SBIR Phase II: Development of a Stoichiometric, Direct-Injected, Soot-Free Engine for Heavy-Duty Applications

SBIR 第二阶段：开发适用于重型应用的化学计量直喷无烟发动机

• 批准号: 1853114
• 负责人: Julie Blumreiter
• 金额: $ 74.72万
• 依托单位: ClearFlame Engines, Inc.
• 依托单位国家: 美国
• 项目类别: Standard Grant
• 财政年份: 2019
• 资助国家: 美国
• 起止时间: 2019-04-01 至 2023-02-28
• 项目状态: 已结题
• 来源: https://www.nsf.gov/awardsearch/showAward?AWD_ID=1853114&HistoricalAwards=false
• 关键词: SBIR; Phase; II; Development; Stoichiometric

Diesel engines remain critical to global economies, but are under threat from increasingly-stringent emissions regulations. Many alternatives, like spark-ignition and electric vehicles, sacrifice some of the performance or range benefits of Diesel-style operation. This creates a market need for technologies that can maintain Diesel engine performance while remaining decoupled from the dirty emissions of Diesel fuel. This proposal centers on the development of the ?ClearFlame Combustion System? (CFCS): a novel combustion process that enables Diesel-style engines to combust low-carbon alternative fuels like ethanol and methanol without sacrificing the power possible with traditional Diesel combustion. Further, the sootless nature of alternative fuels such as methanol and ethanol obviates the need for a Diesel particulate filter, and enables stoichiometric air-fuel ratios to eliminate the need for selective catalytic reduction of NOx (smog). The engine technology has the potential to alter the dynamics of any market dominated by Diesel engines (including heavy-duty transportation, agriculture, rail, and power generation) and can be licensed to, or jointly developed with, OEMs for simple integration into their existing product lines. Phase I results have shown a 30% increase in engine torque at increased efficiency, while engine-out soot emissions are more than 100x lower than that of Diesel engines, falling under the 2010 EPA regulation limit without aftertreatment. This Small Business Innovation Research Phase II project will continue development of the CFCS. The Phase I results showed that three critical CFCS subsystems?engine insulation, alcohol direct injection, and a combustion chamber optimized for stoichiometric combustion with exhaust gas load control?could be developed and integrated to achieve a previously unattainable combination of strong performance and low emissions. This Phase II effort will further advance these key components and demonstrate the benefits of the CFCS on a commercial engine platform, using CFD modeling and engine experiments to show the advantages of the CFCS compared to the Diesel baseline. The goal is to show how the CFCS enables a multi-cylinder heavy-duty engine to simultaneously improve power density by 30% at no loss of efficiency, while also achieving sootless stoichiometric exhaust conditions that are compatible with low-cost and highly-effective three-way catalysis (the same system that enables gasoline and natural gas engines to be much cleaner than Diesel). A Phase II prototype demonstration would realize a longtime industry goal of integrating three-way catalysis with a Diesel-style engine, allowing Diesel-style engines to achieve the emissions profile of the cleanest alternatives (like natural gas).This award reflects NSF's statutory mission and has been deemed worthy of support through evaluation using the Foundation's intellectual merit and broader impacts review criteria.

柴油发动机对全球经济仍然至关重要，但受到日益严格的排放法规的威胁。许多替代方案，例如火花点火式汽车和电动汽车，都会牺牲柴油式操作的一些性能或续航里程优势。这就产生了市场对能够保持柴油发动机性能同时保持与柴油燃料污染排放脱钩的技术的需求。该提案的重点是“ClearFlame 燃烧系统”的开发。 （CFCS）：一种新颖的燃烧过程，使柴油式发动机能够燃烧乙醇和甲醇等低碳替代燃料，而不会牺牲传统柴油燃烧可能产生的功率。此外，甲醇和乙醇等替代燃料的无烟性质消除了对柴油微粒过滤器的需要，并且使化学计量的空燃比能够消除对NOx（烟雾）的选择性催化还原的需要。该发动机技术有潜力改变由柴油发动机主导的任何市场（包括重型运输、农业、铁路和发电）的动态，并且可以授权给原始设备制造商或与原始设备制造商联合开发，以便简单地集成到其现有产品线中。第一阶段的结果显示，发动机扭矩增加了 30%，效率也提高了，而发动机排出的烟灰排放量比柴油发动机低 100 倍以上，低于 2010 年 EPA 规定的无后处理限值。这个小企业创新研究第二阶段项目将继续开发 CFCS。第一阶段的结果表明，可以开发和集成三个关键的 CFCS 子系统——发动机隔热、酒精直接喷射以及针对化学计量燃烧和废气负荷控制进行优化的燃烧室——以实现以前无法实现的强大性能和低排放的结合。第二阶段的工作将进一步推进这些关键部件，并利用 CFD 建模和发动机实验来展示 CFCS 与柴油基准相比的优势，从而在商用发动机平台上展示 CFCS 的优势。目标是展示 CFCS 如何使多缸重型发动机在不损失效率的情况下同时将功率密度提高 30%，同时实现与低成本和高效三元催化兼容的无烟化学计量排气条件（同一系统使汽油和天然气发动机比柴油发动机清洁得多）。第二阶段原型演示将实现将三效催化与柴油发动机相结合的长期行业目标，使柴油发动机能够达到最清洁替代品（如天然气）的排放状况。该奖项反映了 NSF 的法定使命，并通过使用基金会的智力优点和更广泛的影响审查标准进行评估，被认为值得支持。

项目成果

Design Optimization of an Ethanol Heavy-Duty Engine Using Design of Experiments and Bayesian Optimization

使用实验设计和贝叶斯优化设计优化乙醇重型发动机

• DOI: 10.1115/icef2022-90257
• 发表时间: 2022
• 期刊: ASME 2022 ICE Forward Conference
• 作者: Tekgul, Bulut;Liu, I-Han;Vittal, Manohar;Schanz, Robert;Blumreiter, Julie;Johnson, Bernard H.;Magnotti, Gina M.
• 通讯作者: Magnotti, Gina M.