Fuel spray visualization and its impingement analysis on in-cylinder surfaces in a direct-injection spark-ignition engine

Abstract  

Experiments are performed to investigate the effects of fuel spray on in-cylinder mixture preparation and its impingement on cylinder walls and piston top inside a direct-injection spark-ignition engine with optical access to the cylinder. Novel image processing algorithms are developed to analyze the fuel impingement quantitatively on in-cylinder surfaces. The technique is useful to optimize the fuel pressure, injection timing and the number of injections to minimize the fuel impingement on in-cylinder surfaces. E85, which represents a blend of 85% ethanol and 15% gasoline (by volume) is used in this study. Two types of fuel injectors are used; (i) low-pressure production-intent injector with fuel pressure of 3 MPa, and (ii) high-pressure production injector with fuel pressures of 5 and 10 MPa. In addition, the effects of split injection are also presented by maintaining the same amount of fuel used in single injection. It is found that the split injection is an effective way to reduce the overall fuel impingement on in-cylinder surfaces while maintaining a reasonably good air–fuel mixture in the cylinder.     

Simulation of spray combustion in a lean-direct injection combustor

Large-eddy simulation (LES) of a liquid-fueled lean-direct injection (LDI) combustor is carried out by resolving the entire inlet flow path through the swirl vanes and the combustor. A localized dynamic subgrid closure is combined with a subgrid mixing and combustion model so that no adjustable parameters are required for both non-reacting and reacting LES. Time-averaged velocity predictions compare well with the measured data. The unsteady flow features that play a major role in spray dispersion, fuel–air mixing and flame stabilization are identified from the simulation data. It is shown that the vortex breakdown bubble (VBB) is smaller with more intense reverse flow when there is heat release. The swirling shear layer plays a major role in spray dispersion and the VBB provides an efficient flameholding mechanism to stabilize the flame.     

An experimental investigation on spray, ignition and combustion characteristics of biodiesels

Spray, ignition and combustion characteristics of biodiesel fuels were investigated under a simulated diesel-engine condition (885 K, 4 MPa) in a constant volume combustion vessel. Two biodiesel fuels originated from palm oil and used cooking oil were used while JIS#2 used as the base fuel. Spray images were taken by a high speed video camera by using Mie-scattering method to measure liquid phase penetration and liquid length. An image intensifier combined with OH filter was used to obtain OH radical image near 313 nm. Ignition and combustion characteristics were studied by OH radical images. Biodiesel fuels give appreciably longer liquid lengths and shorter ignition delays. At low injection pressure (100 MPa), biodiesel fuels give shorter lift-off lengths than those of diesel. While at high injection pressure (200 MPa), the lift-off length of biodiesel fuel originated palm oil gives the shortest value and that of biodiesel from used cooking oil gives the longest one. Air entrainment upstream of lift-off length of three fuels was estimated and compared to soot formation distance. This study reveals that the viscosity and ignition quality of biodiesel fuel have great influences on jet flame structure and soot formation tendency.     

Flow, spray and combustion analysis by laser techniques in the combustion chamber of a direct-injection diesel engine

The purpose of this paper is to show how the analysis of in -cylinder flow, fuel injection, and combustion by means of state-of-the-art optical techniques, as laser light-sheet, laser doppler anemometry and laser shadowgraphy, can help to support the understanding of the interaction of swirl flow development, spray formation, auto-ignition and combustion in near production-line direct-injection diesel engines and thus advances the development of engines with lower fuel consumption and emissions.     

Effects of turbulence-chemistry interactions on auto-ignition and flame structure for n-dodecane spray combustion

The Engine Combustion Network (ECN) spray A under diesel engine conditions is investigated with a non-adiabatic 5D Flamelet Generated Manifolds (FGM) model with the consideration of detailed chemical kinetic mechanisms. The enthalpy deficit due to droplet vapourisation is considered by employing an additional controlling parameter in the FGM library. In this FGM model, β-PDF is used for the PDF integration over the control variable space. Validation results in non-reacting conditions indicate relatively good agreement between the predicted and experimental data in terms of liquid and vapour penetrations and mixture fraction spatial distribution. In reacting conditions, the effects of variance of mixture fraction and progress variable were examined. The ignition delay time and the quasi-steady flame structure are both affected by the variances. The variance of mixture fraction delays the ignition process and the variance of progress variable accelerates it. For mixture fraction, the ignition process is quicker at any stage in the case of neglecting variance. While things are more complex for progress variable, the ignition process is advanced in the case of neglecting variance at early times, but surpassed by the case of β-PDF later and until auto-ignition. When variance of mixture fraction is considered, the OH mass fraction shows a wide spatial distribution. While if not, a very thin flame is observed with a higher peak in OH, and a very large lift-off length. The variance of progress variable has little impact on the global flame structure, but makes the flame lift-off length much shorter. This study confirms the general observation, that the variance of mixture fraction is of higher importance in high temperature non-premixed combustion, however, we found that the variance of progress variable is far from negligible.     

Interpreting the influence of fuel spray impact on mixture preparation for HCCI combustion with port-fuel injection

This paper addresses the influence of fuel spray impact on fuel/air mixture for combustion in port-fuel injection engines. The experiments include time resolved measurements of surface temperature synchronized with PDA measurements of droplet dynamics at impact and were conducted to quantify the effects of interactions between successive injections on the mixture preparation for combustion in homogeneous charge compression ignition (HCCI) engines. Analysis shows that, during engine warm up, the heat transfer over the entire valve surface occurs within the vaporization-nucleate-boiling regime and the local instantaneous surface temperature correlates with the dynamics of droplets impacting at the same point. A functional relation is found for the heat transfer coefficient, which also describes other experiments reported in the literature. Similarity does not hold after the engine warms up because heat transfer and droplet vaporization at the surface are dominated by multiple interactions between droplets arisen from diverse heat transfer regimes. However, results evidence the existence of a critical surface temperature which sets a transition between overall heat transfer regimes dominated by local nucleate boiling at lower temperatures and by local intermittent transition regimes at higher temperatures. The heat transfer within the overall nucleate boiling regime is shown to be due to a thin film boiling mechanism leading to breakdown of the liquid-film at a nearly constant surface temperature, regardless of injection frequency or any other spray conditions. While at low frequencies this regime is not limited neither by the delivery of liquid to the surface, nor by the removal of vapour from the surface, at higher frequencies it is triggered by enhanced vaporization induced by piercing and mixing the liquid film. The results further evidence the important role of spray impingement for mixture preparation as required for HCCI.     

Effect of flash boiling injection on combustion and PN emissions of DISI optical engine fueled with butanol isomers/TPRF blends

Direct injection spark ignition (DISI) engines have been widely used in passenger cars due to their lower fuel consumption, better controllability, and high efficiency. However, DISI engines are suffering from wall wetting, imperfect mixture formation, excess soot emissions, and cyclic variations. Applying a new fuel atomization technique and using biofuels with their distinctive properties can potentially aid in improving DISI engines. In this research, the effects of isobutanol and 2-butanol and their blends with Toluene Primary Reference Fuel (TPRF) on spray characteristics, DISI engine combustion, and particle number (PN) emissions are investigated for conditions with and without flash boiling of the injected fuel. Spray characteristics are investigated using a constant volume chamber. Then, the combustion, flame propagation, and PN emissions are examined using an optical DISI engine. The fuel temperature is set to 298 K and 453 K for liquid injection and flash boiling injection, respectively. The tested blending ratio is 30 vol% butanol isomers and 70 vol% TPRF. The results of the spray test reveal that liquid fuel plumes are distinctly observed, and butanol blends show a slightly wider spray angle with lower penetration length compared to TPRF. However, under flash boiling injection, the sprays collapse towards the injector axis, forming a more extended single central vapor jet due to the plumes' interaction. Meanwhile, butanol blends yield a narrow spray angle with more extended penetration compared to TPRF. The flame visualization test shows that the flash boiling injection reduced yellow flames compared to liquid fuel injection, reflecting the improvements in mixture formation. Thus, improvements were noted in the heat release and PN emissions. Butanol addition reduced the PN emissions by 43% under regular liquid injection. Flash boiling injection provided an additional 25% reduction in PN emissions.     

An experimental study into the effect of injector pressure loss on self-sustained combustion instabilities in a swirled spray burner

Combustion instabilities depend on a variety of parameters and operating conditions. It is known, especially in the field of liquid rocket propulsion, that the pressure loss of an injector has an effect on its dynamics and on the coupling between the combustion chamber and the fuel manifold. However, its influence is not well documented in the technical literature dealing with gas turbine combustion dynamics. Effects of changes in this key design parameter are investigated in the present article by testing different swirlers at constant thermal power on a broad range of injection velocities in a well controlled laboratory scale single injector swirled combustor using liquid fuel. The objective is to study the impact of injection pressure losses on the occurrence and level of combustion instabilities by making use of a set of injectors having nearly the same outlet velocity profiles, the same swirl number and that establish flames that are essentially identical in shape. It is found that combustion oscillations appear on a wider range of operating conditions for injectors with the highest pressure loss, but that the pressure fluctuations caused by thermoacoustic oscillations are greatest when the injector head loss is low. Four types of instabilities coupled by two modes may be distinguished: the first group features a lower frequency, arises when the injector pressure loss is low and corresponds to a weakly coupled chamber-plenum mode. The second group appears in the form of a constant amplitude limit cycle, or as bursts at a slightly higher frequency and is coupled by a chamber mode. Spontaneous switching between these two types of instabilities is also observed in a narrow domain.     

Effects of fine fuel droplets on a laminar flame stabilized in a partially prevaporized spray stream

A partially prevaporized spray burner was developed to investigate the interaction between fuel droplets and a flame. Monodispersed partially prevaporized ethanol sprays with narrow diameter distribution were generated by the condensation method using rapid pressure reduction of a saturated ethanol vapor–air mixture. A tilted flat flame was stabilized at the nozzle exit using a hot wire. Particle tracking velocimetry (PTV) was applied to measurements of the droplet velocity; the laminar burning velocity was obtained from gas velocity derived from the droplet velocity. Observations were made of flames in partially prevaporized spray streams with mean droplet diameters of 7 μm and the liquid equivalence ratios of 0.2; the total equivalence ratio was varied. In all cases, a sharp vaporization plane was observed in front of the blue flame. Flame oscillation was observed on the fuel-rich side. At strain rates under 50 s⁻¹, the change in the burning velocity with the strain rate is small in fuel-lean spray streams. In spray streams of 0.7 and 0.8 in the total equivalence ratio, burning velocity increases with strain rates of greater than 50 s⁻¹. However, in spray streams with 0.9 and 1.0 in the total equivalence ratio, burning velocity decreases as the strain rate increases. At strain rates greater than 80 s⁻¹, burning velocity decreases with an increased gas equivalence ratio. The effect of mean droplet diameter, and the entry length of droplets into a flame on the laminar burning velocity, were also investigated to interpret the effect of the strain rate on the laminar burning velocity of partially prevaporized sprays.     

Acoustic monitoring of engine fuel injection based on adaptive filtering techniques

Diesel engines injection process is essential for optimum operation to maintain the design power and torque requirements and to satisfy stricter emissions legislations. In general this process is highly dependent upon the injection pump and fuel injector health. However, extracting such information about the injector condition using needle movements or vibration measurements without affecting its operation is very difficult. It is also very difficult to extract such information using direct air-borne acoustic measurements.In this work adaptive filtering techniques are employed to enhance diesel fuel injector needle impact excitations contained within the air-borne acoustic signals. Those signals are remotely measured by a condenser microphone located 25 cm away from the injector head, band pass filtered and processed in a personal computer using MatLab. Different injection pressures examined were 250, 240, 230, 220 and 210 bars and fuel injector needle opening and closing impacts in each case were thus revealed in the time-frequency domain using the Wigner-Ville distribution (WVD) technique. The energy of 7-15 kHz frequency bands was found to vary according to the injection pressure. The developed enhancement scheme parameters are determined and its consistency in extracting and enhancing signal to noise ratio of injector signatures is examined using simulation and real measured signals; this allows much better condition monitoring information extraction.