Approaches for emission reduction in natural gas fueled direct-injection engines

A glow plug (GP) can serve as an effective ignition source in a heavy-duty direct-injection natural gas (DING) engine. Ignition performance can be improved by shielding the GP. The shield protects the GP from cooling by the injected natural gas (NG) jets and also traps NG next to the GP surface, acting as kind of pre-combustion chamber. Achieving rapid filing of the shield by a fuel jet and facilitating flame propagation out are key goals of shield design. However, previous studies found that emissions such as unburned CH4 and soot particles could be trapped inside the shield especially near its top end, contributing a large fraction to the engine exhaust. In this paper, new designs either controlling the NG amount entering the shield or improving the emission propagation out of the shield are proposed to solve the emission issues, and the impacts of these design changes on fuel injection and combustion emissions were computationally investigated. The base case includes an injector with nine 0.2 mm diameter nozzles and a diamond-pattern multi-opening GP shield. A new injector combining one smaller nozzle directed towards the GP shield and eight regular size nozzles was compared, while a new five-opening shield design adding a small opening on the top end of the diamond pattern shield was studied. Compared to the base case, the new two-nozzle-size injector greatly reduced the amount of fuel injected into the shield, which solved the emission issues inside the shield. Over 35% and 95% reductions in the total mass of unburned CH(4 )and soot particles respectively were achieved. Furthermore, the additional opening for the new shield provides an alternative route for fuel flowing out of the shield during fuel injection. However, fuel injection is the main force for fuel motion inside the shield and highly affects the new flow route provided by the additional opening. The unburned CH4 and formed soot particles could not flow out of the shield through the additional opening once fuel injection is finished. Generally, an increase was found for the unburned CH4 and soot mass by using the new five-opening shield, compared to the base case.

Automated summary

This paper proposes new designs to solve the emission issues in a heavy-duty direct-injection natural gas engine. The impacts of these design changes on fuel injection and combustion emissions were computationally investigated. Compared to the base case, a new injector with two nozzle sizes greatly reduced the fuel injected into the shield, achieving significant reductions in unburned CH4 and soot particles. However, a new shield design with five openings did not improve the flow route for fuel out of the shield and resulted in an increase in unburned CH4 and soot mass.