Comparison between direct and indirect (prechamber) spark ignition in the case of a cogeneration natural gas engine, part I: engine geometrical parameters

Daniel Favrat, Roger Röthlisberger
2001
Article

Résumé

The operation of a cogeneration internal combustion engine with unscavenged prechamber ignition was investigated. The objective was to evaluate the potential to reduce the exhaust gas emissions, particularly the CO emissions, without exhaust gas after treatment. The investigation was carried out on a small size gas engine (150kW) and required the development of cooled prechambers and the modification of the engine cylinder heads. The limit of the conventional lean burn operating mode with direct ignition is discussed and the prechamber geometrical configuration is presented. Through the generation of gas jets in the main chamber, the use of a prechamber strongly intensifies and accelerates the combustion process. The prechamber operation reduces significantly the emissions of CO and THC for same NOx emissions. The use of a piston generating significantly more turbulence leads to a somewhat higher fuel conversion efficiency without affecting significantly the CO and THC emissions at low NOx emissions. Further improvement associated with the adjustment of the engine operating parameters and the turbocharger characteristics, as well as a comparison between direct and prechamber ignition operation are presented in the second part (II) of this publication.

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https://infoscience.epfl.ch/record/53416?ln=fr

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Comparison between direct and indirect (prechamber) spark ignition in the case of a cogeneration natural gas engine, part II : engine operating parameters and turbocharger characteristics

Daniel Favrat, Roger Röthlisberger

In a first paper (part I), prechamber ignition in cogeneration natural gas engines has been shown to significantly intensify and accelerate the combustion process, offering a further potential to reduce the exhaust gas emissions while keeping efficiency at a high level. This second part discusses the influence of the engine operating parameters (spark timing and load) and the turbocharger characteristics with the objective of evaluating the potential to reduce the exhaust gas emissions, particularity the CO emissions, below the Swiss limits (NOx and CO emissions: 250 and 650 mg/m3N, 5% O2, respectively), without exhaust gas after treatment. The advantage of using an unscavenged prechamber is conditioned by a significant delay of the spark timing in order to generate substantial gas jets. This results in a large decrease in peak cylinder pressure and in an important reduction of NOx, CO and THC emissions. Minimum emissions are achieved at a spark timing of about 8°CABTDC . In comparison with the direct ignition, the prechamber ignition yields approximately 40% and 55% less CO and THC emissions, respectively. However, this also leads to about 2%-point lower fuel conversion efficiency. The optimisation of the turbocharger results in a recovery of about 1%-point in fuel conversion efficiency, but a consequent change in the exhaust manifold gas dynamics attenuates the reduction in THC emissions. At the rated power output (150kW), the prechamber ignition operation fulfils the Swiss requirements for exhaust gas emissions and still achieves a fuel conversion efficiency higher than 36.5%.

2002

Chargement

The operation of a cogeneration internal combustion engine with unscavenged prechamber ignition was investigated. The objective was to evaluate the potential to reduce the exhaust gas emissions, particularly the CO emissions, below the Swiss limits (NOx and CO emissions: 250 and 650 mg/m3N, 5% O2 , respectively), without exhaust gas after treatment. The investigation was carried out on a small size gas engine (6 cylinders, 122 mm bore, 142 mm stroke) and required the development of cooled prechambers and the modification of the engine cylinder heads. The approach was essentially experimental, but included a numerical simulation based on the CFD-code KIVA-3V in order to assist and guide the experimentation. The numerical simulation was carried out in order to evaluate the differences in flow characteristics at the location of the spark plug electrodes between direct and prechamber ignition. Further, the influence of the prechamber geometrical configuration was investigated through variations of the nozzle orifice diameter, number and orientation, as well as prechamber volume and internal shape. Based on the results of the numerical simulation, the most promising prechamber configuration parameters were selected for experimentation. Then, variations of the selected prechamber configuration parameters, as well as of the piston geometry, of the turbocharger characteristics and of the engine operating parameters, were carried out in order to determine their influence on the engine performance and emissions. Through the generation of gas jets in the main chamber, the use of a prechamber strongly intensifies and accelerates the combustion process. However, this advantage is conditioned by a significant delay of the spark timing in order to generate substantial gas jets. This results in a large decrease in peak cylinder pressure and in an important reduction of NOx, CO and THC emissions. Minimum emissions are achieved at a spark timing of about 8°CABTDC. The prechamber geometrical parametric study indicates that trends which increase the penetration of the gas jets and/or promote an early arrival of the flame front at the piston top land crevice entrance are beneficial to reduce the CO and THC emissions. In comparison with the direct ignition, the prechamber ignition yields approximately 40% and 55% less CO and THC emissions, respectively. However, this also leads to about 2%-point lower fuel conversion efficiency. The optimisation of the turbocharger results in a recovery of about 1%-point in fuel conversion efficiency, but a consequent change in the exhaust manifold gas dynamics causes an increase in THC emissions. At the rated power output (150 kW), the prechamber ignition operation fulfils the Swiss requirements for exhaust gas emissions and still achieves a fuel conversion efficiency higher than 36.5%.

EPFL2001

Chargement

Swiss Motor. Modification d’un moteur diesel pour le fonctionnement au gaz naturel en cogénération. Fonctionnement avec mélange stoechiométrique (l=1) et pauvre (l>>1).

Daniel Favrat, Geoffrey Basil Leyland, Roger Röthlisberger

The Swiss limit for NOx exhaust gas emissions from decentralised electrical power and heat cogeneration units using stationary I.C. engines operating on natural gas, despite a recent increase from 80 to 250 mg/mN3 (5% O2), remains the most severe in force in the world. The only technology currently able to meet this limit - the use of a stoichiometric mixture and a three-way catalyst - results in a relatively low global engine efficiency and suffers from a limited reliability of the exhaust gas treatment system. In this context, the Laboratory for Energy Systems of the EPFL has undertaken to develop new technologies (mixture, ignition,...) on the basis of a converted diesel engine for natural gas operation and to evaluate their reliability as well as their potential to reduce exhaust gas emissions, particularly NOx. The objective of this project is to perform an experimental study of the influence of the operating mode, either a stoichiometric mixture (l = 1) and a 3-way catalyst for exhaust gas treatment or a lean mixture (l >> 1) without catalyst, on the performance and emissions of a Liebherr G 926 engine, in order to establish a basis of comparison for future evaluation of new technologies. The realisation of this project required the construction of a new test bed especially developed for the study of gas engines. In the case of the stoichiometric operating mode, the results show that at an MBT spark timing of 20 °CABTDC, a mechanical power output of 106.3 ± 0.5 kW at 1502 ± 5 rpm and a global efficiency of 35.9 +1,7/-0.6% is achieved. A series of tests with different sparkplugs showed only a weak influence on the engine behaviour. The use of a 3-way catalyst for exhaust gas treatment reduces the NOX and CO emissions comfortably below the limits prescribed by the Swiss Federal Clean Air Act. In the case of the naturally aspirated engine, lean operation with an air to fuel ratio over 1.6 keeps the NOX emissions under the prescribed limit without a catalyst. However, the power output falls below 69 kW and the global efficiency below 35%. By turbocharging and intercooling the intake air and gas mixture the power output was increased from this low level to 150 kW (pme = 12 bar). As with stoichiometric operation, changing the spark plugs has only a weak influence on the engine behaviour. However, an increase of the ignition coil discharge time led to a perceptible reduction of the cycle-by-cycle variability. The results show that the best method of reducing the amount of energy dissipated by the exhaust manifold is to insulate the manifold, rather than water cool it. The insulation preserves more energy for the turbocharger and a high temperature for a possible catalytic exhaust gas after treatment. The reduction of the dead volume located between the cylinder liner, the cylinder head and the cylinder gasket led to a 40 % decrease of the THC emissions. Further, the use of a new piston, generating a higher level of turbulence during the combustion, raised the lean limit and thus reduced NOX emissions below 150 mg/mN3, 5% O2, while still keeping the global efficiency over 37%; these results are valid for a intake mixture temperatures of both 50 and 80 °C, however in the second case at a somewhat lower power output than 150 kW. Despite these improvements, and because of an extremely low CO raw emissions limit, the use of a oxidation catalyst is needed to fulfil the requirements of the Swiss Federal Clean Air Act. In order to reduce the raw CO emissions and to increase the engine global efficiency, this project will continue with a third part aiming to study the potential of an ignition system based on a prechamber.

1998

Chargement

The operation of a cogeneration internal combustion engine with unscavenged prechamber ignition was investigated. The objective was to evaluate the potential to reduce the exhaust gas emissions, particularly the CO emissions, below the Swiss limits (NOx and CO emissions: 250 and 650 mg/m3N, 5% O2 , respectively), without exhaust gas after treatment. The investigation was carried out on a small size gas engine (6 cylinders, 122 mm bore, 142 mm stroke) and required the development of cooled prechambers and the modification of the engine cylinder heads. The approach was essentially experimental, but included a numerical simulation based on the CFD-code KIVA-3V in order to assist and guide the experimentation. The numerical simulation was carried out in order to evaluate the differences in flow characteristics at the location of the spark plug electrodes between direct and prechamber ignition. Further, the influence of the prechamber geometrical configuration was investigated through variations of the nozzle orifice diameter, number and orientation, as well as prechamber volume and internal shape. Based on the results of the numerical simulation, the most promising prechamber configuration parameters were selected for experimentation. Then, variations of the selected prechamber configuration parameters, as well as of the piston geometry, of the turbocharger characteristics and of the engine operating parameters, were carried out in order to determine their influence on the engine performance and emissions. Through the generation of gas jets in the main chamber, the use of a prechamber strongly intensifies and accelerates the combustion process. However, this advantage is conditioned by a significant delay of the spark timing in order to generate substantial gas jets. This results in a large decrease in peak cylinder pressure and in an important reduction of NOx, CO and THC emissions. Minimum emissions are achieved at a spark timing of about 8°CABTDC. The prechamber geometrical parametric study indicates that trends which increase the penetration of the gas jets and/or promote an early arrival of the flame front at the piston top land crevice entrance are beneficial to reduce the CO and THC emissions. In comparison with the direct ignition, the prechamber ignition yields approximately 40% and 55% less CO and THC emissions, respectively. However, this also leads to about 2%-point lower fuel conversion efficiency. The optimisation of the turbocharger results in a recovery of about 1%-point in fuel conversion efficiency, but a consequent change in the exhaust manifold gas dynamics causes an increase in THC emissions. At the rated power output (150 kW), the prechamber ignition operation fulfils the Swiss requirements for exhaust gas emissions and still achieves a fuel conversion efficiency higher than 36.5%.

EPFL2001

Swiss Motor. Modification d’un moteur diesel pour le fonctionnement au gaz naturel en cogénération. Fonctionnement avec mélange stoechiométrique (l=1) et pauvre (l>>1).

Daniel Favrat, Geoffrey Basil Leyland, Roger Röthlisberger

1998