO/NO2 and exhaust temperature levels resulting from efficient combustion, the project IPSY focused on a novel design of porous media and novel catalytic nanostructured materials in a compact unit, with tuneable soot particle collection that will accommodate multifunctional catalytic coatings.
Objectives:
The objectives of the project IPSY is to achieve in diesel combustion processes a global filtration efficiency, even on ultrafine particulates above 95% with a nearly constant fuel consumption at slightly increased back pressure and advanced regeneration strategies in the range of 580 C in an acceptable time, therefore the focus lies on particulate and not only on CO and HC.
These means in detail:
- PM< 0.001 g/km NEDC (New European Driving Cycle);
- NOx : 0.06 g/km NEDC;
- applicability to passenger cars as well as adaptability to truck engines;
- fuel consumption equivalent to the Euro 4 calibration including regeneration;
- ability to run in all driving conditions.
One of the main pillars of the project is to design, develop, construct and test an innovative multifunctional filter reactor (MFR) for treating the particulate and gaseous pollutants from the exhaust streams of a HCCI, partial homogeneity and conventional combustion process of a diesel engine in the complete engine map.
The other main pillar is the development of advanced regeneration strategies to minimise active regeneration cases to avoid the risk of increasing the fuel consumption.
Methodology:
There were different key activities in the project:
Key activity 1
Development and construction of the multifunctional reactor divided in two tasks.
Task 1 - MFR development:
- catalyst synthesis and deposition on small-scale filters;
- construction of the MFR subunits;
- MFR prototype assembly and initial assessment;
- production of two fully-instrumented MFR prototypes for functional tests.
Task 2 - MFR evaluation with engine tests for loading and regeneration:
- testing the MFR on a conventional multi-cylinder engine on steady-state and transient operation (NEDC);
- testing the system with the HCCI engine under steady-state conditions;
- testing the system with applied control algorithms.
Key activity 2
Physical modelling of particulate morphology on particulate trapping and the setting-up of a 3D CFD (computerised fluid dynamics) simulation model including all necessary boundary conditions. Due to the fact that the thermomechanical interactions in the system must be taken into account, the model must include a gas phase as well as a solid wall structure of the DPF (diesel particulate filter) (conjugate heat transfer).
Following this activity, an algorithms for the power-train control unit using the 3D simulation real-time model of the complete exhaust system and different filter characteristics are developed. This takes into account thermal behaviour, coating, loading and soot oxidation for the new filter, as well as the engine out emissions and exhaust temperature of the HCCI diesel engine to integrate the real behaviour of the trap system in the entire vehicle environment.
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