Novel Automotive Waste Heat Recovery Techniques

The United States transportation industry is predicted to consume approximately 13 million barrels of liquid fuel per day by 2025. If one percent of the fuel energy were salvaged through waste heat recovery, there would be a reduction of 130 thousand barrels of liquid fuel per day. This dissertation focuses on automotive waste heat recovery techniques with an emphasis on two novel techniques. The first technique investigated was a combination coolant and exhaust-based Rankine cycle system, which utilized a patented piston-in-piston engine technology. The research scope included a simulation of the maximum mass flow rate of steam (700 K and 5.5 MPa) from two heat exchangers, the potential power generation from the secondary piston steam chambers, and the resulting steam quality within the steam chamber. The secondary piston chamber provided supplemental steam power strokes during the engine's compression and exhaust strokes to reduce the pumping work of the engine. A Class-8 diesel engine, operating at 1,500 RPM at full load, had a maximum increase in the brake fuel conversion efficiency of 3.1%. The second technique investigated the implementation of thermoelectric generators on the outer cylinder walls of a liquid-cooled internal combustion engine. The research scope focused on the energy generation, fuel energy distribution, and cylinder wall temperatures. The analysis was conducted over a range of engine speeds and loads in a two cylinder, 19.4 kW, liquid-cooled, spark-ignition engine. The cylinder wall temperatures increased by 17% to 44% which correlated well to the 4.3% to 9.5% decrease in coolant heat transfer. Only 23.3% to 28.2% of the heat transfer to the coolant was transferred through the TEG and TEG surrogate material. The gross indicated work decreased by 0.4% to 1.0%. The exhaust gas energy decreased by 0.8% to 5.9%. Due to coolant contamination, the TEG output was not able to be obtained. TEG output was predicted from cylinder wall temperatures and manufacturer documentation, which was less than 0.1% of the cumulative heat release. Higher TEG conversion efficiencies, combined with greater control of heat transfer paths, would be needed to improve energy output and make this a viable waste heat recovery technique.

MODELING AND EXPERIMENTAL SETUP OF AN HCCI ENGINE

For the past three decades the automotive industry is facing two main conflicting challenges to improve fuel economy and meet emissions standards. This has driven the engineers and researchers around the world to develop engines and powertrain which can meet these two daunting challenges. Focusing on the internal combustion engines there are very few options to enhance their performance beyond the current standards without increasing the price considerably. The Homogeneous Charge Compression Ignition (HCCI) engine technology is one of the combustion techniques which has the potential to partially meet the current critical challenges including CAFE standards and stringent EPA emissions standards. HCCI works on very lean mixtures compared to current SI engines, resulting in very low combustion temperatures and ultra-low NOx emissions. These engines when controlled accurately result in ultra-low soot formation. On the other hand HCCI engines face a problem of high unburnt hydrocarbon and carbon monoxide emissions. This technology also faces acute combustion controls problem, which if not dealt properly with yields highly unfavorable operating conditions and exhaust emissions. This thesis contains two main parts. One part deals in developing an HCCI experimental setup and the other focusses on developing a grey box modelling technique to control HCCI exhaust gas emissions. The experimental part gives the complete details on modification made on the stock engine to run in HCCI mode. This part also comprises details and specifications of all the sensors, actuators and other auxiliary parts attached to the conventional SI engine in order to run and monitor the engine in SI mode and future SI-HCCI mode switching studies. In the latter part around 600 data points from two different HCCI setups for two different engines are studied. A grey-box model for emission prediction is developed. The grey box model is trained with the use of 75% data and the remaining data is used for validation purpose. An average of 70% increase in accuracy for predicting engine performance is found while using the grey-box over an empirical (black box) model during this study. The grey-box model provides a solution for the difficulty faced for real time control of an HCCI engine. The grey-box model in this thesis is the first study in literature to develop a control oriented model for predicting HCCI engine emissions for control.

Development of a 1-D Catalyzed Diesel Particulate Filter Model for Simulation of the Performance and the Oxidation of Particulate Matter and Nitrogen Oxides Using Passive Oxidation and Active Regeneration Engine Experimental Data

Back-pressure on a diesel engine equipped with an aftertreatment system is a function of the pressure drop across the individual components of the aftertreatment system, typically, a diesel oxidation catalyst (DOC), catalyzed particulate filter (CPF) and selective catalytic reduction (SCR) catalyst. Pressure drop across the CPF is a function of the mass flow rate and the temperature of the exhaust flowing through it as well as the mass of particulate matter (PM) retained in the substrate wall and the cake layer that forms on the substrate wall. Therefore, in order to control the back-pressure on the engine at low levels and to minimize the fuel consumption, it is important to control the PM mass retained in the CPF. Chemical reactions involving the oxidation of PM under passive oxidation and active regeneration conditions can be utilized with computer numerical models in the engine control unit (ECU) to control the pressure drop across the CPF. Hence, understanding and predicting the filtration and oxidation of PM in the CPF and the effect of these processes on the pressure drop across the CPF are necessary for developing control strategies for the aftertreatment system to reduce back-pressure on the engine and in turn fuel consumption particularly from active regeneration. Numerical modeling of CPF's has been proven to reduce development time and the cost of aftertreatment systems used in production as well as to facilitate understanding of the internal processes occurring during different operating conditions that the particulate filter is subjected to. A numerical model of the CPF was developed in this research work which was calibrated to data from passive oxidation and active regeneration experiments in order to determine the kinetic parameters for oxidation of PM and nitrogen oxides along with the model filtration parameters. The research results include the comparison between the model and the experimental data for pressure drop, PM mass retained, filtration efficiencies, CPF outlet gas temperatures and species (NO2) concentrations out of the CPF. Comparisons of PM oxidation reaction rates obtained from the model calibration to the data from the experiments for ULSD, 10 and 20% biodiesel-blended fuels are presented.

DYNAMIC MODEL BASED STATE ESTIMATION IN A HEAVY DUTY DIESEL AFTERTREATMENT SYSTEM FOR ONBOARD DIAGNOSTICS AND CONTROLS

Estimating un-measurable states is an important component for onboard diagnostics (OBD) and control strategy development in diesel exhaust aftertreatment systems. This research focuses on the development of an Extended Kalman Filter (EKF) based state estimator for two of the main components in a diesel engine aftertreatment system: the Diesel Oxidation Catalyst (DOC) and the Selective Catalytic Reduction (SCR) catalyst. One of the key areas of interest is the performance of these estimators when the catalyzed particulate filter (CPF) is being actively regenerated. In this study, model reduction techniques were developed and used to develop reduced order models from the 1D models used to simulate the DOC and SCR. As a result of order reduction, the number of states in the estimator is reduced from 12 to 1 per element for the DOC and 12 to 2 per element for the SCR. The reduced order models were simulated on the experimental data and compared to the high fidelity model and the experimental data. The results show that the effect of eliminating the heat transfer and mass transfer coefficients are not significant on the performance of the reduced order models. This is shown by an insignificant change in the kinetic parameters between the reduced order and 1D model for simulating the experimental data. An EKF based estimator to estimate the internal states of the DOC and SCR was developed. The DOC and SCR estimators were simulated on the experimental data to show that the estimator provides improved estimation of states compared to a reduced order model. The results showed that using the temperature measurement at the DOC outlet improved the estimates of the CO , NO , NO2 and HC concentrations from the DOC. The SCR estimator was used to evaluate the effect of NH3 and NOX sensors on state estimation quality. Three sensor combinations of NOX sensor only, NH3 sensor only and both NOX and NH3 sensors were evaluated. The NOX only configuration had the worst performance, the NH3 sensor only configuration was in the middle and both the NOX and NH3 sensor combination provided the best performance.

AN INVESTIGATION OF VARIABLE VALVE TIMING EFFECTS ON HCCI ENGINE PERFORMANCE

The Homogeneous Charge Compression Ignition (HCCI) engine is a promising combustion concept for reducing NOx and particulate matter (PM) emissions and providing a high thermal efficiency in internal combustion engines. This concept though has limitations in the areas of combustion control and achieving stable combustion at high loads. For HCCI to be a viable option for on-road vehicles, further understanding of its combustion phenomenon and its control are essential. Thus, this thesis has a focus on both the experimental setup of an HCCI engine at Michigan Technological University (MTU) and also developing a physical numerical simulation model called the Sequential Model for Residual Affected HCCI (SMRH) to investigate performance of HCCI engines. The primary focus is on understanding the effects of intake and exhaust valve timings on HCCI combustion. For the experimental studies, this thesis provided the contributions for development of HCCI setup at MTU. In particular, this thesis made contributions in the areas of measurement of valve profiles, measurement of piston to valve contact clearance for procuring new pistons for further studies of high geometric compression ratio HCCI engines. It also consists of developing and testing a supercharging station and the setup of an electrical air heater to extend the HCCI operating region. The HCCI engine setup is based on a GM 2.0 L LHU Gen 1 engine which is a direct injected engine with variable valve timing (VVT) capabilities. For the simulation studies, a computationally efficient modeling platform has been developed and validated against experimental data from a single cylinder HCCI engine. In-cylinder pressure trace, combustion phasing (CA10, CA50, BD) and performance metrics IMEP, thermal efficiency, and CO emission are found to be in good agreement with experimental data for different operating conditions. Effects of phasing intake and exhaust valves are analyzed using SMRH. In addition, a novel index called Fuel Efficiency and Emissions (FEE) index is defined and is used to determine the optimal valve timings for engine operation through the use of FEE contour maps.

Techno-economic analysis of three HVAC retrofitting options

Accounting for around 40% of the total final energy consumption, the building stock is an important area of focus on the way to reaching the energy goals set for the European Union. The relatively small share of new buildings makes renovation of existing buildings possibly the most feasible way of improving the overall energy performance of the building stock. This of course involves improvements on the climate shell, for example by additional insulation or change of window glazing, but also installation of new heating systems, to increase the energy efficiency and to fit the new heat load after renovation. In the choice of systems for heating, ventilation and air conditioning (HVAC), it is important to consider their performance for space heating as well as for domestic hot water (DHW), especially for a renovated house where the DHW share of the total heating consumption is larger. The present study treats the retrofitting of a generic single family house, which was defined as a reference building in a European energy renovation project. Three HVAC retrofitting options were compared from a techno-economic point of view: A) Air-to-water heat pump (AWHP) and mechanical ventilation with heat recovery (MVHR), B) Exhaust air heat pump (EAHP) with low-temperature ventilation radiators, and C) Gas boiler and ventilation with MVHR. The systems were simulated for houses with two levels of heating demand and four different locations: Stockholm, Gdansk, Stuttgart and London. They were then evaluated by means of life cycle cost (LCC) and primary energy consumption. Dynamic simulations were done in TRNSYS 17. In most cases, system C with gas boiler and MVHR was found to be the cheapest retrofitting option from a life cycle perspective. The advantage over the heat pump systems was particularly clear for a house in Germany, due to the large discrepancy between national prices of natural gas and electricity. In Sweden, where the price difference is much smaller, the heat pump systems had almost as low or even lower life cycle costs than the gas boiler system. Considering the limited availability of natural gas in Sweden, systems A and B would be the better options. From a primary energy point of view system A was the best option throughout, while system B often had the highest primary energy consumption. The limited capacity of the EAHP forced it to use more auxiliary heating than the other systems did, which lowered its COP. The AWHP managed the DHW load better due to a higher capacity, but had a lower COP than the EAHP in space heating mode. Systems A and C were notably favoured by the air heat recovery, which significantly reduced the heating demand. It was also seen that the DHW share of the total heating consumption was, as expected, larger for the house with the lower space heating demand. This confirms the supposition that it is important to include DHW in the study of HVAC systems for retrofitting.

Comparison of two HVAC renovation solutions : A case study

Within the aging building stock of Europe, there is great potential of saving energy through renovation and upgrading to modern standards, and to thereby approach the internationally set goals of lower energy use. This paper concerns the planned renovation of the building envelope and HVAC systems in a multi-family house in Ludwigsburg, Germany. Five systemic HVAC solutions were compared, with special focus on two systems: A) Balanced ventilation with HRC + Micro heat pump, and B) Forced exhaust ventilation + Heat pump with exhaust air HRC + Ventilation radiators. Given the predicted heating demand and ventilation rate of the house after renovation, the performance of the two systems was compared, alongside three common systems for reference. Calculations were made using TMF Energi, a tool developed by SP Technical Research Institute of Sweden.    Both systems A and B were found to have the lowest electrical energy use together with the ground source heat pump system for the assumed conditions. For other assumptions, including different climate and degree of insulation, some differences between these three systems were noted. Most significant is the increased electrical use of system B for higher heating loads due to limitations in the power available from the heat source, exhaust air, which is dependent on the ventilation rate.

Energy performance comparison of three innovative HVAC systems for renovation through dynamic simulation

In this paper, dynamic simulation was used to compare the energy performance of three innovativeHVAC systems: (A) mechanical ventilation with heat recovery (MVHR) and micro heat pump, (B) exhaustventilation with exhaust air-to-water heat pump and ventilation radiators, and (C) exhaust ventilationwith air-to-water heat pump and ventilation radiators, to a reference system: (D) exhaust ventilation withair-to-water heat pump and panel radiators. System A was modelled in MATLAB Simulink and systems Band C in TRNSYS 17. The reference system was modelled in both tools, for comparison between the two.All systems were tested with a model of a renovated single family house for varying U-values, climates,infiltration and ventilation rates.It was found that A was the best system for lower heating demand, while for higher heating demandsystem B would be preferable. System C was better than the reference system, but not as good as A or B.The difference in energy consumption of the reference system was less than 2 kWh/(m2a) betweenSimulink and TRNSYS. This could be explained by the different ways of handling solar gains, but also bythe fact that the TRNSYS systems supplied slightly more than the ideal heating demand.

Influence of fuel-borne oxygen on European stationary cycle: diesel engine performance and emissions with a special emphasis on particulate and NO emissions

Exploration of sustainable fuels and their influence on reductions in diesel emissions are nowadays a challenge for the engine and fuel researchers. This study investigates the role of fuel-borne oxygen on engine performance and exhaust emissions with a special emphasis on diesel particulate and nitric oxide (NO) emissions. A number of oxygenated-blends were prepared with waste cooking biodiesel as a base oxygenated fuel. Triacetin, a derivative from transesterified biodiesel was chosen for its high oxygen content and superior fuel properties. The experimental campaign was conducted with a 6-cylinder, common rail turbocharged diesel engine equipped with highly precise instruments for nano and other size particles and other emissions. All experiments were performed in accordance with European Stationary Cycle (ESC 13-mode). A commercial diesel was chosen as a reference fuel with 0% oxygen and five other oxygenated blends having a range of 6.02–14.2% oxygen were prepared. The experimental results revealed that the oxygenated blends having higher a percentage of fuel-borne oxygen reduced particulate matter (PM), particle number (PN), unburned hydrocarbon (UBHC) and carbon monoxide (CO) emissions to a significantly low level with a slight penalty of NO emissions. The main target of this study was to effectively utilise triacetin as an additive for waste cooking biodiesel and suppress emissions without deteriorating engine performance. The key finding of this investigation is the significant reductions in both particle mass and number emissions simultaneously without worsening engine performance with triacetin-biodiesel blends. Reductions in both particle mass and number emissions with a cost-effective additive would be a new dimension for the fuel and engine researchers to effectively use triacetin as an emission suppressor in the future.

The design of charitable fund-raising schemes: matching grants or seed money

For a fixed large donation a matching scheme that simply uses a one-for-one match ratio can actually raise less money than a seed money scheme. But when the match ratio is chosen to reflect the characteristics of the small donor base so as to exhaust the large donor's willingness to give, matching schemes always raise more money and are preferred by both charities and large donors. However, when the large donor chooses the size of her donation, a conflict can arise. The large donor can prefer a smaller leadership gift and more reliance on small donor matching while the charity can prefer seed money.

Relación entre las condiciones de higiene y seguridad y la exposición ambiental a solventes orgánicos en pintores de automóviles de la localidad de barrios unidos, Bogotá 2015

Introducción. Los trabajadores de los talleres de reparación de automóviles conviven diariamente con la exposición a los solventes orgánicos, exposición que se convierte en un riesgo para su salud que generalmente en el corto plazo se presenta como déficits de concentración, memoria y tiempo de reacción y en el largo plazo produciendo graves repercusiones clínicas como efectos mutagénicos y carcinogénicos. Objetivo. Caracterizar las condiciones higiénicas y de seguridad de trabajadores ocupacionalmente expuestos a solventes orgánicos y determinar los niveles ambientales de benceno, tolueno y xileno (BTX) en talleres de lámina y pintura automotriz de la ciudad de Bogotá. Materiales y métodos. Se hizo un estudio de corte transversal en 60 trabajadores que laboran expuestos a solventes orgánicos en talleres de reparación automotriz en Bogotá. Se realizó una encuesta con variables sociodemográficas, laborales y se determinaron los niveles en aire de benceno, tolueno y xileno. Para los muestreos ambientales, las bombas se colocaron en una posición fija representativa del ambiente general, con el objeto de conocer la distribución de los solventes en el área de trabajo. Se realizó un análisis descriptivo por conteos de frecuencia, medidas de tendencia central y dispersión. Se utilizó prueba de bondad de ajuste para distribución normal (Kolmogorov-Smirnov o Shapiro Wilk), prueba t Student para comparación de medias, o en su defecto prueba U de Mann Whitney para comparación de medianas. Para identificar la relación entre las características sociodemográficas y ocupacionales con la exposición a BTX, se utilizaron pruebas de asociación Chi cuadrado o análisis de correlación según la naturaleza de las variables. El nivel de significancia para cada prueba fue 0.05. Resultados. La edad promedio de los trabajadores fue de 43 años y un tiempo total de exposición a solventes de 20 años. Respecto al uso de protección corporal, 45 (75%) de los trabajadores manifestaron que usaban uniforme, mientras que 14 (23,3%) usaban ropa de calle durante la jornada laboral. El 46,7% manifestaron usar protección respiratoria. La concentración de benceno en aire fue entre 0,1 y 0,45 mg/l (mediana de 0,31 mg/l; DE 0,13 mg/l); la de tolueno estuvo entre 8,25 y 27,22 mg/l (mediana de 14,5 mg/l; DE 6.99 mg/l) y la de xileno entre 19,34 y 150,15 mg/l (mediana de 70,12 mg/l; DE 40,82 mg/l). Conclusión. Los pintores de automóviles están expuestos a niveles elevados de solventes en los lugares de trabajo y no cuentan con condiciones de higiene y seguridad industrial adecuados. Un gran número de pintores son informales lo que les impide el acceso a los beneficios del Sistema de Seguridad Social Integral.

Particle dynamics and airflow patterns in a ventilated two-zone enclosure

Understanding the transport mechanisms of aerosol particles in enclosures has broad ramifications in the context of cleaning strategies, and health risk assessment (e. g., occupational exposure). This paper addresses airflow pattern and aerosol transport mechanism in a ventilated two-zone enclosure with the outlet (exhaust location) situated at different locations. A numerical approach that combines a Eulerian simulation of turbulent flow with a Lagrangian particle-tracking algorithm is used. Simulations are carried out using solid suspensions with different sizes (1 to 100 micron) and densities (240 and 2300 kg/m3). The effect of location of the outlet (exhaust) on airflow patterns and aerosol dynamics is analyzed and quantified.