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Renewable, low-carbon biofuels offer the potential opportunity to decarbonize marine transportation. This paper presents a comparative techno-economic analysis and process sustainability assessment of four conversion pathways: (1) hydrothermal liquefaction (HTL) of wet wastes such as sewage sludge and manure; (2) fast pyrolysis of woody biomass; (3) landfill gas Fischer-Tropsch synthesis; and (4) lignin-ethanol oil from the lignocellulosic ethanol biorefinery utilizing reductive catalytic fractionation. These alternative marine biofuels have a modeled minimum fuel selling price between $1.68 and $3.98 per heavy fuel oil gallon equivalent in 2016 U.S. dollars based on a mature plant assessment. The selected pathways also exhibit good process sustainability performance in terms of water intensity compared to the petroleum refineries. Further, the O and S contents of the biofuels vary widely. While the non-HTL biofuels exhibit negligible S content, the raw biocrudes

Corrosion compatibility of stainless steels and nickel (Ni200) was assessed in fast pyrolysis bio-oil produced from pyrolysis of high ash and high moisture forest residue biomass. Sample mass change, ICP-MS and post-exposure electron microscopy characterization was used to investigate the extent of corrosion. Among the tested samples, type 430F and type 316 stainless steels (SS430F and SS316) and Ni200 (~98.5% Ni) showed minimal mass changes (less than 2 mg∙cm−2) after the bio-oil exposures at 50 and 80 °C for up to 168 h. SS304 was also considered to be compatible in the bio-oil due to its relatively low mass change (1.6 mg∙cm−2 or lower). SS410 samples showed greater mass loss values even after exposures at a relatively low temperature of 35 °C. Fe/Cr values from ICP-MS data implied that Cr enrichment in stainless steels would result in a protective oxide layer associated with corrosion resistance against the bio-oil. Post exposure characterization showed continuous and uniform Cr distribution in the surface oxide layer of SS430F, which showed a minimal mass change, but no oxide layer on a SS430 sample, which exhibited a significant mass loss.

The compatibility of 17 elastomers with two dioxolane molecules was assessed by volume change and hardness measurements. Each molecule was blended with diesel in concentrations of 0, 10, 20 and 30 wt.%. The elastomers included two fluorocarbons, six acrylonitrile butadiene rubbers (NBRs), and one each of fluorosilicone, chloroprene rubber (CR), polyurethane, styrene butadiene rubber (SBR), hydrogenated NBR (HNBR), a blend of NBR and PVC (OZO), epichlorohydrin/ ethylene oxide (ECO), ethylene propylene diene monomer (EPDM), and silicone. Specimens of each elastomer were immersed in the test fuels for a period of 4 weeks and measured for property change. Afterwards they were dried at 60°C for 20 h and remeasured. The results showed that the dioxolanes were suitable with many of the elastomers and that the performances were essentially the same for both molecules. The dioxolanes were found to either have negligible impact beyond neat diesel or they produced a small increase in swell. This minimal impact is attributed to the fact that the solubility parameters (especially those associated with polarity and hydrogen bonding) of the dioxolanes are similar to those of diesel. As a result, little change in solubility and hence swell occurred when dioxolane was added to the diesel.

Properties related to the combustion, stability, and compatibility of blends composed of high-viscosity heavy fuel oil (HFO) and highly acidic pyrolysis bio-oil were determined to assess the utilit...

Biomass-derived oils are renewable fuel sources and commodity products and are proposed to partially or entirely replace fossil fuels in sectors generally considered difficult to decarbonize such as aviation and maritime propulsion. Bio-oils contain a range of organic compounds with varying functional groups which can lead to polarity-driven phase separation and corrosion of containment materials during processing and storage. Polar compounds, such as organic acids and other oxygenates, are abundant in bio-oils and are considered corrosive to structural alloys, particularly to those with a low-Cr content. To study the corrosion effects of small carboxylic acids present in pyrolysis bio-oils, type 410 stainless steel (SS410) specimens were exposed in bio-oils with varying formic, acetic, propionic and hexanoic acid contents at 50 °C during 48 h exposures. The specific mass change data show a linear increase in mass loss with increasing formic acid concentration. Interestingly, a mild corrosion inhibition effect on the corrosion of SS410 specimens was observed with the addition of acetic, propionic and hexanoic acids in the bio-oil.

The compatibility of key infrastructure elastomers with five ketone molecules was assessed via solubility studies and volume swell measurements. The elastomer materials included two fluorocarbons, six acrylonitrile butadiene rubbers (NBRs), and one each of fluorosilicone, neoprene, polyurethane, styrene butadiene rubber (SBR), and silicone. The ketone molecules included acetone, 2-butanone, 2-pentanone, 2-nonanone, and cyclopentanone. The ketones were added to gasoline containing 10% ethanol (E10) and a blendstock for oxygenate blending (BOB) in levels ranging from 0% to 30% by volume. The elastomers were exposed for 4 weeks in each test fluid. The solubility was modeled using Hansen solubility parameters and the volume change was determined for each material and test fuel. In general, the volume swell increased with ketone content and corresponded well to the predicted solubilities. In most cases, the highest level of swelling occurred with added cyclopentanone and acetone, while 2-nonanone produced the lowest levels of volume expansion. The chain length of the straight ketones was found to affect the volume swell behavior as volume expansion decreased with increasing chain length. This behavior is attributed to the reduction in polarity and hydrogen bonding with chain length. Neoprene, SBR, and silicone exhibited poor compatibility with the ketone molecules at all blend levels. Fluorocarbon and fluorosilicone also showed poor compatibility but may be suitable for use as static seals in very low blend levels with 2-nonanone. The results were more mixed for polyurethane and the NBRs. In general, better compatibility (low volume swell) was observed for mixtures containing BOB than for E10. This is due to the lower polarity and hydrogen bonding of the BOB.

The compatibility of biodiesel blends with five common elastomers (acrylonitrile rubber or NBR, fluorocarbon, neoprene, ethylene propylene diene monomer or EPDM, and silicone) was assessed using Hansen solubility parameters. A solubility analysis was performed over the full diesel blend range and the model used methyl hydroperoxide, acetaldehyde, and formic acid to represent the decomposition products of biodiesel. An empirical study was also conducted to determine the efficacy of the approach to predict the volume swell of elastomers. This study included the influence of biodiesel with acetaldehyde and formic acid. The solubility model showed good agreement with measured volumes for fluorocarbon, neoprene, EPDM, and silicone. However, solubility curves for NBR did not reflect the measured volume changes, and therefore the solubility parameters used for NBR in this study are not considered reliable. The results showed that formic acid caused higher swelling in NBR, fluorocarbon, neoprene, and silicone than did acetaldehyde. For EPDM, the measured volume decreased with both biodiesel concentration and the addition of formic acid.

Lignocellulosic biomass offers a renewable carbon source which can be anaerobically digested to produce short-chain carboxylic acids. Here, we assess fuel properties of oxygenates accessible from catalytic upgrading of these acids a priori for their potential to serve as diesel bioblendstocks. Ethers derived from C(2) and C(4) carboxylic acids are identified as advantaged fuel candidates with significantly improved ignition quality (>56% cetane number increase) and reduced sooting (>86% yield sooting index reduction) when compared to commercial petrodiesel. The prescreening process informed conversion pathway selection toward a C(11) branched ether, 4-butoxyheptane, which showed promise for fuel performance and health- and safety-related attributes. A continuous, solvent-free production process was then developed using metal oxide acidic catalysts to provide improved thermal stability, water tolerance, and yields. Liter-scale production of 4-butoxyheptane enabled fuel property testing to confirm predicted fuel properties, while incorporation into petrodiesel at 20 vol % demonstrated 10% improvement in ignition quality and 20% reduction in intrinsic sooting tendency. Storage stability of the pure bioblendstock and 20 vol % blend was confirmed with a common fuel antioxidant, as was compatibility with elastomeric components within existing engine and fueling infrastructure. Technoeconomic analysis of the conversion process identified major cost drivers to guide further research and development. Life-cycle analysis determined the potential to reduce greenhouse gas emissions by 50 to 271% relative to petrodiesel, depending on treatment of coproducts.

Bio-oil derived via fast pyrolysis is being developed as a renewable fuel option for petroleum distillates. The compatibility of neat bio-oil with 18 plastic types was evaluated using neat diesel f...

Bio-oil derived via fast pyrolysis is being developed as a renewable fuel option for petroleum distillates. The compatibility of neat bio-oil with six elastomer types was evaluated against the elastomer performance in neat diesel fuel, which served as the baseline. The elastomers included two fluorocarbons, six acrylonitrile butadiene rubbers (NBRs), and one type each of fluorosilicone, silicone, styrene butadiene rubber (SBR), polyurethane, and neoprene. Specimens of each material were exposed to the liquid and gaseous phases of the test fuels for 4 weeks at 60 °C, and properties in the wetted and dried states were measured. Exposure to bio-oil produced significant volume expansion in the fluorocarbons, NBRs, and fluorosilicone; however, excessive swelling (over 80%) was only observed for the two fluorocarbons and two NBR grades. The polyurethane specimens were completely degraded by the bio-oil. In contrast, both silicone and SBR exhibited lower swelling levels in bio-oil compared to neat diesel fuel. T...

The compatibility of elastomeric materials used in fuel storage and dispensing applications was determined for test fuels representing neat gasoline and gasoline blends containing 10 and 17 vol.% ethanol, and 16 and 24 vol.% isobutanol. The actual test fuel chemistries were based on the aggressive formulations described in SAE J1681 for oxygenated gasoline. Elastomer specimens of fluorocarbon, fluorosilicone, acrylonitrile rubber (NBR), polyurethane, neoprene, styrene butadiene rubber (SBR) and silicone were exposed to the test fuels for 4 weeks at 60°C. After measuring the wetted volume and hardness, the specimens were dried for 20 hours at 60°C and then remeasured for volume and hardness. Dynamic mechanical analysis (DMA) was also performed to determine the glass transition temperature (T g ). Comparison to the original values showed that all elastomer materials experienced volume expansion and softening when wetted by the test fuels. The fluorocarbons underwent the least amount of swelling ( 100%). The level of swelling for each elastomer was higher for the test fuels containing the alcohol additions. In general, ethanol produced slightly higher swell than the oxygen equivalent level of isobutanol. When dried, the fluorocarbon specimens were slightly swollen (relative to the baseline values) due to fuel retention. The NBRs and neoprene exhibited shrinkage and embrittlement associated with the extraction of plasticizers. SBR also experienced shrinkage (after drying) but its hardness returned to the baseline value. The dried volumes (and hardness values) of the silicone, SBR and fluorosilicone rubbers closely matched their original values, but the polyurethane specimen showed degradation with exposure to the test fuels containing ethanol or isobutanol. The DMA results showed that the test fuels effectively decreased T g for the fluorocarbons, but increased T g for the NBR materials. The T g values other elastomers were not affected by the test fuels.

This article summarises the compatibility of six elastomers – used in fuel storage and delivery systems – with test fuels representing gasoline blended with up to 85% ethanol. Individual coupons were exposed to test fuels for four weeks to achieve saturation. The change in volume and hardness, when wetted and after drying, were measured and compared with the original condition.

A light-duty diesel engine has been operated in advanced combustion modes known generally as premixed charge compression ignition (PCCI). The emissions have been characterized for several load and speed combinations. Fewer NOx and particulate matter (PM) emissions are produced by PCCI, but higher CO and hydrocarbon (HC) emissions result. In addition, the nature of the PM differs from conventional combustion; the PM is smaller and has a much higher soluble organic fraction (SOF) content (68% vs. 30% for conventional combustion). Three catalyst technologies were studied to determine the affects of HECC on catalyst performance; the technologies were a lean NOx trap (LNT), diesel oxidation catalyst (DOC), and diesel particulate filter (DPF). The LNT benefited greatly from the reduced NOx emissions associated with PCCI. NOx capacity requirements are reduced as well as overall tailpipe NOx levels particularly at low load and temperature conditions where regeneration of the LNT is difficult. The DOC performance requirements for PCCI are more stringent due to the higher CO and HC emissions; however, the DOC was effective at controlling the higher CO and HC emissions at conditions above the light-off temperature. Below light-off, CO and HC emissions are problematic. The study of DPF technology focused on the fuel penalties associated with DPF regeneration or “desoot” due to the different PM loading rates from PCCI vs. conventional combustion. Less frequent desoot events were required from the lower PM from PCCI and, when used in conjunction with an LNT, the lower PM from less frequent LNT regeneration. The lower desoot frequency leads a ∼3% fuel penalty for a mixture of PCCI and conventional loads vs. ∼4% for conventional only combustion.

The influence of fuel rail pressure (FRP) and urea-selective catalytic reduction (SCR) on particulate matter (PM) formation is investigated in this paper along with notes regarding the NOx and other emissions. Increasing FRP was shown to reduce the overall soot and total PM mass for four operating conditions. These conditions included two high speed conditions (2400 rpm at 540 and 270 Nm of torque) and two moderated speed conditions (1400 rpm at 488 and 325 Nm). The concentrations of CO2 and NOx increased with fuel rail pressure and this is attributed to improved fuel-air mixing. Interestingly, the level of unburned hydrocarbons remained constant (or increased slightly) with increased FRP. PM concentration was measured using an AVL smoke meter and scanning mobility particle sizer (SMPS); and total PM was collected using standard gravimetric techniques. These results showed that the smoke number and particulate concentrations decrease with increasing FRP. However the decrease becomes more gradual as very high rail pressures. Additionally, the total PM decreased with increasing FRP; however, the soluble organic fraction (SOF) reaches a maximum after which it declines with higher rail pressure. The total PM was collected for the two 1400 rpm conditions downstream of the engine, diesel oxidationmore » catalyst, and a urea-SCR catalyst. The results show that significant PM reduction occurs in the SCR catalyst even during high rates of urea dosage. Analysis of the PM indicates that residual SOF is burned up in the SCR catalyst.« less

The Navy pilot program investigated cost-effective technologies to reduce emissions from legacy marine engines. High-speed, high-population engine models in both commercial and Navy fleets were targeted. Emission reductions were sought that would minimize fuel penalty as well as installation and operating costs. Navy operating conditions and fuels limited options. Five highly rated technologies were laboratory tested on a Detroit Diesel Corporation 12V-71N engine using two military and three alternative fuels. Two control technologies were then shipboard tested (baseline, 1-year early degradation, and 9-year late-life). Conclusions and recommendations are provided to inform application of these and similar emission control technologies within both commercial and Navy fleets.

This report evaluates infrastructure implications for a high-octane fuel, i.e., a blend of 25% denatured ethanol and 75% gasoline (E25) or higher (E25+), for use with a new high-efficiency type of vehicle. E25+ is under consideration due to federal regulations requiring the use of more renewable fuels and improvements in fuel economy. The existing transportation fuel infrastructure may not be completely compatible with a mid-level ethanol blend (blends above E15 up to E50). It is anticipated that a mid-level ethanol blend will face many of the same hurdles as E15, and a fuel above E25 will face additional barriers. Interviews were conducted with industry stakeholder groups, station inspectors, refueling equipment manufacturers, and other experts. This report also summarizes the patchwork of regulations that cover some, but not all, equipment that is an important aspect in deployment of alternative fuels into the existing infrastructure. It also covers advancements in compatibility and availability of equipment for use with various ethanol blends.

High purity alumina particles were sonicated in distilled water at 20 kHz. Ultrasonic fragmentation of the alumina particles produced a fine particle fraction, which was less than 1 μm in diameter. This fraction became more pronounced with increased duration and applied power. Particle fragmentation was observed to increase slightly with large increases in slurry density, indicating that the formation and collapse of cavitation bubbles were relatively unaffected by the particulate loading levels. Of great importance, the sonified powders exhibited an exotherm consistent with lattice strain energy release, thereby potentially providing an additional driving force for densification during sintering.

The cavitation erosion rate for 316 stainless steel in mercury was found to increase in a nonlinear fashion with the maximum applied power. In addition, the incremental increase in erosion was observed to decrease with increased power in water, yet increased six to seven times when mercury was used as the cavitating fluid.

The sinterability of high purity alumina powders was enhanced by ultrasonication in liquid ammonia. The surfaces of the resulting powders contained agglomerated regions of submicron-sized particles that were metallic in appearance. When heated to 1400 °C, these particles densified into a solid with observable grain bonding and necking.

In 2008 Oak Ridge National Laboratory began a series of experiments to evaluate the compatibility of fueling infrastructure materials with intermediate levels of ethanol-blended gasoline. Initially, the focus was elastomers, metals, and sealants, and the test fuels were Fuel C, CE10a, CE17a and CE25a. The results of these studies were published in 2010. Follow-on studies were performed with an emphasis on plastic (thermoplastic and thermoset) materials used in underground storage and dispenser systems. These materials were exposed to test fuels of Fuel C and CE25a. Upon completion of this effort, it was felt that additional compatibility data with higher ethanol blends was needed and another round of experimentation was performed on elastomers, metals, and plastics with CE50a and CE85a test fuels. Compatibility of polymers typically relates to the solubility of the solid polymer with a solvent. It can also mean susceptibility to chemical attack, but the polymers and test fuels evaluated in this study are not considered to be chemically reactive with each other. Solubility in polymers is typically assessed by measuring the volume swell of the polymer exposed to the solvent of interest. Elastomers are a class of polymers that are predominantly used as seals, and most o-ring and seal manufacturers provide compatibility tables of their products with various solvents including ethanol, toluene, and isooctane, which are components of aggressive oxygenated gasoline as described by the Society of Automotive Engineers (SAE) J1681. These tables include a ranking based on the level of volume swell in the elastomer associated with exposure to a particular solvent. Swell is usually accompanied by a decrease in hardness (softening) that also affects performance. For seal applications, shrinkage of the elastomer upon drying is also a critical parameter since a contraction of volume can conceivably enable leakage to occur. Shrinkage is also indicative of the removal of one or more components of the elastomers (by the solvent). This extraction of additives can negatively change the properties of the elastomer, leading to reduced performance and durability. For a seal application, some level of volume swell is acceptable, since the expansion will serve to maintain a seal. However, the acceptable level of swell is dependent on the particular application of the elastomer product. It is known that excessive swell can lead to unacceptable extrusion of the elastomer beyond the sealed interface, where it becomes susceptible to damage. Also, since high swell is indicative of high solubility, there is a heightened potential for fluid to seep through the seal and into the environment. Plastics, on the other hand, are used primarily in structural applications, such as solid components, including piping and fluid containment. Volume change, especially in a rigid system, will create internal stresses that may negatively affect performance. In order to better understand and predict the compatibility for a given polymer type and fuel composition, an analysis based on Hansen solubility theory was performed for each plastic and elastomer material. From this study, the solubility distance was calculated for each polymer material and test fuel combination. Using the calculated solubility distance, the ethanol concentration associated with peak swell and overall extent of swell can be predicted for each polymer. The bulk of the material discussion centers on the plastic materials, and their compatibility with Fuel C, CE25a, CE50a, and CE85a. The next section of this paper focuses on the elastomer compatibility with the higher ethanol concentrations with comparison to results obtained previously for the lower ethanol levels. The elastomers were identical to those used in the earlier study. Hansen solubility theory is also applied to the elastomers to provide added interpretation of the results. The final section summarizes the performance of the metal coupons.

The Energy Independence and Security Act (EISA) of 2007 was enacted by Congress to move the nation toward increased energy independence by increasing the production of renewable fuels to meet its transportation energy needs. The law establishes a new renewable fuel standard (RFS) that requires the nation to use 36 billion gallons annually (2.3 million barrels per day) of renewable fuel in its vehicles by 2022. Ethanol is the most widely used renewable fuel in the US, and its production has grown dramatically over the past decade. According to EISA and RFS, ethanol (produced from corn as well as cellulosic feedstocks) will make up the vast majority of the new renewable fuel requirements. However, ethanol use limited to E10 and E85 (in the case of flex fuel vehicles or FFVs) will not meet this target. Even if all of the E0 gasoline dispensers in the country were converted to E10, such sales would represent only about 15 billion gallons per year. If 15% ethanol, rather than 10% were used, the potential would be up to 22 billion gallons. The vast majority of ethanol used in the United States is blended with gasoline to create E10, that is, gasoline with up more » to 10% ethanol. The remaining ethanol is sold in the form of E85, a gasoline blend with as much as 85% ethanol that can only be used in FFVs. Although DOE remains committed to expanding the E85 infrastructure, that market will not be able to absorb projected volumes of ethanol in the near term. Given this reality, DOE and others have begun assessing the viability of using intermediate ethanol blends as one way to transition to higher volumes of ethanol. In October of 2010, the EPA granted a partial waiver to the Clean Air Act allowing the use of fuel that contains up to 15% ethanol for the model year 2007 and newer light-duty motor vehicles. This waiver represents the first of a number of actions that are needed to move toward the commercialization of E15 gasoline blends. On January 2011, this waiver was expanded to include model year 2001 light-duty vehicles, but specifically prohibited use in motorcycles and off-road vehicles and equipment. UST stakeholders generally consider fueling infrastructure materials designed for use with E0 to be adequate for use with E10, and there are no known instances of major leaks or failures directly attributable to ethanol use. It is conceivable that many compatibility issues, including accelerated corrosion, do arise and are corrected onsite and, therefore do not lead to a release. However, there is some concern that higher ethanol concentrations, such as E15 or E20, may be incompatible with current materials used in standard gasoline fueling hardware. In the summer of 2008, DOE recognized the need to assess the impact of intermediate blends of ethanol on the fueling infrastructure, specifically located at the fueling station. This includes the dispenser and hanging hardware, the underground storage tank, and associated piping. The DOE program has been co-led and funded by the Office of the Biomass Program and Vehicle Technologies Program with technical expertise from the Oak Ridge National Laboratory (ORNL) and the National Renewable Energy Laboratory (NREL). The infrastructure material compatibility work has been supported through strong collaborations and testing at Underwriters Laboratories (UL). ORNL performed a compatibility study investigating the compatibility of fuel infrastructure materials to gasoline containing intermediate levels of ethanol. These results can be found in the ORNL report entitled Intermediate Ethanol Blends Infrastructure Materials Compatibility Study: Elastomers, Metals and Sealants (hereafter referred to as the ORNL intermediate blends material compatibility study). These materials included elastomers, plastics, metals and sealants typically found in fuel dispenser infrastructure. The test fuels evaluated in the ORNL study were SAE standard test fuel formulations used to assess material-fuel compatibility within a relatively short timeframe. Initially, these material studies included test fuels of Fuel C, CE10a, CE17a, and CE25a. The CE17a test fuel was selected to represent E15 since surveys have shown that the actual ethanol upper limit can be as high as 17%. Later, CE50a and CE85a test fuels were added to the investigation and these results are being compiled for a follow-on report to be published in 2012. Fuel C was used as the baseline reference and is a 50:50 blend of isooctane and toluene. This particular composition was used to represent premium-grade gasoline and was also used as the base fuel for the ethanol blends, where it is denoted by 'C' in the fuel name. The level of ethanol is represented by the number following the letter E. Therefore a 10% blend of ethanol in Fuel C is written as CE10a, where 'a' represents an aggressive formulation of the ethanol that contains water, NaCl, acetic and sulfuric acids per the SAE J1681 protocol. « less

The purpose of this Cooperative Research and Development Agreement (CRADA) between UTBattelle, Inc. and Caterpillar, Inc. was to improve diesel engine efficiency by incorporating advanced materials to enable higher combustion pressures and temperatures necessary for improved combustion. The project scope also included novel materials for use in advanced components and designs associated with waste-heat recovery and other concepts for improved thermal efficiency. Caterpillar initially provided ORNL with a 2004 Tier 2 C15 ACERT diesel engine (designed for on-highway use) and two 600 hp motoring dynamometers. The first year of the CRADA effort was focused on establishing a heavy-duty experimental engine research cell. First year activities included procuring, installing and commissioning the cell infrastructure. Infrastructure components consisted of intake air handling system, water tower, exhaust handling system, and cell air conditioning. Other necessary infrastructure items included the fuel delivery system and bottled gas handling to support the analytical instrumentation. The second year of the CRADA focused on commissioning the dynamometer system to enable engine experimentation. In addition to the requirements associated with the dynamometer controller, the electrical system needed a power factor correction system to maintain continuity with the electrical grid. During the second year the engine was instrumented and baselinemore » operated to confirm performance and commission the dynamometer. The engine performance was mapped and modeled according to requirements provided by Caterpillar. This activity was further supported by a Work-for-Others project from Caterpillar to evaluate a proprietary modeling system. A second Work-for-Others activity was performed to evaluate a novel turbocharger design. This project was highly successful and may lead to new turbocharger designs for Caterpillar heavy-duty diesel engines. During the third (and final) year of the CRADA, a novel valve material was evaluated to assess high temperature performance and durability. A series of prototype valves, composed of a unique nickel-alloy was placed in the engine head. The engine was aggressively operated using a transient test cycle for 200 hours. The valve recession was periodically measured to determine valve performance. Upon completion of the test the valves were removed and returned to Caterpillar for additional assessment. Industrial in-kind support was available throughout the project period. Review of the status and research results were carried out on a regular basis (meetings and telecons) which included direction for future work activities. A significant portion of the industrial support was in the form of information exchange and technical consultation.« less

It is widely recognized that future NOx and PM emission targets for diesel engines cannot be met solely via advanced combustion over the full engine drive cycle. Therefore some combination of advanced combustion methodology with an aftertreatment technology will be required. In this study, NOx reduction, fuel efficiency, and regeneration performance of lean NOx trap (LNT) were evaluated for four operating conditions. The combustion approaches included baseline engine operation with and without EGR, two exhaust enrichment methods (post injection and delayed injection), and one advanced combustion mode to enable high efficiency clean combustion (HECC). A 1.7 liter 4-cylinder diesel engine was operated under five conditions, which represent key interest points for light-duty diesel operation. At the low load setting the exhaust temperature was too low to enable LNT regeneration and oxidation; however, HECC (low NOx) was achievable. HECC was also reached under more moderate loads and the exhaust temperatures were high enough to enable even further NOx reductions by the LNT. At high loads HECC becomes difficult but the LNT performance improves and acceptable regeneration can be met with enrichment methodologies.

The objective of this program was to explore a combination of advanced injection control and urea-selective catalytic reduction (SCR) to reduce the emissions of oxides of nitrogen (NOx) and particulate matter (PM) from a Tier 2 off-highway diesel engine to Tier 3 emission targets while maintaining fuel efficiency. The engine used in this investigation was a 2004 4.5L John Deere PowerTechTM; this engine was not equipped with exhaust gas recirculation (EGR). Under the original CRADA, the principal objective was to assess whether Tier 3 PM emission targets could be met solely by increasing the rail pressure. Although high rail pressure will lower the total PM emissions, it has a contrary effect to raise NOx emissions. To address this effect, a urea-SCR system was used to determine whether the enhanced NOx levels, associated with high rail pressure, could be reduced to Tier 3 levels. A key attraction for this approach is that it eliminates the need for a Diesel particulate filter (DPF) to remove PM emissions. The original CRADA effort was also performed using No.2 Diesel fuel having a maximum sulfur level of 500 ppm. After a few years, the CRADA scope was expanded to include exploration of advanced injection strategiesmore » to improve catalyst regeneration and to explore the influence of urea-SCR on PM formation. During this period the emission targets also shifted to meeting more stringent Tier 4 emissions for NOx and PM, and the fuel type was changed to ultra-low sulfur Diesel (ULSD) having a maximum sulfur concentration of 15 ppm. New discoveries were made regarding PM formation at high rail pressures and the influences of oxidation catalysts and urea-SCR catalysts. These results are expected to provide a pathway for lower PM and NOx emissions for both off- and on-highway applications. Industrial in-kind support was available throughout the project period. Review of the research results were carried out on a regular basis (annual reports and meetings) followed by suggestions for improvement in ongoing work and direction for future work. A significant portion of the industrial support was in the form of experimentation, data analysis, data exchange, and technical consultation.« less